The disclosed technology relates generally to chemical reactors configured to produce chemical substances through electric discharge.
Electric chemical reactions are often used to manufacture particular chemical substances, including by high voltage discharge. One example is the production of a desired molecular substance by plasma reaction of an input gas. The plasma is effective in breaking chemical bonds, thereby facilitating the creation of other chemical bonds. Plasma is used in the production of many desirable chemicals such as producing ammonia from nitrogen and hydrogen, converting carbon dioxide into useful hydrocarbons, and generating ozone from oxygen.
An example of an electric discharge reactor has a reaction cell that receives an input chemical fluid such as a gas or liquid. In some cases the reaction cell may also be pressurized depending upon the particular reaction. The reaction cell typically includes two electrodes of opposing polarity, which in some cases are configured as electrode plates. In some cases a dielectric material is also positioned between the electrodes. For example, in some cases the dielectric material may be deposited on the surface of one of the electrodes. During operation, the input fluid is directed through a passage between the two electrodes and a high voltage is applied. When the applied voltage reaches a sufficient threshold, the electric field between the electrodes breaks down, causing electricity to discharge through the input fluid. The resulting electric current has the ability to break some of the chemical bonds of the input fluid, thereby forming different types of desired molecules.
While electric discharge reactors are useful for manufacturing various gases and other chemical products, the reactors can also have undesirable aspects. As an example, the fluid passage(s) extending through a reaction cell are generally very narrow and are thus prone to becoming contaminated with water or debris carried by the input fluid. The contamination leads to the need to frequently remove and service or replace particular reaction cells. In addition, to achieve the desired electric discharge, a reaction cell is connected to a high-power source such as a transformer driven by a high frequency electronic power converter. The high frequency operation of the transformer can be a source of unwanted electrical noise. Another undesirable aspect of electric discharge reactors is that the electric discharge process is often inefficient, leading to the wasteful generation of much heat. In some cases a reaction cell is cooled with air, water, or another coolant to enable continuing operation of the cell.
Multiple reaction cells are often used to generate a sufficient amount of a reactor product. Installing several reactors at a site while also addressing high frequency noise, removability, and connections to power, input, output, and coolant lines can be difficult. In some cases the complexity of the installation is increased because the reaction cells and associated transformers and power converters are separately mounted in a single cabinet.
There is thus a need in the art for improved electric chemical discharge reactors and associated systems and methods.
One general aspect of the disclosed technology includes an electric discharge reactor. The electric discharge reactor includes a frame supporting a power converter, a transformer and an electric discharge reaction cell. The frame is configured to mount to a vertical surface and includes a component plate extending in a vertical orientation when the frame is mounted to the vertical surface. The power converter and transformer are mounted to the component plate. The electric discharge reaction cell is mounted to the component plate below the power converter. The reaction cell includes at least one power connector configured to be electrically coupled with the power converter and the transformer, an input fluid connector configured to connect the reaction cell to a source of supply fluid for reacting in the reaction cell, an output fluid connector configured to provide a fluid produced by the reaction cell, and a liquid cooling system that includes first and second coolant connectors. According to various implementations, the mounted position of the reaction cell locates the first and second coolant connectors below the power converter, thereby enabling gravity to direct coolant escaping from the liquid cooling system, the first coolant connector, or the second coolant connector away from the power converter.
Implementations according to this aspect may include one or more of the following features. In some cases the power converter is mounted proximate a top end of the frame and the reaction cell is mounted proximate a bottom end of the frame. The reaction cell may include a top half and a bottom half, where the first and second coolant connectors extend from the bottom half of the reaction cell. The at least one power connector extends from the top half of the reaction cell away from the first and second coolant connectors. In some cases at least one of the first and second coolant connectors is located proximate a bottom end of the frame and extends down away from the power converter and the top end of the frame. The transformer may be mounted to the component plate between the power converter and the reaction cell. The reactor further may include a narrow configuration in which the depth of the reactor is greater than the width of the reactor and the height of the reactor is greater than the depth of the reactor. The frame further may include a vertical mounting plate configured to mount to the vertical surface. In such cases the component plate and the vertical mounting plate extend in the vertical orientation along a height of the reactor. In some cases the vertical mounting plate extends in a first horizontal orientation transverse to the vertical orientation along a width of the reactor and in some cases the component plate extends in a second horizontal orientation transverse to the vertical orientation and the first horizontal orientation along a depth of the reactor.
Another general aspect of the disclosed technology includes an electric discharge reaction system. The electric discharge reaction system includes an electric discharge reactor and multiple connection lines. The electric discharge reactor includes a frame with a vertical mounting plate and a component plate. It also includes a power converter mounted to the component plate, a transformer mounted to the component plate below the power converter, and an electric discharge reaction cell mounted to the component plate below the transformer. The reaction cell includes at least one power connector configured to be electrically coupled with the power converter and the transformer, an input fluid connector, an output fluid connector, and a liquid cooling system with first and second coolant connectors. The multiple connection lines of the electric discharge reaction system are coupled to the input fluid connector, the output fluid connector and the first and second coolant connectors. The connection lines extend down below and away from the electric discharge reactor. According to various implementations, the positioning of the first and second coolant connectors and the plurality of connection lines below the power converter enables gravity to direct coolant escaping from the liquid cooling system, the first coolant connector, the second coolant connector, or one or more of the connection lines away from the power converter.
Implementations of this general aspect may include one or more of the following features. In some cases each of the connection lines includes a first end configured to couple to one of the first and second coolant connectors, the input fluid connector and the output fluid connector, and a second end configured to couple to a fluid delivery conduit. In some cases the first and second ends of at least one of the connection lines are formed at a same connection angle. In some cases the first and second ends of each of the connection lines are formed at a same connection angle. The connection angle for each of the connection lines may be different than the connection angles for the other connection lines. The connection lines may include stainless-steel tubing. In some cases the power converter is mounted proximate a top end of the frame and the reaction cell is mounted proximate a bottom end of the frame. The reaction cell may include a top half and a bottom half, where the first and second coolant connectors extend from the bottom half of the reaction cell and where the at least one power connector extends from the top half of the reaction cell away from the first and second coolant connectors. According to various implementations, the component plate and the vertical mounting plate extend along a height of the electric discharge reactor, the component plate further extends along a depth of the electric discharge reactor that is less than the height, and the vertical mounting plate further extends along a width of the electric discharge reactor that is less than the depth. In some cases the electric discharge reaction system includes multiple fluid delivery conduits including, for example, a first coolant conduit, a second coolant conduit, a supply fluid conduit, and a product delivery conduit.
Another general aspect of the disclosed technology includes an electric discharge reaction system. The electric discharge reaction system includes multiple electric discharge reactors and multiple fluid delivery manifolds. In some cases the fluid delivery manifolds include a first coolant manifold, a second coolant manifold, a supply fluid manifold, and a product delivery manifold. The system also includes multiple rigid connection lines. Each of the electric discharge reactors includes a frame with a vertical mounting plate and a component plate, each plate extending in a vertical orientation when the frame is mounted to the vertical surface. Each reactor also includes a power converter and a transformer mounted to the component plate and an electric discharge reaction cell mounted to the component plate below the power converter. The reaction cell includes at least one power connector configured to be electrically coupled with the power converter and the transformer, an input fluid connector coupled to the supply fluid manifold with a first one of the connection lines, an output fluid connector coupled to the product delivery manifold with a second one of the connection lines, and a liquid cooling system with first and second coolant connectors respectively coupled to the first and second coolant manifolds. According to various implementations, the mounted position of the reaction cell locates the first and second coolant connectors and corresponding connection lines below the power converter, thereby enabling gravity to direct coolant escaping from the liquid cooling system, the first coolant connector, the second coolant connector, or one of the connection lines away from the power converter.
Implementations according to this aspect may include one or more of the following features. In some cases each of the rigid connection lines has a first end and a second end. The first and second ends of at least one of the rigid connection lines are formed at a same connection angle. In some cases the first and second ends of each of the rigid connection lines are formed at a same connection angle that is different from the connection angles for the other connection lines.
While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. As will be realized, the various implementations are capable of modifications in various obvious aspects, all without departing from the spirit and scope thereof. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
Turning to the drawings,
As will be understood by those skilled in the art, the power converter 106 and the transformer 108 are constructed to provide sufficient power for driving electric corona discharge reactions within the reaction cell 104. As an example, in some implementations the power converter 106 is constructed or configured to condition and regulate power received from a power supply before resupplying the power to the transformer 108. In some cases the power converter 106 is configured to drive the transformer 108 at a high frequency.
As shown in
In the depicted implementation the reaction cell 104 includes two power connectors 112 for supplying the reaction cell with electricity from the transformer 108. While two power connectors 112 are depicted, the reaction cell 104 may have any suitable number of power connectors. In some cases a reaction cell may have one, two, three or more power connectors depending upon the particular cell design.
As shown in
In various implementations an electric discharge reactor may include other components and/or features in addition to the frame 102, reaction cell 104, power converter 106, and transformer 108 shown in
In cases involving a liquid cooling system, it will be appreciated that liquid coolant escaping from the cooling system poses a threat to sensitive electronic components of the discharge reactor. As examples, in some cases liquid coolant may leak from the cell's coolant connectors or from another part of the liquid cooling system, or escape when connecting or disconnecting coolant lines. According to various implementations, the physical arrangement of the reaction cell 104, power converter 106, and transformer 108 reduces the likelihood that escaping coolant will interfere with the reactor's electrical components. Returning to
In some implementations the connectors for the cell cooling system may be further arranged to maximize the distance between one or more coolant connectors and the power converter 106 and transformer 108. As an example, in the depicted implementation the first coolant connector 122 is positioned on the bottom half of the reaction cell 104, further away from the power converter 106 than the top half of the reaction cell 104. In addition, the second coolant connector 124 is located at the bottom edge of the reaction cell 104. This placement maximizes the distance between the coolant connector 124 and the power converter 106 and transformer 108. In this implementation the placement of both coolant connectors 122, 124 also physically separates the coolant connectors from the cell's power connectors 112, which extend from the top half of the reaction cell 104.
According to some implementations, the relative placement of the reaction cell 104 with respect to the power converter 106 and the transformer 108 also reduces the likelihood that the electrical components will be affected by coolant from the reaction cell's liquid cooling system. Mounting the discharge reactor 100 as shown in
According to some implementations the reaction cell 104, the power converter 106, and the transformer 108 may be bolted or clipped onto the component plate 202 of the frame. Other fastening mechanisms may also be used. Other shapes and configurations for the frame 102 may also be employed in various implementations. As shown in
According to various implementations, an electric discharge reactor system includes an electric discharge reactor and multiple connection lines for coupling the reactor to a feed or supply fluid source, a coolant source, and a product delivery system for delivering a fluid manufactured by the reactor. In some cases a reactor system also includes multiple fluid delivery conduits that couple the reactor connection lines to the fluid source, coolant source, and product delivery system.
Turning to
Continuing with reference to
Corresponding connection lines 322, 324, 326, and 328 couple the conduits to the discharge reactor 100. In this example the connection lines 322, 324, 326, and 328 are made of stainless-steel tubing, which is known to be very stiff or rigid. According to various implementations, one or more of the connection lines are configured to facilitate connecting and disconnecting the stiff connection lines 320 (e.g., from stainless-steel or another material) from the reactor cell 104 and the delivery conduits 310. As an example, in implementations using stiff tubing, the connection angles of both ends of one or more connection lines 320 are the same. The use of identical angles (referred to herein as both connection angles and entry angles) in this way allows for loosening the connectors at each end of the connection line(s) and then easily sliding the connection line(s) out from the corresponding connectors while the discharge reactor 100 and its frame stay firmly attached to a wall or panel. For example, with respect to the implementation in
In some implementations all of the connection lines 320 have ends with identical angles, though the angles may change from line to line. In some cases less than all of the connection lines 320 may have ends with identical angles.
Turning to
Although the various embodiments have been described with reference to preferred implementations, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope thereof.
This application claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional application 63/029,583, filed May 25, 2020 and entitled “Electric Chemical Reactor System,” which is hereby incorporated herein by reference in its entirety.
Number | Date | Country | |
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63029583 | May 2020 | US |