# US 8,785,808 B2 · Plasma whirl reactor apparatus and methods of use

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- Number: US 8,785,808 B2
- Document ID: US8785808B2
- Status: Granted
- Kind: B2
- Application number: 13/746,193
- Filed: 2013-01-21
- Published: 2013-05-23
- Granted: 2014-07-22
- Earliest claimed: 2001-07-16
- Assignees: Foret Plasma Labs, LLC
- Applicants: Foret Plasma Labs, LLC
- Inventors: Todd Foret
- Web page: https://patentgrep.com/patent/US8785808B2

## CPC

- C10B 23/00: Other methods of heating coke ovens
- B01J 19/088: {giving rise to electric discharges (for heating purposes H05B7/00; for the production of ozone C01B13/11, H01T19/00)}
- B01J 19/126: {Microwaves}
- B01J 19/129: {Radiofrequency}
- B01J 19/2405: {provoking a turbulent flow of the reactants, such as in cyclones, or having a high Reynolds-number}
- B23K 10/00: Welding or cutting by means of a plasma
- C01B 3/22: by decomposition of gaseous or liquid organic compounds
- C01B 3/24: of hydrocarbons
- C01B 3/342: {with the aid of electrical means, electromagnetic or mechanical vibrations, or particle radiations}
- C01B 17/046: {without intermediate formation of sulfur dioxide}
- C01B 17/58: Recovery of sulfur dioxide from acid tar or the like {or from any waste sulfuric acid}
- C01F 7/066: Treatment of the separated residue
- C01F 11/18: Carbonates
- C01F 11/24: Chlorides
- C01F 11/46: Sulfates (dehydration of gypsum {for the production of calcium sulfate cements} C04B11/02)
- C04B 7/4453: {using plasmas or radiations}
- C04B 18/04: Waste materials; Refuse
- C10J 3/54: Gasification of granular or pulverulent fuels by the Winkler technique, i.e. by fluidisation
- C10J 3/56: Apparatus; Plants
- C22B 4/005: {using plasma jets (smelting, remelting, refining of metals using a plasma as heat source C22B9/22; generating or handling plasma in general H05H1/00; gas-filled discharge tubes for processing materials in general H01J37/32)}
- D21C 11/12: Combustion of pulp liquors
- H01J 37/32009: {Arrangements for generation of plasma specially adapted for examination or treatment of objects, e.g. plasma sources (plasma generation in general H05H1/24)}
- H05H 1/42: with provisions for introducing materials into the plasma, e.g. powder or liquid {(arc stabilising or constricting arrangements H05H1/3405; coaxial protecting fluids H05H1/341)}
- H05H 1/44: using more than one torch
- B01J 2219/089: Liquid-solid
- B01J 2219/0892: involving catalytically active material
- B01J 2219/0894: Processes carried out in the presence of a plasma
- C01B 2203/0238: the reforming step being a carbon dioxide reforming step
- C01B 2203/0272: containing a non-catalytic decomposition step
- C01B 2203/0861: by plasma
- C10J 2200/09: Mechanical details of gasifiers not otherwise provided for, e.g. sealing means
- C10J 2300/093: Coal
- C10J 2300/0943: Coke
- C10J 2300/0946: Waste, e.g. MSW, tires, glass, tar sand, peat, paper, lignite, oil shale
- C10J 2300/0956: Air or oxygen enriched air
- C10J 2300/0959: Oxygen
- C10J 2300/0969: Carbon dioxide
- C10J 2300/0973: Water
- C10J 2300/0983: Additives
- C10J 2300/123: by electromagnetic waves, e.g. microwaves
- C10J 2300/1238: by plasma
- Y02E 50/30: Fuel from waste, e.g. synthetic alcohol or diesel
- Y02P 40/121: Energy efficiency measures, e.g. improving or optimising the production methods
- Y02P 40/18: Carbon capture and storage [CCS]
- Y02P 40/40: Production or processing of lime, e.g. limestone regeneration of lime in pulp and sugar mills
- Y10S 588/90: Apparatus
- C10B: DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS (cracking oils C10G; underground gasification of minerals E21B43/295)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C01F: COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS (metal hydrides {monoborane, diborane or addition complexes thereof} C01B6/00; salts of oxyacids of halogens C01B11/00; peroxides, salts of peroxyacids C01B15/00; sulfides or polysulfides of magnesium, calcium, strontium, or barium C01B17/42; thiosulfates, dithionites, polythionates C01B17/64; compounds containing selenium or tellurium C01B19/00; binary compounds of nitrogen with metals C01B21/06; azides C01B21/08; {compounds other than ammonia or cyanogen containing nitrogen and non-metals and optionally metals C01B21/082; amides or imides of silicon C01B21/087}; metal {imides or} amides C01B21/092, {C01B21/0923}; nitrites C01B21/50; {compounds of noble gases C01B23/0005}; phosphides C01B25/08; salts of oxyacids of phosphorus C01B25/16; carbides C01B32/90; compounds containing silicon C01B33/00; compounds containing boron C01B35/00; compounds having molecular sieve properties but not having base-exchange properties C01B37/00; compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites, C01B39/00; cyanides C01C3/08; salts of cyanic acid C01C3/14; salts of cyanamide C01C3/16; thiocyanates C01C3/20; {double sulfates of magnesium with sodium or potassium C01D5/12; with other alkali metals C01D15/00, C01D17/00})
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C10J: PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES (synthesis gas from liquid or gaseous hydrocarbons C01B; underground gasification of minerals E21B43/295); CARBURETTING AIR OR OTHER GASES
- C22B: PRODUCTION AND REFINING OF METALS (electrolytic C25); PRETREATMENT OF RAW MATERIALS
- D21C: PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
- H01J: ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS (spark-gaps H01T; electric arc lamps H05B31/00; particle accelerators H05H)
- H05H: PLASMA TECHNIQUE (apparatus or processes specially adapted for producing X-rays H05G2/00); PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS

## Abstract

An apparatus for synergistically combining a plasma with a comminution means such as a fluid kinetic energy mill (jet mill), preferably in a single reactor and/or in a single process step is provided by the present invention. Within the apparatus of the invention potential energy is converted into kinetic energy and subsequently into angular momentum by means of wave energy, for comminuting, reacting and separation of feed materials. Methods of use of the apparatus in the practice of various processes are also provided by the present invention.

## Claims

### Claim 1

A method for producing hydrogen from a carbon-based material comprising:
providing a vessel having an interior defined by a cylindrical portion disposed between a first end and a closed second end, an outlet in said first end that is aligned with a longitudinal axis of said cylindrical portion, and at least one inlet in said first end, and two or more jets or slits mounted tangentially in said cylindrical portion;
atomizing and directing a fluid or gas into said interior of said vessel via said two or more jets or slits to feed a plasma and create angular momentum in said plasma;
generating said plasma from said atomized fluid or gas using said a set of radio frequency coils disposed around or within said cylindrical portion to form a plasma vortex that circulates around said longitudinal axis; and
producing said hydrogen by directing said carbon-based material into said plasma vortex via said at least one inlet such that said plasma vortex reacts with said carbon-based material, wherein said hydrogen that exits through said outlet in said first end.

### Claim 2 (depends on 1)

The method of claim 1, further comprising the step of feeding said material into said inlet using a conveyor, a hopper, a gravity feed, a fluid, a gas, steam or a combination thereof.

### Claim 3 (depends on 1)

The method of claim 1, wherein:
said carbon-based material comprises a gas, a fluid, a semi-solid, a solid or a combination thereof; and
wherein said plasma vortex circulates around a central void.

### Claim 4 (depends on 1)

The method of claim 1, wherein said carbon-based material comprises household garbage, industrial waste, municipal solid waste, package materials, drill cuttings, metal cuttings, sludge, medical waste, red mud, waste electrical and electronic equipment, saw dust, wood chips, black liquor, bagasse, rice straw, animal manure, radioactive waste, coke, coal fines, flyash, biomass, salt cake, unburned carbon, unreacted carbon, volatile organic carbon, flare gas, tail gas, spent acid, fluff, particulate matter or a combination thereof.

### Claim 5 (depends on 1)

The method of claim 1, wherein said fluid or gas comprises water, steam, carbon dioxide, air, oxygen, nitrogen, hydrogen, helium, volatile organic carbon, an ionizable fluid, an ionizable gas or a combination thereof.

### Claim 6 (depends on 1)

The method of claim 1, further comprising a plasma torch disposed within said closed second end that is aligned with said longitudinal axis of said cylindrical portion to introduce a second plasma into said interior of said vessel.

### Claim 7

A method for producing hydrogen from a carbon-based material comprising:
providing a vessel having an interior defined by a cylindrical portion disposed proximate to a first end and a cone shaped portion disposed proximate to said cylindrical portion that forms a first outlet at a second end that is aligned with a longitudinal axis of said cylindrical portion and said cone shaped portion, one or more inlets in said first end, a second outlet at said first end that is aligned with said longitudinal axis of said cylindrical portion, and two or more jets or slits mounted tangentially within said cylindrical portion;
introducing a plasma into said interior using a first plasma source comprising a plasma torch connected to said first end and aligned with said longitudinal axis of said cylindrical portion and said cone shaped portion;
adding energy to said plasma using a second plasma source comprising a set of radio frequency coils disposed around or within said cylindrical portion;
creating angular momentum in said plasma to form a plasma vortex by directing a fluid or a gas into said interior using said two or more jets or slits, wherein said plasma vortex circulates around said longitudinal axis; and
producing said hydrogen and a carbon by directing said carbon-based material into said plasma vortex via said one or more inlets such that said plasma vortex reacts with said carbon-based material, wherein said hydrogen that exits through said second outlet in said first end and said carbon exits through said first outlet in said second end.

### Claim 8 (depends on 7)

The method of claim 7, further comprising the step of creating angular momentum in said plasma before said plasma enters said interior of said vessel by directing a carrier gas into a tube having two or more inlets or slits disposed between said first end and said plasma torch.

### Claim 9 (depends on 7)

The method of claim 7, further comprising the step of introducing a second plasma into said interior of said vessel using a second plasma torch disposed within said outlet at said second end and aligned with said longitudinal axis of said cylindrical portion and said cone shaped portion.

### Claim 10 (depends on 7)

The method of claim 7 further comprising an eductor with a longitudinal axis, connected to said vessel at said second end around said outlet opening with said longitudinal axis of said eductor in coaxial alignment with said longitudinal axis of said cylindrical portion and said cone shaped portion of said vessel.

### Claim 11 (depends on 7)

The method of claim 7, further comprising the step of feeding said carbon-based material into said inlet using a conveyor, a hopper, a gravity feed, a fluid, a gas, steam or a combination thereof.

### Claim 12 (depends on 7)

The method of claim 7, wherein each plasma source comprises an AC plasma torch, DC plasma torch, a microwave plasma torch, an inductively coupled plasma torch or a combination thereof.

### Claim 13 (depends on 7)

The method of claim 7, wherein:
said carbon-based material comprises a gas, a fluid, a semi-solid, a solid or a combination thereof; and
wherein said plasma vortex circulates around a central void.

### Claim 14 (depends on 7)

The method of claim 7, wherein said carbon-based material comprises household garbage, industrial waste, municipal solid waste, package materials, drill cuttings, metal cuttings, sludge, medical waste, red mud, waste electrical and electronic equipment, saw dust, wood chips, black liquor, bagasse, rice straw, animal manure, radioactive waste, coke, coal fines, flyash, biomass, salt cake, unburned carbon, unreacted carbon, volatile organic carbon, flare gas, tail gas, spent acid, fluff, particulate matter or a combination thereof.

### Claim 15 (depends on 7)

The method of claim 7, wherein each plasma source comprises a plasma jet nozzle fed by a fluid.

### Claim 16 (depends on 15)

The method of claim 15, wherein said fluid comprises water, steam, carbon dioxide, air, oxygen, nitrogen, hydrogen, helium, volatile organic carbon, an ionizable fluid, an ionizable gas or a combination thereof.

### Claim 17

A method for producing hydrogen from a carbon-based material comprising:
providing a vessel having a vertical longitudinal axis, a cylindrical middle portion aligned with said vertical longitudinal axis, a top portion, a bottom portion, one or more inlets disposed in said top portion, a top outlet aligned with said vertical longitudinal axis and disposed in said top portion, and a bottom outlet aligned with said vertical longitudinal axis and disposed in said bottom portion;
providing two or more plasma torches mounted tangentially in said cylindrical middle portion such that said plasma torches are substantially aligned with one another in a horizontal plane with respect to said vertical longitudinal axis;
combining said plasma from said plasma torches together to create sufficient angular momentum to form a plasma vortex that circulates around said vertical longitudinal axis within said vessel; and
producing said hydrogen and a carbon by directing said carbon-based material into said plasma vortex via said one or more inlets such that said plasma vortex reacts with said carbon-based material, wherein said hydrogen that exits through said top outlet and a carbon that exits through said bottom outlet.

### Claim 18 (depends on 17)

The method of claim 17, further comprising the step of feeding said carbon-based material into said one or more inlets using a conveyor, a hopper, a gravity feed, a fluid, a gas, steam or a combination thereof.

### Claim 19 (depends on 17)

The method of claim 17, wherein each plasma torch comprises an AC plasma torch, DC plasma torch, a microwave plasma torch, an inductively coupled plasma torch or a combination thereof.

### Claim 20 (depends on 17)

The method of claim 17, wherein:
said bottom portion is cone shaped or substantially flat; or
said vessel is pancake-shaped, cylindrically-shaped or shaped like a cyclone separator.

### Claim 21 (depends on 17)

The method of claim 17, further comprising a set of radio frequency generating coils disposed around an exterior of said circular middle portion, or said circular middle portion and at least a portion of said bottom portion.

### Claim 22 (depends on 17)

The method of claim 17, wherein:
said carbon-based material comprises a gas, a fluid, a semi-solid, a solid or a combination thereof; and
wherein said plasma vortex circulates around a central void.

### Claim 23 (depends on 17)

The method of claim 17, wherein said carbon-based material comprises household garbage, industrial waste, municipal solid waste, package materials, drill cuttings, metal cuttings, sludge, medical waste, red mud, waste electrical and electronic equipment, saw dust, wood chips, black liquor, bagasse, rice straw, animal manure, radioactive waste, coke, coal fines, flyash, biomass, salt cake, unburned carbon, unreacted carbon, volatile organic carbon, flare gas, tail gas, spent acid, fluff, particulate matter or a combination thereof.

### Claim 24 (depends on 17)

The method of claim 17, further comprising another plasma source disposed within said outlet and aligned with said vertical longitudinal axis.

### Claim 25 (depends on 17)

The method of claim 17, further comprising an eductor attached to said bottom outlet and aligned with said vertical longitudinal axis.

### Claim 26 (depends on 17)

The method of claim 17, wherein said two or more plasma torches comprise a first set of plasma torches and said horizontal plane is a first horizontal plane, and further comprising a second set of two or more plasma torches mounted tangentially in said cylindrical middle portion either above or below said first set of plasma torches such that said second set of plasma torches are substantially aligned with one another in a second horizontal plane with respect to said vertical longitudinal axis, and wherein said second set of plasma torches are fed by said fluid or gas, atomize said fluid or gas and direct said atomized fluid or gas into said interior of said vessel.

### Claim 27

A method for producing hydrogen from a carbon-based material comprising:
providing a vessel having a vertical longitudinal axis, a cylindrical middle portion aligned with said vertical longitudinal axis, a top portion, a bottom portion, one or more inlets disposed in said top portion, a top outlet aligned with said vertical longitudinal axis and disposed in said top portion, a bottom outlet aligned with said vertical longitudinal axis and disposed in said bottom portion, and two or more jet nozzles mounted tangentially in said cylindrical middle portion such that said jet nozzles are substantially aligned with one another in a horizontal plane with respect to said vertical longitudinal axis;
atomizing and directing a fluid or gas into said interior of said vessel via said jet nozzles to feed a plasma and create angular momentum in said plasma;
generating said plasma from said atomized fluid or gas within said vessel using a radio frequency source proximate to said plasma jet nozzles to form a plasma vortex that circulates around said vertical longitudinal axis within said vessel; and
producing said hydrogen and a carbon by directing said carbon-based material into said plasma vortex via said one or more inlets such that said plasma vortex reacts with said carbon-based material, wherein said hydrogen that exits through said top outlet and said carbon that exits through said bottom outlet.

### Claim 28 (depends on 27)

The method of claim 27, further comprising the step of feeding said carbon-based material into said one or more inlets using a conveyor, a hopper, a gravity feed, a fluid, a gas, steam or a combination thereof.

### Claim 29 (depends on 27)

The method of claim 27, wherein:
said carbon-based material comprises a gas, a fluid, a semi-solid, a solid or a combination thereof; and
wherein said plasma vortex circulates around a central void.

### Claim 30 (depends on 27)

The method of claim 27, wherein said carbon-based material comprises household garbage, industrial waste, municipal solid waste, package materials, drill cuttings, metal cuttings, sludge, medical waste, red mud, waste electrical and electronic equipment, saw dust, wood chips, black liquor, bagasse, rice straw, animal manure, radioactive waste, coke, coal fines, flyash, biomass, salt cake, unburned carbon, unreacted carbon, volatile organic carbon, flare gas, tail gas, spent acid, fluff, particulate matter or a combination thereof.

### Claim 31 (depends on 27)

The method of claim 27, wherein said fluid or gas comprises water, steam, carbon dioxide, air, oxygen, nitrogen, hydrogen, helium, volatile organic carbon, an ionizable fluid, an ionizable gas or a combination thereof.

### Claim 32 (depends on 27)

The method of claim 27, wherein said radio frequency source comprises a set of radio frequency generating coils disposed around an exterior of said circular middle portion, or said circular middle portion and at least a portion of said bottom portion.

### Claim 33 (depends on 27)

The method of claim 27, wherein the radio frequency source comprises a microwave plasma torch.

### Claim 34 (depends on 27)

The method of claim 27, wherein said two or more jet nozzles comprise a first set of jet nozzles and said horizontal plane is a first horizontal plane, and further comprising a second set of two or more nozzles mounted tangentially in said cylindrical middle portion either above or below said first set of jet nozzles such that said second set of jet nozzles are substantially aligned with one another in a second horizontal plane with respect to said vertical longitudinal axis, and wherein said second set of jet nozzles are fed by said fluid or gas, atomize said fluid or gas and direct said atomized fluid or gas into said interior of said vessel.

### Claim 35

A method for producing hydrogen from a carbon-based material comprising:
providing a vessel having an interior defined by a cylindrical portion disposed proximate to a first end and a cone shaped portion disposed proximate to said cylindrical portion that forms a second outlet at a second end that is aligned with said longitudinal axis of said cylindrical portion and said cone shaped portion, a first outlet in said first end that is aligned with a longitudinal axis of said cylindrical portion and said cone shaped portion, at least one inlet in said first end, and two or more jets or slits mounted tangentially in said cylindrical portion;
atomizing and directing a fluid or gas into said interior via said two or more jets or slits to feed a plasma and create angular momentum in said plasma;
generating said plasma from said atomized fluid or gas using a set of radio frequency coils disposed around or within said cylindrical portion and said cone shaped portion to form a plasma vortex that circulates around said longitudinal axis; and
producing said hydrogen and a carbon by directing said carbon-based material into said plasma vortex via said at least one inlet such that said plasma vortex reacts with said carbon-based material, wherein said hydrogen exits through said first outlet in said first end and a carbon that exits through said second outlet in said second end.

### Claim 36 (depends on 35)

The method of claim 35, further comprising the step of feeding said material into said inlet using a conveyor, a hopper, a gravity feed, a fluid, a gas, steam or a combination thereof.

### Claim 37 (depends on 35)

The method of claim 35, wherein:
said carbon-based material comprises a gas, a fluid, a semi-solid, a solid or a combination thereof; and
wherein said plasma vortex circulates around a central void.

### Claim 38 (depends on 35)

The method of claim 35, wherein said carbon-based material comprises household garbage, industrial waste, municipal solid waste, package materials, drill cuttings, metal cuttings, sludge, medical waste, red mud, waste electrical and electronic equipment, saw dust, wood chips, black liquor, bagasse, rice straw, animal manure, radioactive waste, coke, coal fines, flyash, biomass, salt cake, unburned carbon, unreacted carbon, volatile organic carbon, flare gas, tail gas, spent acid, fluff, particulate matter or a combination thereof.

### Claim 39 (depends on 35)

The method of claim 35, further comprising the step of introducing a second plasma into said interior of said vessel using a plasma torch disposed within said second outlet at said second end and aligned with said longitudinal axis of said cylindrical portion and said cone shaped portion.

### Claim 40 (depends on 35)

The method of claim 35, further comprising an eductor attached to said outlet and aligned with said longitudinal axis.