OES Use and Vaporization Modeling for Fly-Ash Plasma Vitrification

Results are presented of optical emission spectroscopy (OES) application asa control tool to improve fly-ash plasma vitrification. A twin-torch plasmasystem has been used for the fly-ash processing, and a new OES method hasexamined metallic vapors above the melt. The method allows the study ofnonhomogeneous optically thin plasmas exhibiting a symmetry plane withoutsophisticated tomographic systems. The dc arc torches are mounted above acold crucible filled with a synthetic glass. The arc intensity is from200 to 400 . Argon is introduced into the torches along the cathodeand the anode, while argon, oxygen or hydrogen are injected through thelance between the torches. Local plasma temperatures above the melt havebeen evaluated using measured relative intensities of spectral lines ofthe plasma-forming gas. Metallic vapor concentration in the plasma isdeduced from the intensity ratio of the metal–gas spectral lines. Leadoxide has been used to study heavy-metal behavior at the fly-ash plasmavitrification. Distribution of the lead along the crucible surface,depending on the plasma-forming gas composition as well as the concentrationevolution with time, have been examined. The elemental analysis of theresultant glass has been measured by scanning electron microscopy (SEM)with energy-dispersive spectrometry (EDS). A predictive model has beenadapted to simulate the noncongruent vaporization of heavy metals from themelt. According to the data obtained, steep variations of the volatility ofthe elements depend strongly on reducing properties of gases controllingthe plasma composition near the melted surface. In addition, the melttemperature and the redox potential of the gas phase are found to be themost critical parameters.     

Effect of Cathode Nozzle Geometry and Process Parameters on the Energy Distribution for an Argon Transferred Arc

The influence of two nozzle geometries and three process parameters (arc current, arc length and plasma sheath gas flow rate) on the energy distribution for an argon transferred arc is investigated. Measurements are reported for a straight bore cylindrical and for a convergent nozzle, with arc currents of 100 A and 200 A and electrode gaps of 10 mm and 20 mm. These correspond to typical operating parameters generally used in plasma transferred arc cutting and welding operations. The experimental set up consisted of three principal components: the cathode-torch assembly, the external, water-cooled anode, and the reactor chamber. For each set of measurements the power delivered to each system component was measured through calorimetric means, as function of the arc’s operating conditions. The results obtained from this study show that the shape of the cathode torch nozzle has an important influence on arc behaviour and on the energy distribution between the different system components. A convergent nozzle results in higher arc voltages, and consequently, in higher powers being generated in the discharge for the same applied arc current, when compared to the case of a straight bore nozzle. This effect is attributed to the fluidynamic constriction of the arc root attachment, and the consequential increase in the arc voltage and thus, in the Joule heating. The experimental data so obtained is compared with the predictions of a numerical model for the electric arc, based on the solution of the Navier–Stokes and Maxwell equations, using the commercial code FLUENT©. The original code was enhanced with dedicated subroutines to account for the strong temperature dependence of the thermodynamic and transport properties under plasma conditions. The computational domain includes the heat conduction within the solid electrodes and the arc-electrode interactions, in order to be able to calculate the heat distribution in the overall system. The level of agreement achieved between the experimental data and the model predictions confirms the suitability of the proposed, “relatively simple” model as a tool to use for the design and optimization of transferred arc processes and related devices. This conclusion was further supported by spectroscopic measurements of the temperature profiles present in the arc column and image analysis of the intensity distribution within the arc, under the same operating conditions.     

Relating Spectroscopic Measurements in a Plasma Cutting Torch to Cutting Performance

The relationship between plasma properties and cutting performance for a plasma arc cutting system was investigated. Plasma properties such as temperature and composition were measured using spectroscopic techniques in a 200 amp oxygen plasma cutting system. In addition to the plasma properties, the symmetry of the cylindrical cutting arc was also quantified. Cutting performance was measured by analyzing the edge quality of sample cuts. The most important measure of edge quality for this study was the angle of the cut edge. Operating parameters investigated included the effect of shield gas flow and geometry changes caused by cathode erosion. The measured plasma properties are used to account for the observed increase in recommended cutting speed for different consumable designs which operated at the same current level. A strong correlation was also shown between the measured arc symmetry and the cutting performance.     

Generation of Long, Laminar Plasma Jets at Atmospheric Pressure and Effects of Flow Turbulence

Long, laminar plasma jets at atmospheric pressure of pure argon and a mixture of argon and nitrogen with jet length up to 45 times its diameter could be generated with a DC arc torch by restricting the movement of arc root in the torch channel. Effects of torch structure, gas feeding, and characteristics of power supply on the length of plasma jets were experimentally examined. Plasma jets of considerable length and excellent stability could be obtained by regulating the generating parameters, including arc channel geometry, gas flow rate, and feeding methods, etc. Influence of flow turbulence at the torch nozzle exit on the temperature distribution of plasma jets was numerically simulated. The analysis indicated that laminar flow plasma with very low initial turbulent kinetic energy will produce a long jet with low axial temperature gradient. This kind of long laminar plasma jet could greatly improve the controllability for materials processing, compared with a short turbulent arc jet.     

Effects of Nozzle Length and Process Parameters on Highly Constricted Oxygen Plasma Cutting Arc

The influence of nozzle length and two process parameters (arc current, mass flow rate) on the plasma cutting arc is investigated. Modeling results show that nozzle length and these two process parameters have essential effects on plasma arc characteristics. Long nozzle torch can provide high velocity plasma jet with high heat flux. Both arc voltage and chamber pressure increase with the nozzle length. High arc current increases plasma velocity and temperature, enhances heat flux and augments chamber pressure and thus, the shock wave. Strong mass flow has pinch effect on plasma arc inside the torch, enhances the arc voltage and power, therefore increases plasma velocity, temperature and heat flux.     

Biomass conversion to hydrogen-rich synthesis fuels using water steam plasma

In this study, an experimental plasma-chemical reactor equipped with an arc discharge water steam plasma torch was used for biomass conversion to hydrogen-rich synthesis fuels. Glycerol and crushed wood were used as biomass sources. The effects of different conversion parameters including the water steam flow rate, treated material flow rate, and plasma torch power were studied. The experimentally obtained results were compared with the model based on the thermodynamic equilibrium. Additionally, the quantification of the plasma conversion system in terms of energy efficiency and specific energy requirement was performed. It has been found that the synthesis gas can be effectively produced from the biomass using water steam plasma.     

An Optical Emission Study on Expanding Low-Temperature Cascade Arc Plasmas

The optical emission spectra from expanding low-temperature cascade arc plasmas were studied. The objective of this study was to examine the distinctive features of low-temperature cascade arc plasmas in comparison with a radio frequency (RF) plasma source. The principal results obtained in this study were: (1) in an expanding cascade arc plasma jet, active heavy particles (mainly excited argon or helium neutral species under our operating conditions), rather than electrons, are responsible for the excitation of reactive species when a reactive gas is injected into the plasma jet, (2) the excitation of reactive species was found to be controlled by the electronic energy levels of these excited argon or helium neutrals, (3) changing the operating parameters affected only the emission intensities of excited species, and no effect on the emission nature of plasmas was observed.     

Trace metal assay of thorium oxide by atomic emission spectrometry

Summary An Atomic Emission Spectrometric (AES) method has been developed for the direct determination of twenty-two metallic elements at trace concentrations in thorium oxide. The method is based on the use of a d.c. arc — carrier distillation technique with 12% composition of a mixed carrier, viz. AgCl+SrF₂ in 5:1 proportion, and is equally applicable to both volatile and refractory analytes. A direct reading emission spectrometer with computerised data acquisition and processing facility has been used in these studies. The standardisation procedure includes study of volatilisation/excitation characteristics of the analyte elements to optimise choice and proportion of the carrier and signal integration time apart from optimisation of other experimental parameters such as arc current, viewing position of the arc plasma, sample charge etc. The detection limits for the analytes lie in the range 0.1–50 ppm while the precision of determinations is better than 15% for most of the elements as evaluated from the repetitive analyses of spiked samples.     

Modeling of a free-burning,high-intensity arc at elevated pressures

A previously established model has been applied to a free-burning high-intensity argon arc at elevated pressures for simulating the situations experienced, for example, in plasma processing or in underwater welding. With the calculated thermodyanmic and transport properties and appropriate boundary conditions, solutions of the entire arc are obtained with exception of the electrode sheath regions. The results show that the arc contracts as the pressure increases. As a consequence of this contraction, the current density, the enthalpy flux, and the voltage drop increase also while the velocity of the induced cathode jet decreases.     

Experimental Study on the Thermal Argon Plasma Generation and Jet Length Change Characteristics at Atmospheric Pressure

The generation, jet length and flow-regime change characteristics of argon plasma issuing into ambient air have been experimentally examined. Different torch structures have been used in the tests. Laminar plasma jets can be generated within a rather wide range of working-gas flow rates, and an unsteady transitional flow state exists between the laminar and turbulent flow regimes. The high-temperature region length of the laminar plasma jet can be over an order longer than that of the turbulent plasma jet and increases with increasing argon flow rate or arc current, while the jet length of the turbulent plasma is less influenced by the generating parameters. The flow field of the plasma jet has very high radial gradients of plasma parameters, and a Reynolds number alone calculated in the ordinary manner may not adequately serve as a criterion for transition. The laminar plasma jet can have a higher velocity than that of an unsteady or turbulent jet. The long laminar plasma jet has good stiffness to withstand the impact of laterally injected cold gas and particulate matter. It could be used as a rather ideal object for fundamental studies and be applied to novel materials processing due to its attractive stable and adjustable properties.     

Kinetic Modeling of Plasma Methane Conversion Using Gliding Arc

Plasma methane (CH4) conversion in gliding arc discharge was examined. The result data of experiments regarding the performance of gliding arc discharge were presented in this paper. A simulation which is consisted some chemical kinetic mechanisms has been provided to analyze and describe the plasma process. The effect of total gas flow rate and input frequency refers to power consumption have been studied to evaluate the performance of gliding arc plasma system and the reaction mechanism of decomposition.Experiment results indicated that the maximum conversion of CH4 reached 50% at the total gas flow rate of 1 L/min. The plasma reaction was occurred at the atmospheric pressure and the main products were C (solid), hydrogen, and acetylene (C2H2). The plasma reaction of methane conversion was exothermic reaction which increased the product stream temperature around 30～50℃.     

Atomic and molecular emission spectroscopy on an expanding argon/methane plasma

A supersonically expanding cascaded arc plasma in argon is analyzed axperimentally by emission spectroscopy. The thermal cascaded arc plasma is allowed to expand through a conically shaped nozzle in the arc anode into the vacuum vessel. In the nozzle monomers (C _n H _v ) are injected. The monomers are dissociated and ionized by the argon carrier plasma, and transported toward a substrate by means of the expansion. Emission spectroscopy is used to obtain temperatures and particle densities. By varying external parameters (e.g., arc power, gas flow rates) plasma parameters can be linked with (e.g. parameters (e.g., refractive index).     

A numerical study of expected accuracy and precision in Calibration-Free Laser-Induced Breakdown Spectroscopy in the assumption of ideal analytical plasma

Calibration-Free Laser-Induced Breakdown Spectroscopy (CF-LIBS) has been proposed several years ago as an approach for quantitative analysis of Laser-Induced Breakdown Spectroscopy spectra. Recently developed refinement of the spectral processing method is described in the present work. Accurate quantitative results have been demonstrated for several metallic alloys. However, the degree of accuracy that can be achieved with Calibration-Free Laser-Induced Breakdown Spectroscopy analysis of generic samples still needs to be thoroughly investigated. The authors have undertaken a systematic study of errors and biasing factors affecting the calculation in the Calibration-Free Laser-Induced Breakdown Spectroscopy spectra processing. These factors may be classified in three main groups: 1) experimental aberrations (intensity fluctuations and inaccuracy in the correction for spectral efficiency of a detection system), 2) inaccuracy in theoretical parameters used for calculations (Stark broadening coefficients and partition functions) and 3) plasma non-ideality (departure from thermal equilibrium, spatial and temporal inhomogeneities, optical thickness, etc.). In this study, the effects of experimental aberrations and accuracy of spectral data were investigated, assuming that the analytical plasma is ideal. Departure of the plasma conditions from ideality will be the object of future work. The current study was based on numerical simulation. Two kinds of metallic alloys, iron-based and aluminum-based, were studied. The relative weight of the error contributions was found to depend on the sample composition. For the here-investigated samples, the experimental aberrations contribute to the overall uncertainty on the quantitative results more than theoretical parameters. The described simulation method can be applied to the Calibration-Free Laser-Induced Breakdown Spectroscopy analysis of any other kind of sample.     

Hydrogen/argon plasma jet with methane addition

Spatial distributions of plasma parameters are presented for a H₂/Ar plasma jet with addition of methane. The plasma has been generated at atmospheric pressure by a 200 A (20 kW) nontransferred do arc. Optical emission spectroscopy has been used for the measurements assuming the plasma jet to be optically thin and to have an axial symmetry. Local spectral ernissivity values have been evaluated using a routine Abel inversion procedure. Half- width and emissivity of H spectral line have been measured to determine the electron density and temperature of the plasma. The densities of excited C, CH radicals have been evaluated from the absolute emissivities of relevant molecular emission bands measured in limited spectral intervals in the visible spectrum. The emissivity ratios have been used to fund rotational and vibrational temperatures. The results supply information on methane decomposition and the behavior of molecular radicals in close-to-thermal plasma jets.     

Arc plasma in air with calcium and fluorine—II. Effect of fluorine on radial distribution of calcium particles

The radial distributions of temperature, Ca and Ca⁺ spectral line intensities, and CaO and CaF bands intensities were determined in a d.c. arc. The results, when combined with the calculation of the plasma composition, made it possible to determine the radial distribution of the total calcium in the plasma without and with fluorine. The addition of F caused a higher gradient in the radial density distribution of Ca in the plasma. This might have been caused by chemical reactions between Ca and F which occurred at the arc periphery and probably induced a change in the mass transport parameters.     

Heat Generation and Particle Injection in a Thermal Plasma Torch

The operation of plasma guns used for plasma spraying involves a continuous movement of the anode arc root. The resulting fluctuations of voltage and thermal energy input introduce an undesirable element in the spray process. This paper deals with the effects of these arc instabilities on the plasma jet, and the behavior of particles injected in the flow. The first part refers to the formation of the plasma jet. Measurements show that the static behavior of the arc depends strongly upon the plasma-forming gas mixture, especially the mass flow rate, of the heavy gas, injection mode, nozzle diameter, and arc current. These parameters control the electric field in the arc column, the arc length, its stability, and the gas velocity and temperature. The dynamic behavior of the arc is examined to determine how the tempeature and velocity of the plasma gas vary with voltage variations. Relationships between the gas velocity at the nozzle exit and the lifetime of the arc roots, and the independent operating parameters of the gun can be established from a dimensional analysis. The second part discusses the interaction between the plasma jet and the particles injected into the flow. The parameters controlling particle injection and trajectory are examined to determine how injection velocity must vary with particle size and density to achieve a given trajectory. The effect of the transverse injection of the powder carrier gas is investigated using a 3-D computational fluid dynamics code. Finally, the effect of the jet fluctuations on particle trajectory is studied under the assumption that the jet velocity follows the voltage variation. The result is a continuous variation of the particle spray jet position in the flow. Experimental observations confirm the model predictions.     

Comparative Study of Flow Characteristics Inside Plasma Torch with Different Nozzle Configurations

A numerical analysis of the influence of different nozzle configurations on the plasma flow characteristics inside D.C plasma torches is presented to provide an advanced nozzle design basis for plasma spraying torches. The assumption of steady-state, axis-symmetric, local thermodynamic equilibrium, and optically thin plasma is adopted in a two-dimensional modeling of plasma flow inside the plasma torch. The PHOENICS software is used for solving the governing equations, i.e. the conservation equations of mass, momentum, and energy along with the equations describing the K-epsilon model of turbulence. The calculated arc voltages are consistent with the experimental results when arc current, gas inflow rate, and working gas are the same as the experimental parameters. Temperature, axial velocity contours inside plasma torches, profiles along the torch axis and profiles at the outlet section are presented to show the plasma flow characteristics. Comparisons are made among those torches. The results show that torches with different anode nozzle configurations produce different characteristics of plasma flows, which suggest some important ideas for the advanced nozzle design for plasma spraying. In order to validate the model and to show its level of predictivity, a comparison of the model with experimental results encountered in the literature is presented in the last part.     

Atmospheric‐pressure spin plasma jets processing of polymethylmethacrylate surface using experimental design methodology

Atmospheric‐pressure spin plasma jets (APSPJs) have been developed to induce surface modifications on polymethylmethacrylate (PMMA). In this study, an experimental design methodology was used to investigate the influence of process parameters [such as radio frequency (RF) power, processing gap, and number of treatment cycles] on the characteristics of PMMA surface treated by APSPJs. It was observed from the atomic force microscope (AFM) and scanning electron microscope (SEM) results that the surface morphology of PMMA treated by direct plasma is much rougher than that treated by remote plasma. The direct plasma used in APSPJs processing created a substantial amount of nanostructure grains. Moreover, the measured XPS results showed that the O/C ratios of the PMMA surface were substantially increased and subsequently water contact angle decreased on direct plasma treatment. This decrease is due to an increase of oxygen‐containing functional groups on the PMMA surface by the APSPJs processing. From the statistical analysis, the RF power and the processing gap were found to play a major role in enhancing the hydrophilic properties of PMMA surface. In contrast, the number of treatment cycles played only a secondary role in this case. Finally, in this study the APSPJs processing was demonstrated to be an effective method for surface modification of PMMA by controlling processing parameters during the treatment process. Copyright © 2009 John Wiley & Sons, Ltd.     

Energy Fluctuations in a Direct Current Plasma Torch with Inter-Electrode Inserts Operated at Reduced Pressure

Direct current (dc) plasma torch with inter-electrode inserts has the merits of fixed arc length, relative high enthalpy and may show advantages in future plasma processes where stability and controllability are must-have. Energy fluctuations in the plasma may result from power supply ripple, arc length variation, and/or acoustic oscillation. Using an improved power supply with a flat waveform, the characteristics of an argon plasma energy instabilities under reduced pressure were studied by means of simultaneously monitoring the arc voltage and arc current spectrum. Dependence of the arc fluctuation behavior on the plasma generating parameters, such as the current intensity, the plasma gas flow rates and the vacuum chamber pressure were investigated and discussed. Results show that the plasma torch has a typical U-shaped voltage-ampere characteristic (VAC). The correlation between the VAC and the probability of energy distributions was studied. Through pressure measurements at the cathode cavity and the vacuum chamber, the existence of sonic flow in the inter-electrode insert channel was confirmed.     

Influence of the Gas Injection Angle on the Jet Characteristics of a Non-transferred DC Plasma Torch

The non-transferred direct current (DC) plasma torch has been widely used in various industrial applications due to its special jet characteristics. The jet characteristics are determined by different factors, including the working parameters, the torch construction, the gas injection angle (GIA) etc. As there is little study on the influence of the GIA on the jet characteristics, experimental study on the GIA’s effects on the jet characteristics has been carried out on a specially designed non-transferred DC plasma torch, whose GIA can be changed by replacing a gas injection component. The arc voltages and thermal efficiencies of the plasma torch, the specific enthalpies and jet lengths of the plasma jets at different working conditions were obtained and analyzed. It has been found that the GIA greatly affects the arc voltage, the thermal efficiency, the specific enthalpy and the jet length. Based on these findings, plasma torch with appropriate GIA could be used to help generating the plasma jet with desired characteristics.