Conversion of heavy fossil hydrocarbons (HFH) to a variety of value-added chemicals and/or fuels can be enhanced using microwave (MW) and/or radio-frequency (RF) energy. Variations of reactants, process parameters, and reactor design can significantly influence the relative distribution of chemicals and fuels generated as the product. In one example, a system for flash microwave conversion of HFH includes a source concentrating microwave or RF energy in a reaction zone having a pressure greater than 0.9 atm, a continuous feed having HFH and a process gas passing through the reaction zone, a HFH-to-liquids catalyst contacting the HFH in at least the reaction zone, and dielectric discharges within the reaction zone. The HFH and the catalyst have a residence time in the reaction zone of less than 30 seconds. In some instances, a plasma can form in or near the reaction zone.

In order to suppress discharge of an unreacted content in a chemical reaction apparatus for irradiating a content with microwaves, a chemical reaction apparatus includes: a horizontal flow-type reactor in which a liquid content horizontally flows with an unfilled space being provided thereabove; a microwave generator that generates microwaves; and a waveguide that transmits the microwaves generated by the microwave generator to the unfilled space in the reactor, wherein the inside of the reactor is partitioned into multiple chambers to by overflow-type partition plates and that allow the content to flow thereover and an underflow-type partition plate that allows the content to flow thereunder.

A system for processing hydrocarbon materials, comprising a hydrocarbon feedstock source; a process gas source; a waveguide; and a reaction tube structure. The process gas source comprises one or more sources of gases selected from the group consisting of helium, argon, krypton, neon, xenon, methane, propane, butane, ethane, acetylene, propylene, butylene, ethylene, carbon monoxide, carbon dioxide, water vapor, hydrogen, and nitrogen. The waveguide comprises a lateral portion comprising housing having a first end portion configured to be connected to a microwave generator, a closed opposite end portion, a primary axis extending from the first end portion to the second end portion, and a central portion having an opening, wherein the central portion has a depth that is smaller than a corresponding depth of the first end portion and the second end portion, and a coaxial portion having a first end portion connected to the opening and a lateral dimension that is perpendicular to the primary axis. The reaction tube structure comprises an outer wall made of a dielectric material, and is configured such that when hydrocarbon feedstock from the feedstock source and process gas from the process gas source are fed into the reaction tube structure and microwaves are received in the waveguide, one or more surface waves are propagated in the reaction tube structure to form a plasma within the reaction tube structure and cause the feedstock and process gas to react and form into a product stream, and wherein the reaction tube structure has a lateral dimension that is perpendicular to the lateral portion and parallel to the coaxial portion, and the reaction tube structure is connected to a second end of the coaxial portion.

A variety of microwave-based plasma reactors are presented which are intended for operation at high pressures, from 0.1 to 10 bar, and a high flow rate. Further, reactors can operate without the presence of a dielectric material, which can degrade in time requiring replacement and causing downtime for the unit. Applications for these devices include heating, reforming, and pyrolyzing the reactants.

Apparatus for treating materials with plasma, comprising a microwave generator (15), a waveguide (20) and a tubular torch (30), comprising three coaxial tubes (33, 35, 37) and a central section (30.2) connected to the waveguide (20) by means of a body (50) having a cavity (52) through which the tubes pass. A plasma containment chamber is defined in the outer tube (35) at the cavity (52) of the body (50).