Plasma-arc vaporization chamber with wide bore

A vaporization chamber comprising:

• a male electrode;
• a female electrode comprising a first material, the female electrode having a first end, a second end opposite the first end, and an internal chamber formed within the female electrode in between the first end and the second end, wherein the internal chamber comprises an entry region, a frusto-conical region, and an isthmus region, the entry region being disposed at the first end and configured to receive a working gas, the frusto-conical region extending from the entry region to the isthmus region, wherein the isthmus region has a diameter of at least 0.400 of an inch and extends to the second end along a longitudinal axis of the female electrode, the second end forming a mouth through which a fluid can exit the internal chamber along the longitudinal axis;
• a vortexing gas injector disposed proximate the first end and fluidly coupled to the entry region of the internal chamber, wherein the vortexing gas injector is configured to receive a working gas, to produce a vortexing stream of the working gas, and to supply the vortexing stream of working gas to the frusto-conical region of the internal chamber;
• a combustible gas supply system fluidly coupled to the vortexing gas injector, wherein the combustible gas supply system provides a combustible gas as at least a portion of the working gas to the vortexing gas injector;
• an electrical connection point disposed on at least one of the male electrode and the female electrode, wherein the electrical connection point is configured to deliver energy to the vortexing stream of working gas in the frusto-conical region upon receiving power from a power supply, thereby producing an arc capable of fully vaporizing powders between the male electrode and the female electrode within the frusto-conical region of the internal chamber and producing a vortexing stream of plasma that flows into the isthmus region;
• a target region configured to act as lining for the female electrode in at least a portion of the frusto-conical region and in at least a portion of the isthmus region of the internal chamber, wherein the target region comprises a second material that is distinct from the first material and that is conductive, and the target region is configured to protect at least a portion of the female electrode from direct contact with the arc;
• a material delivery port configured to deliver powder into the isthmus region of the internal chamber at an angle counter to the flow of the vortexing stream of plasma;
• and
• a mouth flange cooling chamber disposed at the second end of the female electrode adjacent to the mouth, wherein the mouth flange cooling chamber is configured to permit circulation of cooling fluid around the longitudinal axis, thereby cooling the mouth when plasma exits the internal chamber.