System and process with power jet modules and method thereof

A processing system for producing a product material from a liquid mixture, comprising:

• a first array of two or more power jet modules adapted to jet the liquid mixture into multiple streams of droplets and force the multiple streams of droplets into the processing system, wherein each power jet module comprises a power jet;
• a dispersion chamber comprising a second array of two or more openings which are adapted to be coupled to the first array of the two or more power jet modules,
• wherein each power jet module from the first array of the two or more power jet modules matches each opening from the second array of the two or more openings such that each opening of the dispersion chamber is coupled to each power jet module,
• wherein each power jet module comprises a power jet having a third array of two or more nozzle orifices, and
• wherein each orifice is adapted to jet the liquid mixture into multiple streams of droplets such that each opening of the dispersion chamber is adapted to receive the multiple streams of droplets from the third array of the two or more nozzle orifices for the multiple streams of droplets to be dispersed with one or more gas flows therein into multiple streams of gas-liquid mixture droplets within the dispersion chamber;
• and
• a reaction chamber connected to the dispersion chamber and adapted to process the multiple streams of the gas-liquid mixture droplets into the product material, wherein each power jet module is attached to a sidewall of a chamber body of the dispersion chamber.

A method to producing a product material from a liquid mixture on a processing system with a first array of two or more power jet modules, adapted to jet the liquid mixture into multiple streams of droplets, comprising:

• delivering one or more gases into the processing system, wherein the processing system comprises:
• a first array of two or more power jet modules adapted to jet the liquid mixture into multiple streams of droplets and force the multiple streams of droplets into the processing system, wherein each power jet module comprises a power jet;
• a dispersion chamber comprising a second array of two or more openings which are adapted to be coupled to the first array of the two or more power jet modules,
• wherein each power jet module from the first array of the two or more power jet modules matches each opening from the second array of the two or more openings such that each opening of the dispersion chamber is coupled to each power jet module,
• wherein each power jet module comprises a power jet having a third array of two or more nozzle orifices, and
• wherein each nozzle orifice is adapted to jet the liquid mixture into multiple streams of droplets such that each opening of the dispersion chamber is adapted to receive the multiple streams of droplets from the third array of the two or more nozzle orifices for the multiple streams of droplets to be dispersed with one or more gas flows therein into multiple streams of gas-liquid mixture droplets within the dispersion chamber;
• and
• a reaction chamber connected to the dispersion chamber and adapted to process the multiple streams of the gas-liquid mixture droplets into the product material;
• jetting the liquid mixture into the multiple streams of droplets through each nozzle orifice of the third array of the two or more nozzle orifices from each power jet such that each opening of the dispersion chamber is adapted to receive the multiple streams of droplets from the third array of the two or more nozzle orifices for the multiple streams of droplets to be dispersed with one or more gas flows therein into multiple streams of gas-liquid mixture droplets within the dispersion chamber;
• processing the multiple streams of the gas-liquid mixture droplets inside the reaction chamber of the processing system into the product material.