Carbon Blacks Produced by Thermal Plasma: the Influence of the Reactor Geometry on the Product Morphology

Carbon black (CB) nanopowders were obtained by plasma decomposition of methane at various flow rates using inductively coupled thermal plasma torch system of 35 kW. Nitrogen was also introduced in some experiments along with the methane. Using a cylindrical shape reactor the obtained powders were composed mainly of spherical particles, non-uniform in terms of particles size with diameters between 30 and 150 nm. The shape and size of this reactor resulted in the presence of recirculation areas enabling the formation of large CB particles and other secondary volatile compounds. Changing the reactor to a conical geometry resulted in the production of CB powders showing a crystalline and flake-like morphology made of sheets having 6–16 graphitic planes. The conical shape avoids the presence of recirculation areas and promotes the formation of a uniform powder morphology throughout the reactor.     

Carbon Nanoparticle Production by Inductively Coupled Thermal Plasmas: Controlling the Thermal History of Particle Nucleation

The process control for reproducibility, uniformity, and achievement of desired structures for carbon black generated in thermal plasma devices is studied in this paper through modeling, and correlated with experimental results. A numerical simulation of the flow and energy fields, stream function lines and the quench rates of the plasma gas in a conical shape reactor at different pressures was made. An argon plasma is used with highly diluted methane (0.6–7%) as the carbon precursor. The quench rates were studied in order to observe the flow development and hence the thermal history of particle nucleation. Three pressure cases of 20.7, 55.2 and 101.3 kPa and two plasma powers cases of 10 and 20 kW were studied. The modeling results enabled carbon nanoflakes production in the experimental tests performed on an inductively coupled thermal plasma system. Results indicate a robust process control enabling very little particle morphology variation over this wide range of reactor pressure values and varying plasma power, and a very high reproducibility of the particle morphologies obtained.     

Reactor design and energy concepts for a plasma process of acetylene black production

Acetylene black can be produced from methane decomposition in a plasma reactor. Different types of plasma reactor are designed for this purpose and a parametric analysis of the system is made. Carbon yield in the reactor seems to be dependent on methane flow rate and plasma power. The results obtained from various types of material analysis of the product obtained show that in some conditions carbon produced under plasma has qualities similar to acetylene black obtained by classical processes.     

Methane Conversion to Hydrogen and Carbon Black by DC-Spark Discharge

A continuous production of hydrogen and carbon black from methane without CO₂ emission in atmospheric pressure has been investigated by non thermal decomposition of methane using a system of direct current (DC)-spark discharge plasma, which has great advantages over other systems, like thermal plasma or catalytic conversion of methane in H₂ production. A plasma reactor with specific design of electrodes was employed to examine the reactor performance regarding operating conditions such as feed flow rate, input power and electrodes distance. The experimental results showed that designed reactor increases not only the concentration of the produced hydrogen in continues condition but also guarantees stable plasma. As the methane supply rate increased, the hydrogen concentration decreased but on the other hand the hydrogen volume flow rate increased. In general, under the specified operating condition (power?=?21 W and methane flow rate?=?150?ml/min), the plasma converter produced a hydrogen concentration of 45?% at hydrogen volume flow rate of 75?ml/min.     

Syngas Production from Propane Using Atmospheric Non-thermal Plasma

Propane steam reforming using a sliding discharge reactor was investigated under atmospheric pressure and low temperature (420 K). Non-thermal plasma steam reforming proceeded efficiently and hydrogen was formed as a main product (H₂ concentration up to 50%). By-products (C₂-hydrocarbons, methane, carbon dioxide) were measured with concentrations lower than 6%. The mean electrical power injected in the discharge is less than 2 kW. The process efficiency is described in terms of propane conversion rate, steam reforming and cracking selectivity, as well as by-products production. Chemical processes modelling based on classical thermodynamic equilibrium reactor is also proposed. Calculated data fit quiet well experimental results and indicate that the improvement of C₃H₈ conversion and then H₂ production can be achieved by increasing the gas fraction through the discharge. By improving the reactor design, the non-thermal plasma has a potential for being an effective way for supplying hydrogen or synthesis gas.     

Cobalt ferrite for direct cracking of methane to produce hydrogen and carbon nanostructure: Effect of temperature and methane flow rate

Cobalt ferrite (CoFe₂O₄) was used as a catalyst for direct methane cracking. The reaction was accomplished in a fixed bed reactor at normal atmospheric pressure, while gas flow rate (20–50 mL/min) and reaction temperature (800–900 °C) were varied. The fresh CoFe₂O₄ morphology is sponge-like particle with inverse spinel structure as revealed from SEM and XRD results. The methane conversions and hydrogen formation rate were increased with reaction temperature, while catalyst stability and induction period decreased. Increases of gas flow rate > 20 mL/min led to a decrease the overall catalytic activity of CoFe₂O₄ for methane cracking. The XRD results of spent catalysts revealed that CoFe alloy was the active phase of methane cracking. TGA analysis showed that the largest amount of deposited carbon was 70.46 % at (20 mL/min, 900 °C), where it was 34.40 % at (50 mL/min, 800 °C). The deposited carbon has the shape of spherical carbon nanostructures and/or nano sprouts as observed with SEM. Raman data confirmed the graphitization type of the deposited carbon.     

Non-oxidative conversion of methane into various petrochemical grades over tunable tri-metallic Fe-W-Mo/HZSM-5 catalyst systems

Most mono-metallic catalysts applied in non-oxidative conversion of methane exhibit low catalyst activity and limited selectivity towards useful petrochemicals. In this study, a series of thermally stable and tunable 5.4 wt% metal/support Fe-W-Mo/HZSM-5 catalyst systems were synthesized, characterized, and applied in non-oxidative conversion of methane in a custom-made stainless-steel reactor at various process conditions. Analysis of products from the reactor was done using Shimadzu 2014 gas chromatograph. Varying the amount of Fe, W, and Mo on HZSM-5 greatly influenced catalyst activity in terms of methane conversion and product distribution. When the quantities of Fe and W were increased to 2.25 wt% each and the quantity of molybdenum reduced to 0.9 wt% in the overall 5.4 wt% metal/ HZSM-5 catalyst, the resultant catalyst system became most active in methane conversion (17.4%) at 800 °C. Reducing the quantity of Fe and W each to 1.35 wt% and increasing Mo to 2.7 wt% in the overall 5.4 wt% catalyst, the resultant catalyst system became less selective towards C₂ hydrocarbons and coke, but highly selective towards xylene and benzene. Therefore, this study demonstrates that varying metal loading presents an opportunity to tune the 5.4 wt% binary Fe, W, and Mo on HZSM-5 to achieve desired methane conversion and product distribution.     

Gasification of Municipal Solid Wastes in Plasma Arc Medium

Many thermal processes have been developed in order to eliminate the municipal solid wastes or produce energy from them. These processes include a wide range of applications from the simplest burning system to plasma gasification. Plasma gasification is based on re-forming of molecules after all molecules convert to smaller molecules or atoms at high temperatures. In this work, the production of fuel gas is aimed by plasma gasification of municipal solid wastes in high temperatures. Because of this, a plasma reactor of the capacity of 10 kg h^?1 was designed which can gasify municipal solid wastes. Plasma gasification with and without steam and oxygen was performed in temperatures of 600, 800, 1000, 1200, 1400 and 1600 °C in the reactor. A gas mixture containing methane, ethane, hydrogen, carbon dioxide and monoxide, whose content varies with temperature, was obtained. It was found that plasma gasification (or plasma pyrolysis, PG), plasma gasification with oxygen (PGO) and plasma gasification with steam (PGS) were more prone to CO formation. A gas product which was consisted of 95% CO between 1200 and 1400 °C was produced. It was observed that a gas with high energy capacity may be produced by feeding oxygen and steam into the entrance of the high temperature region of the reactor.

     

Direct Non-oxidative Methane Conversion by Non-thermal Plasma: Experimental Study

The direct non-oxidative conversion of methane to higher hydrocarbons in non-thermal plasma, namely dielectric barrier discharge and corona discharge, has been investigated experimentally at atmospheric pressure. In dielectric barrier discharge, the methane is mainly converted to ethane and propane with small amounts of unsaturated and higher hydrocarbons. While in corona discharge, methane was activated mainly to acetylene with small amount of other higher hydrocarbons. Decreasing the gas flow or increasing power input will improve the methane conversion and product yields. It is found that the methane conversion and main product yield against the input specific energy were special functions in both dielectric barrier discharge and corona discharge, independent of the reactor size, and whether fixing flow rate or power input and changing the power input or flow rate. The corona discharge is a promising alternative method for methane conversion to produce acetylene and hydrogen at low temperature.     

A High-Efficiency Reactor for the Pulsed Plasma Conversion of Methane

The authors recently developed a high-frequency pulsed plasma process for methane conversion to acetylene and hydrogen using a co-axial cylindrical (CAC) type of reactor. The energy efficiency represented by methane conversion rate per unit input energy has been improved so that such a pulsed plasma has potential for commercial acetylene production. A pulsed plasma consists of a pulsed corona discharge and a pulsed spark discharge. Most of energy is injected over the duration of the pulsed spark discharge. Methane conversion using this kind of pulsed plasma is a kind of pyrolysis enhanced by the pulsed spark discharge. In this study, a point-to-point (PTP) type of reactor that can produce a discharge channel over the duration of a pulse discharge was used for the pulsed plasma conversion of methane. The energy efficiency and carbon formation on electrodes have been improved. The influences of pulse frequency and pulse voltage on methane conversion rate and product selectivity were investigated. The features of methane conversion using PTP and CAC reactors were discussed.     

Conversion of Methane and Carbon Dioxide in a DBD Reactor: Influence of Oxygen

A continuous plug flow reactor supported by a dielectric barrier discharge (DBD) is used to study the conversion of methane, carbon dioxide, and oxygen at different compositions. The three studied gases were diluted with helium to 3 % with an overall flow rate of 200 sccm. The 13.56 MHz plasma was ignited at atmospheric pressure. The product stream and the inlet flow were analyzed by a FTIR spectrometer equipped with a White-cell and by a quadrupole mass spectrometer. The DBD reactor generates hydrogen, carbon monoxide, ethane, ethene, acetylene, formaldehyde, and methanol. Additional oxygen in the feed has positive effects on the yield of methanol, formaldehyde and carbon monoxide and reduces the total consumed energy. The hydrogen yield reaches its maximum at medium amounts of oxygen in the inlet flow. The conversion of methane increases to a limiting value of about 35 %. Methane rich feeds increase the yield of hydrogen, ethane and methanol. On the other hand, additional oxygen has a negative influence on the produced amount of C2 hydrocarbons. The conversion of methane and carbon dioxide as well as the yield of synthesis gas components and C2 hydrocarbons increases by changing the plasma power to higher values.     

Development of a liquid chromatography-tandem mass spectrometry method for plasma-free metanephrines with ion-pairing turbulent flow online extraction

Liquid chromatography–tandem mass spectrometry has become the preferred technology to measure unconjugated metanephrine and normetanephrine in plasma because of its high sensitivity and specificity over immunoassay and gas chromatography–mass spectrometry. In our earlier study, plasma metanephrines were extracted with offline ion-pairing solid-phase extraction and quantified by liquid chromatography–tandem mass spectrometry with porous graphitic carbon column based chromatography. In this study, we aim to automate the sample preparation with turbulent flow online extraction technology and maintain or improve the analytical performance previously achieved from the offline approach. The online extraction was done with a mixed-mode cation exchange turbulent flow chromatography column assisted with ion-pairing reagent and porous graphitic column was used for chromatographic separation. The total online extraction and analytical LC runtime was 12 min. This method was linear from 6.3 to 455.4 pg/mL for metanephrine; 12.6 to 954.5 pg/mL for normetanephrine with an accuracy of 80.6% to 93.5% and 80.9% to 101.7%, respectively. The lower limit of quantitation was 6.3 pg/mL for metanephrine and 12.6 pg/mL for normetanephrine. Inter-assay and intra-assay precision for metanephrine and normetanephrine at low and high concentration levels ranged from 2.0% to 10.5%. In conclusion, we have developed a fast and sensitive automated online turbulent flow extraction method for the quantitative analysis of plasma metanephrines. Ion-pairing reagent was necessary for the success of this method.     

Methane activation on PdMn/C-ITO electrocatalysts using a reactor-type PEMFC

Various palladium and manganese supported in a mix of carbon and indium thin oxide (PdMn/C-ITO) compositions were synthesized by a sodium borohydride reduction process for methane activation at low temperatures in a proton exchange membrane fuel cell (PEMFC) reactor. These electrocatalysts were characterized by X-ray diffraction, transmission electron microscopy (TEM), X-ray photoelectron spectroscopy XPS, inductively coupled plasma mass spectrometry ICP-MS, attenuated total reflection-Fourier transform infrared spectroscopy, cyclic voltammetry and a PEMFC reactor. The diffractograms of PdMn/C-ITO electrocatalysts revealed the face-centered cubic structure of palladium and the bixbyite cubic structure of In₂O₃. TEM experiments showed mean nanoparticle sizes between 4.7 and 5.2 nm for all electrocatalysts. XPS results showed the presence of palladium and manganese oxides, as well as Pd⁰ species. Cyclic voltammograms of PdMn/C-ITO electrocatalysts showed an increase in current density values after the methane adsorption, this result is related to formation of methanol or formic acidic. Polarization curves at 80 °C acquired in a PEMFC reactor showed that PdMn(70:30)/C-ITO and PdMn(50:50)/C-ITO have superior performance when compared to Pd/C-ITO indicating the beneficial effect of adding Mn, this behavior can be attributed to the bifunctional mechanism or to the electronic effect of support.

     

Methane Decomposition on the Surface of Molybdenum Nanoparticles at Room Temperature

The decomposition of methane on molybdenum nanoparticles was studied experimentally at room temperature. The molybdenum nanoparticles were synthesized in the gas phase using UV laser photolysis of Mo(CO)6 vapor in a flow reactor. The working part of the flow reactor was equipped with quartz windows for introducing the radiation from a pulsed Nd:YaG laser operating at the fourth harmonic (266 nm) at a frequency of 10 Hz. Methane was used as a carrier gas. As a result of irradiation of a mixture of methane with Mo(CO)6 vapors in the gas phase at room temperature, nanoparticles with sizes of 2–50 nm were synthesized. The phase composition of the nanoparticles included pure molybdenum, molybdenum carbide Mo2C, and molybdenum oxide MoO3. During the reaction, the hydrogen yield was measured with a VG-7 highly sensitive hydrogen analyzer based on a semiconductor metal–dielectric sensor. The measured H2 concentration varied from 5 to 25 ppm depending on the concentration of Mo(CO)6. The possibility of methane decomposition on molybdenum nanoparticles at room temperature was discussed based on the obtained data.     

Effects of fluorination modification on pore size controlled electrospun activated carbon fibers for high capacity methane storage

Electrospun carbon fibers were prepared as a methane storage medium. Chemical activation was carried out using potassium carbonate to develop the pore structure, which can provide sites for the uptake of methane, and then fluorination surface modification was conducted to enhance the capacity of storage. Chemical activation provided a highly microporous structure, which is beneficial for methane storage, with a high specific surface area greater than 2500 m²/g. The pore size distribution showed that the prepared samples have pore sizes in the range of 0.7–1.6 nm. The effect of fluorination surface modification was also investigated. The functional groups, which were confirmed by XPS analysis, played an important role in guiding methane gas into the carbon silt pores via the attractive force felt by the electrons in the methane molecules due to the high electronegativity of fluorine. Eventually, the methane uptake increased up to 18.1 wt.% by the synergetic effects of the highly developed micropore structure and the guiding of methane to carbon pores by fluorine.     

DC-Pulsed Plasma for Dry Reforming of Methane to Synthesis Gas

The carbon dioxide reforming of methane to synthesis gas under DC-pulsed plasma was investigated. The effects of specific input energy and feed ratio on the product distribution and also feed conversion was studied. At the input energy of about 11 eV/molecule per methane and/or carbon dioxide the feed conversion of 38% for CH₄ and 28% for CO₂ and product selectivity of 74% has been attained for H₂ and CO at feed flow rate of 90 ml/min. The energy consumption in this work displays potential to further study and optimization of the process. The importance of the electron impact reactions in the process was discussed. The results show that by prudent tuning of system variables, the process be able to run in the way of synthesis gas, instead of hydrocarbon production.     

Methane Conversion Using Dielectric Barrier Discharge：Comparison with Thermal Process and Catalyst Effects

The direct conversion of methane using a dielectric barrier discharge has been experimentally studied. Experiments with different values of flow rates and discharge voltages have been performed to investigate the effects on the conversion and reaction products both qualitatively and quantitatively. Experimental results indicate that the maximum conversion of methane has been 80% at an input flow rate of 5 ml/min and a discharge voltage of 4 kV. Experimental results also show that the optimum condition has occurred at a high discharge voltage and higher input flow rate. In terms of product distribution, a higher flow rate or shorter residence time can increase the selectivity for higher hydrocarbons. No hydrocarbon product was detected using the thermal method, except hydrogen and carbon. Increasing selectivity for ethane was found when Pt and Ru catalysts presented in the plasma reaction. Hydrogenation of acetylene in the catalyst surface could have been the reason for this phenomenon as the selectivity for acetylene in the products was decreasing.     

Characterization of plasma polymerized hydrocarbons using CP–MAS 13C-NMR

Plasma polymerized hydrocarbons made from ethane and methane were produced under different reactor conditions and probed by solid-state carbon-13 nuclear magnetic resonance (¹³C-NMR) with cross-polarization and magic-angle sample spinning. NMR experiments provided structural information about the plasma polymers. The conditions of low power, high hydrocarbon gas flow rate, and no added hydrogen gas appeared to give the highest amount of nonprotonated sp³ hybridized carbons in the films for the reactor design used. The use of methane or ethane as reactor gas did not affect plasma polymer structure significantly.     

Performance of a mixed-conducting ceramic membrane reactor with high oxygen permeability for methane conversion

A mixed-conducting perovskite-type Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCFO) ceramic membrane reactor with high oxygen permeability was applied for the activation of methane. The membrane reactor has intrinsic catalytic activities for methane conversion to ethane and ethylene. C₂ selectivity up to 40–70% was achieved, albeit that conversion rate were low, typically 0.5–3.5% at 800–900°C with a 50% helium diluted methane inlet stream at a flow rate of 34 ml/min. Large amount of unreacted molecular oxygen was detected in the eluted gas and the oxygen permeation flux improved only slightly compared with that under non-reactive air/He experiments. The partial oxidation of methane to syngas in a BSCFO membrane reactor was also performed by packing LiLaNiO/γ-Al₂O₃ with 10% Ni loading as the catalyst. At the initial stage, oxygen permeation flux, methane conversion and CO selectivity were closely related with the state of the catalyst. Less than 21 h was needed for the oxygen permeation flux to reach its steady state. 98.5% CH₄ conversion, 93.0% CO selectivity and 10.45 ml/cm² min oxygen permeation flux were achieved under steady state at 850°C. Methane conversion and oxygen permeation flux increased with increasing temperature. No fracture of the membrane reactor was observed during syngas production. However, H₂-TPR investigation demonstrated that the BSCFO was unstable under reducing atmosphere, yet the material was found to have excellent phase reversibility. A membrane reactor made from BSCFO was successfully operated for the POM reaction at 875°C for more than 500 h without failure, with a stable oxygen permeation flux of about 11.5 ml/cm² min.     

Nano-Particle Sizing in a Thermal Plasma Synthesis Reactor

The radio frequency inductively coupled thermal plasma synthesis process, based on the use of solution precursors as the process feedstock, has been employed for the production of ceria (CeO₂) nano-powders. A sampling probe has been developed to continuously withdraw synthesized nano-powders from all desired positions within the plasma chamber for subsequent analysis. Using this probe, it was possible to study the 3D mapping of the plasma synthesis process. A flow of helium was introduced into the sampling probe to quench sampled particles and to prevent further particle growth within the sampling probe. Numerical simulations of the plasma flow were performed to study the influence of the probe tip geometry on the plasma flow. The reactor wall product collection method was also applied for sampling probe performance verification. The effects of selected plasma power and reactor pressure on the synthesized nano-powders size were investigated with this sampling probe. The results indicated that size distribution of the synthesized nano-powders is locally monomodal, with particles sizes as small as 4 nm being synthesized.