Design advances for improving the performance of a plasma torch. The use of one or more of various advances described herein can improve the efficiency and effectiveness of the torch, the reactor and the manufacturing process. The use of the torch with hydrogen plasma gas, natural gas feedstock, and carbon black production are also described.

The present disclosure relates to a process and an apparatus for producing powder particles by atomization of a feed material in the form of an elongated member such as a wire, a rod or a filled tube. The feed material is introduced in a plasma torch. A forward portion of the feed material is moved from the plasma torch into an atomization nozzle of the plasma torch. A forward end of the feed material is surface melted by exposure to one or more plasma jets formed in the atomization nozzle. The one or more plasma jets being includes an annular plasma jet, a plurality of converging plasma jets, or a combination of an annular plasma jet with a plurality of converging plasma jets. Powder particles obtained using the process and apparatus are also described.

The present disclosure relates to a process and an apparatus for producing powder particles by atomization of a feed material in the form of an elongated member such as a wire, a rod or a filled tube. The feed material is introduced in a plasma torch. A forward portion of the feed material is moved from the plasma torch into an atomization nozzle of the plasma torch. A forward end of the feed material is surface melted by exposure to one or more plasma jets formed in the atomization nozzle. The one or more plasma jets being includes an annular plasma jet, a plurality of converging plasma jets, or a combination of an annular plasma jet with a plurality of converging plasma jets. Powder particles obtained using the process and apparatus are also described.

Methodologies, systems, and devices are provided for producing metal spheroidal powder products. Dehydrogenated and spheroidized particles are prepared using a process including introducing a metal hydride feed material into a plasma torch. The metal hydride feed material is melted within a plasma in order to dehydrogenate and spheroidize the materials, forming dehydrogenated and spheroidized particles. The dehydrogenated and spheroidized particles are then exposed to an inert gas and cooled in order to solidify the particles into dehydrogenated and spheroidized particles. The particles are cooled within a chamber having an inert gas.

Methodologies, systems, and devices are provided for producing metal spheroidal powder products. Dehydrogenated and spheroidized particles are prepared using a process including introducing a metal hydride feed material into a plasma torch. The metal hydride feed material is melted within a plasma in order to dehydrogenate and spheroidize the materials, forming dehydrogenated and spheroidized particles. The dehydrogenated and spheroidized particles are then exposed to an inert gas and cooled in order to solidify the particles into dehydrogenated and spheroidized particles. The particles are cooled within a chamber having an inert gas.

Provided are a fine particle manufacturing apparatus and a fine particle manufacturing method, which manufacture smaller fine particles. The fine particle manufacturing apparatus has: a raw material supply unit that supplies raw materials for producing fine particles into a thermal plasma flame; a plasma torch in which the thermal plasma flame is generated and the raw materials supplied by the raw material supply unit is evaporated by the thermal plasma flame to form a mixture in a gaseous state; a plasma generation unit that generates the thermal plasma flame inside the plasma torch; and a gas supply unit that supplies quenched gas to the thermal plasma flame, wherein the gas supply unit supplies the quenched gas with time modulation of the supply amount of the quenched gas.

In order to attain an efficient decomposition process by water plasma, a decomposition processor includes a water plasma generator which is configured to inject water plasma, from the injection port, by arc discharge generated between negative and positive electrodes; and a supply device configured to supply a decomposition target object to a water plasma jet stream injected from the water plasma generator, wherein the decomposition target object is decomposed by the water plasma. The supply device has a nozzle for providing the decomposition target object from a tip, and the negative electrode, the injection port, the positive electrode and the nozzle are arranged in that order along the center axis line of the injection port. The tip of the nozzle is placed inside of the water plasma jet stream.

In order to attain an efficient decomposition process by water plasma, a decomposition processor includes a water plasma generator which is configured to inject water plasma, from the injection port, by arc discharge generated between negative and positive electrodes; and a supply device configured to supply a decomposition target object to a water plasma jet stream injected from the water plasma generator, wherein the decomposition target object is decomposed by the water plasma. The supply device has a nozzle for providing the decomposition target object from a tip, and the negative electrode, the injection port, the positive electrode and the nozzle are arranged in that order along the center axis line of the injection port. The tip of the nozzle is placed inside of the water plasma jet stream.

In order to stabilize injection of water plasma, a vortex water flow generator forms a vortex water flow for passing arc discharge. The vortex water flow generator includes a cylindrical portion configured to form a vortex water flow along an inner circumference, a first middle partition and a second middle partition protruding from the inner circumference of the cylindrical portion. The first middle partition and the second middle partition respectively have an opening to include a center axis line position of the cylindrical portion. An opening of the second middle partition on the side of the positive electrode is larger than an opening of the first middle partition on the side of the negative electrode.

In order to stabilize injection of water plasma, a vortex water flow generator forms a vortex water flow for passing arc discharge. The vortex water flow generator includes a cylindrical portion configured to form a vortex water flow along an inner circumference, a first middle partition and a second middle partition protruding from the inner circumference of the cylindrical portion. The first middle partition and the second middle partition respectively have an opening to include a center axis line position of the cylindrical portion. An opening of the second middle partition on the side of the positive electrode is larger than an opening of the first middle partition on the side of the negative electrode.