Numerical simulation of a novel non-transferred arc plasma torch operating with nitrogen

High power plasma torches with higher electro-thermal efficiency are required for industrial applications. To increase the plasma power and electrothermal efficiency, conventional torches are being modified to operate with molecular gases such as air and nitrogen. Since increasing arc current enhances the heat loss to the anode, torches are being developed to operate under high voltage and low current. The plasma flow dynamics and electromagnetic coupling with plasma flow inside the torch etc. are highly complex and knowledge on the same is required to develop high torches with higher efficiency. Unfortunately detailed experimentation on the same is very difficult. Numerical modeling and simulation is one of the best tools to understand the physics involved in such complex processes. A 2D numerical model is developed to simulate the characteristics of the plasma inside the torch. Though plasma is not in local thermodynamic equilibrium (LTE) close to the electrodes, LTE is assumed everywhere in the plasma to avoid complex and time consuming calculations. Other valid assumptions used in the model are plasma flow is optically thin, laminar and incompressible. Flow, energy and electromagnetic equations are solved with appropriate boundary conditions and volume sources using SIMPLE algorithm with finite volume method. Temperature dependent thermophysical properties of nitrogen are used for the simulations. Simulations are carried out for different experimental conditions. The effects of arc current, gas flow rate of plasma generating gas and sheath gas injected above the bottom anode on the arc voltage, electrothermal efficiency of the torch, plasma temperature and plasma velocity are simulated. Predicted results are compared with experimental results. (author)