Granted Patent B2

US 12,215,026 · App. 18/119,360 · Granted Feb 4, 2025

Inventors: David S. Soane (Coral Gables, FL); James Nathan Ashcraft (Jupiter, FL); Jason Samuel Hummelt (Palm Beach Gardens, FL); Mark Ellis Soderholm (Palm Beach Gardens, FL); Mathew Leeds (Palm Beach Gardens, FL); Alexander Olson Santana (Tequesta, FL); Matthew Elijah O'Reilly (Riviera Beach, FL)

Assignee: Transform Materials LLC

C01B3/34B01D53/047B01D53/14B01J4/002B01J19/081B01J19/126B01J19/2415C01B3/52C07C2/78C10G32/04C10G53/08H01J37/32192B01D2257/702B01J2219/0004B01J2219/0869B01J2219/0875B01J2219/0894B01J2219/3325C01B2203/142C10G2300/1025C10G2300/201C10G2300/4081C10G2300/80H01J37/32431

Abstract

Claims (29)

1. A method for transforming a hydrocarbon-containing inflow gas into outflow gas products, comprising directing reactants into a system comprising a gas delivery subsystem, a plasma reaction chamber, a microwave subsystem, and an effluent separation and disposal subsystem,

wherein the hydrocarbon in the hydrocarbon-containing inflow gas is a gas selected from the group consisting of ethane, propane, and butane;

i. wherein the gas delivery subsystem is in fluid communication with the plasma reaction chamber and directs the reactants into the plasma reaction chamber;

the gas delivery subsystem comprising a delivery conduit and a gas injector, wherein the reactants consist of gaseous reactants, wherein the gaseous reactants comprise the hydrocarbon-containing inflow gas and a hydrogen-rich reactant gas;

wherein the gas injector comprises an injector body comprising two or more separate gas feeds, a first gas feed conveying the hydrocarbon-containing inflow gas into the plasma reaction chamber through a first set of one or more nozzles, and a second gas feed conveying the hydrogen-rich reactant gas into the plasma reaction chamber through a second set of one or more nozzles, and

wherein the delivery conduit is in fluid communication with the gas injector, wherein the delivery conduit comprises a feed gas conveying circuit that delivers the hydrocarbon-containing inflow gas into the gas injector, and wherein the delivery conduit further comprises an auxiliary gas conveying circuit that delivers the hydrogen-rich reactant gas into the gas injector, each of the hydrocarbon-containing inflow gas and the hydrogen-rich reactant gas being delivered into the gas injector, through the gas injector, and into the plasma reaction chamber through a separate pathway;

ii. wherein the plasma reaction chamber is disposed within an elongate reactor tube, the elongate reactor tube having a proximal end and a distal end and being dimensionally adapted for interaction with the microwave subsystem,

iii. wherein the microwave subsystem comprises an applicator that interacts with the elongate reactor tube by directing microwave energy into the plasma reaction chamber,

wherein the plasma reaction chamber is disposed in a region of the elongate reactor tube that passes through the applicator and intersects it perpendicularly, and

wherein the microwave subsystem directs the microwave energy into the plasma reaction chamber and energizes the hydrocarbon-containing inflow gas within the region of the elongate reactor tube to form a non-thermal plasma, and wherein the non-thermal plasma transforms the hydrocarbon in the hydrocarbon-containing inflow gas and the hydrogen in the hydrogen-rich reactant gas into the outflow gas products, wherein the outflow gas products comprise acetylene and hydrogen;

wherein the outflow gas products flow within the plasma reaction chamber towards the distal end of the elongate reactor tube and emerge from the distal end to form an effluent stream that enters the effluent separation and disposal subsystem in fluid communication with the elongate reactor tube, and

iv. wherein the effluent separation and disposal subsystem comprises at least one of a hydrogen separation subsystem for removing the hydrogen from the effluent stream, an acetylene separation subsystem for removing the acetylene from the effluent stream, and an absorption column for removing higher-order hydrocarbons from the effluent stream, wherein the higher-order hydrocarbons are hydrocarbons having three or more carbon atoms.

2. The method of claim 1 , wherein the hydrocarbon-containing inflow gas is derived from a mixed gas source.

3. The method of claim 2 , wherein the mixed gas source is natural gas.

4. The method of claim 2 , wherein the mixed gas source is a biogas.

5. The method of claim 1 , wherein the hydrogen-rich reactant gas comprises a recycled gas formed from a portion of the outflow gas products, wherein the recycled gas is delivered through a recycled gas conveying circuit into the auxiliary gas conveying circuit to form at least a portion of the hydrogen-rich reactant gas that enters into the gas injector.

6. The method of claim 1 , wherein the hydrogen-rich reactant gas consists essentially of hydrogen.

7. The method of claim 1 , wherein the elongate reactor tube comprises a proximal portion at the proximal end, wherein the gas injector conveys the hydrocarbon-containing inflow gas, and the hydrogen-rich reactant gas into the proximal portion, and the hydrocarbon-containing inflow gas and the hydrogen-rich reactant gas flow distally therefrom towards the plasma reaction chamber.

8. The method of claim 1 , wherein the applicator is a single-arm applicator.

9. The method of claim 1 , wherein the microwave subsystem further comprises a power supply, a magnetron, and a waveguide, whereby the power supply energizes the magnetron to produce the microwave energy, the microwave energy being conveyed by the waveguide to the applicator.

10. The method of claim 9 , wherein the magnetron produces L-band microwave energy.

11. The method of claim 1 , wherein the effluent separation and disposal subsystem further comprises a solids filter and a cold trap.

12. The method of claim 1 , wherein the effluent separation and disposal subsystem comprises the adsorption column.

13. The method of claim 1 , wherein at least one of the one or more nozzles in the first set of one or more nozzles or the second set of one or more nozzles is oriented at an angle to a longitudinal axis of the plasma reaction chamber or at an angle to a transverse axis of the plasma reaction chamber.

14. The method of claim 1 , wherein at least one of the one or more nozzles in the first set of one or more nozzles or the second set of one or more nozzles is oriented at an angle to a longitudinal axis or a transverse axis of the injector body.

15. The method of claim 1 , wherein the hydrocarbon-containing inflow gas entering the plasma reaction chamber from the first set of one or more nozzles and the hydrogen-rich reactant gas entering the plasma reaction chamber from the second set of one or more nozzles create a vortex of the gases within the plasma reaction chamber.

16. The method of claim 1 , wherein the hydrogen separation subsystem is in fluid communication with a recycled gas conveying circuit, wherein at least a portion of the hydrogen removed from the effluent stream by the hydrogen separation subsystem is recycled into the recycled gas conveying circuit into the auxiliary gas conveying circuit to form at least a portion of the hydrogen-rich reactant gas that enters into the gas injector.

17. The method of claim 1 , wherein the effluent separation and disposal subsystem comprises at least two of the following: the hydrogen separation subsystem, the acetylene separation subsystem, and the absorption column.

18. The method of claim 17 , wherein the effluent separation and disposal subsystem comprises the acetylene separation subsystem and the absorption column.

Assignments (4)

Continuity (6)

References Cited (209)