Provided are multi-phase heating systems for bidispersed and polydispersed particle applications. Provided is a multi-phase reactor comprising a reaction chamber for containing a catalyst wherein the catalyst reacts with a fluid material. A heating system arranged around the reaction chamber comprises a first heater for heating a core of the chamber and a second heater for heating a periphery of the chamber, where combined heating from the first and second heaters provide the reaction chamber at a temperature for clustering of the fluid material for reaction with the catalyst. Also provided is an additive manufacturing printer comprising a first heater for heating a core of the chamber and a second heater for heating a periphery of the chamber, wherein combined heating from the first and second heaters provide the chamber at a temperature for clustering of printable material for extrusion through a nozzle.

A system for producing hydrogen gas includes a first container, a microwave emitter configured to direct a microwave to the first container, a steam condenser, a second container and an effluent conduit. The first container includes a first container body configured to hold a quantity of water and aluminum particles inside. The steam condenser connects the first container with a first end of the effluent conduit. A second end of the effluent conduit can be inserted in the second container. The microwave emitter can be operated to direct a microwave to the water and aluminum particles (when the water aluminum particles are present inside of the first container). The radiation of the water and aluminum particles with the microwave will cause hydrogen gas to dissociate from the water. The hydrogen gas will travel through the steam condenser and the effluent conduit to be stored in the second container.

A system for pyrolysis of plastic includes a fluidized bed pyrolysis unit including a first microwave generator and a pyrolysis vessel, the pyrolysis vessel including a first inlet configured to receive a plastic feedstock, and a second inlet configured to receive one or more fluids, wherein a first microwave absorbent material is positionable within the pyrolysis vessel; and a first fluidized bed catalytic reactor unit positioned downstream of the pyrolysis vessel and including a second microwave generator and a first catalytic reactor vessel, wherein a second microwave absorbent material and a first catalytic material are positionable within the first catalytic reactor vessel.

Embodiments of the invention relate to systems and methods for cracking hydrocarbons into hydrogen gas and carbon using heating of a fluidized bed. The systems and methods utilize electrically conductive carbon or graphite particles as a fluidized bed material for heating hydrocarbon feedstock to at least a pyrolysis temperature. The electrically conductive carbon, graphite, or other particles may be heated by electrically powered sources that include induction heating, microwave heating, millimeter wave heating, joule heating and/or plasma heating. Combustion heating may also be employed in varying amounts with varying combinations of electrically powered heating sources.

Methods and systems for producing spherical graphite particles is disclosed. The method comprises feeding a slurry to a spray dryer. The slurry comprises a plurality of first particles and a petroleum pitch. The slurry is dispensed from a nozzle of the spray dryer to produce a second plurality of particles. The sphericity of the second plurality of particles is different from a sphericity of the first plurality of particles. The second plurality of particles is fed from the spray dryer to a vertical graphitization column, where the second plurality of particles are heated to produce a third plurality of particles. The sphericity of the third plurality of particles is different from the sphericity of the first plurality of particles. The third plurality of particles can be a plurality of spherical graphite particles.