WO2019083645A2 - Système de réacteur modulaire pour réactions exothermiques - Google Patents

Système de réacteur modulaire pour réactions exothermiques

Info

Publication number
WO2019083645A2
WO2019083645A2 PCT/US2018/051863 US2018051863W WO2019083645A2 WO 2019083645 A2 WO2019083645 A2 WO 2019083645A2 US 2018051863 W US2018051863 W US 2018051863W WO 2019083645 A2 WO2019083645 A2 WO 2019083645A2
Authority
WO
WIPO (PCT)
Prior art keywords
plate
modular
reactor
exothermic
reactor system
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2018/051863
Other languages
English (en)
Other versions
WO2019083645A3 (fr
Inventor
Joseph A. Murray
Julie A. Morris
Tushar Tank
Melissa Brent HILL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
IH IP Holdings Ltd
Original Assignee
IH IP Holdings Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by IH IP Holdings Ltd filed Critical IH IP Holdings Ltd
Publication of WO2019083645A2 publication Critical patent/WO2019083645A2/fr
Publication of WO2019083645A3 publication Critical patent/WO2019083645A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J19/087—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
    • B01J19/088—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J3/00—Processes of utilising sub-atmospheric or super-atmospheric pressure to effect chemical or physical change of matter; Apparatus therefor
    • B01J3/03—Pressure vessels, or vacuum vessels, having closure members or seals specially adapted therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J3/00—Processes of utilising sub-atmospheric or super-atmospheric pressure to effect chemical or physical change of matter; Apparatus therefor
    • B01J3/04—Pressure vessels, e.g. autoclaves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
    • B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
    • B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
    • B01J2219/0809—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes employing two or more electrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
    • B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
    • B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
    • B01J2219/0824—Details relating to the shape of the electrodes
    • B01J2219/0826—Details relating to the shape of the electrodes essentially linear
    • B01J2219/083—Details relating to the shape of the electrodes essentially linear cylindrical
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
    • B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
    • B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
    • B01J2219/0824—Details relating to the shape of the electrodes
    • B01J2219/0832—Details relating to the shape of the electrodes essentially toroidal
    • B01J2219/0833—Details relating to the shape of the electrodes essentially toroidal forming part of a full circle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
    • B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
    • B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
    • B01J2219/0837—Details relating to the material of the electrodes
    • B01J2219/0841—Metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/19—Details relating to the geometry of the reactor
    • B01J2219/192—Details relating to the geometry of the reactor polygonal
    • B01J2219/1923—Details relating to the geometry of the reactor polygonal square or square-derived

Definitions

  • the present disclosure relates generally to the field of exothermic reactor systems and, more particularly, to a low cost, modular reactor for use in producing exothermic reactions under a wide variety of conditions and using a wide variety of materials.
  • the present disclosure comprises a modular reactor system for carrying out exothermic reactions.
  • the modular reactor system comprises of a standard base plate and two or more interchangeable top plates configured to meet the requirements of different energy production processes, or different phases of an energy production process.
  • different top plates may be provided for solid-state reactors, plasma reactors, and electrolytic reactors, all of which are configured for use with the same standard base plate.
  • different top plates may be configured for use with the standard base plate during different phases of an energy production process.
  • Such phases could include a preparation phase and an operation phase.
  • the different phases may include sub-phases that require different top plates.
  • the preparation phase may comprise a cleaning phase and an activation phase.
  • a modular exothermic reactor system includes: a first end plate; and two or more interchangeable second end plates, each second end plate configured to be alternately assembled with the first end plate to form a reactor housing, wherein a cavity is formed in the first end plate, said cavity configured to form, at least in part, a sealed chamber internally within the reactor housing when one of the second end plates is assembled with the first end plate to form the reactor housing.
  • the two or more interchangeable second end plates may be configured for different phases of a multi-phase energy production process.
  • the two or more interchangeable second end plates may include a preparation phase plate for a preparation phase of the energy production process and an operation plate for an operation phase of the energy production process.
  • the preparation phase plate may include a cleaning plate including an electrically isolated electrode configured to generate a plasma in the sealed chamber to clean the first end plate, and at least one gas port for at least one of supplying gas to and evacuating gas from the sealed chamber during a cleaning process.
  • the cleaning plate may include two gas ports configured to enable a gas flow through the sealed chamber during the cleaning process.
  • the preparation phase plate may include an activation plate including an electrically isolated electrode configured to generate a plasma in the sealed chamber to plate the cavity of the first end plate with a reaction material, and at least one gas port for at least one of supplying gas to and evacuating gas from the sealed chamber during an activation process.
  • the activation plate may include two gas ports configured to enable a gas flow through the sealed chamber during the activation process.
  • the operation plate may be configured to initiate an exothermic reaction in the sealed chamber.
  • the operation plate may be configured for a solid-state reactor.
  • the operation plate includes a heating element configured to heat a reaction material in the sealed chamber to initiate an exothermic reaction.
  • the operation plate may include a magnetic coil.
  • the operation plate may be configured for a plasma reactor.
  • the operation plate may include an electrode to initiate an exothermic reaction.
  • the operation plate may be configured for an electrolytic reactor.
  • the operation plate may include at least two electrically isolated electrodes and a liquid port configured for introduction of electrolyte to the sealed chamber.
  • the operation plate may include at least one gas port for at least one of supplying gas to and evacuating gas from the sealed chamber during an operation phase.
  • the operation plate may include two gas ports configured to enable a gas flow through the sealed chamber during the operation phase.
  • the reactor housing may include two or more interchangeable second end plates configured for different energy production processes.
  • One of the interchangeable second end plates may include a solid-state reactor plate configured for use in a solid-state reactor.
  • the solid-state reactor plate may include a heating element configured to heat a reaction material in the sealed chamber to initiate an exothermic reaction.
  • the solid-state reactor second end plate may include a magnetic coil.
  • One of the interchangeable second end plates may include a plasma reactor plate configured for use in a plasma reactor.
  • the plasma reactor plate may include an electrode to initiate an exothermic reaction.
  • One of the interchangeable second end plates comprises an electrolytic reactor plate configured for use in an electrolytic reactor.
  • the electrolytic reactor plate may include at least two electrically isolated electrodes and a liquid port configured for introduction of electrolyte to the sealed chamber.
  • At least one of the interchangeable second end plates may include a gas port for at least one of supplying gas to and evacuating gas from the sealed chamber during an operation phase.
  • At least one of the interchangeable second end plates may include two gas ports configured to enable a gas flow through the sealed chamber during the operation phase.
  • One or more expansion plates may be disposed between the first end plate and the second end plate.
  • the first end plate, second end plate, and one or more expansion plates may each include a cavity that form a part of the sealed chamber when the plates are assembled together.
  • the first end plate may include a first planar contact surface, a first circular groove surrounding a mouth of a cavity, and a first continuous circular wall between the first circular groove and the mouth of the cavity, the first continuous circular wall having an annular sealing surface.
  • An expansion plate may be positioned between the first end plate and a second end plate when the second end plates is assembled with the first end plate to form the reactor housing.
  • the expansion plate may include: a planar contact surface for facing the first planar contact surface; a continuous circular wall extending from the planar contact surface, wherein the continuous circular wall is at least partially received by the first circular groove when the expansion plate is positioned between the first end plate and second end plate when the reactor housing is assembled.
  • Each second end plate may include: a second planar contact surface for facing the first planar contact surface when the second end plate is assembled with the first end plate to form the reactor housing; and a second continuous circular wall extending from the second planar contact surface, wherein the second continuous circular wall is at least partially received by the first circular groove or a circular groove of the expansion plate when the second end plate is assembled with the first end plate to form the reactor housing.
  • FIG. 1A is a diagrammatic representation of a modular reactor system according to at least one embodiment.
  • FIG. IB is a diagrammatic representation of a modular reactor system according to at least one other embodiment.
  • FIG. 2A is a perspective view of a base plate for a modular reactor system according to at least one embodiment.
  • FIG. 2B is a perspective view of an expansion plate for a modular reactor system according to at least one embodiment.
  • FIG. 3 is a perspective view of a top plate for a modular reactor system according to at least one embodiment.
  • FIG. 4 is an exploded perspective view of a modular reactor system according to at least one embodiment.
  • FIG. 5 illustrates an exemplary top plate used in a modular reactor system during a cleaning phase of an energy production process.
  • FIG. 6 illustrates an exemplary top plate used in a modular reactor system during an activation phase of an energy production process.
  • FIG. 7 illustrates an exemplary top plate used in a modular reactor system to assemble a solid-state reactor.
  • FIG. 8 illustrates an exemplary top plate used in a modular reactor system to assemble a plasma reactor.
  • FIG. 9 illustrates an exemplary top plate used in a modular reactor system to assemble an electrolytic reactor.
  • FIGS. 1A and IB show an exemplary reactor system 100.
  • the modular reactor system 100 comprises two or more plates that are stacked together to form a reactor housing 102.
  • the plates at the ends of a stack are referred to herein generally as end plates. Plates between the two end plates are referred to herein as intermediate plates or expansion plates.
  • the components described herein can be arranged, combined, and interchanged a variety of ways to meet different usage needs.
  • the modular reactor system 100 includes a standard base plate 120 and two or more interchangeable or differed top plates 150 configured to meet the requirements of different energy production processes, or different phases of an energy production process.
  • one or more plates 200 may be added between the base plate 120 and top plates 150 as shown in FIG. IB.
  • the modular reactor system 100 may comprise a standard top plate 150 and two or more interchangeable base plates 120.
  • the reactor system 100 may comprise two or more base plates 120, each of which can be used with two or more top plates 150.
  • the expansion plates 200 may also be
  • At least one of the base plate 120 and top plate 150 has a cavity such that a sealed chamber is formed when the reactor housing 102, for example as shown in FIG. 4, is formed by assembly of at least a base plate 120 and top plate 150 in stacked relationship.
  • the base plate 120 has an upper side 122 and a lower side 124, and the top plate 150 (FIG. 3) can be described as having an upper side 152 and a lower side 154.
  • the upper side 122 of the base plate 120 in use is directed toward the lower side 154 of the top plate 150, each having respective cooperatively sealing structures by which the base plate 120 and top plate 150 are sealed together in final assembly and use, in embodiments of the modular reactor system 100 without an intervening expansion plate 200.
  • the upper side 122 of the base plate 120 has an upwardly-facing planar contact surface 126 that abuts a downwardly facing planar contact surface of the lower side 154 of the top plate 150 (FIG. 3) upon assembly of the modular reactor system 100 without an intervening expansion plate.
  • a circular groove 130 is defined in the upper side 122 of the base plate 120 surrounding an open mouth of a cavity 134 defined in the base plate 120 from the upper side 122 to an interior floor surface 136, which is shown as planar in the illustrated embodiment of FIG. 2A.
  • a continuous circular wall 140 having a terminal upwardly facing annular sealing surface 142, surrounds the mouth 132.
  • the groove 130, and wall 140 are concentrically arranged.
  • the cylindrical interior surface of the wall 140 defines a radially outward boundary of the cavity 134.
  • a bottom panel 144 is attached to the lower side of the base plate 120 by fasteners 146 as shown in FIGS. 2A and 4.
  • the bottom panel 144 serves to insulate or thermally couple the base plate 120 in various embodiments. As illustrated, the bottom panel 144 maintains a thermal element 104 in contact with the base plate 120 for cooling or heating purposes.
  • the lower sider 154 of the top plate 150 has a downwardly-facing planar contact surface 155 that abuts the upwardly-facing planar contact surface 126 of the base plate 120 (FIG. 2A) upon assembly of the modular reactor system 100 without an intervening expansion plate.
  • a downwardly-facing recessed annular sealing surface 160 surrounds an open mouth of a cavity 164 defined in the top plate 150 from the lower side 154 to an interior cap surface 166, which is shown as planar in the illustrated embodiment of FIG. 3.
  • a continuous circular wall 170 extends from the contact surface 155, having a terminal downwardly-facing annular sealing surface 172, concentrically surrounds the sealing surface 160.
  • the afore-mentioned cooperatively sealing structures by which the base plate 102 and top plate 150 are sealed together in final assembly in embodiments of the modular reactor system 100 without an intervening expansion plate, include: (from the base plate 120) the wall 140, its terminal sealing surface 142, and the groove 130; and (from the top plate 150) the wall 170, its terminal sealing surface 172, and the sealing surface 160.
  • the wall 140 of the base plate 120 is concentrically arranged with the wall 170 of the top plate.
  • the cylindrical exterior of wall 140 is dimensioned by diameter to be received by and engage the cylindrical interior of the wall 170 for assembly of the reactor housing 102.
  • the cylindrical interior and exterior of the wall 170 are dimensioned by respective diameters to engage the cylindrical interior and exterior of the groove 130.
  • the wall 170 of the top plate 150 is received within and engages the groove 130 of the base plate 120, and an upper extent of the wall 140 of the base plate is received within and engages a lower extent of the wall 170 of the top plate 150.
  • the upward-facing sealing surface 142 of the base plate 120 engages, directly or indirectly in various embodiments, the downward-facing sealing surface 160 of the top plate 150.
  • the downward-facing sealing surface 172 of the top plate 150 engages, directly or indirectly in various embodiments, a recessed upwardly-facing sealing surface within the groove 130 of the base plate 150.
  • the sealing surfaces of the base plate 102 and top plate 150 engage indirectly by way of seals, which may be for example deformable O-rings or other deformable structures, sandwiched between base plate 120 and top plate 150 features upon assembly.
  • seals which may be for example deformable O-rings or other deformable structures, sandwiched between base plate 120 and top plate 150 features upon assembly.
  • a first seal 190 is placed into or in alignment with the recessed sealing surface 160 of the top plate 150
  • a second seal 192 is placed on or in alignment with the groove 130 of the base plate 120.
  • the seals 190 and 192 are compressed between the plates 120 and 150 to form an air-tight seal surrounding a sealed chamber in the reactor housing 102.
  • the first seal 190 may be described as an inner seal with respect to the sealed chamber as being more closely exposed to the interior of the housing 102 relative to the second seal 192, which may similarly be described as an outer seal.
  • the sealed chamber in the reactor housing is defined by the at least one cavity of the base plate 120 and top plate 150.
  • the reactor housing has a sealed chamber cooperatively defined by the cavity 134 of the base plate 120 and the cavity 164 of the top plate 150, the sealed chamber having a floor and ceiling defined respectively by the interior floor surface 136 and the interior cap surface 166.
  • Vacuum seals or high pressure seals may be used depending on the particular application.
  • the inner first seal 190 may comprise a high pressure seal and the outer second seal 192 may comprise a vacuum seal.
  • the inner first seal 190 may comprise a vacuum seal and the outer second seal 192 may comprise a high pressure seal.
  • the inner seal 190 may comprise a seal rated for both vacuum and high pressure and the outer seal 192 can be omitted.
  • the outer seal 192 and the inner seal 190 may be omitted.
  • the base plate 120 and top plate 150 may be secured together by fasteners, for example by threaded bolts 196 as shown in the embodiments of FIG. 4.
  • the threaded post portions of the bolts that pass through respective through holes 167 (see also FIG. 5) formed through the top plate 150 from the upper side 152 to the lower side 154 and engage aligned threaded bolt holes 148 formed in the upper side 122 of the base plate 120.
  • the top plate 150 is trapped between the heads of the bolts and the base plate 120.
  • seals 190 and 192 are used, the tightening compresses the seals.
  • the seals are selected of different materials in different embodiments according to use.
  • Polymers, deformable metals, and textiles may be selected. Thermal properties are taken into account such that the seals do not fail for example in higher temperature uses.
  • the tightening effects direct sealing engagement of the sealing surface 142 of the base plate 120 and the sealing surface 160 of the top plate 150, and/or direct sealing engagement of the sealing surface 172 of the top plate 150 with the sealing surface within the groove 130 of the base plate 150.
  • the contact surface 126 also reaches direct sealing engagement with the contact surface 155 in some
  • top plate 150 and base plate 120 are formed as four corner holes, each of which is near one of four corners of each plate, and four side holes, each of which is formed near a marginal side of each plate midway between two corner holes.
  • Other numbers of bolts and corresponding hole patterns are within the scope of these descriptions.
  • jacking screws that engage both the base plate 120 and top plate 140 may be used.
  • the top plate 140 has threaded jacking holes 168 (see FIGS. 4 and 5) that engage jack screws and align with the portions of the upper surface 126 of the base plate 120 where no corresponding holes are formed.
  • the jack screws can thus be threaded from above the upper side 152 of the top plate 140 and into the jacking holes 168.
  • the terminal ends of the threaded posts of the jack screws then ultimately protrude from the lower side 154 of the top plate 150 and abut the upper surface 126 of the base plate 120 to forcibly separate the top plate 140 therefrom by continued turning of the screws.
  • the bolts 196 can be used as jacking screws.
  • one or more expansion plates 200 may be added between the base plate 120 and top plate 150.
  • an expansion plate 200 has upper side 202 and a lower side 204, each having
  • the expansion plate 200 can be coupled with a base plate 120 from below, a top plate 150 from above, or stacked with one or more other expansion plates.
  • the upper side 202 of the expansion plate 200 has an upwardly-facing planar contact surface 206, a circular groove 210 surrounding an open mouth of a cavity defined as a cylindrical bore 234 through the expansion plate from the upper side 202 to the lower side 204, and a continuous circular wall 220, having a terminal upwardly facing annular sealing surface 222 that surrounds the mouth of the 234.
  • These features of the upper side 202 of the expansion plate 200 that are similarly termed as those of the upper side 122 of the base plate 120 serve similarly with regard to coupling and sealing with the lower side 154 of the top plate 150.
  • the lower side 204 of the expansion plate 200 includes features, similar to those of the lower side of the top plate 150, that serve also similarly with regard to coupling and sealing with the upper side 122 of base plate 120 or the upper side 202 of another expansion plate 200 depending on a stack being assembled.
  • the bore 234 of the expansion plate 200 aligns with a cavity 134 of a lower base plate 120, and a cavity 164 of a higher top plate 150. Where more than one expansion plate 200 is used, their bores 234 also align in the stack.
  • a reactor housing can be assembled with a lower base plate 120, an upper top plate 150, and any number of intervening expansion plates 200 depending on the size requirements for the sealed chamber.
  • the expansion plate 200 can seal from above and below by use of seals 190 and 192, or without such seals as already described with regard the sealing of the base plate 120 and top plate 150.
  • the plates 120, 150, and 200 of the reactor housing 102 are constructed of materials that can sustain high temperatures, vacuum, and/or high pressure, such as stainless steel.
  • the material should not react with the fuel materials of interest.
  • materials such as stainless steel, nickel alloys (e.g., Inconel, Incoloy), or titanium may be used.
  • materials such as aluminum alloys, copper alloys, and silver alloys can be used.
  • Aluminum alloys are better suited for heat sink uses but have low strength and a relatively low melting point. Copper alloys have higher melting points and offer good corrosion resistance, but may not be suited for the certain fuel materials.
  • Silver alloys have higher melting points than aluminum alloys and are not implicated in contamination of exothermic reactions, but may be more expensive. If strength is a concern, coatings with high thermal conductivity, e.g., DLC, could be used in
  • the exemplary base plate 120 and top plate 150 shown in FIGS. 2A and 3 in one embodiment are dimensioned to form a block approximately three inches by three inches by three inches when the reactor system 100 shown in exploded view in FIG. 4 is assembled and secured.
  • the size of the block so formed varies in other embodiments, and can be selected for example in accordance to the desired power output of the reactor.
  • One aspect of the modular exothermic reactor system 100 is that two or more interchangeable top plates 150 may be configured for use with the same standard base plate 120.
  • the interchangeable top plates 150 may be configured for use in a different type of energy production processes, i.e., for different types of reactors.
  • different top plates 150 may be provided for solid-state reactors, plasma reactors, and electrolytic reactors, all of which are configured for use with the same base plate 120.
  • the modular exothermic reactor system 100 can contain, be loaded with, and/or can process one or more reaction materials, which can vary according to purpose and arrangement.
  • a reaction material can be, for example, a transition metal or metal alloy such as palladium, nickel or platinum, exposed to hydrogen gas, or one of its isotopes or other elemental species, under pressure.
  • a reaction material can be a material that absorbs, adsorbs, contains or retains, chemically or structurally, otherwise gaseous or fluidic species of hydrogen, any isotope of hydrogen, or other elemental species.
  • a reaction material can be a substance in powder, foil, plate, fluidic, gaseous, solid and/or crystalline form.
  • Hydrogen or other species may be loaded into or onto a host structure or substance to constitute a reaction material prior to placement in the reactor system 100 or the reaction material may be prepared within the reaction system 100 by introduction of components of the reaction material into the reactor system 100 for processing the components to fabricate the reaction material therein.
  • Reaction material can be loaded or placed into the reactor system 100 or can be a material part of a component of any of the reactor components described herein and illustrated in the drawings.
  • Various reactor types are within the scope of these descriptions with regard to the reactor system 100 as described below. While solid-state reactors, plasma reactors, and electrolytic reactors are particularly described, these descriptions relate as well to other reactor types and uses for material processing and/or the preparation, triggering, and/or harnessing of reaction materials and exothermic reactions.
  • Solid-state reactors can contain hydrogen or deuterium in a solid form which is then released as a gas upon heating.
  • Plasma reactors can contain hydrogen or deuterium gas in which a voltage is applied across electrodes to create a plasma that contains ionic species.
  • Electrolytic reactors can contain electrodes submerged in a solution and a voltage applied across the electrodes in order to induce the flow of current through the solution.
  • different top plates 150 may be configured for use with the standard base plate 120 during different phases of an energy production process.
  • the modular exothermic reactor system 100 comprises a base plate 120 and two or more interchangeable top plates 150 configured for use with the base plate 120 during different phases of an energy production process.
  • Such phases could include a preparation phase and an operation phase.
  • the different phases may include sub-phases that require different top plates 150.
  • the preparation phase may comprise a cleaning phase and an activation phase, each requiring a different top plate.
  • the cleaning phase may require a cleaning phase top plate and the activating phase may require an activation phase plate.
  • a base plate 120 and/or other plates used in a previous reaction are cleaned of residual material and byproducts.
  • a reaction material is treated or prepared to enable an exothermic reaction during a subsequent operation phase. Additional phases may be necessary based on the requirements of the energy-production process.
  • the interchanging of top plates 150 could be done in a controlled environment, e.g., a glovebox with an inert atmosphere.
  • FIG. 5 shows an exemplary top plate 150A for use with a modular exothermic reactor during a cleaning phase of an energy production process.
  • the cleaning phase top plate 150A referred to hereinafter as a cleaning plate, may be used with a solid-state reactor, plasma reactor, and/or electrolytic reactor.
  • the cleaning plate 150A can be attached to the base plate 120 (FIG. 2A) to form a sealed chamber as previously described.
  • the exemplary cleaning plate 150A includes an electrode 156a formed as a rod and configured to generate a plasma.
  • the electrode 156a protrudes through the cleaning plate into the sealed chamber.
  • the electrode 156a is made of molybdenum.
  • the material of the electrode 156a for the cleaning process can be varied so a wide range of materials can be used for the electrode 156a.
  • the electrode 156a is electrically isolated from the surrounding material of the cleaning plate by a dielectric material.
  • a voltage differential is created between the reactor housing 102 and the electrode 156a in order to generate the plasma.
  • the reactor housing 102 is held at a positive potential to induce an electron flow to reaction material in contact with the inner surface of the sealed chamber.
  • the cleaning plate includes a heater that can be used to raise the temperature of the reactor according to specification.
  • the cleaning plate 150A may further include one or more gas ports 174 opening into the interior of the cavity 164. Respective gas lines 176 convey gases to or from the gas ports 174. Two gas ports 174 allow gas flow through the reactor when a plasma is not being generated, which can provide more efficient cleaning. If only one gas port 174 is available due, e.g., to sizing constraints, proper cleaning can still be achieved, but gas introduction and vacuum would occur in separate steps during the cleaning process.
  • An example cleaning process designed for the cleaning plate 150A described above would be configured to accommodate the continuous flow of an inert gas, e.g. argon, through the reactor housing 102 for a set period of time after which the reactor is vacuumed to a set level.
  • the top plate 150A may be configured to
  • top plate 150A and the base plate 120 should also be configured to allow the chamber to be vacuumed down to an appropriate level.
  • FIG. 6 shows an exemplary top plate 150B for use with a modular exothermic reactor system 100 during an activation phase of an energy production process.
  • the activation phase top plate 150B referred to herein as an activation plate, is similar to the cleaning plate.
  • the activation plate 150B comprises an electrode 156b and one or more gas ports 174 and respective gas lines 176.
  • the electrode 156b is electrically isolated from the material of the activation plate 150B and protrudes through the activation plate and into the sealed chamber. In this example, the electrode 156b generates a plasma for plating the inner surfaces of the sealed chamber with a reaction material.
  • the activation process may require an electrode 156b with a different material than the electrode 156a for the cleaning process, which may necessitate different top plates 150A and 150B for the cleaning phase and activation phase. In some embodiments, the same top plate 150 may be used for both the cleaning and activation phases. Those skilled in the art will appreciate that the activation plate is not required for some energy production processes.
  • a top plate 150 used for the cleaning phase may be configured to comprise one or more electrodes.
  • the electrodes of the cleaning plate are thereby switched out by the electrodes of the activation plate.
  • the electrodes remain in the sealed chamber when the cleaning plate is replaced by the activation plate. In this embodiment, the electrodes are cleaned during the cleaning phase so that the
  • the exemplary illustrated top plate 150 can be used in a modular exothermic reactor system 100 during an operation phase of an energy production process. During the operation phase, an exothermic reaction is triggered and generates heat.
  • the operation phase top plate 150 referred to herein generically as the operation plate, comprises the cavity 164 as previously described that forms a sealed chamber to contain for example solid-state reaction material.
  • the top plate 150 further includes or more gas ports 174 and respective gas lines 176 to supply and/or evacuate gas from the sealed chamber.
  • the gas port 174 can be selectively, for example by use of a gas line 176, connected to a source of vacuum and a source of gas at different times depending on the requirements of the solid- state reaction process.
  • a gas flow through the sealed chamber can be maintained during the exothermic reaction.
  • the modular exothermic reactor system 100 comprises a base plate 120 and two or more interchangeable top plates 150 configured for use with the base plate 120 for different types of energy production process.
  • different top plates 150 may be provided for solid-state reactors, plasma reactors, and electrolytic reactors, all of which are used with the same standard base plate 120.
  • the embodiment of the top plate 150 shown in FIG. 3 is a simple example of a top plate 150 for the operation phase of a solid-state reactor.
  • FIG. 7 shows another example of a top plate 150C configured for use during the operation phase of a solid-state reactor.
  • the top plate 150C in this example is similar to the top plate 150 in FIG. 3 with the addition of a heating element 158 to heat the reaction material by conduction and initiate the exothermic reaction in the sealed chamber of the reactor housing 102.
  • the heating element 158 in this example is a resistive heating element that protrudes through the solid-state top plate 150C and into the sealed chamber of the reactor.
  • the resistive heating element 158 may be thermally insulated from the surrounding material of the top plate 150C so that the reactor is heated from inside and the heat flows outward from the sealed chamber.
  • the heating element 158 may be embedded in the top plate 150C or base plate 120 as shown in FIG. 4 as represented by the thermal element 104.
  • the heating element 158 may comprise a magnetic coil that produces a magnetic field that heats up ferromagnetic materials inductively, without actually having a heating element inside or even in contact with the reactor chamber.
  • the magnetic coil may be used if the reaction material is ferromagnetic and the reactor housing 102 is non-magnetic, e.g., nickel and austenitic stainless steel.
  • the magnetic coil may be placed, for example, on an outer surface of the top plate 150C.
  • the reaction material is placed in the sealed chamber before the plates are assembled together.
  • the solid-state reaction material may comprise nanoparticles or other solid material loaded with a hydrogen gas, deuterium, or tritium.
  • the solid-state reaction material may be plated onto the inner surfaces of the cavities 134 (FIG. 2A) and 164 (FIG. 3) of the base plate 120 and top plate 150 and the bore 234 of the expansion plate 200.
  • FIG. 8 illustrates an exemplary top plate 150D configured for use during the operation phase of a plasma reactor.
  • the top plate 150D for the plasma reactor comprises a cavity 164 and an electrode 156d that protrudes into the sealed chamber formed when the top plate 150D and base plate 120 are assembled together.
  • the electrode 156d is fed through the top plate 150D and is electrically isolated from the surrounding material of the top plate.
  • the top plate 150D further includes one or more gas ports 174 and respective gas lines 176 to supply and/or evacuate gas from the sealed chamber as previously described.
  • the interior walls of the cavity 134 (FIG. 2A) of the base plate 120, the cavity 164 of the top plate 150D, and the bore 234 (FIG. 2B) of the expansion plate 200 may be coated with a reaction material.
  • the reaction material in the form of a foil or mesh can be secured to the inner surfaces of the cavities 134 and 164 of the base plate 120 and top plate 150D and the bore 234.
  • the foil or mesh may be electrically isolated from or in direct contact with the surrounding material depending on the preferred set-up.
  • FIG. 9 illustrates an exemplary top plate 150E configured for use in an electrolytic reactor.
  • the top plate 150E for the electrolytic reactor includes two electrodes 156e and 157 and one or more liquid ports and respective lines 177 to supply and/or evacuate liquid from the sealed chamber.
  • the electrodes 156e and 157 protrude into the sealed chamber formed when the top plate 150E and base plate 120 are assembled together.
  • a first electrode 156e in the form of a rod protrudes through the top plate 150E along a central axis of the sealed chamber.
  • a second electrode 157 in the form of a coil surrounds the first electrode 156e. Both electrodes 156e and 157 are electrically isolated from the material of the top plate 150E.
  • the top plate 150E may further include a gas port for introducing one or more reactive gases.
  • either liquid port may be configured as a gas port for gas flow. If no gas port is used, a certain portion of walls of the cavity 164 of the top plate 150E can be plated with a catalytic material in order to allow for the recombination of generated gases throughout operation. Likewise, a gas port for recirculation of fluid can be coated in the catalytic material if the configuration of the electrodes 156e and 157 does not allow for coating of the cavity walls.

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  • Chemical Kinetics & Catalysis (AREA)
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  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)

Abstract

L'invention concerne un système de réacteur modulaire qui comprend une plaque de base et au moins deux plaques supérieures interchangeables conçues pour satisfaire aux exigences de différents procédés de production d'énergie, ou de différentes phases d'un procédé de production d'énergie. Dans certains modes de réalisation, une plaque de base standard et des plaques supérieures différentes peuvent être fournies pour des types de réacteurs différents, tous étant conçus pour être utilisés avec la même plaque de base standard. Dans d'autres modes de réalisation, une plaque de base standard et au moins deux plaques supérieures différentes peuvent être fournies pour différentes phases pour une phase de préparation et une phase de fonctionnement d'un procédé de production d'énergie.
PCT/US2018/051863 2017-09-20 2018-09-20 Système de réacteur modulaire pour réactions exothermiques Ceased WO2019083645A2 (fr)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023170254A1 (fr) * 2022-03-11 2023-09-14 D-Crbn Bv Réseau de réacteurs à plasma parallèle massif destiné aux applications de conversion de gaz

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5948704A (en) * 1996-06-05 1999-09-07 Lam Research Corporation High flow vacuum chamber including equipment modules such as a plasma generating source, vacuum pumping arrangement and/or cantilevered substrate support
US6502530B1 (en) * 2000-04-26 2003-01-07 Unaxis Balzers Aktiengesellschaft Design of gas injection for the electrode in a capacitively coupled RF plasma reactor
GB0021815D0 (en) * 2000-09-06 2000-10-18 Lofting Marcus J Plasma enhanced gas reactor
WO2018226917A2 (fr) * 2017-06-08 2018-12-13 Industrial Heat, Llc Réacteur à plaques à faible coût pour réactions exothermiques

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023170254A1 (fr) * 2022-03-11 2023-09-14 D-Crbn Bv Réseau de réacteurs à plasma parallèle massif destiné aux applications de conversion de gaz
BE1030331B1 (nl) * 2022-03-11 2023-10-09 D Crbn Bv Een massieve parallelle plasmareactor voor gasconversietoepassingen

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