Method and apparatus for producing carbride products

A method comprising the steps of:

• providing a reactor having a chamber defined therein which has a longitudinal axis and longitudinally separated upstream and downstream ends, wherein the chamber comprises a combustion zone and a reaction zone such that the combustion zone longitudinally extends from said upstream end to a surface boundary between the zones and such that the reaction zone longitudinally extends from said surface boundary to said downstream end;
• establishing a flow of a combustible mixture in the combustion zone so as to flow in a direction generally toward the reaction zone, wherein the combustible mixture comprises a mixture of a fuel and an oxidant comprising oxygen:
• combusting the combustible mixture in the combustion zone to produce hot combustion products which flow generally toward and into the reaction zone;
• injecting at least one reactant into the chamber from at least one outlet of at least one reactant nozzle such that said at least one reactant exits said at least one reactant nozzle outlet at said surface boundary in a direction generally parallel to said longitudinal axis, wherein temperature conditions in at least a portion of the reaction zone are at least about 1400.degree. C. and wherein the elemental molar ratio of carbon to oxygen for the combination of the combustible mixture and said at least one reactant is at least about 0.8:1, said at least one reactant being capable of reacting in the reaction zone to form a carbide compound;
• whereby a product powder comprising the carbide compound is produced in the reaction zone.

A method comprising the steps of:

• providing a reactor having a chamber defined therein which has a longitudinal axis and longitudinally separated upstream and downstream ends, wherein the chamber comprises a combustion zone and a reaction zone such that the combustion zone longitudinally extends from said upstream end to a surface boundary between the zones and such that the reaction zone longitudinally extends from said surface boundary to said downstream end;
• establishing a flow of a combustible mixture in the combustion zone so as to generally flow in a direction generally toward the reaction zone, wherein the combustible mixture comprises a mixture of a fuel and an oxidant;
• combusting the combustible mixture in the combustion zone to produce hot combustion products which flow generally toward and into the reaction zone;
• injecting at least one reactant into the chamber from at least one outlet of at least one reactant nozzle such that said at least one reactant is substantially gaseous as injected into said chamber and such that said at least one reactant exits said at least one reactant nozzle outlet at said surface boundary in a direction generally parallel to said longitudinal axis, wherein temperature conditions in at least a portion of the reaction zone are at least about 1400.degree. C. and wherein the elemental molar ratio of carbon to oxygen for the combination of the combustible mixture and said at least one reactant is at least about 0.8:1, said at least one reactant being capable of reacting in the reaction zone to form a carbide compound;
• whereby a product powder comprising the carbide compound is produced in the reaction zone.