Plasma-assisted melting
AssigneeBTU International, Inc.
InventorsSatyendra Kumar, Devendra Kumar
Life of this patent
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Abstract
Apparatus and methods for plasma-assisted melting are provided. In one embodiment, a plasma-assisted melting method can include: (1) adding a solid to a melting region, (2) forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall, (3) sustaining the plasma in the cavity such that energy from the plasma passes through the wall into the melting region and melts the solid into a liquid, and (4) collecting the liquid. Solids that can be melted consistent with this invention can include metals, such as metal ore and scrap metal. Various plasma catalysts are also provided.
Claims49
A plasma-assisted melting method comprising:
- Forming a plasma in a cavity by subjecting a first gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst;
- wherein the plasma catalyst comprises at least one of an active plasma catalyst and a passive plasma catalyst;
- wherein the catalyst comprises at least one of metal, inorganic material, carbon, carbon-based alloy, carbon-based composite, electrically conductive polymer, conductive silicone elastomer, polymer nanocomposite, and an organic-inorganic composite;
- heating a second gas with the plasma;
- adding a solid to a melting vessel;
- directing the heated second gas toward the solid sufficient to at least melt the solid into a liquid;
- and
- collecting the liquid.
A plasma-assisted melting method comprising:
- forming a plasma in a cavity by subjecting a first gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst;
- wherein the catalyst is in the form of at least one of a nano-particle, a nano-tube, a powder, a dust, a flake, a fiber, a sheet, a needle, a thread, a strand, a filament, a yarn, a twine, a shaving, a sliver, a chip, a woven fabric, a tape, and a whisker;
- heating a second gas with the plasma;
- adding a solid to a melting vessel;
- directing the heated second gas toward the solid sufficient to at least melt the solid into a liquid;
- and
- collecting the liquid.
A plasma-assisted melting method comprising:
- forming a plasma in a cavity by subjecting a first gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma, catalyst;
- wherein the plasma catalyst comprises an active plasma catalyst including at least one ionizing particle;
- heating a second gas with the plasma;
- adding a solid to a melting vessel;
- directing the heating second gas toward the solid sufficient to at least melt the solid into a liquid;
- and
- collecting the liquid.
A plasma-assisted melting method comprising:
- adding a solid to a melting region;
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall;
- wherein the plasma catalyst comprises at least one of an active plasma catalyst and a passive plasma catalyst;
- wherein the catalyst comprises at least one metal, inorganic material, carbon, carbon-based alloy, carbon-based composite, electrically conductive polymer, conductive silicone elastomer, polymer nanocomposite, and an organic-inorganic composite;
- sustaining the plasma in the cavity such that energy from the plasma passes through the wall into the melting region and melts the solid into liquid;
- and
- collecting the liquid.
A plasma-assisted melting method comprising:
- adding a solid to a melting region;
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall;
- wherein the plasma catalyst comprises at least one of an active plasma catalyst and a passive plasma catalyst;
- and
- wherein the catalyst is in the form of at least one of a nano-particle, a nano-tube, a powder, a dust, a flake, a fiber, a sheet, a needle, a thread, a strand, a filament, a yarn, a twine, a shaving, a sliver, a chip, a woven fabric, a tape, and a whisker.
A plasma-assisted melting method comprising:
- adding a solid to a melting region;
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall;
- wherein the plasma catalyst comprises an active plasma catalyst including at least one ionizing particle;
- sustaining the plasma in the cavity such that energy from the plasma passes through the wall into the melting region and melts the solid into liquid;
- and
- collecting the liquid.
A plasma-assisted melting method comprising:
- adding a solid to a melting region;
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall;
- sustaining the plasma in the cavity such that energy from the plasma passes through the wall into the melting region and melts the solid into liquid;
- wherein the melting region is substantially defined by the wall of an inner tube and wherein the cavity is defined between the inner tube and an outer tube substantially surrounding the inner tube;
- wherein the inner tube has an outer diameter and the outer tube has an inner diameter, wherein the ratio of the inner diameter to the outer diameter is between about 2.5 and about 3.0;
- and
- collecting the liquid.
A plasma-assisted melting method comprising:
- adding a solid to a melting region;
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall;
- and
- wherein the cavity has a first axial end, the method further comprises launching the radiation into the main cavity from at least the first axial end;
- sustaining the plasma in the cavity such that energy from the plasma passes through the wall into the melting region and melts the solid into liquid;
- and
- collecting the liquid.
A plasma-assisted melting method comprising:
- adding a solid to a melting region;
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall;
- sustaining the plasma in the cavity such that energy from the plasma passes through the wall into the melting region and melts the solid into liquid;
- wherein the cavity has a spiral shape that is wrapped around the melting region;
- and
- collecting the liquid.
A plasma-assisted melting method comprising:
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst;
- wherein the subjecting comprises directing the electromagnetic radiation from a plurality of radiation sources into the cavity;
- wherein the plurality of radiation sources comprises at least one ring of magnetrons;
- conveying metal through the plasma until the metal melts into a molten metal;
- and
- collecting the molten metal.
A plasma-assisted melting method comprising:
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst;
- wherein the plasma catalyst comprises at least one of an active plasma catalyst and a passive plasma catalyst;
- conveying metal through the plasma until the metal melts into a molten metal;
- and
- collecting the molten metal.
A plasma-assisted melting method comprising:
- forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst;
- conveying metal through the plasma until the metal melts into a molten metal;
- wherein the conveying is on a heat-resistant conveyor and the plasma is formed beneath the conveyer;
- and
- collecting the molten metal.
Dependencies are inferred from the claim text.