WO2011088353A1 - Polyatomic gas splitter - Google Patents
Polyatomic gas splitter Download PDFInfo
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- WO2011088353A1 WO2011088353A1 PCT/US2011/021344 US2011021344W WO2011088353A1 WO 2011088353 A1 WO2011088353 A1 WO 2011088353A1 US 2011021344 W US2011021344 W US 2011021344W WO 2011088353 A1 WO2011088353 A1 WO 2011088353A1
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- constituent gases
- polyatomic gas
- quenching
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/32—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by electrical effects other than those provided for in group B01D61/00
- B01D53/323—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by electrical effects other than those provided for in group B01D61/00 by electrostatic effects or by high-voltage electric fields
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2257/00—Components to be removed
- B01D2257/30—Sulfur compounds
- B01D2257/302—Sulfur oxides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2257/00—Components to be removed
- B01D2257/40—Nitrogen compounds
- B01D2257/404—Nitrogen oxides other than dinitrogen oxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2257/00—Components to be removed
- B01D2257/50—Carbon oxides
- B01D2257/504—Carbon dioxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2257/00—Components to be removed
- B01D2257/80—Water
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2259/00—Type of treatment
- B01D2259/80—Employing electric, magnetic, electromagnetic or wave energy, or particle radiation
- B01D2259/818—Employing electrical discharges or the generation of a plasma
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/24—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by centrifugal force
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H2245/00—Applications of plasma devices
- H05H2245/10—Treatment of gases
- H05H2245/17—Exhaust gases
Definitions
- the present invention relates to methods and apparatus for dissociating a polyatomic gas into one or more constituent gases.
- Sequestration has been proposed as a solution to industrially-produced greenhouse gas emissions.
- permanently stored gases generally are not processed and leakages from subsurface aquifers and reservoirs can lead to grand-scale disasters.
- constituents of these gas pollutants can be valuable, and the value from these constituents cannot be extracted by sequestration.
- the present invention provides methods and apparatus for dissociating a polyatomic gas and separating from the polyatomic gas one or more gases having a molecular weight lower than the polyatomic gas (i.e., one or more constituent gases).
- a polyatomic gas such as carbon dioxide (CO 2 ) can be dissociated according to the methods of the present invention into carbon monoxide (CO) and oxygen (O 2 ).
- the present invention also provides methods and apparatus for recycling an
- FIG. 1 is a schematic diagram of an apparatus for dissociating a polyatomic gas into one or more constituent gases according to ah embodiment of the present invention.
- FIG. 2 is an expanded view of a portion of the embodiment of FIG. 1 showing the holding compartment and the dissociation compartment.
- FIG. 3 is a schematic diagram of a portion of an apparatus according to an embodiment of the present invention showing the arrangement of a plurality of loop-shaped conduits.
- FIG. 4 is an expanded view of the embodiment of FIG. 1 showing the quenching compartment and the separator.
- FIG. 5 is a schematic diagram of an apparatus for recycling an industrially-produced polyatomic gas according to an embodiment of the present invention.
- compositions are described as having, including, or comprising specific components, or where methods are described as having, including, or comprising specific process steps, it is contemplated that compositions of the present invention also consist essentially of, or consist of, the recited components, and that the methods of the present invention also consist essentially of, or consist of, the recited processing steps.
- the present invention provides methods for dissociating a polyatomic gas and separating from the polyatomic gas one or more constituent gases.
- the method comprises indirectly heating a polyatomic gas with a high-temperature plasma to thermally dissociate the polyatomic gas into one or more constituent gases, quenching the one or more constituent gases, and separating or removing the one or more constituent gases.
- the polyatomic gas is a gas selected from the group consisting of carbon dioxide, water vapor, nitrogen oxides, sulfur oxides and mixtures thereof.
- the polyatomic gas is carbon dioxide.
- the polyatomic gas can be provided as a pure gas or as a gas comprising a polyatomic gas.
- the gas comprising a polyatomic gas can be air, or a polyatomic gas that has been diluted with one or inert gases such as nitrogen.
- the one or more constituent gases are gases selected from the group consisting of carbon monoxide (CO), diatomic oxygen (O 2 ), hydrogen (H 2 ) and nitrogen (N 2 ).
- CO carbon monoxide
- O 2 diatomic oxygen
- H 2 hydrogen
- N 2 nitrogen
- the polyatomic gas is C0 2
- the one or more constituent gases are CO and 0 2 .
- the polyatomic gas is heated indirectly with a high-temperature plasma.
- a high-temperature plasma refers to a plasma having a temperature between about 3000 and about 10000 .
- the high-temperature plasma has a temperature between about 3000 K and about 8000 .
- the high-temperature plasma and the polyatomic gas are not commingled.
- any working gas can be used to generate the plasma without concern about contaminating the one or more constituent gases with the working gas.
- Suitable working gases include, but are not limited to, air, CO 2 , nitrogen, one or more inert gases such as argon, helium, or neon, and mixtures thereof.
- the plasma can be generated from the working gas by any method known in the art as long as a high-temperature, continuous and sustainable plasma is generated. Suitable methods include, but are not limited to, low pressure ( ⁇ 50 mTorr) plasma (e.g., as described in U.S. Patent No. 5,916,455), penning discharge plasma (e.g., as described in U.S. Patent No.
- the high-temperature plasma is generated by an electric arc.
- An electric arc gas heater consists of an anode, cathode and arc discharge. Electric arcs often produce temperatures between about 3000K and about 8000K or higher, affording virtually instantaneous reaction of the polyatomic gas even when placed in indirect thermal contact.
- Indirect heating of the polyatomic gas with a high-temperature plasma causes the ⁇ ⁇ polyatomic gas to dissociate into one or more constituent gases.
- the polyatomic gas is CO2
- indirect heating with a high-temperature plasma dissociates the CO2 into CO and 0 2 .
- the one or more constituent gases are quenched.
- the quenching step helps to prevent the occurrence of the reverse reaction (i.e., the one or more constituent gases recombining to form the polyatomic gas) and the formation of unwanted side products.
- One method for quenching the constituent gases is by expansive cooling. Methods for expansive cooling are known in the art and any method can be used.
- the constituent gases can be directed through a compartment with a diverging geometry to decrease the temperature of the constituent gases by expansive cooling.
- the quenching step may comprise increasing the flow rate of the one or more constituent gases through the diverging compartment.
- One suitable method for increasing the flow rate is by using a centrifugal fan. Other suitable methods are known in the art and any may be used.
- the quenching step may comprise quenching the constituent gases by heat exchange.
- Methods for quenching by heat exchange are known in the art and any method can be used.
- the constituent gases are directed through a compartment surrounded by water pipes or other heat exchange elements.
- the one or more constituent gases are removed or separated from the polyatomic gas.
- the removing or separating step helps to prevent the occurrence of the reverse reaction and the formation of unwanted side products.
- this step may shift the equilibrium of the dissociation reaction to the right, thereby increasing the dissociation reaction and the formation of the one or more constituent gases.
- Methods for removing or separating constituent gases are known in the art and any method can be used.
- One method for removing or separating the one or more constituent gases is according to their magnetic properties. Such methods are known in the art and any method can be used. According to one method, the one or more constituent gases are directed to a cyclonic separator including a magnetic field. The cyclonic separator separates the one or more constituent gases by their masses as well as their magnetic properties. Various parameters, such as the strength of the magnetic field, the length of the magnetic field, and the macroscopic velocity of the gas flow across the gradient magnetic field, can be varied to optimize separation, increasing the yield and/or the purity of the one or more constituent gases.
- the one or more constituent gases can be used, without further separation or with partial separation, as a feed stream to a downstream reactor, where the constituent gases can be reacted further (e.g., as discussed below).
- Carbon dioxide can be dissociated into carbon monoxide and oxygen at very high temperatures according to reaction (1 ) below:
- thermal dissociation of carbon dioxide into carbon monoxide and oxygen generally is not observed to a significant degree below a temperature of about 2000 K at standard, pressure.
- rapid heating can help limit the generation of side products such as various carbon species.
- a feed stream comprising carbon dioxide is placed in indirect thermal contact with a high-temperature plasma.
- a feed stream comprising carbon dioxide can be channeled in an enclosed passageway through the high-temperature plasma, such that the feed stream comprising carbon dioxide is rapidly heated to a temperature of at least about 1500 K.
- the carbon dioxide is dissociated into carbon monoxide (CO) and diatomic oxygen (O2).
- CO and O2 can be quenched by rapid cooling.
- the CO and O2 are directed through a compartment with a diverging geometry to decrease the temperature of the CO and O2 by expansive cooling.
- the method may further comprise increasing the flow rate of the CO and O2 through the diverging geometry using a centrifugal fan.
- O? can be removed. Removal of oxygen shifts the dissociation reaction (1) to the right, leading to the formation of more CO and O2.
- the CO and O2 can be separated from the polyatomic gas.
- the CO and O2 can be channeled to a cyclonic separator including a magnetic field.
- the cyclonic separator separates the CO and O2 by their masses (O2 is heavier than CO) as well as their magnetic properties (0 2 is paramagnetic, while CO has a small dipole moment).
- the CO and O can be optionally cooled further (e.g., by expansion and/or heat exchange) to help prevent the reverse reaction and/or the formation of unwanted side products.
- the methods may be varied to optimize the start-up input or increase efficiency.
- the methods can be performed adiabatically to optimize startup input energy.
- the methods can include various heat recovery steps to increase energy efficiency.
- the methods can be combined with an existing industrial process that produces large amounts of polyatomic gas pollutants, thereby helping to reduce emission of such gas pollutants and to obtain valuable constituents from such gas pollutants.
- the feed stream comprises a less pure polyatomic gas obtained from an existing industrial process and the product stream comprises one or more constituent gases that may be recycled and used as the feed stream for the existing industrial process.
- the method for recycling an industrially-produced polyatomic gas comprises providing a product stream from an industrial process, wherein the product stream comprises the polyatomic gas; indirectly heating the product stream comprising the polyatomic gas from the industrial process with a high-temperature plasma, thereby causing dissociation of the polyatomic gas into one or more constituent gases; quenching the one or more constituent gases; separating the one or more constituent gases; and feeding a product stream comprising one or more constituent gases to the industrial process.
- Fischer- Tropsch process is a coal liquefaction process that produces liquid fuels by gasifying coal to produce synthetic gas (or syngas, which is a mixture of carbon monoxide and hydrogen), which is then catalytically converted into liquid fuels.
- the Fischer-Tropsch process produces large volumes of carbon dioxide as a byproduct, which is released into the atmosphere and causes severe environmental problems.
- the methods of the present invention can be combined with the Fischer-Tropsch process.
- the carbon dioxide by-product from the Fischer-Tropsch process can be captured and used as the feed stream in the methods of the present invention, and the carbon monoxide obtained by the present methods can be recycled and used as a feed stream for the Fischer-Tropsch process.
- This combination significantly improves the efficiency of the Fischer-Tropsch process and minimizes environmental concerns in connection with waste treatment from the Fischer-Tropsch process.
- the method comprises providing a product stream from the Fischer- Tropsch process, wherein the product stream comprises C0 2 ; indirectly heating the product stream comprising C0 2 with a high-temperature plasma, thereby causing dissociation of C0 2 into CO and 0 2 ; quenching the CO and 0 2 ; separating the CO and 0 2 ; and feeding a product stream comprising CO to the Fischer-Tropsch process.
- the present invention also provides apparatus for dissociating a polyatomic gas into one or more constituent gases and separating or removing from the polyatomic gas the one or more constituent gases.
- the apparatus comprises a dissociation compartment, a separator, and a quenching compartment.
- FIG. 1 illustrates an apparatus according to an embodiment of the present invention.
- Apparatus 10 comprises a reactor 12 in which a polyatomic gas is thermally dissociated into one or more constituent gases, and a separator 14 that separates the one or more constituent gases for collection and optional further processing.
- the reactor 12 generally comprises three main compartments that are co-axially arranged and in fluid communication with each other, namely, a holding compartment 16, a dissociation compartment 18, and a quenching compartment 20.
- the reactor 12 and the separator 14 are connected by a feed-line 22, which extends at a
- the reactor 12 also comprises a plasma generator 30 and one or more heat exchangers 32, 34, which along with the construction of the separator 14, will be described in more detail below.
- a feed stream 36 comprising a polyatomic gas can be introduced into the holding compartment 16 via a feed-line 38.
- the holding compartment 16 can include conventional components such as one or more inlet valves for regulating the input flow rate of the polyatomic gas.
- the holding compartment 16 includes an outlet manifold 42 to communicate with the dissociating compartment 18. As shown in FIG. 3, this manifold, for example, can comprise a plurality of gas lines 44, each of which is in fluid communication with a corresponding loop-shaped conduit 46. The outlets 48 of these loop-shaped conduits in turn feed into the quenching compartment 20.
- the loop-shaped conduits are arranged in parallel to each other and are placed between the anode 50 and the cathode 52 of the plasma generator 30.
- the feed gas 36 e.g., C0 2
- the loop-shaped conduits 46 is heated (e.g., by conduction and radiation) by a plasma 54 generated between the anode and the cathode of the plasma generator.
- Each loop-shaped conduit 46 can include one or more loops. The number of loops, the size of each loop, and the diameter of the conduit are designed to maximize the residence time of the feed gas in thermal communication with the plasma.
- the inside diameter of the loop-shaped conduit should be sufficiently large to allow necessary gas flow and an acceptable output.
- the inside diameter of the conduits can be in the range of about 20 % to about 100 % of the plasma diameter.
- the loop-shaped conduits preferably are made of an efficient heat-conducting material which can be selected from various metals and alloys.
- a plasma generator 30 can include a power source 56, an anode 50, a cathode 52, an inlet and an outlet for channeling a working gas 58 between the anode and the cathode, and channels for circulating a coolant 60 to protect the electrodes and for heat recovery.
- a high-energy electric spark i.e., an electric arc
- the temperature of the plasma can be controlled by varying the current and the voltage applied to the two electrodes. Excess heat generated by the plasma can be recovered by a coolant 60
- the heat exchanger 62 can be in thermal contact with one or more thermal electric generator plates 64 to convert the thennal energy into electricity.
- the electrical output 66 can be used to sustain the plasma, thereby realizing a substantial reduction in the electrical energy input required by the system as a whole. Any additional electrical energy required can be
- a "green" energy source for example, solar panels
- additional heat exchangers can be used to further increase the thermal efficiency of the system.
- a second heat exchanger 68 can be placed about the feed loop of the plasma working gas to capture additional waste heat.
- the quenching compartment 20 can be coaxially positioned with the dissociation compartment 18.
- the quenching compartment can have a generally diverging geometry resembling a nozzle. Because of the geometry of the quenching compartment, the relative pressure within the quenching compartment is much lower than the pressure in the dissociation compartment. This reduces the temperature of the one or more constituent gases (e.g., CO and O 2 ) as they are channeled into the quenching compartment from the dissociation compartment. Such quenching takes place rapidly and helps prevent the reverse reaction and formation of unwanted side products.
- the exterior wall of the quenching compartment can be surrounded by water pipes or other heat exchange elements 32, 34.
- a centrifugal fan 26 can be present at the outlet 28 of the quenching compartment to force the flow of the output stream to the separator 14.
- the separator can be configured as a cyclonic separator, for example as described in U.S. Patent Publication No. 2009/0223875, the disclosure of which is incorporated by reference herein.
- the separator 14 can be vertically-oriented, and can include magnetic plates 70 and separate outlets 72 and 78 for the constituent gases.
- an outlet 72 positioned close to the lower portion of the separator 14 is designed to collect the heavier constituent gas 74 (e.g., O2).
- a repeller mesh 76 (which can induce a negative charge, thus able to repel anions, e.g., oxygen anions) can be placed around an outlet 78 positioned near the upper portion of the separator 14, which is designed to collect the lighter constituent gas 80 (e.g., CO).
- the output stream is directed to a vertically-oriented separator 14 where separation of the one or more constituent gases (e.g., CO and O 2 ) is effected.
- the apparatus of the present invention can be combined with a downstream reactor in which the product stream from the apparatus of the present invention, or a portion thereof, becomes the feed stream for the downstream reactor.
- the apparatus of the present invention can be combined with a reactor of the Fischer-Tropsch process.
- the present invention provides an apparatus for recycling an industrially-produced polyatomic gas.
- the apparatus comprises a reactor for an industrial process, wherein die industrial process produces the polyatomic gas; and an apparatus for dissociating the polyatomic gas.
- the apparatus for dissociating the polyatomic gas can be any of the apparatus described above.
- FIG. 5 illustrates an apparatus for recycling an industrially-produced polyatomic gas according to an embodiment of the present invention.
- the apparatus for recycling an industrially-produced polyatomic gas 88 comprises a reactor for an industrial process 82 and an apparatus for dissociating the polyatomic gas 10.
- the apparatus 10 produces a product stream comprising one or more constituent gases 80 (e.g., CO).
- the product stream comprising one or more constituent gases 80 becomes a feed stream for the industrial process reactor 82.
- Additional reactants 86 are fed to the industrial process reactor 82.
- the one or more constituent gases 80 and additional reactants 86 undergo an industrial process, producing a polyatomic gas 36 and additional products 84.
- the polyatomic gas 36 and additional products 84 are separated and then a product stream comprising the polyatomic gas 36 (e.g., CO2) becomes the feed stream for the apparatus 10.
- a product stream comprising the polyatomic gas 36 e.g., CO2
- the present invention encompasses embodiments in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting on the present invention described herein. Scope of the present invention is thus indicated by the appended claims rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.
Abstract
The present invention relates to a method for dissociating a polyatomic gas into one or more constituent gases. The present invention also relates to an apparatus comprising a dissociating compartment, a quenching compartment, and a separator.
Description
081381 1.106/1 1
POLYATOMIC GAS SPLITTER
CROSS-REFERENCE TO RELATED APPLICATIONS
[00011 This application claims benefit under 35 U.S. C. § 1 19(e) of United States provisional patent application no. 61 /295,658, filed January 15, 2010, the disclosure of which is herein incorporated by reference.
FIELD OF THE INVENTION
[00021 The present invention relates to methods and apparatus for dissociating a polyatomic gas into one or more constituent gases.
BACKGROUND OF THE INVENTION
[0003 J Scientific evidence suggests that centuries of burning fossil fuels and the associated large-scale emission and accumulation of air pollutants in the atmosphere have led to recent rapid global climate change. Vehicle exhaust, power plants, and industrial operations emit greenhouse gases (e.g., carbon dioxide (CO2), nitrogen oxides (NOx), water vapors, methane (CHj), ozone, and chlorofluorocarbons (CFCs)) and other gas pollutants (e.g., sulfur oxides (SOx)) into the atmosphere, thereby trapping heat near the Earth's surface and causing a greenhouse effect. Much research is being conducted to develop greener industrial processes
that would cause lower greenhouse gas emission levels and/or incorporate treatment of greenhouse gases prior to direct release into the atmosphere.
[0004] Sequestration has been proposed as a solution to industrially-produced greenhouse gas emissions. However, permanently stored gases generally are not processed and leakages from subsurface aquifers and reservoirs can lead to grand-scale disasters. In addition, constituents of these gas pollutants can be valuable, and the value from these constituents cannot be extracted by sequestration.
SUMMARY OF THE INVENTIO
(0005J The present invention provides methods and apparatus for dissociating a polyatomic gas and separating from the polyatomic gas one or more gases having a molecular weight lower than the polyatomic gas (i.e., one or more constituent gases). For example, a polyatomic gas such as carbon dioxide (CO2) can be dissociated according to the methods of the present invention into carbon monoxide (CO) and oxygen (O2).
[0006] The present invention also provides methods and apparatus for recycling an
industrially-produced polyatomic gas.
BRIEF DESCRIPTION OF THE FIGURES
[0007] It should be understood that certain drawings are not necessarily to scale, with emphasis generally being placed upon illustrating the principles of the present invention. The drawings are not intended to limit the scope of the present invention in any way.
[0008] FIG. 1 is a schematic diagram of an apparatus for dissociating a polyatomic gas into one or more constituent gases according to ah embodiment of the present invention.
|0009] FIG. 2 is an expanded view of a portion of the embodiment of FIG. 1 showing the holding compartment and the dissociation compartment.
[OOl Oj FIG. 3 is a schematic diagram of a portion of an apparatus according to an embodiment of the present invention showing the arrangement of a plurality of loop-shaped conduits.
(00111 FIG. 4 is an expanded view of the embodiment of FIG. 1 showing the quenching compartment and the separator.
[0012] FIG. 5 is a schematic diagram of an apparatus for recycling an industrially-produced polyatomic gas according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
(0013J In order that the invention herein described may be fully understood, the following detailed description is set forth.
[0014] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as those commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods, apparatus and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods, apparatus and materials are described below. The methods, apparatus, materials, and examples are illustrative only, and are not intended to be limiting. All publications, patents and other documents mentioned herein are incorporated by reference in their entirety.
[0015) Throughout this specification, the word "comprise" or variations such as "comprises" or "comprising" will be understood to imply die inclusion of a stated integer or groups of integers but not the exclusion of any other integer or group of integers.
[0016] Throughout this specification, where compositions are described as having, including, or comprising specific components, or where methods are described as having, including, or comprising specific process steps, it is contemplated that compositions of the present invention
also consist essentially of, or consist of, the recited components, and that the methods of the present invention also consist essentially of, or consist of, the recited processing steps.
[0017| In the specification, where an element or component is said to be included in and/or selected from a list of recited elements or components, it should be understood that the element or component can be anyone of the recited elements or components, or the element or component can be selected from a group consisting of two or more of the recited elements or components. Further, it should be understood that elements and/or features of a composition, an apparatus, or a method described herein can be combined in a variety of ways without departing from the spirit and scope of the present invention, whether explicit or implicit herein.
[0018) The use of the terms "include," "includes," "including," "have," "has," or "having" should be generally understood as open-ended and non-limiting unless specifically stated otherwise.
[0019J The use of the singular herein includes the plural (and vice versa) unless specifically stated otherwise. In addition, where the use of the term "about" is before a quantitative value, the present invention also includes the specific quantitative value itself, unless specifically stated otherwise. As used herein, the term "about" refers to a ± 10% variation from the nominal value unless otherwise indicated or inferred.
[0020| The term "a" or "an" may mean more than one of an item.
[0021 J The terms "and" and "or" may refer to either the conjunctive or disjunctive and mean "and/or".
[0022] It should be understood that the order of steps or order for performing certain actions is immaterial so long as the present invention remains operable. Moreover, two or more steps or actions may be conducted simultaneously.
[0023] The present invention provides methods for dissociating a polyatomic gas and separating from the polyatomic gas one or more constituent gases. The method comprises indirectly heating a polyatomic gas with a high-temperature plasma to thermally dissociate the polyatomic gas into one or more constituent gases, quenching the one or more constituent gases, and separating or removing the one or more constituent gases.
10024] The polyatomic gas is a gas selected from the group consisting of carbon dioxide, water vapor, nitrogen oxides, sulfur oxides and mixtures thereof. Preferably, the polyatomic gas is carbon dioxide. The polyatomic gas can be provided as a pure gas or as a gas comprising a polyatomic gas. The gas comprising a polyatomic gas can be air, or a polyatomic gas that has been diluted with one or inert gases such as nitrogen.
[0025J The one or more constituent gases are gases selected from the group consisting of carbon monoxide (CO), diatomic oxygen (O2), hydrogen (H2) and nitrogen (N2). When the polyatomic gas is C02, the one or more constituent gases are CO and 02.
[0026] In the first step, the polyatomic gas is heated indirectly with a high-temperature plasma. As used herein, the term "high-temperature plasma" refers to a plasma having a temperature between about 3000 and about 10000 . Preferably, the high-temperature plasma has a temperature between about 3000 K and about 8000 .
[0027] In the methods of the present invention, the high-temperature plasma and the polyatomic gas are not commingled. As such, any working gas can be used to generate the plasma without concern about contaminating the one or more constituent gases with the working gas. Suitable working gases include, but are not limited to, air, CO2, nitrogen, one or more inert gases such as argon, helium, or neon, and mixtures thereof.
|0028j The plasma can be generated from the working gas by any method known in the art as long as a high-temperature, continuous and sustainable plasma is generated. Suitable methods include, but are not limited to, low pressure (< 50 mTorr) plasma (e.g., as described in U.S. Patent No. 5,916,455), penning discharge plasma (e.g., as described in U.S. Patent No.
7,294,283), capacitively coupled radio frequency plasma (e.g., as described in U.S. Patent No. 5,274,306), inductively coupled plasma (e.g., as described in U.S. Patent No. 5,683,548), microwave generated plasma (e.g., as described in U.S. Patent No. 5,202,095), and AC or DC electrical discharge (e.g., as described in U.S. Patent No. 5,296,670), each of these patents is incorporated by reference herein.
[0029] Preferably, the high-temperature plasma is generated by an electric arc. An electric arc gas heater consists of an anode, cathode and arc discharge. Electric arcs often produce temperatures between about 3000K and about 8000K or higher, affording virtually instantaneous reaction of the polyatomic gas even when placed in indirect thermal contact.
[0030] Indirect heating of the polyatomic gas with a high-temperature plasma causes the ^~ polyatomic gas to dissociate into one or more constituent gases. For example, when the polyatomic gas is CO2, indirect heating with a high-temperature plasma dissociates the CO2 into CO and 02.
[0031] In the second step, the one or more constituent gases are quenched. The quenching step helps to prevent the occurrence of the reverse reaction (i.e., the one or more constituent gases recombining to form the polyatomic gas) and the formation of unwanted side products. One method for quenching the constituent gases is by expansive cooling. Methods for expansive cooling are known in the art and any method can be used. In some embodiments for quenching
by expansive cooling, the constituent gases can be directed through a compartment with a diverging geometry to decrease the temperature of the constituent gases by expansive cooling.
[0032] Additionally, or alternatively, the quenching step may comprise increasing the flow rate of the one or more constituent gases through the diverging compartment. One suitable method for increasing the flow rate is by using a centrifugal fan. Other suitable methods are known in the art and any may be used.
[0033] Additionally, or alternatively, the quenching step may comprise quenching the constituent gases by heat exchange. Methods for quenching by heat exchange are known in the art and any method can be used. In some embodiments for quenching by heat exchange, the constituent gases are directed through a compartment surrounded by water pipes or other heat exchange elements.
[0034J Following the quenching step, the one or more constituent gases are removed or separated from the polyatomic gas. The removing or separating step helps to prevent the occurrence of the reverse reaction and the formation of unwanted side products. In addition, this step may shift the equilibrium of the dissociation reaction to the right, thereby increasing the dissociation reaction and the formation of the one or more constituent gases. Methods for removing or separating constituent gases are known in the art and any method can be used.
[0035] One method for removing or separating the one or more constituent gases is according to their magnetic properties. Such methods are known in the art and any method can be used. According to one method, the one or more constituent gases are directed to a cyclonic separator including a magnetic field. The cyclonic separator separates the one or more constituent gases by their masses as well as their magnetic properties. Various parameters, such as the strength of the magnetic field, the length of the magnetic field, and the macroscopic velocity of the gas flow
across the gradient magnetic field, can be varied to optimize separation, increasing the yield and/or the purity of the one or more constituent gases.
[0036] Additionally, or alternatively, the one or more constituent gases can be used, without further separation or with partial separation, as a feed stream to a downstream reactor, where the constituent gases can be reacted further (e.g., as discussed below).
[0037] While the scope of the present invention covers dissociation of various polyatomic gases, carbon dioxide will be used to illustrate in detail the present invention without any intention to limit the scope of the present invention.
[0038] Carbon dioxide can be dissociated into carbon monoxide and oxygen at very high temperatures according to reaction (1 ) below:
C02 ¾ CO + ½ 02 (1 )
Because the equilibrium of reaction ( 1 ) lies strongly to the left, thermal dissociation of carbon dioxide into carbon monoxide and oxygen generally is not observed to a significant degree below a temperature of about 2000 K at standard, pressure. In addition, rapid heating can help limit the generation of side products such as various carbon species. Accordingly, a very high temperature heat source is required for the thermal dissociation of CO , such that heat energy can be directed rapidly and efficiently to the COj molecules and break the C=0 bonds.
[0039] According to the methods of the present invention, a feed stream comprising carbon dioxide is placed in indirect thermal contact with a high-temperature plasma. In some embodiments, a feed stream comprising carbon dioxide can be channeled in an enclosed passageway through the high-temperature plasma, such that the feed stream comprising carbon dioxide is rapidly heated to a temperature of at least about 1500 K. With indirect heating, the carbon dioxide is dissociated into carbon monoxide (CO) and diatomic oxygen (O2).
[ 00401 Following the dissociation step, the CO and O2 can be quenched by rapid cooling. In some embodiments, the CO and O2 are directed through a compartment with a diverging geometry to decrease the temperature of the CO and O2 by expansive cooling. The method may further comprise increasing the flow rate of the CO and O2 through the diverging geometry using a centrifugal fan.
[0041] In preferred embodiments, O? can be removed. Removal of oxygen shifts the dissociation reaction (1) to the right, leading to the formation of more CO and O2.
[0042J Following the quenching step, the CO and O2 can be separated from the polyatomic gas.
In the separation step, the CO and O2 can be channeled to a cyclonic separator including a magnetic field. The cyclonic separator separates the CO and O2 by their masses (O2 is heavier than CO) as well as their magnetic properties (02 is paramagnetic, while CO has a small dipole moment).
[0043] After the separation step, the CO and O can be optionally cooled further (e.g., by expansion and/or heat exchange) to help prevent the reverse reaction and/or the formation of unwanted side products.
[0044] In further embodiments, the methods may be varied to optimize the start-up input or increase efficiency. For example, the methods can be performed adiabatically to optimize startup input energy. Alternatively, the methods can include various heat recovery steps to increase energy efficiency.
[0045] In yet further embodiments, the methods can be combined with an existing industrial process that produces large amounts of polyatomic gas pollutants, thereby helping to reduce emission of such gas pollutants and to obtain valuable constituents from such gas pollutants. In these methods, the feed stream comprises a less pure polyatomic gas obtained from an existing
industrial process and the product stream comprises one or more constituent gases that may be recycled and used as the feed stream for the existing industrial process. In some embodiments, the method for recycling an industrially-produced polyatomic gas comprises providing a product stream from an industrial process, wherein the product stream comprises the polyatomic gas; indirectly heating the product stream comprising the polyatomic gas from the industrial process with a high-temperature plasma, thereby causing dissociation of the polyatomic gas into one or more constituent gases; quenching the one or more constituent gases; separating the one or more constituent gases; and feeding a product stream comprising one or more constituent gases to the industrial process.
[0046] An example of an existing industrial process is the Fischer- Tropsch process. The Fischer-Tropsch process is a coal liquefaction process that produces liquid fuels by gasifying coal to produce synthetic gas (or syngas, which is a mixture of carbon monoxide and hydrogen), which is then catalytically converted into liquid fuels. The Fischer-Tropsch process produces large volumes of carbon dioxide as a byproduct, which is released into the atmosphere and causes severe environmental problems.
|0047| The methods of the present invention can be combined with the Fischer-Tropsch process. In this embodiment, the carbon dioxide by-product from the Fischer-Tropsch process can be captured and used as the feed stream in the methods of the present invention, and the carbon monoxide obtained by the present methods can be recycled and used as a feed stream for the Fischer-Tropsch process. This combination significantly improves the efficiency of the Fischer-Tropsch process and minimizes environmental concerns in connection with waste treatment from the Fischer-Tropsch process.
(0048] In this embodiment, the method comprises providing a product stream from the Fischer- Tropsch process, wherein the product stream comprises C02; indirectly heating the product stream comprising C02 with a high-temperature plasma, thereby causing dissociation of C02 into CO and 02; quenching the CO and 02; separating the CO and 02; and feeding a product stream comprising CO to the Fischer-Tropsch process.
[0049] The present invention also provides apparatus for dissociating a polyatomic gas into one or more constituent gases and separating or removing from the polyatomic gas the one or more constituent gases. The apparatus comprises a dissociation compartment, a separator, and a quenching compartment.
[0050] FIG. 1 illustrates an apparatus according to an embodiment of the present invention. Apparatus 10 comprises a reactor 12 in which a polyatomic gas is thermally dissociated into one or more constituent gases, and a separator 14 that separates the one or more constituent gases for collection and optional further processing. The reactor 12 generally comprises three main compartments that are co-axially arranged and in fluid communication with each other, namely, a holding compartment 16, a dissociation compartment 18, and a quenching compartment 20. The reactor 12 and the separator 14 are connected by a feed-line 22, which extends at a
90 degree angle to the gas flow path 24 along the three compartments of the reactor 12. A centrifugal fan 26 is installed inside the feed-line 22 adjacent to the outlet 28 of the quenching compartment 20. The reactor 12 also comprises a plasma generator 30 and one or more heat exchangers 32, 34, which along with the construction of the separator 14, will be described in more detail below.
[00511 As illustrated in FIG. 2, a feed stream 36 comprising a polyatomic gas (e.g., C02) can be introduced into the holding compartment 16 via a feed-line 38. The holding compartment 16
can include conventional components such as one or more inlet valves for regulating the input flow rate of the polyatomic gas. The holding compartment 16 includes an outlet manifold 42 to communicate with the dissociating compartment 18. As shown in FIG. 3, this manifold, for example, can comprise a plurality of gas lines 44, each of which is in fluid communication with a corresponding loop-shaped conduit 46. The outlets 48 of these loop-shaped conduits in turn feed into the quenching compartment 20.
(0052] The loop-shaped conduits are arranged in parallel to each other and are placed between the anode 50 and the cathode 52 of the plasma generator 30. As shown in FIG. 3, the feed gas 36 (e.g., C02) traveling through the loop-shaped conduits 46 is heated (e.g., by conduction and radiation) by a plasma 54 generated between the anode and the cathode of the plasma generator. Each loop-shaped conduit 46 can include one or more loops. The number of loops, the size of each loop, and the diameter of the conduit are designed to maximize the residence time of the feed gas in thermal communication with the plasma. For example, while narrower conduits can accommodate a larger number of loops and promote more efficient heating, the inside diameter of the loop-shaped conduit should be sufficiently large to allow necessary gas flow and an acceptable output. As a general rule, the inside diameter of the conduits can be in the range of about 20 % to about 100 % of the plasma diameter. To optimize heat transfer, the loop-shaped conduits preferably are made of an efficient heat-conducting material which can be selected from various metals and alloys.
[0053] With continued reference to FIG. 2 and FIG. 3, a plasma generator 30 can include a power source 56, an anode 50, a cathode 52, an inlet and an outlet for channeling a working gas 58 between the anode and the cathode, and channels for circulating a coolant 60 to protect the electrodes and for heat recovery. When electrical power is applied between the anode and
the cathode, a high-energy electric spark (i.e., an electric arc) is generated between the anode and the cathode, which ionizes the working gas and generates a high-temperature plasma 54. The temperature of the plasma can be controlled by varying the current and the voltage applied to the two electrodes. Excess heat generated by the plasma can be recovered by a coolant 60
circulating around the cathode element as well as a heat exchanger 62 thermally connected to the cathode. The heat exchanger 62 can be in thermal contact with one or more thermal electric generator plates 64 to convert the thennal energy into electricity. The electrical output 66 can be used to sustain the plasma, thereby realizing a substantial reduction in the electrical energy input required by the system as a whole. Any additional electrical energy required can be
supplemented by a "green" energy source, for example, solar panels, to further the goal of reducing fuel utilization. Also, additional heat exchangers can be used to further increase the thermal efficiency of the system. For example, a second heat exchanger 68 can be placed about the feed loop of the plasma working gas to capture additional waste heat.
[0054] Referring to FIG. 1, the quenching compartment 20 can be coaxially positioned with the dissociation compartment 18. The quenching compartment can have a generally diverging geometry resembling a nozzle. Because of the geometry of the quenching compartment, the relative pressure within the quenching compartment is much lower than the pressure in the dissociation compartment. This reduces the temperature of the one or more constituent gases (e.g., CO and O2) as they are channeled into the quenching compartment from the dissociation compartment. Such quenching takes place rapidly and helps prevent the reverse reaction and formation of unwanted side products. To increase the rate of quenching, the exterior wall of the quenching compartment can be surrounded by water pipes or other heat exchange elements 32,
34. A centrifugal fan 26 can be present at the outlet 28 of the quenching compartment to force the flow of the output stream to the separator 14.
[0055] Referring to FIG. 1 and FIG. 4, the separator can be configured as a cyclonic separator, for example as described in U.S. Patent Publication No. 2009/0223875, the disclosure of which is incorporated by reference herein. The separator 14 can be vertically-oriented, and can include magnetic plates 70 and separate outlets 72 and 78 for the constituent gases.
|0056) Free radicals have magnetic moments and are thus influenced by external magnetic fields. The deflection of species by a magnetic field has been described by the following equation:
wherein 1 = length of the field; δΗ/δχ = magnetic field gradient; ε = kinetic energy of molecules; μ = M*g* o (wherein M can have values -J, -J+ 1 , ... J; g is the Lande factor, and μο is the Bohr magnetron). Thus, an inhomogeneous or gradient magnetic field can be established under certain process conditions in order to separate the free radicals by their magnetic moments. J 00571 The magnetic field can be generated by one or more electromagnetic plates 70 located at the lower portion of the vertically-oriented separator 14. The combination of gravity and magnetic attraction effectively removes one or more constituent gases (e.g., oxygen) from the mixture of the output stream.
[0058| As shown in FIG. 4, an outlet 72 positioned close to the lower portion of the separator 14 is designed to collect the heavier constituent gas 74 (e.g., O2). To optimize separation, a repeller mesh 76 (which can induce a negative charge, thus able to repel anions, e.g., oxygen anions) can be placed around an outlet 78 positioned near the upper portion of the separator 14, which is designed to collect the lighter constituent gas 80 (e.g., CO). After the
quenching compartment 20, the output stream is directed to a vertically-oriented separator 14 where separation of the one or more constituent gases (e.g., CO and O2) is effected.
[0059J In further embodiments, the apparatus of the present invention can be combined with a downstream reactor in which the product stream from the apparatus of the present invention, or a portion thereof, becomes the feed stream for the downstream reactor. For example, the apparatus of the present invention can be combined with a reactor of the Fischer-Tropsch process.
[0060] In these embodiments, the present invention provides an apparatus for recycling an industrially-produced polyatomic gas. The apparatus comprises a reactor for an industrial process, wherein die industrial process produces the polyatomic gas; and an apparatus for dissociating the polyatomic gas. The apparatus for dissociating the polyatomic gas can be any of the apparatus described above.
[0061] FIG. 5 illustrates an apparatus for recycling an industrially-produced polyatomic gas according to an embodiment of the present invention. The apparatus for recycling an industrially-produced polyatomic gas 88 comprises a reactor for an industrial process 82 and an apparatus for dissociating the polyatomic gas 10. As discussed above, the apparatus 10 produces a product stream comprising one or more constituent gases 80 (e.g., CO). The product stream comprising one or more constituent gases 80 becomes a feed stream for the industrial process reactor 82. Additional reactants 86 are fed to the industrial process reactor 82. The one or more constituent gases 80 and additional reactants 86 undergo an industrial process, producing a polyatomic gas 36 and additional products 84. The polyatomic gas 36 and additional products 84 are separated and then a product stream comprising the polyatomic gas 36 (e.g., CO2) becomes the feed stream for the apparatus 10.
[0062] The present invention encompasses embodiments in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting on the present invention described herein. Scope of the present invention is thus indicated by the appended claims rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.
Claims
1 . A method of dissociating a polyatomic gas, comprising:
indirectly heating a polyatomic gas with a high-temperature plasma, thereby causing dissociation of the polyatomic gas into one or more constituent gases;
quenching the one or more constituent gases; and
separating the one or more constituent gases.
2. The method of claim 1 , wherein the polyatomic gas is a gas selected from the group consisting of carbon dioxide, water vapor, nitrogen oxides, sulfur oxides and mixtures thereof.
3. The method of claim J , wherein the high-temperature plasma is generated by an electric arc.
4. The method of claim 1, wherein the high-temperature plasma has a temperature between about 3000 and about 8000 K.
5. The method of claim 1 , wherein the one or more constituent gases are quenched by expansion.
6. The method of claim 1 , wherein the separating the one or more constituent gases comprises using a magnetic field.
7. The method of claim 1 , further comprising separating the one or more constituent gases using a centrifugal force.
8. A method for recycling an industrially-produced polyatomic gas, comprising: providing a product stream from an industrial process, wherein the product stream comprises the polyatomic gas;
indirectly heating the product stream comprising the polyatomic gas from the industrial process with a high-temperamre plasma, thereby causing dissociation of the polyatomic gas into one or more constituent gases;
quenching the one or more constituent gases;
separating the one or more constituent gases; and
feeding a product stream comprising one or more constituent gases to the industrial process.
9. The method of claim 8, wherein the industrial process is the Fischer- Tropsch process.
10. An apparatus for dissociating a polyatomic gas comprising: a dissociation compartment, the dissociation compartment comprising a plasma generator; a separator comprising one or more magnetic plates; and a quenching compartment positioned between the dissociation compartment and the separator, wherein the quenching compartment comprises a diverging geometry.
1 1. The apparatus of claim 10, wherein the dissociation compartment and the quenching compartment are coaxially arranged.
12. The apparatus of claim 10, wherein the quenching compartment comprises a centrifugal fan.
13. The apparatus of claim 10, wherein the separator further comprises electrically charged elements.
14. An apparatus for recycling an industrially-produced polyatomic gas comprising:
a reactor for an industrial process, wherein the industrial process produces the polyatomic gas; and
an apparatus for dissociating the polyatomic gas, wherein the apparatus comprises:
a dissociation compartment, the dissociation compartment comprising a plasma generator;
a separator comprising one or more magnetic plates; and
a quenching compartment positioned between the dissociation compartment and the separator, wherein the quenching compartment comprises a diverging geometry.
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