Modular plasma reformer treatment system

Abstract

A modular plasma treatment system has interchangeable and easily accessible inner and outer electrodes that concentrically nest within an outer housing of one or more plasma reformers. The inner and outer electrodes have self-centering features that allow for blind-fitting of the interchangeable inner and outer electrodes during electrode replacement and maintenance. A plurality of reformers that generate different types of plasmas are preferably arranged serially to allow for a mixture of separate plasmas within the same reaction area and to increase utilization of short-lived radicals.

What is claimed is: 
     
         1 . A modular plasma treatment system, comprising:
 a first outer housing of a first plasma reformer having a first exhaust inlet for receiving a first input gaseous stream and a first exhaust outlet for expelling a first output gaseous stream, wherein the first outer housing comprises a first housing inner receiving chamber;   a first outer electrode sized and dimensioned to abut first housing portions of the first housing inner receiving chamber such that the first outer electrode does not substantially move when set in place within the first housing inner receiving chamber, wherein the first outer electrode comprises a first electrode inner receiving chamber;   a second outer electrode sized and dimensioned to abut the first housing portions of the first housing inner receiving chamber such that the second outer electrode does not substantially move when set in place within the first housing inner receiving chamber, wherein the second outer electrode comprises a second electrode inner receiving chamber;   a first inner electrode sized and dimensioned to abut first electrode portions of the first electrode inner receiving chamber such that the first inner electrode does not substantially move when set in place within the first electrode inner receiving chamber; and   a second inner electrode sized and dimensioned to abut second electrode portions of the second electrode inner receiving chamber such that the second inner electrode does not substantially move when set in place within the second electrode inner receiving chamber.   
     
     
         2 . The modular plasma treatment system of  claim 1 , wherein the first housing inner receiving chamber and a first exterior portion of the first outer electrode comprise self-centering features that center the first outer electrode with respect to the first outer housing as the first outer electrode is set in place within the first housing inner receiving chamber. 
     
     
         3 . The modular plasma treatment system of  claim 2 , wherein the self-centering features comprise a tapered wall of the first housing inner receiving chamber that centers the first and second outer electrodes when either is set in place within the first housing inner receiving chamber. 
     
     
         4 . The modular plasma treatment system of  claim 2 , wherein the self-centering features comprise a tapered exterior cross-section of the first outer electrode that widens against the first housing portions of the first housing inner receiving chamber as the first outer electrode is set in place within the first housing inner receiving chamber. 
     
     
         5 . The modular plasma treatment system of  claim 1 , wherein the first electrode inner receiving chamber and a first exterior portion of the first inner electrode comprise self-centering features that center the first inner electrode with respect to the first inner electrode inner receiving chamber as the first inner electrode is set in place within the first inner electrode inner receiving chamber. 
     
     
         6 . The modular plasma treatment system of  claim 5 , wherein the self-centering features comprise a tapered wall of the first electrode inner receiving chamber that centers the first inner electrode when the first inner electrode is set in place within the first electrode inner receiving chamber. 
     
     
         7 . The modular plasma treatment system of  claim 5 , wherein the self-centering features comprise a tapered exterior cross-section of the first inner electrode that widens against the first electrode portions of the first electrode inner receiving chamber as the first inner electrode is set in place within the first electrode inner receiving chamber. 
     
     
         8 . The modular plasma treatment system of  claim 1 , wherein the first outer electrode and the first inner electrode, when set in place within the first housing inner receiving chamber, are configured to provide a first plasma gap for a first plasma and wherein the second outer electrode and the second inner electrode, when set in place within the first housing inner receiving chamber, are configured to provide a second plasma gap for a second plasma different from the first plasma. 
     
     
         9 . The modular plasma treatment system of  claim 1 , wherein the first plasma reformer comprises a dielectric barrier discharge plasma reformer to generate a dielectric barrier discharge plasma. 
     
     
         10 . The modular plasma treatment system of  claim 9 , wherein the first outer electrode comprises interior conductive formertions to generate electric field gradients between points of the conductive projections. 
     
     
         11 . The modular plasma treatment system of  claim 10 , wherein the interior conductive projections comprise conductive screw tips screwed into holes of the first outer electrode. 
     
     
         12 . The modular plasma treatment system of  claim 10 , wherein at least two of the interior conductive projections comprise different dimensions from one another to provide different electric field gradients to precipitate particulate matter having different properties. 
     
     
         13 . The modular plasma treatment system of  claim 9 , wherein the first exhaust inlet comprises surface features that alter air pressure within an excitation chamber of the first plasma reformer to direct the first input gaseous stream in a cyclone motion to points of highest energy density inside the excitation chamber. 
     
     
         14 . The modular plasma treatment system of  claim 13 ,
 wherein the first plasma reformer comprises a rotating glide arc reformer and the second plasma reformer comprises a DBD plasma reformer,   at least one of the first outer electrode and the first inner electrode rotate a textured surface to direct the first input gaseous stream in a cyclone motion to points of highest energy density inside an excitation chamber of the rotating glide arc reformer.   
     
     
         15 . The modular plasma treatment system of  claim 14 , further comprising coaxial electrodes that discharge into each of the glide-arc plasma and the DBD plasma. 
     
     
         16 . The modular plasma treatment system of  claim 1 , further comprising:
 a second outer housing of a second plasma reformer having a second exhaust inlet for receiving a second input gaseous stream and a second exhaust outlet for expelling a second output gaseous stream, wherein the second outer housing comprises a second housing inner receiving chamber;   a third outer electrode sized and dimensioned to abut second housing portions of the second housing inner receiving chamber such that the third outer electrode does not substantially move when set in place within the second housing inner receiving chamber, wherein the third outer electrode comprises a third electrode inner receiving chamber;   a fourth outer electrode sized and dimensioned to abut the second housing portions of the second housing inner receiving chamber such that the fourth outer electrode does not substantially move when set in place within the second housing inner receiving chamber, wherein the fourth outer electrode comprises a fourth electrode inner receiving chamber;   a third inner electrode sized and dimensioned to abut third electrode portions of the third electrode inner receiving chamber such that the third inner electrode does not substantially move when set in place within the third electrode inner receiving chamber; and   a fourth inner electrode sized and dimensioned to abut fourth electrode portions of the fourth electrode inner receiving chamber such that the fourth inner electrode does not substantially move when set in place within the fourth electrode inner receiving chamber,
 wherein the first output gaseous stream feeds the second input gaseous stream. 
   
     
     
         17 . The modular plasma treatment system of  claim 16 , wherein the rotating glide arc reformer generates a glide-arc plasma and the DBD plasma reformer generates a DBD plasma. 
     
     
         18 . The modular plasma treatment system of  claim 17 , further comprising a magnetic field generator that generates a magnetic field around the co-axial electrodes. 
     
     
         19 . The modular plasma treatment system of  claim 18 , wherein the first outer housing of the first plasma reformer is disposed above a particulate filter expelling the first output gaseous stream to transfer waste heat from the first output gaseous stream to an oxidant conduit. 
     
     
         20 . The modular plasma treatment system of  claim 19 , wherein the air source comprises at least one of a blower and an on-board turbocharger. 
     
     
         21 . The modular plasma treatment system of  claim 1 , wherein the plasma treatment system oxidizes particulate matter in a reaction zone between the first inner electrode and the first outer electrode. 
     
     
         22 . The modular plasma treatment system of  claim 21 , wherein the air dryer uses a desiccant to remove water vapor from the intake air. 
     
     
         23 . The modular plasma treatment system of  claim 1 , further comprising an air drier that receives intake air from an air source and outputs dried air, wherein the first exhaust inlet receives the dried air and outputs oxidants to the first output gaseous stream. 
     
     
         24 . The modular plasma treatment system of  claim 1 , further comprising a voltage transformer integrated with a feedthrough of the first plasma reformer to deliver power from the voltage power transformer to the first outer electrode and the first inner electrode. 
     
     
         25 . The modular plasma treatment system of  claim 1 , further comprising a fuel injector that injects fuel into the first input gaseous stream. 
     
     
         26 . The modular plasma treatment system of  claim 25 , wherein the first plasma reformer comprises at least one of a DBD reformer and a rotating glide-arc reformer. 
     
     
         27 . The modular plasma treatment system of  claim 1 , further comprising a microwave generator that generates microwaves directed towards the first outer housing. 
     
     
       28. A method of treating a hydrocarbon stream, comprising:
 directing the hydrocarbon stream into a first reaction zone;   energizing, within the first reaction zone, the hydrocarbon stream flowing between a pair of coaxial electrodes comprising substantially coextensive and overlapping inner and outer electrodes to generate an energized hydrocarbon stream;   directing the energized hydrocarbon stream into a second reaction zone at least partly downstream of the pair of coaxial electrodes, and directing a microwave energy at the energized hydrocarbon stream in the second reaction zone; and   directing the energized hydrocarbon stream into a third reaction zone downstream of the pair of coaxial electrodes, the third reaction zone having a third reaction zone plasma generated by a second set of electrodes in the third reaction zone and of a different type than the pair of coaxial electrodes.   
     
     
       29. The method of  claim 28 , wherein the pair of coaxial electrodes generates a dielectric barrier discharge plasma or a glide-arc plasma. 
     
     
       30. The method of  claim 28 , wherein the energized hydrocarbon stream is energized by a first plasma generated in the first reaction zone. 
     
     
       31. The method of  claim 30 , further comprising the step of generating a second plasma in the second reaction zone in part using the microwave energy. 
     
     
       32. The method of  claim 31 , wherein the second plasma is a different type of plasma than the first plasma. 
     
     
       33. The method of  claim 31 , further comprising confining the first and second plasmas within a linear portion of a physical barrier. 
     
     
       34. The method of  claim 31 , wherein the third reaction zone plasma is a glide-arc plasma generated by the second set of electrodes. 
     
     
       35. The method of  claim 31 , wherein the first plasma is formed by the pair of coaxial electrodes and more than one plasma is present in at least one of the second reaction zone or third reaction zone. 
     
     
       36. The method of  claim 35 , wherein the pair of coaxial electrodes is in linear alignment with the second set of electrodes. 
     
     
       37. The method of  claim 30 , further comprising directing the energized hydrocarbon stream through a common reaction zone coupled between the first reaction zone and the second reaction zone, wherein the second reaction zone is configured to sustain a second plasma different than the first plasma and the third reaction zone plasma, and the common reaction zone is configured to sustain both of the first plasma and the second plasma. 
     
     
       38. The method of  claim 30 , wherein the first plasma is a dielectric barrier discharge plasma formed at least in part by the inner electrode, wherein a dielectric layer is disposed on a surface of the inner electrode. 
     
     
       39. The method of  claim 28 , further comprising generating a low pressure zone relative to an adjacent pressure zone within the first reaction zone. 
     
     
       40. The method of  claim 28 , further comprising forming a precipitate from the energized hydrocarbon stream. 
     
     
       41. The method of  claim 28 , further comprising generating a product from the energized hydrocarbon stream, wherein the product comprises hydrogen. 
     
     
       42. A plasma device, comprising:
 a first reaction zone having a pair of electrodes, substantially coextensive and overlapping each other, about a shared axis of elongation of the electrodes and configured to energize a gas stream therein;   an emitter configured to direct microwave energy towards the energized gas stream in a second reaction zone downstream of the pair of electrodes; and   a third reaction zone downstream of the pair of electrodes and having a third reaction zone electrode, wherein at least one of the second reaction zone or the third reaction zone is configured to maintain more than one plasma therein using at least one excitation source.   
     
     
       43. The plasma device of  claim 42 , wherein the pair of electrodes comprises a first electrode, wherein the first electrode is configured to generate a first plasma with a second electrode. 
     
     
       44. The plasma device of  claim 43 , wherein the emitter further directs microwave energy toward a portion of one of the pair of electrodes or an outlet of the first reaction zone. 
     
     
       45. The plasma device of  claim 43 , wherein the pair of electrodes comprises the second electrode. 
     
     
       46. The plasma device of  claim 43 , wherein the emitter is directed toward the second reaction zone downstream of the first plasma. 
     
     
       47. The plasma device of  claim 42 , wherein a conductive projection in the first reaction zone generates an electric field gradient in the first reaction zone with another conductive projection.