Application of In-Flight Melting Technology by RF Induction Thermal Plasmas to Glass Production

An innovative in-flight glass melting technology with induced thermal plasmas was developed for the purpose of energy conservation and environmental protection. Two-dimensional modeling was used to simulate the thermofluid fields in the plasma torch. The in-flight melting behavior of glass raw material was investigated by various analysis methods. Results showed that the plasma temperature was up to 10000 K with a maximum velocity over 30 m/s, which made it possible to melt the granulated glass raw material within milliseconds. The carbonates in the raw material decomposed completely and the compounds in the raw material attainted 100% vitrification during the in-flight time from the nozzle exit to substrate. The particle melting process is similar to the unreacted-core shrinking model.

Numerical and Experimental Investigation on the In-Flight Melting Behaviour of Granulated Powders in Induction Thermal Plasmas

An innovative in-flight glass melting technology with thermal plasmas was developed for the purpose of energy conservation and environment protection. In this study, modelling and experiments of argon-oxygen induction thermal plasmas were conducted to investigate the melting behaviour of granulated soda-lime glass powders injected into the plasma. A two-dimensional local thermodynamic equilibrium （LTE） model was performed to simulate the heat and momentum transfer between plasma and particle. Results showed that the particle temperature was strongly affected by the flow rate of carrier gas and the particle size of raw material. A higher flow rate of carrier gas led to lower particle temperature and less energy transferred to particles which resulted in lower vitrification. The incomplete melting of large particles was attributed to the lower central temperature of the particle caused by a larger heat capacity. The numerical analysis explained well the experimental results, which can provide valuable practical guidelines for the process control in the melting process for the glass industry.

Comparative Study of Decomposition of CCl_4 in Different Atmosphere Thermal Plasmas

Decomposition of carbon tetrachloride was studied theoretically in the most commonly used thermal plasma atmosphere such as H2, N2, O2 and water steam. A code developed by the National Aeronautics and Space Administration （NASA） was adopted to calculate the chemical equilibrium distribution and energy consumption of the decomposition of CC;4 in the H2, N2, O2 and water steam atmosphere thermal plasma respectively, with a temperature range of 500 K to 5000 K. In the neutral condition （H2, N2, atmosphere） formation of solid carbon was observed and in the oxygen-atmosphere （O2 and water steam） solid carbon formation disappeared through controlling the ratio of C/O. This indicates that the formation of polycyclic aromatic hydrocarbons （PAHs） is impossible theoretically. The energy consumption in the N2 atmosphere was much higher than that in the H2, O2 and water steam atmosphere at 1500 K.

Three-dimensional numerical simulation of heating and melting behaviors of cerium oxide powders in radio frequency thermal plasma

The present study aims at the numerical simulations of the melting process of cerium oxide particles in RF thermal plasma.The physical model and the calculating method were described firstly;the interaction between cerium oxide particles and plasma was analyzed;specific attention was given to the effects of particle initial size,injection velocity on the particle melting and trajectory in plasma.The influence of the temperature field and velocity field distribution of the plasma around the particle trajectory on the melting effect is analyzed,and the relationship between the heat absorption efficiency of the particles and the particle size reduction process is further determined.It is also found that there exists an optimal particle initial injection velocity which led to a more concentrated final particle size distribution and a more significant reduction of particle size.The results could provide effective guidance for understanding the plasma spheroidization process of uranium dioxide and cerium dioxide powder particles.

Quasi-direct numerical simulations of the flow characteristics of a thermal plasma reactor with counterflow jet

Three-dimensional quasi-direct numerical simulations have been performed to investigate a thermal plasma reactor with a counterflow jet. The effects of the momentum flux ratio and distance between the counterflow jet and the thermal plasma jet on the flow characteristics are addressed. The numerical results show that the dimensionless location of the stagnation layer is significantly affected by the momentum flux ratio, but it is not dependent on the distance.Specifically, the stagnation layer is closer to the plasma torch outlet with the increase of the momentum flux ratio. Furthermore, the flow regimes of the stagnation layer and the flow characteristics of the thermal plasma jet are closely related to the momentum flux ratio. The characteristic frequencies associated with the different regimes are identified. The deflecting oscillation flow regimes are found when the momentum flux ratio is low, which provokes axial velocity fluctuations inside the thermal plasma jet. By contrast, for cases with a high momentum flux ratio, flapping flow regimes are distinguished. The thermal plasma jets are very stable and the axial velocity fluctuations mainly exist in the stagnation layer.

Improvement of AlN Thermal Conductivity Based on Reductive Compound Additives

AlN ceramics were prepared by plasma activation sintering(PAS)with compound additives yttrium acetylacetonate(Y(acac)_(3))and melamine(C_(3)H_(6)N_(6)).The effects of compound additives on the microstructure,density,and thermal properties of Al N ceramic were studied.Y(acac)3and C_(3)H_(6)N_(6)can form Y_(2)O_(3),residual organic carbon and reducing gas during the heating process,which improves the Al N sintering performance at a temperature of 1700℃and the bulk thermal conductivity.When the content of Y(acac)_(3)is 10 wt%and C_(3)H_(6)N_(6)is 3 wt%,the thermal conductivity of Al N ceramics is 105.6 W/(m·K),which is much higher than that of Al N ceramics with Y_(2)O_(3)under the same sintering conditions.This work provides theoretical reference for the preparation of high-performance Al N ceramic.

Production of pig iron from red mud waste fines using thermal plasma technology

Red mud, an insoluble residue produced during alkali leaching of bauxite, is considered as a low-grade iron ore containing 30% to 50% iron. The present paper deals with the use of thermal plasma technology for producing pig iron from red mud waste fines. The smelting reduction of red mud was carried out in a 35 kW DC extended arc thermal plasma reactor. Red mud was properly mixed with fluxes and graphite （fixed carbon, 99%） as a reductant as per stoichiometric requirement. The effect of various process parameters like a reductant, fluxes and smelting time on iron recovery was studied and optimized. An optimum condition for the maximum recovery of iron was obtained. A new thermal plasma process applicable to direct iron making from red mud waste fines that would achieve significant utilization of red mud was proposed.

Vitrification of MSWI Fly Ash by Thermal Plasma Melting and Fate of Heavy Metals

Municipal solid waste incinerator （MSWI） fly ash with high basicity （about 1.68） was vitrified in a thermal plasma melting furnace system. Through the thermal plasma treatment, the vitrified product （slag） with amorphous dark glassy structure was obtained, and the leachability of hazardous metals in slag was significantly reduced. Meanwhile, it was found that the cooling rate affects significantly the immobility of heavy metals in slag. The mass distribution of heavy metals （Zn, Cd, Cr, Pb, As, Hg） was investigated in residual products （slag, secondary residues and flue gas）, in order to analyze the behavior of heavy metals in thermal plasma atmosphere. Heavy metal species with low boiling points accounting for the major fraction of their input-mass were adsorbed in secondary residues by pollution abatement devices, while those with high boiling points tended to be encapsulated in slag.

Deformation Behavior of Nanostructured Ceramic Coatings Deposited by Thermal Plasma Spray

Al2O3-13 wt pet TiO2 coating deposited by direct current plasma spray consists of nanostructured region and micro-lamellae. Bend test shows that the ceramic coating can sustain some deformation without sudden failure. The deformation is achieved through the movement of nano-particles in the nanostructured region under tensile stress.

Understanding CO_2 decomposition by thermal plasma with supersonic expansion quench

CO2 pyrolysis by thermal plasma was investigated,and a high conversion rate of 33% and energy efficiency of 17% were obtained.The high performance benefited from a novel quenching method,which synergizes the converging nozzle and cooling tube.To understand the synergy effect,a computational fluid dynamics simulation was carried out.A quick quenching rate of 10~7Ks（-1） could be expected when the pyrolysis gas temperature decreased from more than 3000 to 1000 K.According to the simulation results,the quenching mechanism was discussed as follows： first,the compressible fluid was adiabatically expanded in the converging nozzle and accelerated to sonic speed,and parts of the heat energy converted to convective kinetic energy; second,the sonic fluid jet into the cooling tube formed a strong eddy,which greatly enhanced the heat transfer between the inverse-flowing fluid and cooling tube.These two mechanisms ensure a quick quenching to prevent the reverse reaction of CO2 pyrolysis gas when it flows out from the thermal plasma reactor.

Enthalpy Probe Technique for Thermal Plasma Diagnostics

The measuring principle and experimental results of the enthalpy probe technique for thermal plasma diagnostics are presented. Its calibration and errors are discussed. Typical results are presented for the system operation in an Ar/H2(5 % H2) plasma arc jet under a reactor chamber pressure of 101.3 kPa. The plasma temperature and velocity profiles are measured. The center temperature and velocity are 6600 K and 850 m/s for plasma power 9 kW at axial location of 17 mm.

Carbon Dioxide Reforming of Methane to Syngas by Thermal Plasma

Experiments were conducted on syngas preparation from dry reforming of methane by carbon dioxide with a DC arc plasma at atmospheric pressure. In all experiments, nitrogen gas was used as the working gas for thermal plasma to generate a high-temperature jet into a horizontal tube reactor. A mixture of methane and carbon dioxide was fed vertically into the jet. In order to obtain a higher conversion rate of methane and carbon dioxide, chemical energy efficiency and fuel production efficiency, parametric screening studies were conducted, in which the volume ratio of carbon dioxide to methane in fed gases and the total flux of fed gases were taken into account. Results showed that carbon dioxide reforming of methane to syngas by thermal plasma exhibited a larger processing capacity, higher conversion of methane and carbon dioxide and higher chemical energy efficiency and fuel production efficiency. In addition, thermodynamic simulation for the reforming process was conducted. Experimental data agreed well with the thermodynamic results, indicating that high thermal efficiency can be achieved with the thermal plasma reforming process.

Preliminary Study of Thermal Treatment of Coke Wastewater Sludge Using Plasma Torch

Thermal plasma was applied for the treatment of coke wastewater sludge derived from the steel industry in order to investigate the feasibility of the safe treatment and energy recovery of the sludge. A 30 kW plasma torch system was applied to study the vitrification and gas production of coke wastewater sludge. Toxicity leaching results indicated that the sludge treated via the thermal plasma process converted into a vitrified slag which resisted the leaching of heavy metals. CO2 was utilized as working gas to study the production and heat energy of the syngas. The heating value of the gas products by thermal plasma achieved 8.43 k J/L, indicating the further utilization of the gas products. Considering the utilization of the syngas and recovery heat from the gas products, the estimated treatment cost of coke wastewater sludge via plasma torch was about 0.98 CNY/kg sludge in the experiment. By preliminary economic analysis, the dehydration cost takes an important part of the total sludge treatment cost. The treatment cost of the coke wastewater sludge with 50 wt.% moisture was calculated to be about 1.45 CNY/kg sludge dry basis. The treatment cost of the coke wastewater sludge could be effectively controlled by decreasing the water content of the sludge. These findings suggest that an economic dewatering pretreatment method could be combined to cut the total treatment cost in an actual treatment process.

Microstructure studies of air-plasma-spray-deposited CoNiCrAlY coatings before and after thermal cyclic loading for high-temperature application

In the present study, bond-coats for thermal barrier coatings were deposited via air plasma spraying（APS） techniques onto Inconel 800 and Hastelloy C-276 alloy substrates. Scanning electron microscopy（SEM）, transmission electron microscopy（TEM）, X-ray diffraction（XRD）, and atomic force microscopy（AFM） were used to investigate the phases and microstructure of the as-sprayed, APS-deposited Co Ni Cr Al Y bond-coatings. The aim of this work was to study the suitability of the bond-coat materials for high temperature applications. Confirmation of nanoscale grains of the γ/γ′-phase was obtained by TEM, high-resolution TEM, and AFM. We concluded that these changes result from the plastic deformation of the bond-coat during the deposition, resulting in Co Ni Cr Al Y bond-coatings with excellent thermal cyclic resistance suitable for use in high-temperature applications. Cyclic oxidative stability was observed to also depend on the underlying metallic alloy substrate.

Fast inactivation of microbes and degradation of organic compounds dissolved in water by thermal plasma

The multifunctionality and the advantages of thermal plasma for the fast inactivation of viable cells and degradation of organic compounds dissolved in waste water are presented.A complete bacterial inactivation process was observed and studied using a thermal plasma treatment source with very short application times,in particular for Staphylococcus aureus bundle spore survival.The survival curves and analyses of the experimental data of the initial and final densities of S.aureus bacteria show a dramatic inhibitory effect of the plasma discharge on the residual bacteria survival ratio.As the exposure time increased,the inactivation process rate increased for direct exposure more than it did for indirect exposure.The evaluation of direct and indirect exposure was based on the analysis of the ultraviolet spectrum from the absorbance spectra of the organic compound dye called benzene sulfonate（C（16）H（11）N2Na O4S）and of viable cells called S.aureus.Organic compounds were degraded and viable cells were killed in a short time by thermal plasma.Moreover,analyses of total carbon,total organic carbon,and total inorganic carbon showed a fast decrease in organically bound carbon,however,this was not as fast as the absorbance spectra revealed by the exposure time increasing more for direct exposure than indirect exposure.After 100 s of exposure to the organic compound dye the removal had a maximun of 40%for samples with indirect exposure to the plasma and a maximum of 90%for samples with the direct exposure.For both samples,where some organic contaminants still remained in treated water,four electrolytes（KCl,Na Cl,Na2SO4,and CH3COONa）were added to be effective for complete sterilization,reaching a purity of 100%.A proposal is made for an optimized thermal plasma water purification system（TPWPS）to improve fast inactivation of microbes and the degradation of organic compounds dissolved in water（especially for direct exposure rather than indirect exposure）using a hybrid plasma torch with an electrical power of 125 kW（500 V–250 A）producing a high-temperature（10 000 K–19 000 K）plasma jet with a maximum gas consumption of 28 mg s^-1.

A New Grade Carbon Black Produced by Thermal Plasma Process

This paper presents a new route about producing carbon black, by which the natural gas cracking is carried out in the absence of oxygen thanks to an electric energy supply externally given by a plasma jet. The carbon black produced by this process has a narrow size distribution and a small average diameter of 38 nm as well as a highly branched aggregate. The higher DBP value of 1.40 ml/g shows it should be a high structure carbon black. The FTIR spectra shows that there are lots of aromatic c-c bonds and a large amount of nitrogen-containing functional groups on the carbon blacks surface, such as -NH, -CN as well as -CH, -OH, -COOH groups.

Numerical study of the effect of coflow argon jet on a laminar argon thermal plasma jet

The effects of the velocity and width in coflow argon jet inlet on the flow characteristics of laminar argon thermal plasma jet flowing into the cold air have been studied by the large eddy simulation methods. The Kelvin–Helmholtz instability between argon thermal plasma jet and coflow argon jet causes the transition from a laminar jet to a turbulent jet in the presence of coflow argon jet. Moreover, increasing the velocity and width in coflow argon jet inlet can enhance turbulent transport and provoke coherent structure in the downstream of thermal plasma jet. And the mixing characteristics between argon thermal plasma, coflow argon and ambient air are strengthened. In addition, the width in coflow argon jet inlet has a significant effect on the distribution of temperature in the upstream of thermal plasma jet. It was also found that the transition occurs in advance with the increase of velocity and width in coflow argon jet inlet.

Large eddy simulation on the flow characteristics of an argon thermal plasma jet

Large eddy simulations based on the CFD software Open FOAM have been used to study the effect of Reynolds number and turbulence intensity on the flow and mixing characteristics of an argon thermal plasma jet.Detailed analysis was carried out with respect to four aspects:the average flow field,the instantaneous flow field,turbulence statistical characteristics and the selfsimilarity.It was shown that for the argon thermal plasma jet with low Reynolds number,increasing the turbulence intensity will increase the turbulent transport mechanism in the mixing layer rather than in the jet axis,leading to the faster development of turbulence.The effect of the turbulent transport mechanism increases with increasing Reynolds number.However,the characteristics of flow and mixing are not affected by turbulence intensity for high Reynolds number situations.It was also found that the mean axial velocity and mean temperature in the axis of the turbulent thermal plasma jet satisfy the self-similarity aspects downstream.In addition,decay constant K is 1.25,which is much smaller than that(5.7-6.1)of the turbulent cold gas jet and has nothing to do with the Reynolds number or turbulence intensity in the jet inlet.

Synthesis of Fullerene by Pyrolysis of Acetylenein Thermal HF-Plasma

Carbon soot containing fullerene was continuously produced in volume by pyrolyzing acetylene in thermal HF-Plasma. The characteristics of the carbon soot and C60 were analyzed by thtransmission electron microscopy, UV/visible, IR and Raman spectroscopy. The results show that the main ingredients of the carbon soot with size of about 25 nm are amorphous carbon, graphite and fullerene. The fullerene yield in carbon soot is about 2.5 g·h^-1. Compared with the graphite arc discharge method, the acetylene thermal plasma method is a preferential one for synthesis of fullerene.

MoP with rich species generated via radio frequency thermal plasma for higher alcohols synthesis from syngas

In this paper, the molybdenum phosphide(MoP) catalysts(TPR-MoP and TPR-MoP-Pla) were prepared by the traditional method and the RF(radio frequency) thermal plasma technique respectively and characterized by x-ray diffraction(XRD), x-ray photoelectron spectroscopy(XPS), transmission electron microscope(TEM), hydrogen temperature-programmed desorption(H_2-TPD) and carbon monoxide temperature-programmed desorption(CO-TPD) measurements,and their catalytic performance for HAS was evaluated. The results showed that the total and C_(2+) alcohols selectivity of the catalyst after plasma treatment(TPR-MoP-Pla) were enhanced.The enhanced catalytic performance could be related to more dislocation defects and the synergistic effect between Mo^(0–2+) and Mo^(4+) valence species in the TPR-MoP-Pla catalyst. In addition, this work suggests that thermal plasma treatment can be used as a new preparation technique for the synthesis of materials with rich species.