Operation manual for industrial plasma systems
The operation manual for industrial plasma systems
Industrial Plasma Torches and
equipment for their operation
PLAZARIUM TPS
Model: PLAZARIUM TPS
-
The PLAZARIUM TPS industrial plasma system is a combination of equipment integrated into a structural and functional package intended for conversion of electric energy into thermal energy with production of high-temperature ionized gas stream.
The plasma system is designed as a single monoblock with equipment for operation of plasma torches, with arc starting devices (oscillators), superheaters, and industrial steam plasma torches connected to it.The process steam plasma torches within the PLAZARIUM TPS plasma system are intended for creation of a high-temperature plasma jet of large volume and heat power. They are applied in any plasma-chemical reactors for plasma gasification and remelting of different raw materials types, for disposal of hazardous waste with full destruction and with production of ecologically pure synthesis gas(СО + Н2) , in afterburners for the purpose of gas purification from harmful admixtures (resins, dioxins and furans), and for other process uses.
Process plasma torches with capacity of 30 to 350 kW are manufactured in series, and with capacity over 350 kW, under the client’s order. An industrial plasma system is supplied complete with 1 to 10 primary plasma torches and up to 10 backup plasma torches. The bulk temperature of the heated steam (the plasma flame zone) is over 5000 °С. 
The composition of the water-steam plasma: The water-steam plasma consists mainly of hydrogen and oxygen, both of these components are active agents in oxidation-reduction reactions.
Gasification in steam atmosphere provides the way for complete conversion of carbon and hydrogen in the gasified substance into synthesis gas(СО + Н2), the presence of surplus hydrogen from the steam allows for regulating the ratio of carbon monoxide and hydrogen in the synthesis gas. The volume ratio of hydrogen in the synthesis gas obtained by plasma gasification amounts to 50 to 70%.
The quality of synthesis gas obtained by plasma gasification is as good as the quality of synthesis gas obtained by steam reforming of natural gas.
You can learn more about all the advantages of water-steam plasma and steam plasma torches in the corresponding article on our website.
The maximum calorific capacity of synthesis gas obtained by plasma gasification is 22800 kJ/kg, and it can be stored for future use in the production of thermal and electric energy, production of hydrogen, production of synthetic fuel with subsequent obtaining of motor fuel, and also as additional gas for mixing with natural gas (СН4) and using the obtained gas mixture to cheapen or to increase the consumed volume of natural gas for various needs.
The PLAZARIUM TPS plasma system is a complete set of all the necessary blocks and systems required for functioning and controlling of the primary and backup plasma torches.
The TPS plasma system can be manufactured not only with steam plasma torches but also with air plasma torches and plasma torches for different gas mixtures, depending on the customer’s needs and tasks. The plasma-forming medium can consist of one-, two- or multicomponent gases (argon, helium, nitrogen, air, mixture of argon and nitrogen with hydrogen, oxygen, hydrogen, methane, syngas, ammonia, water, etc).
When manufacturing a plasma system, all the future operating conditions of the plasma torch and the plasma-chemical reactor are taken into consideration: the environmental conditions where the plasma torch and the plasma-chemical reactor will be operated, the type of its use by the consumer (gasification and disposal of waste, robotized systems, metal melting, surface modification, scientific-research purposes, etc). The PLAZARIUM TPS industrial plasma systems have the following advantages:- The customer-specific systems can be set up in accordance with any different types and capacities of plasma torches and different plasma-forming mediums;
- The power systems are manufactured according to the inverter technology, they have the minimum weight and minimum dimensions;
- Due to its compact dimensions and minimal external utilities of the monoblock, which are manufactured as the industrial version, the plasma system can be built into any process chain of an existing production cycle;
- Mobility (can be installed into transportation vehicles, maritime containers and mobile plasma gasification plants, plasma pyrolysis plants, and plasma cracking plants);
- Centralized, fully digital control of all the devices and processes in the
PLAZARIUM TPS plasma system, duplicated with fully analogue control, allows for using the plasma system in any conditions; - Possibility of output of partial or full control of the plasma system to a higher-level control system.
-
Plasma torches for automated and human-controlled robotic systems
- Used for removal of mines and destruction of detonators of explosive objects (remotely controlled systems for ammunition detonator neutralization);
- Used at nuclear power plants for various purposes under conditions of radiation-hazardous facilities;
- Used in any places where safe presence of people is impossible but thermal influence of high temperatures (3000-5000 °С) is necessary at a distance.
Plasma heaters (melting plasma torches) of different applications
Intended for use in various plasma-chemical processes and plasma reactors: plasma gasification and remelting of various types of raw materials and waste, ignition and plasma illumination of furnace chambers in boilers, plasma ignition of carbon dust, etc.
Read more ...Plasma torches for surface modification
Surfaces of various materials change their properties when exposed to plasma. As a result of surface treatment, the water affinity, the friction coefficient, the wear and tear, the molecular weight and the chemical composition of the surface layer will change.
Introducing of carbon, nitrogen, or silicon into the plasma allows for cementing, cyaniding, and siliconizing of steels. Such treatment enhances the hardness, heat resistance, and wear resistance of the most loaded contact surfaces of tool and machine parts. Plasma surface etching processes can also be performed.
Read more ...
Metallurgical plasma torches
Intended for remelting refractory and ultra pure materials, recovery of pure materials, purifying, production of monocrystals and disperse materials.
Read more ...
Plasma generators intended for scientific-research purposes
They are used for the widest variety of research studies at high temperatures and stream velocities, particularly for studying thermophysical, aerodynamic and other scientific processes. The various spheres and technologies where plasma generators intended for scientific-research purposes are used, keep expanding.
Read more ... -
PLAZARIUM TPS plasma system:Characteristics Value Total power 100 to 3500 kW (Note 1) AC mains voltage, V 3 phases, 380±10% (Note 2) Supply voltage frequency, Hz 50/60 Power consumed by the primary process equipment up to 20% of the total power of the primary plasma torches Ambient operating temperature range, °С - 60 to + 50 Overall dimensions, L×W×H, m correspond with the size of shipping containers (10/15/20/30/40 feet)Number of containers 1 Total plasma system weight, tons 2,5 to 6 (depending on the total power) Operation mode (Operation cycle ratio) Continuous, non-stop (duty cycle=100%)
Plasma torches within the TPS plasma system:Characteristics Value Total power of the plasma torches, kW 30 up to 350 (Note 3) Maximum operating current, A from 250 up to 400 Operating voltage, V from 320 up to 875 Operating range of the plasma torch ±40% of the operating power of each plasma torch Current type DC Cooling Water, closed-loop Arc stabilization Vortex / Magnetic / ESA Magnetic Life cycle of consumable elements (anode and cathode), hoursup to 300 / 1000 (Note 4) Plasma-forming medium steam / air / any gas required according TOR (Note 5) Bulk temperature of the heated steam (flare zone), °С more 5000 Plasma torch weight (packing not included), kg from 2 up to 10 (depending on the power) Operation mode (Operation cycle ratio) Continuous, non-stop (duty cycle =100%)
Notes:
1 - There is a scientific version of a plasma system with a single plasma torch with a power of 15 and 25 kW (available for order only to universities and scientific organizations), as well as a version of a plasma system with a single plasma torch with a power of 35, 50, 65 or 90 kW. All scientific plasma systems require an external cooling system and an external system for generating and supplying plasma-forming gas (with the exception of the version for the use of steam as a plasma-forming gas).
2 - The power supply sources and the other energy systems provide for automatic adaptation to any input voltage within the range of 380-450 V for three phases.
3 - Plasma torches with capacity of up to 2500 kW inclusively can be manufactured according to the customer’s individual TOR.
4 - The life cycle of consumable elements depends on the manufacturing technology and type of the electrode, the type of arc stabilization, the type of plasma-forming medium, and characteristics of the power supply source.
5 - The plasma torches are developed for a particular plasma forming gas (STEAM / AIR / NITROGEN / ARGON / OXYGEN / HYDROGEN / METHANE / SYNTHESIS-GAS, etc.) according to the characteristics in the customer’s TOR.
6 - All the characteristics of the plasma torches and the plasma system are manufactured in accordance with the customer’s TOR.
7 - The structural design of the plasma torch and the entire plasma system is defined by the Contractor after agreeing the overall and connection dimensions with the Customer. -
PLAZARIUM TPS plasma system:Item Quantity, pcs. Primary plasma torches 1 to 10 Backup plasma torches up to 10 Steam superheaters 1 per each plasma torch Start-up (arc starting) system of the plasma torch 1 per each plasma torch Operating manual 1 Warranty card 1 Structure of the plasma system monoblock: Power supply sources of the plasma system 1 per each plasma torch Closed-circuit cooling system for power supply sources and plasma torches 1 Plasma-forming steam generating, superheating and supplying system 1 Plasma-forming medium flow control device 1 Remote control and information display console (Note 1) 1 Connections and common utilities between the plasma system monoblock and the plasma torches 1 set per each plasma torch Auxiliary equipment (optional): ESA magnetic arc stabilization device (Note 2) 1 per each plasma torch
Notes:
1 - The control system is either independent for the entire plasma system, or fully integrated into the main console of the head unit.
2 - The type of arc stabilization depends on the plasma torch model and the required characteristics of the plasma system. -
PLAZARIUM TPS with a total powerfrom 100 to 3500 kW is available to all customers and is available by official request.
Operation manual for scientific plasma systems
The operation manual for scientific plasma systems
PLAZARIUM TPS with power from15 to 90 kW is available to all customers and is available by official request.Certificates and declarations
EU CERTIFICATE OF COMPLIANCE
INDUSTRIAL PLASMA SYSTEM
PLAZARIUM TPS have been checked and found in compliance with the European Parliament апd Council Directives:
(2014/35/EU) of 26.02.2014 Low Voltage Directive,
(2006/42/ЕС) of 17.05.2006 Machinery Safety Directive.
Validity: 31.05.2019 - 30.05.2024
EU DECLARATION OF CONFORMIТY
INDUSTRIAL PLASMA SYSTEM
PLAZARIUM TPS complies covering European Parliament апd Council Directives:
(2014/35/EU) of 26.02.2014 Low Voltage Directive,
(2006/42/ЕС) of 17.05.2006 Machinery Safety Directive.
Validity: 31.05.2019 - 30.05.2024
EAC DECLARATION OF CONFORMIТY
INDUSTRIAL PLASMA SYSTEM
PLAZARIUM TPS complies with covering Technical Regulation of the Eurasian Economic Union (Armenia, Belarus, Kazakhstan, Kyrgyzstan, Russia):
(TR TS 004/2011) Low Voltage Directive,
(TR TS 020/2011) Electromagnetic compatibility (EMC).
Validity: 23.04.2019 - 22.04.2024 -
Centralized, fully digital control of all the devices and processes in the PLAZARIUM TPS plasma system, duplicated with fully analogue control, are located on the central part of the monoblock.
The touchpad has a modern software with the capability of programming and customization to the individual customer requirements. Availability of remote upgrade and remote control greatly simplifies the management ofPLAZARIUM TPS plasma system.
Digital control of all the parameters of thePLAZARIUM TPS industrial plasma system allows for proceeding to fully digital synthesis of production processes using water-steam plasma.
The multi-language interface facilitates access for operators from different countries to the settings and control of the main processes and of each block of the plasma system separately.
The software of thePLAZARIUM TPS industrial plasma system provides for manual digital control of each individual block, and also for fully automated control according to pre-programmed algorithms with possibility of changing them for a particular production process.
The software includes the 3-level user interface:
- For the operator,
- For the production engineer of the enterprise
- For the (research) technology design engineer (change of the static and dynamic output current-voltage characteristics and other parameters).
The first two levels are implemented in the operator console by the means of a graphic screen, the third level is implemented by the means of a PC connection via LAN.
 | The The plasma system is designed as a single monoblock with equipment for operation of plasma torches, with arc starting devices (oscillators), superheaters, and industrial steam plasma torches connected to it. |
| The process steam plasma torches within the |   |
| Process plasma torches with capacity of 30 to 350 kW are manufactured in series, and with capacity over 350 kW, under the client’s order. An industrial plasma system is supplied complete with 1 to 10 primary plasma torches and up to 10 backup plasma torches. The bulk temperature of the heated steam (the plasma flame zone) is over 5000 °С. |
|
| The composition of the water-steam plasma: The water-steam plasma consists mainly of hydrogen and oxygen, both of these components are active agents in oxidation-reduction reactions.
Gasification in steam atmosphere provides the way for complete conversion of carbon and hydrogen in the gasified substance into synthesis gas The quality of synthesis gas obtained by plasma gasification is as good as the quality of synthesis gas obtained by steam reforming of natural gas. You can learn more about all the advantages of water-steam plasma and steam plasma torches in the corresponding article on our website. |   |
| The maximum calorific capacity of synthesis gas obtained by plasma gasification is |
|
| The The TPS plasma system can be manufactured not only with steam plasma torches but also with air plasma torches and plasma torches for different gas mixtures, depending on the customer’s needs and tasks. The plasma-forming medium can consist of one-, two- or multicomponent gases (argon, helium, nitrogen, air, mixture of argon and nitrogen with hydrogen, oxygen, hydrogen, methane, syngas, ammonia, water, etc). | 
|
| When manufacturing a plasma system, all the future operating conditions of the plasma torch and the plasma-chemical reactor are taken into consideration: the environmental conditions where the plasma torch and the plasma-chemical reactor will be operated, the type of its use by the consumer (gasification and disposal of waste, robotized systems, metal melting, surface modification, scientific-research purposes, etc). |
The
|   |