A STUDY OF THE METHAMATTON OF A FLOWING * H2- 00 GAS MIXTURE TN A PLASMA CATALYZED REACTOR PART T- THE METHAT “AARON OF A FLOWTNG H2- CO GAS MIXTURE TN A PLASMA CATALYZED REACTOR PART A - THE MICROWAVE PLASMA AS CATALYST TR THE METHANATION STEP Thesis for the Degree of M. S. MICHIGAR STATE UNIVERSITY RICHARD L. HOLLOWAY 1973 ABSTRACT THE METHANATION OF A FLOWING H2 - CO GAS MIXTURE IN A PLASMA CATALYZED REACTOR By Richard L. Holloway MixTures of H2 - CO were conTinuously pasTed Through a microwave plasma in a quarTz Tubular reacTor. Conversions up To 25% were obTained for residence Times of 0.07 To 1.5 seconds and pressures of 2 To 50 mmHg. CH4 conversions increased wiTh increasing H2 concenTraTion, wiTh a 4:1 volumeTric raTio giving The highesT yield under The experimenTal operaT- ing condiTions. The power ThaT gave The highesT yield To CH4 was 250 To 600 waTTs, wiTh Thermal decomposiTion of hydrocarbons occurring aT higher power levels. ApproximaTely I50 waTTs were required To mainTain The microwave plasma. CHECH was idenTified as The major biproducT, and a mechanism lncorporaTing a (CH-) inTermediaTe is posTulaTed To accounT for The Two hydrocarbon producTs. A STUDY OF THE METHANATION OF A FLOWING H2 — CO GAS MIXTURE IN A PLASMA CATALYZED REACTOR PART I - THE METHANATION OF A FLOWING H2 — co GAS MIXTURE IN A PLASMA CATALYZED REACTOR PART II - THE MICROWAVE PLASMA AS CATALYST IN THE METHANATION STEP By a. Richard L: Holloway A THESIS SubmiTTed To Michigan STaTe UniversiTy in parTial fulfillmenT of The requiremenTs for The degree of MASTER OF SCIENCE DeparTmenT of Chemical Engineering 1973 (A ACKNOWLEDGMENTS The auThor graTefulIy acknowledges The DeTroiT Edison Company and The Division of Engineering Research aT Michigan STaTe UniversiTy for Their financial supporT of This work. AppreciaTion is exTended To Dr. M. C. Hawley, Dr. B. W. Wilkinson, and Dr. J. Asmussen for Their Technical assisTance and guidance during The course of The projecT. TABLE OF CONTENTS ABSTRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACKNOWLEDGMENTS . . TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . PARTII - THE METHANATION OF A FLOWING H2 - CO GAS MIXTURE IN A PLASMA CATALYZED REACTOR . . . . . . . . . . . . . . . MaTerials and EquipmenT . . . . . . . . . . . . . . . . . ExperimenTal Procedure . . . . . . . . . . . . . . . . . Model of SysTem and DefiniTions . . . . . . . . . . . . . ResulTs and Discussion . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . References 0 O O O O O O I I O O O O O O I O O O Q PART H - THE MICROWAVE PLASMA AS CATALYST IN THE METHANATION STEP DescripTion of Plasma CharacTerisTics and ParameTers . . Microwave Plasma ChemisTry and Proposed ReacTion Mechanism Microwave Plasma ReacTor and RF SysTem . . . . . . . . . References 0 O O O O O O O O O O O O O O O O O O O O O O 0 APPENDIX A - Infrared SpecTra DaTa APPENDIX B - Residence Time CompuTer Program 11 12 I4 28 29 30 31 4O 51 ll. 12. LIST OF FIGURES Process Flow Diagram for The Plasma CaTaIyzed MeThanaTion . Chemical Processing EquipmenT . RF Plasma ReacTor . Equilibrium ConsTanTs for H2 - CO - CH4 . MeThane Yield Versus Residence Time . MeThane Yield Versus Power InpuT ElecTron DensiTy as a FuncTion of LengTh and Radius for The TE*||2 Mode . . . . . DissociaTion RaTe ConsTanT K1 Versus E/P Cylindrical Plasma ReacTor The RF SysTem . Behavior of The Plasma CaviTy When The ExciTaTion Frequency is ConsTanT . . . . . . . . . . . . . . The TE*||| Mode used in ExperimenTal Work . iv 21 24 26 33 39 41 42 44 50 LIST OF TABLES Page I. Summary of ExperimenTal Runs . 15 INTRODUCTION Many chemical reacTions in elecTric discharge or plasma have been sTudied over The pasT TwenTy years,1’2’3'4’8 The majoriTy of These being in baTch sysTems. However, never has The need been greaTer To pursue The possibiliTy of producTion of synTheTic naTural gas from coal in a conTinuous flowing plasma reacTor. In view of The criTical supply and demand siTuaTion for energy in This counTry and The increasing concern on environmenTaI quaIiTy iT is essenTial ThaT new coal process- ing Techniques be invesTigaTed Through engineering research and develop- menT. This sTudy is a reporT and analysis of The firsT resulTs of The research efforT aT Michigan STaTe UniversiTy To produce meThane from CO and H2 via microwave caTalysis. The sysTem for meThanaTion experimenTs consisTed of a flowing H2 - CO gas mixTure Through a microwave field To produce The caTalysis effecT. IT should be emphasize ThaT The projecT alThough speculaTive in naTure enTails a unique, unexplored area in boTh plasma opTimizaTion and chemical process developmenT. The overall research projecT is broken down inTo separaTe sTudies of The meThanaTion in a plasma reacTor, gasificaTion in a plasma, hydro- _ genaTion of coal in a plasma, and finally The uITimaTe goal of a combined meThanaTion and gaslficaTion process. Preliminary economics for a plasma sysTem have been developed by Asmussen, Hawley, and Wilkinson in The original Michigan STaTe UniversiTy research proposal.14 Their speculaTive economics indicaTed a poTenTial l5% savings in capiTal lnvesTmenT and a IO% decrease in operaTing cosT. FurTher experimenTal work will esTablish a firmer base case for preliminary design and comparison wiTh oTher schemes in coal processing. The Two rouTes for producing SNG (high BTu gas) which are being developed and commercialized are I) SNG from naphTha and 2) SNG from coal. BoTh schemes are similar in ChemisTry; i.e., boTh require gasificaTion, shifT, and meThanaTion. The chemical reacTions for These sTeps are wriTTen for SNG from coal as follows: (a) GasificaTion 2C + 2H O + 2C0 + 2H 2 2 (b) ShifT C0 + H20 + 002 + H2 (c) MeThanaTion nickel 3H2 + CD + CH4 + H20 caTalysT The neT process can be summarized as 2C + ZHZO + CH4 + CO2 A unique feaTure of The projecT is ThaT The microwave source pro- vides only The energy To mainTain The plasma for caTalysis of The meThan- aTion reacTion. This will also be The case in fuTure work on a plasma reacTor which will carry ouT boTh The gasificaTion and meThanaTion reacTions in a single uniT, Thus eliminaTing a porTion of The cosle process equip- menT of The currenT SNG rouTes. Many invesTigaTors have sTudied The producTion of hydrocarbons in elecTric discharges and There have been several H2 - CO - C02 sTudies in microwave,5’6 megaherTz,7 and corona discharges.8’9 One of parTicular inTeresT is by Epple and ApT7 who have shown if possible To converT mixTures of H2 and 002 To meThane in elecTrical discharges ranging in frequency from 2-llO megacycles. Their work was performed in a sTaTic sysTem wiTh residence Times of 2—3 minuTes and reporTed conversions as high as 55% of The ToTal inpuT of carbon To CH4. PART I - THE METHANATION OF A FLOWING H2 - CO GAS MIXTURE IN A PLASMA CATALYZED REACTOR MATERIAL AND EQUIPMENT The process flow diagram is shown in Figure 1. A 5 TT3 cylinder was used for The premix Tank, wiTh a gas regulaTor ThaT gave a consTanT discharge pressure of 5 psig. The premix Tank was evacuaTed and Then flushed several Times wiTh H2 To remove any oxygen ThaT mighT have been in Tank afTer use. Oxygen being a free radical accepTor musT be com- pleTely eliminaTed in order To achieve The meThanaTion sTep.. The feed gases are Then passed over a CaSO4 packed bed To insure The removal of any H20 since This drives The meThanaTion reacTion in The reverse direc- Tion. Flow raTes are Then measured using a roTameTer wiTh a selecTion of roTameTer Tubes ThaT allowed a flow range of 5-l0,000 cc/min aT S.T.P. The gases were preheaTed in some experimenTs using a high volTage-low amp elecTrical source which conducTed a currenT Through a 30' secTion of 1/32" OD pipe. The reacTor sysTem consisTs of a I2" diameTer caviTy wiTh cooling coils around The ouTer perimeTer and l/64" holes for elecTric field sTrengTh probes (Figure 3). As The hoT gases leave The preheaTer They enTer The I" OD quarTz Tube where The plasma is generaTed and The reacTion Takes place. ReacTor discharge gases are Then passed Through a Two sTage cooling sysTem, The firsT a dry ice-eTherne gycol soluTion (-30°F) and Then a waTer baTh. This cooling secTion may be bypassed if sufficienT naTural convecTion occurs from The reacTor ouTIeT To The cooling sysTem from The pipe. A final drying bed of CaSO4 is uTilized To remove any Traces 5 . 83333: REES asundm mom amnwaac team nuooonm ..«onymah- cum pmaunxo OBIITII MWWIIIIII’ . mad assod> mcflaooo nevus —wWW— anducooom Hoohquon hunv . madaooo andaaum mWw mH FIIIIil¢ 0959 mcahhn bade a S - mm I - Hovoadvom 3o Figure 2 . Chemical processing equipment Figure 3 . rf plasma reactor of waTer produced from The reacTion. WaTer absorbs in The same region as CH4 in The IR so musT be removed. The IR analysis was done wiTh a Perkin-Elmer specTrophoTomeTer uTilizing a l meTer gas cell. A reference cell was also used. AfTer The gases were analyzed They were drawn Through The vacuum pump and discharge To an exhausT fan. InsTrumenTaTion consisTed of TemperaTure and pressure gages locaTed abouT The reacTor and cooling sysTem, along wiTh sample poinTs for mass SpecTra. Piping up To The preheaTer was 1/4" OD copper Tubing while 1/2" OD sTainless sTeel was used afTer The preheaTer. Due To The exTremely Toxic naTure of The CD, a MSA carbon monoxide deTecTor was used during all work. A safeTy shield enclosed The reacTor as an explosion proTecTion device. During The course of The experimenTal work The following mechanical or process problems were encounTered. Problem: The enTire sysTem had To be vacuum TighT wiTh a leakage raTe of less Than 2 cc/min of air. AcTion: All connecTions were sealed wiTh gypToI or high vacuum grease. Problem: High power inpuTs caused The deposiTion of carbon on The walls and The quarTz reacTor Tube To melT. AcTion: Provided an air cooling sysTem in The reacTor caviTy and changed The power divider To reduce power inpuT. Problem: PreheaTer was fabricaTed wiTh sTainless sTeel Tubes conTaining nickel which aT higher pressures could produce CH4 due To The caTalysis effecT. AcTion: Nickel in Tubes was poisoned using sulfur dioxide. Problem: TemperaTure measuremenT of gases under high vacuum. iO AcTion: An infrared pyromeTer was TesTed. Problem: Excessive dusT from drying Tube collecTed on I.R. cell mirrors. AcTion: Glass wool filTer was insTalled afTer drying Tube. EXPERIMENTAL PROCEDURE The compleTe sysTem is firsT evacuaTed To less Than I mm Hg. The H2 - CO feed valve is opened To esTablish a flowing sysTem under high vacuum and purge ouT any remaining air. As an iniTial sTarT-up sTep, The roTameTer flow is seT To IOO cc/min of H2 - CO mixTure and a pres- sure of 2 mm Hg. The microwave rf source is Turned on and The sliding shorT adjusTed To produce enough power To creaTe The necessary ioniza- Tion required To esTablish a plasma. The caviTy (plasma) lengTh is Then adjusTed in order To opTimize or reTune The plasma. Once The plasma is generaTed The pressure is increased sTep wise, each Time adjusTing The sliding shorT and caviTy lengTh (see Part II. Microwave Plasma ReacTor Design for mechanical deTails). When The sysTem has reached sTeady sTaTe, The reacTor discharge is analyzed on The Infrared SpecTrophoTomeTer by scanning The 4000-1300 cm.1 region. The appropriaTe variables are recorded and The sysTem changed To a new seT of parameTers. 11 MODEL OF SYSTEM AND DEFINITIONS Consider a H2 - CO gas mixTure flowing Through a Tubular reacTor wiTh a microwave plasma being generaTed inside The Tube producing a chemical reacTion. This is illusTraTed below along wiTh The associaTed variables. The objecTive of The plasma caTalyzed reacTor is To maxi- mlze conversion To meThane by The following reacTion, while (1) 3H2 + CO —-—-—--+-CH4 + H20 minimizing power requiremenTs and biproducT formaTion. uf P . ‘ %Gv Tin , V, Ne, Te .27 Tb R [PW Tin - inleT TemperaTure P - sysTem pressure uf - volumeTric flow raTe of H2 - CO mixTure which is a funcTion of The sysTem pressure, P, and inleT TemperaTure, Iin' - raTio of HZ/CO V - reacTor volume dependenT on The caviTy lengTh PW - power absorbed in caviTy Ne - elecTron densiTy which is a funcTion of pressure, P, and power absorbed, EW_ Te - elecTron TemperaTure in reacTor which is dependenT on elecTron densiTy, Ne, and power, EW_ Tb - bulk TemperaTure of gas leaving plasma reacTor %GV - percenT by volume of hydrocarbon producT in reacTor discharge which is a funcTion of The following, 12 1) 2) 3) 4) 5) 13 TemperaTure, IQ! and Te Pressure, E_ -_- ElecTron densiTy, N_e_ VolumeTric flow raTe, 2i! and raTio of H2/CO, 3 Power absorbed in caviTy, EW_ If we assume no volume change occurs in The reacTor The design equaTion for The sysTem is shown in equaTion (2). (2) where (CH4) r 3;.- _J d(CH4) r(Tb,Te,P,Ne,R) meThane concenTraTion raTe of reacTion of reacTanTs RESULTS AND DISCUSSION The firsT meThanaTion experimenTs shown in Table 1 (runs l300l- 20lO4) had flow raTes of lOOO-3000 cc/min producing very small resi- dence Times in The plasma reacTor. All previous works’7 in This area had been on sTaTic sysTems using very high residence Times of 2-3 minuTes, however in The iniTial work on The economics of The projecT residence Times of less Than 2 seconds were necessary To esTablish saTisfacTory power savings. The power levels were above 1500 waTTs which creaTed a plasma wiTh a reddish glow ThaT compleTely filled The quarTz Tube in The caviTy. There was no basis for sTarTing aT These power levels, excepT providing enough power To produce The plasma in The flowing H2 - CO sysTem. The firsT H2 - CO feed Tried was a l0:l mixTure (by volume) of hydrogen rich gas. Since previous experimenTal work on hydrogen in a microwave plasma had been conducTed by Asmussen, O’l' one of The principal invesTigaTors, The iniTial generaTion of The plasma was done in a hydrogen rich feed. The TEOII mode was The resonanT frequency used in These runs corresponding To a caviTy lengTh of 9.8 cm. The flowing gases were analyzed on The IR specTrophoTomeTer in These runs, however, They showed no meThane bands. Also mass specTra samples gave negafive resulTs. However, a very significanT finding of These runs (lBOOI-20l04) was The observaTion of a carbon deposiTlon on The quarTz Tube wall. This cerTainly indicaTed The presence of a chemi- cal reacTion occurring in The flowing gas mixTure. Figure 4, for The 14 15 m__mz co m+on m+o: mzocm ona+ N+Lmzc = mm.0 .m.P 0pm = : mm = .\v hoFom = vw.0 Nm._ 00, = : 0v = _\v 00.00 = mm.0 mm._ 00 = : 0v : —\v mo_0m = Nm. _ no; OVN = = on : —\v VOFOM = 50.0 0N0. I I N__*0H 0.m_ 0n = _\v m0_om = pF.0 mm. 00m N__*mp 0.m_ 0m 00— _\v N0_om co_+mEco$ v10 uo>comno +mc_+ N 00.0 mm. on N__*mH 0.m_ MF 00— _\v P0_0m oo+_oE ona+ N+Emao .uoEL0+ m+0am+05 I I 0.0 000.0 ova F_0mh 0.0 00 000— —\0_ v0_0N I I 0.0 000.0 0V0 = 0.0 mm 000— _\0_ mopom I I : 0m0. 000— = 0.0 mm 000_ _\0_ N0_0N I I : N0. 00NP : 0.0 m_ 000— _\0P _0—0N I I : 0_.0 000 = , 0.0 om 000? _\0_ «oom— II m__mz 033+ co mc_EL0+ m+_moQou concmo I I : 0P.0 000— = 0.0 on 000— _\0_ m00m_ I I = NNO. mop— F_omh 0.0 mm 000m _\0_ Noon— Aoco_>+oom Lo v10 0:0 oozocm mc+ooam mmme new a. I I 0.0 0m0. 00N_ F—omk 0.0 m_ 000— _\0_ _00m_ mxcmeom Conan: v00 oomgoe_+ m++mz 0002 so 0155 :_E\oo 00\NI Logan: o>Lno oE:_o> mecov Lozoa v .c+0:o. .moca on_+ o_+mL czc m. u I_moc m >+_>mo mom meme m+mo _o+:oE_coaxm ._ o_nmh 16 0 >0. N0. 00v = = mm m0 _\v 0000M 0 >0. N0. nmm = : mm m0 _\¢ 0000M 0 n0. mm. 0_N = = m_ m__ —\v nooom 0 00.. mm. 00m = = m_ m__ _\v 0000M 0 00._ mm. mom : = m_ m_F _\v 0000M 0 mm. mm. 050 = : mp m__ _\v e000m 0 en._ 0v. 0mm : = 0. m0 P\v 0000M 0 0m._ >_.F 00w : 0.m_ 0P mm _\v N000m m n_.N 0m. 00m N__*0H 0.m_ m_ on _\v _000m N I I on. no. NF—*0H 0.m_ NF 00? _\e mppom : I I on. 00— = = N_ = _\v N__0m : I I mm. 00m = : 0_ = _\v F—Pom = I I 5N. 00m = = 0F : .\v 0_F0m : I I Fe. 00m = = m. = _\v 00—0m mcbocoooc L0+ so_ 0+ a. co mecm++_smcoc+ u N I I 00.. 05m NFP*mH m.m~ 0m 00— .\v 00—0m mxcmsom Logan: eIo oom.oe_+ m++mz 0005 so 0:52 c_s\oo 00\NI Conan: o>cao oe:.o> Noocoo mcoon v .c+m:o_ .moca _3o_w o_+mc csc m. u I_moc >+_>oo mom ooo+ Auo:c_+coov m+mo _m+coe_coaxm ._ o_nmh l7 0 00.0 0.. 0v> : = ow m0 _\v mp>0m 0 00.0 m.. 000 = = 0e m0 _\v N_>0m 0 00.0 m._ mvm = : 00 m0 _\v _—>0m 0 mv.0 0.0 men = z. 0v m__ .\< 00>0m 0 «0.0 0._ mem : : ow 00 _\v 00>0m 0 00.. m._ mmm : : 0v m0 _\v 00>0m 0 00.. 0. >00 : : mN m0 _\v >0>0m 0 0.0 mm. 000 = : 0. m0 _\v 00>0m 0 >—.N mm. 00m = : 0. m0 _\v mo>0m 0 0.0 >0. >mm = = N m0 _\v v0>0m 0 0.0 >0. 0v. : = N 00 _\v m0>0m 0 v.0 >0. .mm : = N m0 P\v N0>0m 0 v.0 >0. 000 : = N m0 _\v _0>0m 0 mv.0 N0.0 0_v = = 0N m0 F\v F_00m 0 mv.0 N0.0 omN N__*m> 0.m_ mN m0 _\v 0.00m mxcmeom Conan: v10 oom.os_+ m++mz @008 so 0155 c_E\oo 00\NI Conan: o>cao oE:_o> Noocoo mcozoa v .c+0co_ .moca F30: o_+mc CDC 0. u I_moc >+_>mo mom noo+ Roo::_+coov m+m0 _m+cos_coaxm .— 0_nm> l8 NN I I >0. >mv = = N 00 .\. woe—m NN I I m0. >00 = = 0N m0 .\_ movpm NN I I mm. 0>m = = 0. m0 .\. Nov—m NN I I mm. >v0 : = 0. m0 .\. .0e_m —N N.0 0.. 00v = = me m0 _\_ 0_m_m —N N.0 0.. 00m : : me m0 .\. 00m.m 0N N.0 ... omm : : mm m0 _\. 00m_m 0N m_.0 0.0 00v = = 0N m0 .\_ >0m_m 0N m_.0 0.0 0>> = = 0N m—_ .\. mom—m 0N N.0 00. 00> = = 0N m0 .\. mom—m 0— N.0 mo. 0m0 : : 0N m0 .\. vom.m 0F N.0 >0. 0>m = = N m0 _\. mOMFm 0F N.0 m.0 0.0 = = 0. m0 _\. Non—m 0F 00.. mm.0 0N0 : = 0. m0 _\. .0m_m smL+ mo. >La a s0. n._ com = = as mm _\e m_kom 0 0m._ m.— 00v N__*m> 0.m_ 0v m0 .\v v.>0m mxcosom conszc v10 oom.os.+ m++mz ouos so miss c.s\oo 00\NI Loasac o>czo os:.o> Noocoo mcoon v .c+0co. .moca _3o.+ o_+mc ass a. u I.moc >+.>mo mom voo+ .voac.+coov m+mo .m+cos.coaxm ._ o.nm> l9 0N 00.. >0. 00> = = N 00 .\v 000.0 >N NN. 00. 00N = = 0N 00 .\v >00.0 >N v0. 00. 000 = = 0N 00 .\0 000.0 >N «0. 00. 000 : : 0N 00 .\v 000.0 0N 0N. 00. 000 = = 0. 00 .\v «00.0 0N 0N. 00. 000 = : 0. 00 .\v 000.0 boost Ioc m_m.co+ms ..m .0 mco.+ 0N we. 00. 000 z : 0. 00 .\v N00.0 Imc+coocoo .+m:u v00o0 5+.3 noco>oo >..m.+cma mcocc.s m. 0N NN. 00. 000 = = 0. 00 .\v .00.0 0N I I .. 000 : = 00 00 _\. ..v.0 0N I I 00. 000 = = ON 00 _\. 0.v.0 0N I I 00. 00> : = ON 00 _\. 000.0 0N I I 00. 000 = : 0. 00 .\. 000.0 0N I I 00. 000 = : 0. 00 .\. >0v.0 0N I I >0. 000 = = N 00 .\. 00v.0 0N I I >0. V00 N..*m> 0.0. N 00 .\. 00e.0 mxcmsom conszc vzo oom.os.+ m++mz ouos so mzss c.s\oo 00\NI consac o>czo os:.o> oocoo Lozoa v .;+0co. .moca .30.. o.+mc cac m. m I.moc >+.>mo mom boo. .oo::.+coo. m+mo .m+c®E.c@aXm 20 .+0.+:o Lo+omoc +0 oca+mcoaso+ 0cm ocsmmoca s0+m>m co 00mmn os.+ 0oc00.mom . ... +Lma c. nommso.0 m. 000s +0 oa>> .>+.>mo c. noncomom c0300 .m+o> . NM? .mo0> 0cm 0.ma 0 +0 mco.+.vcoo co+0sm+oL +0 30.. 000 .. "m0+oz 0N 00.. >0. 000 = = N 00 .\v N.0.0 0N 0 >0. 0Nv : = N 00 .\v ..0.0 0N 0 >0. 0>N : = N 00 .\v 0.0.0 0N 00.. >0. 000 N..*0> 0.0. N 00 .\v 000.0 mxcmsmm Looszc 0:0 oom.0s.+ m++mz 000s so mzss c.s\oo 00\NI Eonssc 0>cao os:.o> Nmocov 0L0300 v .c+0c0. .moca .zo.+ o.+mc csc m. a I.moc >+.>mo mm0 000+ .00::.+coo. m+mo _m+cos.coaxm .. 0.nm> Equilibrium Constants , X 10000 1000 100 10 21 C" l— __ 3H2 + C0 w-r‘CHu + H20 C: F'- I: r- I J 700 800 900 1000 Temperature . °K Figure‘I. Equilibrium constants for Hz-CO-Cflu system 22 H2 - C0 sysTem was used To explain This phenomena. IT can be seen ThaT above 850°K any meThane formed would be Thermally decomposed To carbon. During These runs hoT spoTs were observed in The plasma aT The walls, and once The quarTz Tube sTarTed To melT which would indicafe Tempera- Tures above 1500°K, iT was The general conclusion ThaT The reddish elecTric discharge was Too hoT a plasma To produce meThane. AfTer These firsT runs The elecTrical sysTem was modified by varying The sliding shorT posiTion on The power divider which reduced The power absorbed in The caviTy. Also in order To provide addiTional cooling a forced air circulaTion sysTem was insTalled in The caviTy. IT was felT ThaT longer residence Times would be required in The colder plasma so new roTameTers were insTalled. Coupled wiTh These modifica- Tions was The need To change The caviTy lengTh To keep The resonanT frequency consTanT. The caviTy lengTh was increased To 13.8 cm and This corresponded To The TE*l12 hybrid mode (discussed fully in ParT ll). Since during our iniTial runs (l300l-20l04) no Trouble was experienced in The generaTion of The plasma The feed mixTure was changed To 4:1 hydrogen To carbon monoxide (by volume). This beTTer reflecTed The sToichomeTry of The meThanaTion reacTion. AfTer These mechanical mod— ificaTions The power could be varied from IOO-800 waTTs and The flow beTween 5-l|0 cc/min aT The roTameTer pressure and TemperaTure. The nexT experimenTs (runs 3OIOI-30ll3) were successful in ThaT meThane was produced and idenTified by The IR bands aT 2980 cm" and l300 cm"l as shown in IR specTra number 2 and 5. Comparison wiTh lR specTra 3 and 4 also confirms The presence of meThane when The plasma was generaTed. This is The firsT reporTed producTion of meThane in a microwave plasma using a conTinuous flowing H2 - C0 feed. No aTTemst 23 were made To maximize The amounT of meThane in These runs, however meThane was observed wiTh flow raTes from 75-l00 cc/min, residence Times of .25 - I.I sec, and power levels of 200-300 waTTs. The plasma con~ sisTed 0T Two blueish spherical shaped glows in The quarTz Tube. IT was necessary To deTermine qualiTaTiver The amounT of meThane produced in The plasma for each seT of condiTions. A gas mixTure in a raTio of 37:9:I of H2 — CO - CH4 (represenTing IOS conversion of CD To CH4 if no oTher hydrocarbons are formed) by volume was prepared and analyzed on The IR aT a varieTy of pressures commonly used during experimenTal runs. These are shown in IR curves l6 and I7. The percenT by volume of meThane in each run was Then deTermined based on The area under The meThane IR peak aT 2980 cm”l compared To The sTandard aT The corresponding pressure. The percenT by volume in runs 3010I-30113 varied from 0.1 - l.5%. Once meThane had been produced wiTh plasma caTalysis iT was neces- sary To deTermine opTimum condiTions which would maximize The hydro- carbon yield. One imporTanT parameTer explored was The residence Time, which is a funcTion of boTh roTameTer flow raTe, and reacTor TemperaTure and pressure. By holding The power and pressure consTanT, and varying The flow iT was found The percenT meThane in The plasma reacTor gas discharge wenT Through a maximum. This is shown in Figure 5. A possible explanaTion To This experimenTal observaTion may be ThaT aT longer resi- dence Times The bulk gas TemperaTure (or elecTron TemperaTure) are high enough To Thermodynamically favor The reverse reacTion or oTher side reacTions such as formaTion of carbon or aceTylene. Figure 4 shows The equilibrium consTanTs for The meThanaTion reacTion as a funcTion of TemperaTure. ms.» 00:00.00H msmH0> 0.0.» 000290: . 0 0ns0Hm 0E.» 00:00.09. .303 0.0 H H039. SEE 0.» 0.30002. 0.. 0.. 0... N... 0.. 0. .u. N. _ . . — _ _ _ . . 0303 00m H039”. 00.88 0. u 05000.2. 24 0.. N.. 0.. 928 ionpoxd UT {7H3 ewnTOA Aq 010 25 AnoTher variable was The amounT of power puT inTo The plasma caviTy. As discussed before The plasma CharacTerisTics were un- favorable for any hydrocarbon producTion above 1000 waTTs. Several runs showed similar resulTs when The pressure and flow were held consTanT and The power varied. This is shown in Figure 6. Since in order To mainTain The plasma iT Took abouT 125-I75 waTTs, The opTimum power range for meThanaTion lies beTween 250-650 waTTs depending on The pressure and flow raTe. The volumeTric raTio of hydrogen To carbon monoxide in The feed gas is an imporTanT parameTer in deTermining opTimum operaTing condi- Tions. The iniTial runs (13001—13004) were aT a |0:l raTio and showed no meThane, however The power levels were‘kxahigh and a differenT caviTy lengTh was used which boTh produced unfavorable condiTions. The majoriTy of runs were wiTh a 4:l H2 — CO raTio. A special case TesTed was a l:l Hz/CO feed. These experimenTs resulTed in a greale reduced amounT of meThane in The producT gas sTream and required subsTanTially .‘higher power leyels To mainTain The plasma. IR specTra 20 wiTh runs 3l30l-3l4ll shows These experimenTs. This is consisTenT wiTh our proposed mechanism in which generaTion of The hydrogen radical would be The raTe conTroIling sTep (discussed in ParT ll). Higher power levels were required since The ionizaTion poTenTial of The CO molecule ls much greaTer Than ThaT of hydrogen, and consequenle This feed raTio will favor a hoTTer plasma which is unsuiTable for The meThana- Tion sTep. The effecT of pressure on The yield of meThane is a very signifi- canT facTor In esTablishing The operabiliTy and feasibiliTy of The meThanaTion reacTion. From The experimenTal daTa, The highesT yield 26 000. 0.065 0. fl5000nf H0300 0=0H0> 0.0.0 ocmnpmz . 0 0H50Hm 000 000 00> 5800 0: so: 0358 0.4 R 0.3000me :.E\oo 00 n 30.. C O 0 Eu 0 .m Em 0 .2 00\ m 3. G.E\oo 00 30.. — wand» N 005000.... #0000. 9.0.2. 300.0. 0500.9 0.00." .000. 03.03 3030.. 000 J 000 _ 00¢ . 000 A com A 00. N M V“ L0 323 nonpoxd u; THQ BmI’IIOA Aq o/o 27 of meThane was 5.4% by volume aT 2 mm Hg. This corresponds To approx- imaTer 25% conversion of The C0 in The flowing feed gas. Bell'slz’l3 work showed ThaT aTlower pressures The value of Kl, The raTe consTanT for generaTion of The hydrogen radical, is higher and hence greaTer chemical reacTiviTy (Figure 8). Our resulTs would seem To indicaTe This also, however due To differenT Types of elecTrical discharges and resonanT frequencies used This has yeT To be fully subsTanTiaTed. Since The main problem encounTered in subsTaining higher pressures was The plasma beoomintho hoT above 50 mm Hg, furTher modificaTions in The cooling sysTem or esTablishmenT of a colder Type plasma aT higher pressure will be of high prioriTy. One oTher hydrocarbon idenTified in The producT gas by mass specTro- phoTomeTry was aceTylene. Epple and ApT7 reporTed This same biproducT in Their sTaTic sysTem. Because of The very poor sensiTiviTy and broad band aceTylene has in The infrared region, if was noT possible To deTer- mine qualiTaTively The amounT In each run. IR specTra 24, of a l:l mixTure of meThane-aceTylene shows This very broad band aT 3200-3300 cm-l. Comparing This wiTh The experimenTal runs recorded on The IR, The amounT of aceTylene in The producT gas would in all cases by much less Than The amounT of meThane. FurTher research conducTed during The wriTing of This paper has shown aceTylene produced exclusively wiTh a 4:1 H2 - C0 feed using The TE011 mode. The conversion of CO To CHECH based on a meThane free producT was 15% aT 15 mmHg and 0.4 sec. residence Time. SUMMARY This research efforT, of The DeparTmenT of Chemical Engineering and The DeparTmenT of ElecTrical Engineering and SysTems Sciences, reporTs The firsT producTion of meThane in a microwave plasma using a flowing hydrogen—carbon monoxide sysTem. The highesT yield found was 5.4% by volume meThane in The producT gas (corresponding To 25% conversion of C0). Residence Times below 2 seconds were found To be mosT saTisfacTory and enhance The overall economics of The projecT. Power levels beTween 250—650 waTTs were found To give The highesT yields of meThane. Pressures were TesTed beTween 2-50 mm Hg wiTh The highesT conversions obTained aT The lower pressures. AceTylene was idenTified as a biproducT, and a proposed mechanism for The meThana- Tion reacTion including This side reacTion was developed. SignificanT advancemenTs in The area of high pressure - cold plasma Technology allowed hydrocarbon producTion for The flowing gas mixTure. 28 REFERENCES Venugopalon, M., ReacTions Under Plamsa CondiTions, Vol. I (Wiley I968). McTaggarT, F. K., Plasma ChemisTry in ElecTrical Discharges, Elsevier, New York (I967). Baddour, R. F., and Timmins, R. S., The ApplicaTion of Plasma To Chemical Processing, MIT Press, Cambridge (1967). BlausTein, B. 0., Advances in ChemisTry Series No. 80, A.C.S, WashingTon, D.C. (I969). BlausTein, B. D. and Fu, V.C., Chemical ReacTions in EIecTrical Discharges, Adv. Chem. Ser. 80, A.C.S, WashingTon, D.C. (I969). McTaggarT, F. K., AusTraIian J. Chem. l7, Il82 (I964). Epple, R. P. and ApT, C. M., The FormaTion of MeThane from SynThesis Gas by High Frequency RadiaTion, Gas OperaTions Research ProjecT PF-27, Am. Gas. Assoc. Inc. (July 1962). WendT, G., and Evans, G. M., J.A.C.S. 50, 2610 (I928). LunT, R. W., Proc. Roy. Soc. (London) l08A, I72 (I925). Asmussen, J. and Fredericks, R. M., Appl. Phys. LeTTers, I9, 508 (I971). Asmussen, J., Fredericks, R. M. and HaTch, A. J., Behavior of a Bounded Plasma Inside a Microwave CaviTy aT High and Low submiTTed To J. Applied Physics in SepTember I972. Pressures, Bell, A. T., Ind. Eng. Chem. Fund., Vol. II (I972). Bell, A. T., Chem. Eng. Pro. Symp., Ser. No. I12, Vol. 67, (1972). Asmussen, J., Hawley, M. C., and Wilkinson, 8. W., SynTheTic NaTural Gas from Plasma CaTalysTed Chemical ReacTions, Michigan STaTe Research Proposal (I972). 29 PART II - THE MICROWAVE PLASMA AS CATALYST FOR THE METHANATION REACTION 3O DESCRIPTION OF.PLASMA CHARACTERISTICS AND PARAMETERS In The convenTionaI meThanaTion reacTion of H2 - CO a nickel caTa- lysT is employed. IT is The purpose of This research To uTilize a plasma (or elecTric discharge) as an economically feasible subsTiTuTe for The solid caTalysT. IT is imporTanT To emphasize ThaT only The energy for mainTaining The plasma for caTalysis will be puT inTo The sysTem wiTh The microwave source. The minimum energy required To mainTain a microwave plasma has been esTimaTed To be 150 waTTs. JusT as The reacTion raTe is a funcTion of such parameTers as porosiTy and pore size of The solid caTalysT pelleT, The plasma parameTers such as elec- Tron densiTy, elecTron TemperaTure, and elecTric field sTrengTh deTer- mine The overall kineTics and reacTion raTe. ElecTric dischargesare classified inTo Two Types, an "E—discharge" and "H—discharge." The meThanaTion wiThin The plasma reacTor is of The E—Type discharge which is characTerized by low bulk gas TemperaTures and high elecTron Temper- aTures (2000 - I0,000°K). A H-Type discharge in a gaseous sysTem pos- sesses equal elecTron, ion, and neuTraI parTicIe TemperaTures of up To 10,000°K. An imporTanT parameTer in The plasma sysTem is The elecTron densiTy which is nonuniform boTh axially and radially in The quarTz'Tube plasma reacTor. This nonuniformiTy of The elecTric discharge resulTs in a plasma reacTor wiTh only zones of high reacTion efficiency. In our work usually Two or Three zones were visible for The meThanaTion using H2 and 31 32 C0. Also radial zones, or rings, leave open The possibiliTy of bypass- ing Thus causing low chemical and elecTrical conversion efficiencies (Figure 7). MaThemaTically The elecTron densiTy, or concenTraTion can be expressed as 3N 32(r2N ) 32N e D e e Uf 32_'+ —2'-_—__'-—'+ D __—§-= RionizaTion = NevionizaTion r 3r2 32 where D is The ambipolar diffusion coefficienT which can be expressed as a funcTion of The elecTron energy, kTe, and a mobiliTy Term “e- The raTe of ionizaTion, R, is proporTional To The elecTron densiTy and is convenTlonally defined as Nevion’ where Vion is The ionizaTlon frequency. In characTerizing a plasma The concepT of TemperaTure is difficulT To define. This is because The kineTic Theory relaTes TemperaTure To The kineTic energy of The gas molecules. However, The elecTrons will have very high kineTic energies due To Their relaTively low masses and very high velociTies which gives an "elecTron TemperaTure" ThaT is much larger Than The "kineTic TemperaTure." Thus defining raTe consTanTs can be made possible by use of an "equivalenT TemperaTure" defined by Epple and ApT8 as The equilibrium TemperaTure To which The sysTem would have To be broughT in order To aTTain The composiTion observed on chemi- cal analysis of The consTiTuenTs. In an elecTric discharge or plasma iT has been found ThaT The suiTable parameTer To describe The sysTem is E/p, where E is The elecTric field sTrengTh and p The ToTal pressure. Previous workB’5 has shown ThaT aT higher values of E/p, The average elecTron energy is larger, Thus The chemical reacTiviTy of The sysTem is greaTer (Figure 8). This occurs since elecTrons have a larger acceleraTion aT higher values of E and aT lower pressures. The smaller number of collisions occurring aT low 33 I? 178 max (D C.‘ 0 'U l G h o H 44 o 1 °’ H 0 0 s: 0 6.9 cavity length, cm AA) ne electron density diameter, cm Figure 7 . Electron density as a function of length and radius for the TE* 112 mode 13.8 34 pressure permiT an elecTron To gain large amounTs of energy. IT should be noTed ThaT all work on This area has been on sysTems wiTh low elec- Tron densiTies using baTch Type reacTors. The meThanaTion reacTion is in a flowing sysTem wiTh elecTron densiTies suSpecTed To be much higher Than Those previously explored. MICROWAVE PLASMA CHEMISTRY AND PROPOSED REACTION MECHANISM The microwave plasma source will produce a nonequilibrium plasma wiTh a large number of free radicals aT low bulk gas TemperaTures.6’7 This is made possible Through use of The cold E—Type discharge.6 Besides free radicals ionic species can be generaTed from inTeracTions beTween The aTomic and molecular hydrogen species, however Their effecT on The overall reacTion raTe and kineTics are neglecTible. In a sTeady sTaTe discharge The concenTraTion of H2+ is governed by The raTe of iTs formaTion Through ionizaTion of molecular hydrogen. Since The plasma is approximaTely neuTraI The concenTraTion of H + is considerably below 2 ThaT of The free elecTrons. Yamonel reporTed raTe consTanTs for genera- Tion of H2+ Two orders of magniTude smaller Than The corresponding free radical raTe. For The H2 - CO - CH4 - H20 sysTem in a plasma reacTor a mulTiTude of reacTions could possibly occur as IisTed below (eqn 1-11). lniTiaTion (1) H20 + O- + OH- (2) C0 + H- + CO H- (3) CH° + H2 + CHZ- + H° (4) CH2- + H2 + CH3- + H- PropagaTion (5) C0 + OH- + C0 + H° 2 (6) CH3- + H2 + CH4 + H- (7) OH: + H2 + H20 + H° 35 36 TerminaTion (8) CH- + CH- + CH 5 CH (9) CH2- + CHZ- + C2H4 (10) CH3° + CH3: + C2H6 (11) H- + H- + H2 The reacTion mechanism proposed for The meThanaTion sTep is shown in equaTions 12-16. Included in This is a heferogenous recombinaTion Term due To hydrogen radicals diffusing To The wall and recombining. This mechanism is purely speculaTive for The meThanaTion in a plasma, however does incorporaTe The basic [CH-] inTermediaTe which would be required To produce CH4 and CH E CH found in our experimenTal work. k1 (12) e + H2 -+ 2H- k2 (13) CO + H2 + H- —+ CH- + H20 k3 (14) CH- + 2H2 —+ CH4 + H- k 4 (15) ZCH- -+ CH 5 CH k w (16) 2H- —+ H2 AT equilibrium The raTe of formaTion of CH- and H- can be assumed To be equal To zero (d(CH-)/dT = 0). AddiTionally The wall recombina- Tion raTe consTanT can be assumed To be small compared To k3 and k4. Based on These assumpTions~HmaraTe of formaTion of meThane and aceTylene are shown in equaTions I7 and 18. _ , 2 _ 5/2 1/2 l/2 (17) rCH4 — k3[CH ][H2] — 1.41 k3 [H2] [Ne] (kl/k4) _ , 2 _ (18) rCH 5 CH - k4 [CH ] — 2 k1 [Ne][H2] 37 IT should be noTed ThaT for This proposed mechanism boTh The raTes are independenT of The carbon monoxide concenTraTion. This is due To The facT ThaT The raTe conTroIling sTep is The formaTion of The hydrogen radical governed by k ExperimenTal evidence has shown The raTio of 1. The raTe of formaTion of meThane To aceTylene is on The order of .01 - I and using an elecTron densiTy of 1010 cm—3 The values of k3 and k4 can be esTimaTed To be beTween 100 - |000 (cm3)2/mole2 sec. This compares favorably wiTh experimenTally deTermined raTe consTanTs for oTher free radical reacTions.8 GeneraTion of The CH- and H- radical in The plasma reacTor will be The raTe conTroIling sTeps since boTh of These are highly reacTive inTermediaTes. The dissociaTion raTe consTanT k1 is convenTionaIly defined in an elecTric discharge (EquaTion 19) from The (19) k = (8/nMe)1/2(kT )3/2 IO 6 0 exp (—e/kTE)dc l E Me = mass of elecTron kTE = elecTron energy \ ‘- - . ‘. .\\ r’ . e‘\ = dIsso:IaTIon energy 0 = dissociaTion cross secTion Maxwell-BoIszan disTribuTion of elecTron energies. Khare and MoiseiwiTsch2 TheoreTically deTermined values for The dissociaTion cross secTion for The exciTaTion of ground sTaTe molecular hydrogen To The replusive sTaTe. In Their work They considered This The only process conTribuTing To The dissociaTion and Their calculaTed values were In 4 3,5 ’good agreemenT wiTh previous experimenfal findings by Poole. Bell has deTermined k1 for The exciTaTion of hydrogen as a funcTion of elecTron 38 TemperaTure (or E/p The raTio of elecTric field sTrengTh To gas pressure). This is shown in Figure 8. The formaTion of The CH- radical can be visualized as a bimolecular inserTion of H- To The C0 molecule, forming a pseudo inTermediaTe CO H- which combines wiTh a hydrogen molecule To give The CH- inTermediaTe and a wafer molecule. Dissociation Rate Constant . x1 (cn3/sec) 10’8 10'9 ~10 10‘11 39 .. I.— Bell, A. T. . Ind. Eng. Chem. Vol. 11(1972) i I I I I i I 10 20 30 E/P (Volt/Cm Torr) FigureB . Dissociation rate constant K1 versus electric field strength divided by pressure . MICROWAVE PLASMA REACTOR AND RF SYSTEM The microwave plasma caviTy is shown in Figures 2,9,I0. The reacTanT gases pass Through The plasma creaTed in The quarTz Tube while pressures in The sysTem can be varied from 2-100 mm Hg. Cool- ing is provided by waTer coils on The caviTy and forced air circulaTion Through The caviTy. A probe coupling allows The rf energy To be inTro- duced inTo The caviTy and produce The plasma. This probe lengTh can be adjusTed which changes The effecTive elecTrical field sTrengTh pro- ducing variaTions in reacTion raTes and elecTron densiTy. Radial and axial measuremenTs of The elecTrical field sTrengTh is accomplished Through small porTs in The caviTy. The adjusTable caviTy lengTh serves To reTune The plasma as power, pressure, and probe lengTh are varied. AdjusTmenT of The caviTy lengTh keeps The plasma resonance equal To The exciTaTion frequency. The IefT—hand group of curves in Figure 11 demonsTraTes The behavior of The plasma caviTy when The exciTaTion frequency and The caviTy size are fixed. The sTabIe operaTing poinTs, a,b, show ThaT as The incidenT power is increased The plasma densiTy increases relaTively liTTle. The plasma caviTy sysTem adjusTs iTself To a sTable operaTing poinT, a, which is deTermined primarily by The plasma caviTy resonanT frequency, (i.e., caviTy dimensions and exciTaTion frequency). When The incidenT power is greale increased The operaTing poinT moves To poinT b and The caviTy becomes more deTunned. ThaT is, only a small 40 41 0.30.000 0300... 000.0510 . 0 0.50.... 02.3000 onemzomH 009.9... 05.030 930.. «Hon. 0530...... 00:00.50 ...Hon. 92.5 Meson. mosam 4.201%. ...0 zOHBUflm mmomo 00.5... .020de 3.330 09.09.. 030090.03 puonm madeAHLJHHHHW/xx I)///; , 0:...960 000.. meadnsoo oponm Hoexooo capoeusweo Hudxuoo canoeoaneo 42 53.3 mm 05. . ow 9."de Hccffin 996m Ink J _ _ _III III III II.— II USA 1 I I I I_ _ puonm _ mcaodam _ “camazondu mumazoo / A, oohsom 35300an _ _ H.933 mm b N f N F K L nj 1T _ _ /I 330m 330m _ _ vapomfiwom 3.5305 ‘J 1' _ 43 fracTion of The addiTional incidenT power is absorbed inTo The plasma and The excess power is reflecTed from The caviTy. Thus The deTunning of The sysTem by The presence of The plasma does noT allow a significanT fracTion of The addiTional incidenT power info The caviTy. Even The addiTion of impedance maTching devices beTween The caviTy and The inpuT Transmission line only sligthy improves The caviTy sysTem performanceg. This small change in densiTy for a large change in incidenT power is a fundamenTal problem when aTTempTing To produce a variable, high densiTy plasma inside a microwave caviTy. One proposed soluTion To This problem is To conTinuously vary The exciTaTion frequency while The rf plasma is susTained. Halverson and HaTch9 have shown ThaT by increasing The exciTaTion frequency while holding The incidenT power consTanT The densiTy of a rf plasma inside The caviTy can be increased seven Times. However, This frequency Tun- ning generally requires an expensive rf source and is a Tedious process. An alTernaTive soluTion is To conTinuously vary The caviTy dimen- sions. Fredericks and Asmussen10 have shown ThaT cylindrical, variable lengTh caviTies can be Tuned To allow The variaTion of The plasma den- siTy from less Than one criTical densiTy To over 10 criTical densiTies aT low pressures. The performance of These caviTies can be qualiTaTively undersTood by examining The graphical model as a funcTion of caviTy lengTh L. By holding in incidenT power consTanT aT Pin} and increasing The caviTy lengTh from L1 To L2 To L3 The power absorbed curve shifTs To higher densiTies as shown in Figure 11. For lengTh L1 The empTy caviTy resonanT frequency equals The exciTaTion frequency. When The incidenT power is increased To Pin3 breakdown occurs inside The caviTy and a microwave plasma is susTained aT The sTable operaTing poinT b. 44 .unmumcoo 3 >ocodvoum noflmfioxo 05 avg? 53gb mammfim o5 mo nogmaom T A mEov 5390p mama?“ AZV . 2 989m 5 m .m m llllh ll lllllll ....l 1H Ill-I 0 m5 ‘Il nH .. E ca H a: ma“ mmvNamva I.Im 5 A .3 A Md . 9:50 mmoH amok/om lllll I. HA II'C 9E8 wonHOmnm Hoe/om .ISAAOd 45 By conTinuously increasing The caviTy lengTh The caviTy becomes progres~ sively beTTer Tuned and The absorbed power and hence densiTy increase Tracing ouT The power loss curve bcd. Finally, a caviTy lengTh, L3, is reached aT poinT d where The inTersecTion beTween The power absorbed curve and The loss line is only marginally sTable. For any lengTh larger Than L3 The plasma is abruple exTinguished and The plasma caviTy sysTem drops ouT of resonance. In order To reigniTo The plasma The caviTy lengTh musT be reduced To approximaTely L1. The curves of Figure ll have been ploTTed for a consTanT pressure and fixed caviTy inpuT coupling. AlTering The pressure will change boTh The power loss and power absorbed curves, while alTering The inpuT coup- ling will modify The power absorbed curves. IT is imporTanT To remember ThaT There can exisT pressures when The slope of The power loss curve is always greaTer Than The power absorbed curves. Then all inTersecTions beTween These Two curves will be sTable operaTing poinTs. NoTe also ThaT increasing The plasma densiTy decreases The coupling of energy To The plasma“, i.e., given The incidenT power Pi The heighT of The n3’ power absorbed curves decreases as The densiTy increases. The Transfer of energy from The microwave rf source of The gas molecules is broughT abouT by elecTrons undergoing collisions wiTh The gas molecules. ElecTrons gain and accumulaTe Thermal energy unTil a sizeable fracTion of The ToTal collisions They undergo wiTh The gas molecules change from elasTic To inelasTic. When The elecTron undergoes an inelasTic collision iT imparTs a large fracTion of iTs ToTal energy which resulTs in The exciTaTion or ionizaTion of The gas. In order To describe The microwave plasma maThemaTically Maxwell's equaTions are solved for The differenT fields. Maxwell's equaTion in 46 The elecTromagneTic Theory (EM) relaTes The elecTric (E) and magneTic (§) fields To The currenT densiTy (j) and charge densiTy (p) which pro- duce These fields. ExcepT in The case of a sTaTic sysTem, E, E, p, and j are Time varying quanTiTies. In The maThemaTical developmenT IT is more convenienT To define 5 and E in Terms of E and E. (20) E = soar? where 80 = permiTTiviTy of free space (21) g = “o“rfi ”o = permeabiliTy of free space Er = relaTive dielecTric consTanT ur = relaTive permeabiliTy For a plasma medium wiTh Time harmonic fields (varying as e‘wT) we can wriTe Maxwell's equaTions 22-25. (22)v-‘E’=o,p=o (23) v-iizo (24) V x E = - jwuofi <25) in-i= jweOE+il lf equaTion (25) is expanded for The case of a weakly ionized plasma, Then The conTribuTion 3 is mainly from The moTion of The elec- Trons (26). (26) j = - ne e? where he = elecTron densiTy cm—3 e = charge on elecTron + c 0 V = macroscopic velocuTy of elecTrons .+ From Boszmann's equaTion in plasma Theory V can be relaTed To The elecTric field sTrengTh (equaTion 27) and rewriTing equaTion (25) in (27) V-= —e E/m(jw + v) where m _ mass of elecTron w operaTing frequency v collison frequency of elecTrons Terms of This gives The following (equaTion 28) - T] _ (28) vxfi=jweog+ e (v 1;) E m(v2 + ) w 2 2 VXH=jw€E |—__P_____J_\)_ p O v2+w2 UL)(\)2.}.002) _ 2 1/2_ where mp — (ne e /m€O) — plasma elecTron frequency. lnsTead of defining a complex conducTiviTy for The plasma we can esTablish an equivalenT relaTive dielecTric consTanT, er, which 2 2 w w : —' : _.__L___’2._2.___—_ (29) er (er 'JEi) l 2 2 J m 2 2 v + w (v + w ) 2 we v (.082 where er — l - —§—E—-§- and 81 — ;--§—E——§ v + w v T w is characTerized by specifying The densiTy, i.e., (wp/w)2, and v/w. The deTailed derivaTion of The general characTerisTic equaTion for l2,|3 The eigenfrequencies has been carried ouT by oThers. A com- puTer soluTion for The general characTerisTic equaTion for The TE*111 is displayed in Figure 12. For direcT comparison wiTh experimenTal resulTs resonanT caviTy lengThs are calculaTed lnsTead of The usual resonanT frequencies. ThaT is, given a consTanT resonanT frequency equal To The exciTaTion frequency of 2.450 GHz The resonanT lengTh of The caviTy is ploTTed as a funcTion of plasma frequency and v/w. Due To The presence of The plasma free space boundary aT r = a boTh Transverse elecTric and magneTic modes are required To saTisfy The boundary condi- l2,l4 Tions . Thus resonanT modes of This sTrucTure cannoT, in general, be separaTed inTo purely Transverse elecTric (TE) and Transverse mag- neTic (TM) modes, buT mosT modes have boTh TE and TM parTs and are called hybrid modes.l2 Because of The hybrid naTure of The caviTy 48 resonances and The inTroducTion of new modes by The plasma The usual caviTy mode idenTificaTion scheme is noT applicable. IT is convenienT To classify The resonanT frequencies as such. 1. "PerTurbed" cylindrical caviTy resonances. The resonances are The empTy caviTy elecTromagneTic resonances which are "perTurbed" by The presence of The plasma. Thus The forward and backward Traveling waveguide modes associaTed wiTh These resonances always have a phase velociTy greaTer Than The Speed of lighT, i.e., They are fasT wave elecTromognecTic modes. This group of resonances can be furTher divided inTo Two subclasses of modes: a. TEOmp or TMOmp; m > 0. These resonances are pure TE and TM resonances since They are ¢ independenT and Thus They are labeled wiTh respecT To The TE and TM modes on a circular waveguide. AT high plasma densiTies and for high losses These modes approach The coaxial mode ThaT has The same index as The empTy caviTy. b. TEnmp or TMnmp; n > O, m > 0. These modes are hybrid resonances. They are labeled wiTh respecT To The TE or TM modes in an empTy circular waveguide inTo which They degeneraTe when The plasma densiTy equals zero. As has been used by oThers12 The asTerisk denoTes The hybrid modes. IT is useful To noTe ThaT for high plasma densiTies and zero losses (i.e., v/m = O) The TE* resonance (or TM* resonance) approaches The TM resonance nmp nmp nmp ' ' ' 'Th eTal i cenTe (or TEn, m+1,p resonance) in a coaXIaI wavegUIde wn a m I c r conducTor. The TE*111 mode shown in Figure 12 belongs To This family of modes. However, for large values of collision frequency (i.e., for a lossy plasma) The resonanT frequency increases, decreases, and Then 49 increases again reTurning To The TE111 coaxial caviTy resonanT frequency. This is shown in Figure 12 for v/w = 0.6 or larger. The plasma-caviTy could be operaTed in many differenT caviTy resonances simply by adjusTing The caviTy lengTh and inpuT coupling. For example, The following empTy caviTy modes have eigenfrequencies equal To 2.450 GHz when The caviTy is varied from 6 cm To 20 cm. TElll’ TMOll’ TEZII’ T5011' TMlli’ TE112’ TM012' TE212’ TE012, TM112, TE113, eTc. WiTh The proper caviTy lengTh and rf coaxial coupling (i.e., loop or probe) The plasma caviTy sysTem will susTain a plasma on any of These modes. However, only The TMOlp’ TE011p modes, where p = 1,2, or 3, were sTudied exTensively. Figure 10 shows The diagram of The exTernal rf sysTem. The rf source used for The plasma generaTion was a 2.45 GHz magneTron oscillaTor which delivers llkw of conTinuous wave power. The rf power passes Through a circulaTor and power divider where The sliding shorT is used To vary power. The power passes Through The incidenT and reflecTed couplers where The ToTal power incidenT on The caviTy can be calculaTed (equaTion 30). The power incidenT on The caviTy is fed info a coaxial ToTal power incidenT on caviTy = 2.72 (incidenT power) - 1.53 (reflecTed power) (30) sysTem, and The probe lengTh couples The power inTo The differenT resonanT modes of The plasma. SO €783 Hmucosflomxo 5 com: 6608 H: *HH baa. . N." onsmmh a N23 3 83 2: S as To 1 _ _ 0.“) _ 0.0 o.m 7.. lmé 6.0 I log. Imom. led o q H \—. l H o o 3\ m.m S we ‘quueI Aumzo- PI 10. 11. 12. 13. 14. REFERENCES Yamane, M. J., Chem. Phys. 49, 4624 (1968). Khare, S. P., Proc. Phys. Soc. 88, 607 (1966). Bell, A. T., Ind. Eng. Chem. Fund. Vol. II (1972). Poole, H. G., Proc. Roy. Soc. Ser. No. l, 415, 424 (1937). Bell, A. T., Chem. Eng. Pro. Symp Ser. No. 112 Vol. 67, (1972). BabaT, G. 1., J. lnsT. ElecT. Engrs. 24, 27 (I947). Asmussen, J., Hawley, M. C., and Wilkinson, B. W., Michigan STaTe Research Proposal (1972). Epple, R. P., and ApT, C. M., The FormaTion of MeThane from SynThesis Gas by High Frequency RadiaTion, Gas OperaTions Research ProjecT PF-27, Am. Gas Assoc. (July 1962). Halverson, S. L., and HaTch, A. J., Appl. Phys. LeTTers, Vol. 14, pp. 79-81, (1969). Fredericks, R. M., and Asmussen, J., J. Appl. Phys., Vol. 42, pp. 3647-9 (1971). Boyen, H. L., Messiaen, A. M., and Vandeplas, P. E., J. Appl. Phys., Vol. 40, pp. 2296-2305 (1969). Agdur, 8., and Eneander, B., J. Appl. Phys., Vol. 33, pp. 575-581 (1962). ShoheT, J. L., and MoskowiTz, C., J. Appl. Phys., Vol. 36, pp. 1756-1759 (1965). HarringTon, R. F., Time Harmonic ElecTromagneTic Fields, New York, McGraw-Hill, pp. 219 (1961). 51 APPENDIX A Infrared SpecTra for MeThanaTion ReacTion 8.0 6.0 4.0 MICRONS 5.0 %) aDNvuIWSNvm 2000 25 FREQUENCY lCM“) mm arm 2 3000 70' Ca 004/_ 35 smut FLOW 5"?- ORIGIN VENT PART NO. 337-1203 PERKIN-ELMEH . on on HON—Sun .02 5; a ing .5825» .I...\.. moon: E .5030 wring .. «.....st “ION d}\8 mg od . oé .13. g 80a 80m 06 mZOan oi nd o.n comm 0N 1%) aoNvuIWSNvm o 5% ages: .oz :5. 5950... v Ema a z s 53 ac Ed ding... 32 Iii-02g luguafla 25... a. 0‘4: «53. en mzoaui oi _ 3.. 9N (%) SDNVLLIWSNWJ. o 5.75.51 32.3» .oz :5. 5953 a!!! 010 n g... anus—an z. o n u.— )V a glue?! 302. .23 3“ 3.5... od 0.0 .340. “8.030! 06 wzog oi n6 0.0 nN 1%) aDNvuIWSNvm 2. H. 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