Evaluation of process conditions for methane pyrolysis applying the triple thermal plasma system

Abstract

Among various thermal plasma sources for CH4 pyrolysis, singular direct current (DC) thermal plasma has limited capacity, erosion, and efficiency. However, the triple thermal plasma system has been applied for nanomaterial synthesis and exhibited results overcoming these limitations. This study used the triple thermal plasma system to investigate the most suitable conditions for CH4 pyrolysis. CH4 conversion rate and selectivity of H2 and C2H2 were analyzed by varying the CH4 flow rate and quenching conditions at a fixed power supply of approximately 30 kW, and the specific energy requirement (SER) per 1 kg H2 was compared with that of previous works. The maximum conversion rate was 97% at 50 L/min of CH4, which is approximately 7% higher than earlier studies under conditions with similar process enthalpy. In addition, the conversion of CH4 to C2H2 and further to heavier hydrocarbons proceeded one order of magnitude faster than the reaction time expected by the gas-phase reaction. This result is attributed to the easy penetration of CH4 into the core region with the highest temperature and the strong interaction between the processing gas and graphite surface due to the arrangement of the torches in the triple plasma system. C2H2 selectivity was relatively high, while it was less affected by the increase in the quenching gas than generally expected. This finding was attributed to the naturally fast quenching rate without quenching gas due to the structure expanding from the first to the second graphite. While quenching can enhance selectivity by stabilizing the radicals as intermediates such as H2 or C2H2, it depressed the following reaction with dehydrogenation. Thus, the quenching conditions must be optimized. Finally, we demonstrated that the triple thermal plasma enhanced CH4 pyrolysis regarding H2 production efficiency.