The invention relates to a process for treating a composition with a plasma, a reactor for treating a composition with a plasma and a process for capturing a compound contained in a plasma.

The production and consumption of devices comprising material such as electronic components, plastic material and/or metallic material constantly increase worldwide. For ecological reasons and because such materials may be valuable and/or toxic, methods have been developed to recycle devices comprising such materials.

The recycling of devices may be difficult, especially when the devices comprise a mixture of different materials. In particular, electronic devices such as laptops, phones, computers, vehicles, solar panel..., comprise a mixture of metals, heavy metals, resin, polymers and other components.

The conventional recycling methods generally involve a succession of hydrometallurgic and/or pyrometallurgic operations. However, such operations are highly energy-consuming, generate pollutants gases and/or lead to soil and water contamination with for example heavy metals.

Moreover, hydrometallurgic and/or pyrometallurgic operations are set up for a specific type of material and are not easily adaptable to other types of materials or materials having a different composition.

Further, hydrometallurgic and/or pyrometallurgic operations do not allow to extract and recover successively and/or selectively different types of components from a waste material. Therefore, these methods do not allow, for example, to recover selectively and with a high purity degree, the different components of a device such as, for example, an electronic device.

Recently, methods have been developed to recycle compounds from a matrix using a thermal plasma. A plasma is a particular state of matter which may comprise a mixture of ions, electrons, radical species, neutral atoms and/or neutral molecules. Due to its composition, a plasma is highly electrically conductive and possesses specific properties compared to the other states of matter (solid, liquid and gas). A plasma may be generated by submitting neutral gas to microwaves, to a strong electric field or to an electromagnetic field, until said neutral gas becomes partially or fully ionized. A non-equilibrium plasma (also called "cold plasma") is initially formed thanks to the latter process and by further energizing this non-equilibrium plasma, an equilibrium plasma (also called "thermal plasma") is then generated.

A non-equilibrium plasma is a plasma which is not at thermodynamic equilibrium because the electrons temperature is higher than the temperature of heavy species such as ions, and neutral atoms and/or molecules. Such a non-equilibrium plasma is generally obtained at a pressure comprised between 0.1 to 10 000 Pascal (Pa).

In an equilibrium plasma or thermal plasma, on the contrary, all the species (electrons, radicals, ions...) are at the same temperature. Such a thermal plasma is generally obtained at a pressure higher than 10 000 Pascal (Pa). A thermal plasma is more energetic and exhibit a higher temperature than a non-equilibrium plasma and is therefore the type of plasma that is used for example to recycle compounds from a matrix.

However, it is difficult to control the temperature of a thermal plasma once formed and such a process does not allow, for example, to extract, with a satisfactory yield, metals or metal complexes which are thermal sensitive. Moreover, the compounds that are extracted with a thermal plasma may be contaminated by residues, for example organic or inorganic residues, contained in the matrix as such a process is not selective.

Therefore, there still exists a need for methods allowing to overcome at least one of the drawbacks of the prior art methods and allowing, in particular, to recover selectively and with an satisfactory purity compounds from a composition comprising different materials. An object of the invention is a process for treating, with a plasma, a composition comprising at least a first compound and a second compound, characterized in that said process comprises at least:

- generating, within an enclosure, a non-equilibrium plasma flow from a gas present in said enclosure, and

- treating the composition contained in said enclosure with said non-equilibrium plasma flow so as to extract at least a portion of said first compound.

The process for treating the composition being performed with a non-equilibrium plasma, it is thus possible to control the temperature of said plasma. By controlling the temperature of the plasma, it is for example possible to control the vapor pressure of the first and second compounds. This process therefore allows to selectively extract, at least partially, the first compound from the composition, in particular by influencing the difference in the boiling temperature and/or vapor pressure between the first and second compounds. By extracting the first compound from the composition, the process allows to separate, at least partially, the first compound from the second compound which remains in the composition. In this process, the first compound is different than the second compound. As the non-equilibrium plasma is less energetic than an equilibrium plasma, the composition may be treated while minimizing or even avoiding deterioration/degradation of the composition, in particular avoiding deterioration/degradation of the first and/or second compounds, and/or the deterioration/degradation of their derivatives, contained in the non-equilibrium plasma. Deterioration/degradation of a compound means here that the structure of said compound has been modified in such a manner that this compound cannot be recovered under his initial form or as a derivative, and is not recyclable, valuable or usable anymore.

During the process, the compound may be extracted under its initial form or under the form of one of its derivatives. When the first compound is extracted under the form of one of its derivatives, the latter may be generated by reaction of the non-equilibrium plasma with said first compound or by reaction between the first and the second compounds, said reaction being induced by the non-equilibrium plasma. In a preferred embodiment, the first compound may be totally extracted from the composition.

After extracting partially or totally the first compound from the composition, the second compound remains in the composition and the composition is therefore enriched in the second compound. The second compound may remain in the composition under its initial form or under the form of one of its derivatives. When the second compound remains in the composition under the form of one of its derivatives, the latter may be generated by reaction of the non-equilibrium plasma with said second compound or by reaction between the first and the second compound, said reaction being induced by the non-equilibrium plasma.

Within the frame of the present description, a derivative of a compound is defined for example as a reduced, oxidized, halogenated, in particular chlorinated, form of the compound. In particular, a derivative is a form of a compound in which the compound is still recyclable, valuable and usable. A derivative is a form of a compound from which the compound may be recovered under its initial form or under the form of another derivative. A derivative of a compound is therefore different from the product(s) obtained by deterioration/degradation of said compound.

According to a first embodiment, the first compound may be an impurity and the second compound may be a compound of interest. According to this embodiment, the treatment of the composition with the non-equilibrium plasma may allow to extract or remove at least a portion of the first compound, i.e. the impurity, from the composition, and therefore to enrich the composition with the second compound, i.e. the compound of interest. In a preferred embodiment, the first compound may be totally extracted from the composition and at the end of the process, the second compound may be recovered in a purified state.

Within the frame of the present description, a compound is considered pure when the compound comprises not more than 10% by weight, preferably not more than 5% by weight, and more preferably not more than 3% by weight of impurities and/or other compounds over the total weight of the compound.

According to a second embodiment, the first compound may be a compound of interest and the second compound may be an impurity. According to this embodiment, the treatment of the composition with the non-equilibrium plasma may allow to extract the compound of interest in a purified state while leaving the impurity inside the enclosure as a residue of the composition. In a preferred embodiment, the first compound may be totally extracted and at the end of the process, the whole first compound may be recovered in a purified state.

According to a third embodiment, the first compound may be a first compound of interest and the second compound may be a second compound of interest. According to this embodiment, the treatment of the composition with the non-equilibrium plasma may allow to extract or remove at least a portion of the first compound of interest and therefore to enrich the composition in the second compound of interest. In a preferred embodiment, the first compound of interest may be totally extracted from the composition and at the end of the process, the second compound of interest may be recovered in a purified state inside the enclosure. The first compound once extracted by the plasma may also be recovered, for example by a filtration/capture material, in particular a porous material. According to this preferred embodiment, the process allows to separate the first and the second compounds of interest.

The first compound may be chosen for example among a metal, a metal derivative, an alloy of two or more metals, a polymer, an organic compound, and a resin. When the first compound is a metal, the metal may be chosen for example among tin (Sn), copper (Cu), tantalum (Ta), iron (Fe), silver (Ag), manganese (Mn), gold (Au), palladium (Pd), lithium (Li), cobalt (Co), antimony (Sb) and magnesium (Mg).

The second compound may be chosen for example among a metal, a metal derivative, an alloy of two or more metals, a polymer, an organic compound and a resin. When the second compound is a metal, the metal may be chosen for example among tin (Sn), copper (Cu), tantalum (Ta), iron (Fe), silver (Ag), manganese (Mn), gold (Au), palladium (Pd), lithium (Li), cobalt (Co), antimony (Sb) and magnesium (Mg).

In a preferred embodiment, at least one of the first and second compounds may be a metal, a metal derivative, or an alloy of two or more metals.

According to another embodiment, the composition may comprise three or more compounds. Each the first, second and third embodiments may apply regardless the number of compounds in the composition. According to this embodiment, the process may allow to separate one compound from the two other compounds, the two other being separated subsequently or not, the first compound being the extracted compound or the compound that remains in the enclosure.

When the composition comprises three or more compounds, each of said three or more compounds may be chosen among a metal, a metal derivative, an alloy of two or more metals, a polymer, an organic compound and a resin. When said three or more compounds comprise one or more metals, the metal may be chosen among tin (Sn), copper (Cu), tantalum (Ta), iron (Fe), silver (Ag), manganese (Mn), gold (Au), palladium (Pd), lithium (Li), cobalt (Co), antimony (Sb) and magnesium (Mg).

Within the frame of the description, a metal refers to the atomic form of such metal and a metal derivative or metal alloy refers to a molecular form of said metal.

According to still another embodiment, the process may be used to extract selectively different compounds from a composition. According to this embodiment, the composition may comprise n different compounds and the process may be performed (n-1) times. Each time the process is performed, one compound among the n compounds may be extracted from the composition through the non-equilibrium plasma flow. Once the process has been performed n-1 times, the last compound may remain in the enclosure.

Various operating parameters may be controlled to perform the process.

A first operating parameter may be the type of gas present within the enclosure.

According to an embodiment, the gas present in the enclosure may comprise at least one inert gas. According to this embodiment, the gas present within the enclosure may be chosen among argon (Ar), helium (He), nitrogen (N2), and one of their mixtures. The non-equilibrium plasma that is generated from a gas comprising an inert gas or a mixture of inert gas, may comprise reactive species. The reactive species may comprise electrons, ions and/or radical species.

The flow rate of the inert gas injected into the enclosure may range from 1 to 5000 ml/min, preferably from 50 to 2000 ml/min, more preferably from 100 to 1000 ml/min.

Treatment of the composition with a non-equilibrium plasma comprising reactive species may allow for example to induce a chemical reaction between the first and the second compounds. According to this exemplary embodiment, the first compound may be extracted under the form of one of its derivatives. According to another exemplary embodiment, treatment of the composition with a non-equilibrium plasma comprising reactive species may allow to extract the first compound by vaporization.

According to another embodiment, the gas present in the enclosure may comprise at least one inert gas and may further comprise at least one additional reactive gas. According to this embodiment, the at least one additional reactive gas may be chosen among O2, H ₂ 0, H ₂ , NH ₃ , N ₂ , CI2, Br ₂ , I2 or the like, and one of their mixtures. According to this embodiment, the non-equilibrium plasma generated from such a gas may comprise reactive species and additional reactive species.

Treatment of the composition with a non-equilibrium plasma comprising additional reactive species may allow to extract the first compound under its initial form and leave the second compound in the enclosure under the form of one of its derivatives, or extract the first compound under the form of one of its derivatives and leave the second compound in the enclosure under its initial form, or extract the first compound under the form of one of its derivatives and leave the second compound in the enclosure under the form of one of its derivatives.

The flow rate of the additional reactive gas may range from 20 to 2000 ml/min, preferably from 30 to 1000 ml/min, more preferably from 30 to 500 ml/min.

According to a preferred embodiment, when gas contained within the enclosure comprises at least one inert gas and at least one additional reactive gas, the flow rate of the inert gas may be higher than the flow rate of the additional reactive gas. Preferably, the flow rate of the additional reactive gas may represent 0.1 to 50% of the total gas flow rate, the total gas flow rate being the summation of the inert gas flow rate and the reactive gas flow rate.

In the process, the at least one inert gas and the at least one additional reactive gas may be injected into the enclosure by means of one or more injectors.

A second operating parameter may be the pressure inside the enclosure.

The enclosure may be maintained at a desired pressure by means of a pressure regulating device as second controlling device. Said pressure regulating device may be in communication with the enclosure through a second opening and may create a depression in the enclosure through said opening. The pressure regulating device may comprise, for example, a valve and a pump. Preferably, the pressure regulating device may allow to place the inside of the enclosure at a low pressure. By placing the inside of the enclosure at a low pressure a gas flow between the first opening and the second opening may be generated.

Controlling the pressure, in particular maintaining the pressure below 10 000 Pa, preferably below 5 000, and more preferably below 2 500 Pa, may allow to maintain the plasma flow in a non-equilibrium state.

Further, controlling the pressure, in particular maintaining the pressure below 10 000 Pa, preferably below 5 000 Pa, and more preferably below 2 500 Pa, may allow to extract the first compound (or other compounds contained in the composition) by vaporization. Advantageously, such a pressure allows to vaporize the first compound (or other compounds contained in the composition) at a lower temperature compared to a vaporization at atmospheric pressure. In other words, maintaining the pressure inside the enclosure below 10 000 Pa, preferably below 5 000 Pa, and more preferably below 2 500 Pa, allows to decrease the boiling point of the compounds to be extracted. Advantageously, such a process allows to avoid deterioration/degradation of the compounds contained in the composition.

The pressure residing inside the enclosure before generating the non-equilibrium plasma from the gas present in the enclosure may range from 0.1 to 10 000 Pa, preferably from 0.5 to 5 000, preferably from 1 to 3 500, preferably from 1 to 2 500 Pa, preferably from 10 to 1 500 Pa, and more preferably from 300 to 900 Pa.

A third operating parameter may be the state of matter injected inside the enclosure.

The matter injected inside the enclosure is in a gaseous state and a plasma may be generated by a plasma generation device allowing to heating said gas or to submit said gas to microwaves, to an electric field or to an electromagnetic field.

According to an embodiment, the non-equilibrium plasma of the invention is not generated by an electric arc which would generate a non- homogeneous plasma at a high temperature not capable of treating the entire surface of the composition at the same time. Advantageously, the non equilibrium plasma used in the present invention is a homogenous plasma, which fully covers the entire surface of the composition and allows to treat efficiently the entire surface at the same time.

According to a preferred embodiment, the plasma may be generated by submitting said gas to an electromagnetic field, for example by using a radiofrequency generator as third controlling device. The radiofrequency generator may be connected, for example, to a coil arrangement or device comprising inductive wires surrounding the enclosure. Preferably, the coil arrangement or device is placed around a portion of the enclosure which may be located between the first opening and the second opening. According to this preferred embodiment, the radiofrequency generator generates a non-equilibrium plasma from the gas present in the enclosure by applying a power to the radiofrequency generator ranging from 50 to 6000 W, preferably from 50 to 3000 W, and more preferably from 50 to 2000 W. More particularly, the radiofrequency generator may generate a non-equilibrium plasma flow from the gas flow present in the enclosure. Preferably, the non equilibrium plasma flow circulates from the portion of the enclosure surrounded by the coil arrangement or device to the second opening.

The non-equilibrium plasma once generated may possess one, two or three of the following physical features, or the four following physical features: a power ranging from 50 to 6000 W, preferably from 50 to 3000 W, more preferably from 50 to 300 W, and more preferably from 50 to 200 W; the power of the plasma may be measured by measuring the temperature of the plasma using for example thermal cameras or calorimetry; an intensity below 1A, preferably ranging from 0,02 A to 1 A, preferably from 0,06 A to 0,8 A, preferably from 0,1 A to 0,7 A, and more preferably from 0,2 A to 0,6 A; the intensity of the plasma may be measured using for example an oscilloscope or an ammeter on the electrodes of the generator; a voltage ranging from 100 V to 6 kV, preferably from 150 V to 2 kV, preferably from 180 V to 1 kV, and more preferably from 200 V to 500 V; the voltage of the plasma may be measured using for example an oscilloscope or a voltmeter on the electrodes of the generator; a frequency ranging from 10 MHz to 45 MHz, preferably 10 MHz to 42 MHz, and more preferably 15 MHz to 40 MHz; the frequency of the plasma may be measured using an oscilloscope on the electrodes of the generator.

The physical features of the non-equilibrium plasma allow to have a plasma reactive enough to generate reactive species from the gas present into the enclosure and gentle enough to avoid deterioration/degradation of the compounds of interest present in the composition.

The intensity and voltage of the plasma may depend of the power value applied by the plasma generation device to the gas present into the enclosure. The power of the non-equilibrium plasma may be controlled in particular by controlling the power of the radiofrequency generator.

Once generated, the non-equilibrium plasma flow may have a temperature lower than 500 °C, preferably lower than 350°C, and more preferably lower than 250°C. Advantageously, such temperature is much lower than the temperature of a thermal plasma flow which is usually above 1000°C. The low temperature of the non-equilibrium plasma allows to avoid deterioration/degradation of the compounds of interest present in the composition.

In a preferred embodiment, once the non-equilibrium plasma flow has been generated, the pressure inside the enclosure may be regulated during the process by the pressure regulating device so as to be maintained between 0.1 to 5000 Pa, preferably from 100 to 3500 Pa, and more preferably from 300 to 900 Pa. Therefore, the plasma flow is maintained at a non-equilibrium state in the course of the process, preferably along the whole duration of the process.

Advantageously, the pressure inside the enclosure being reduced, the boiling point of the compound(s) contained in the composition, and which has(ve) to be extracted, may be lowered and the extraction of said compound(s) may be favored. Such compound(s) may therefore be extracted at a lower temperature than with the thermal plasma.

Preferably, the radiofrequency generator may function or operate continuously until the end of the process, for example until the desired amount of first compound is extracted from the composition. Preferably, the same power may be applied to the radiofrequency generator during the whole process.

According to a preferred embodiment, the composition may be arranged within the enclosure so as to be crossed by the non-equilibrium plasma flow, preferably between the portion of the enclosure surrounded by the coil arrangement or device and the second opening.

According to another embodiment, the composition may be placed on a support within the enclosure, the support being placed preferably between the portion of the enclosure surrounded by the coil arrangement or device and the second opening.

According to a preferred embodiment, the support may be a crucible, preferably a crucible able to be heated by induction such as a carbon crucible, in particular a crucible having a high density such as a carbon crucible having a density of 1.90 to 2.30, preferably 1.95 to 2.10, and more preferably of 2.03 to 2.07.

A fourth operating parameter may be the temperature of the support on which the composition is placed.

According to a possible embodiment, the temperature of the support, preferably the crucible, may not be modified and the composition placed on said support, may be at the temperature of the non-equilibrium plasma flow, preferably at a temperature lower than 500°C.

According to another possible embodiment, the temperature of the support, preferably the crucible, may be modified, in particular the support may be heated or cooled, by a fourth controlling device. According to this possible embodiment, the temperature of the composition may be heated or cooled depending on the temperature of the non-equilibrium plasma flow. According to this embodiment, the temperature of the composition may be different than the temperature of the non-equilibrium plasma flow, in particular it is higher or lower. According to this embodiment, the temperature of the support may be heated or cooled by means of a heat exchanger, for example a circuit of heat transfer fluid which may be in contact with the support or may surround said support.

When the support is heated, the fourth controlling device may be a resistance heating/heat resistor which may be in contact with the support or may surround said support.

According to a preferred embodiment, when the support is heated, the fourth controlling device may be an electromagnetic induction generator. The electromagnetic induction may be applied for example on the support using a coil arrangement or device surrounding the enclosure, said coil arrangement or device being connected to an electromagnetic induction generator.

According to an exemplary embodiment, the temperature of the support, preferably the crucible, may be modified, i.e. heated or cooled by means of a heat exchanger, for example a circuit of heat transfer fluid which may be in contact with the crucible and/or may surround said crucible.

When the support is heated, the temperature of the crucible may be increased by means of one or more heating element(s), for example heating wire(s), heating resistance(s)..., which may be in contact with the crucible and/or may surround said crucible.

According to a preferred embodiment, when the support is heated, the temperature of the support may be increased by means of electromagnetic induction. Electromagnetic induction may be applied for example to the support using a coil arrangement or device surrounding the enclosure, said coil arrangement or device being connected to an induction generator.

Advantageously, heating or cooling the composition via heating or cooling the support, may allow to better control the extraction of the first compound. According to one exemplary embodiment, increasing the temperature of the composition may allow to melt the composition or one of the compounds of the composition so as to optimize its extraction. According to another embodiment, cooling the composition may allow to prevent the deterioration of thermosensitive compounds contained in the composition. According to still another embodiment, cooling the composition may allow to reduce the free enthalpy of a reaction between two compounds contained in the composition or between the reactive species of the plasma flow and a compound contained in the composition in order to promote this reaction, for example for the reduction of Ta ₂ 0s to Ta by the plasma flow.

The heating or cooling of the support may be applied during the whole duration of the process or only during certain duration of the process.

Therefore, treating the composition with a non-equilibrium plasma may allow to control the process by adapting said process, in particular adapting operating parameters of the process, to the type of compounds contained in the composition and/or to the type of compounds to be extracted. In particular, operating parameters such as for example the power of the plasma, the pressure inside the enclosure and/or the temperature of the composition may be controlled. Such a control is not possible with an equilibrium or thermal plasma which by definition has a very high temperature that is very difficult to control.

According to an embodiment, the process may comprise the capture of the extracted first compound by a porous material, such as foam, felt or wool, traversed by the non-equilibrium plasma flow comprising said extracted first compound, preferably a porous material formed by fibers such as organic fibers, for example human or animal hair, inorganic fibers, plastic fibers, carbon fibers, glass fibers or rock fibers. According to a preferred embodiment, the porous material may be a carbon felt.

In an exemplary embodiment, the composition may comprise two or more compounds to be extracted. According to this embodiment, the process for treating the composition may be performed successively for each compound. Advantageously, the operating parameters may be controlled for each iteration or performance of the process. For example, the operating parameters from one iteration or performance to the other may be the same or may differ by one or more operating parameter(s). According to an embodiment, the process may comprise a pretreatment of the composition before treating the composition with a non-equilibrium plasma flow. The pretreatment may not involve any plasma and may be, for example, a pretreatment process where the support is heated while the enclosure is at a reduced pressure, said pretreatment process allowing to vaporize one or more compounds of the composition.

According to another embodiment, the enclosure may, for example, be part of a reactor, preferably a cylindrical reactor, with transparent wall(s), for example quartz wall(s). Preferably, the wall(s) may allow an operator placed outside the enclosure to visually monitor the inside of the enclosure. The process may thus be visually controlled by, for example, visualizing color changes in the composition, filing of the porous material with extracted compounds. Advantageously, quartz is not heated by induction and quarts wall(s) therefore remain at low temperature during the process.

This process may be used purify, recycle and/or transform devices such as electronic components (phones, computers...); plastic materials; condensators; battery; solar panel; computers; bulb, especially LED bulb or low-energy bulbs; metallic materials; glass; minerals to be refined and the like.

Another object of the invention is a process for capturing at least one compound, characterized in that it comprises: generating a plasma flow comprising said at least one compound in a gaseous state, and capturing said at least one compound through a porous material crossed by said plasma flow, the temperature of said porous material being at a temperature T1 at which said compound is in a liquid or solid state.

According to a preferred embodiment, the plasma flow generated is a non-equilibrium plasma flow.

The porous material may be a three dimension (3D) material such as foam, felt or wool, traversed by the non-equilibrium plasma flow comprising said compound, preferably a porous material formed by fibers such as organic fibers, for example human or animal hair, inorganic fibers, plastic fibers, carbon fibers, glass fibers or rock fibers.

The process for capturing a compound may be applied to a non-equilibrium plasma flow and to an equilibrium (or thermal) plasma flow. The compound contained in the plasma flow may be under a gaseous form due to its extraction or vaporization from a composition, for example using a plasma flow.

The compound contained in the non-equilibrium plasma flow may be chosen for example among a metal, a metal derivative, an alloy of two or more metals, a polymer, an organic compound and a resin. When the first compound is a metal, the metal may be chosen among tin (Sn), copper (Cu), tantalum (Ta), iron (Fe), silver (Ag), manganese (Mn), gold (Au), palladium (Pd), lithium (Li), cobalt (Co), antimony (Sb) and magnesium (Mg).

Advantageously, the temperature of the porous material may be lower than the boiling point of the compound contained in the plasma flow and said compound may be captured by the porous material as a liquid or as a solid. In a preferred embodiment, the whole non-equilibrium plasma flow comprising the compound may necessary cross the porous material and the total amount of the compound contained in the non-equilibrium plasma flow may be captured by the carbon felt.

According to an embodiment, the dimensions and the volume of the porous material may be adapted to the amount of compound present in the non-equilibrium plasma flow.

According to another embodiment, the porous material may have a porosity of at least 30%, preferably of at least 40%, more preferably of at least 50%.

The porous material may be electrically conductive or may not be electrically conductive. Preferably, the porous material is not thermally conductive.

Advantageously, the compound captured by the porous material may be recovered or isolated by rinsing the porous material or by destroying said porous material.

In a first exemplary embodiment, the porous material comprising the captured compound may be rinsed by a solvent such as for example water, acid solvent, basic solvent, alcohol (for example ethanol), acetone and the like. When rinsing of the porous material has been achieved, the solvent contains the captured compound which may then be recovered or isolated by evaporating said solvent. According to this exemplary embodiment, the porous material may be reused in another process for capturing a compound.

In a second exemplary embodiment, the porous material may be a carbon felt comprising the captured compound and may be treated by a non equilibrium plasma according to the previously described process for treating a composition, said plasma comprising oxygen (O ₂ ) as additional reactive gas. With such a process, the carbon felt may be extracted under the form of carbon dioxide (CO ₂ ) and the captured compound may be recovered in a pure form.

In a third exemplary embodiment, the porous material may be a carbon felt comprising the captured compound and may be treated by a non equilibrium plasma according to the previously described process for treating a composition, said plasma comprising hydrogen (H ₂ ) as additional reactive gas. With such a process, the carbon felt may be extracted under the form of methane (CH ₄ ) and the captured compound may be recovered in a pure form.

Advantageously, the method for recovering the captured compound contained in the porous material may be chosen depending on the type of captured compound (metal, metal derivative, organic compound...), i.e. the type of compound contained in the non-equilibrium plasma flow crossing the porous material. The method for recovering the captured compound may also be chosen depending on the sensitivity of said captured compound to solvent, temperature...

According to another embodiment, the non-equilibrium plasma flow may comprise more than one compound. According to this embodiment, all the compounds contained in the non-equilibrium plasma flow may be captured in the porous material or only some of the compounds may be captured in the porous material.

According to still another embodiment, the process may be stopped to change to porous material and the process may be restarted with the same operating parameters or with different operating parameters once the porous material has been changed. According to an example of this embodiment, the porous material may be changed because it is full of the extracted compound and the process may be restarted with a new porous material to continue capturing the same compound. According to another example of this embodiment, the porous material may be changed to capture a different compound with a new porous material.

According to one embodiment, the process for capturing a compound may be used in the previously described process for treating a composition. According to this embodiment, the porous material may be placed between the support for the composition to be treated and the second opening of the enclosure, so as to be crossed by the non-equilibrium plasma flow. Therefore, when the compound is extracted from the composition, the non-equilibrium plasma flow conveys said extracted compound before and during the crossing of the porous material. Still according to this embodiment, the whole non-equilibrium plasma flow comprising the extracted compound may necessary cross the porous material and the total amount of the extracted compound may be captured by porous material.

Another object of the invention is a reactor for treating a composition comprising at least a first compound and a second compound with a plasma, characterized in that it comprises: an enclosure containing the composition, a generation device configured to generate a non-equilibrium plasma flow from a gas present within said enclosure so that said plasma gas flow comes into contact with the composition with a view to treating said composition, and one or more controlling devices configured to control one or more operating parameters of the reactor so as to maintain the plasma flow at said non-equilibrium state.

This reactor allows to treat the composition with a non-equilibrium plasma flow, i.e. with softer conditions compared to an equilibrium (or thermal) plasma.

A first possible operating parameter may be the type of gas present within the enclosure.

According to an embodiment, the gas that is present within the enclosure may comprise at least one inert gas and may optionally comprise an additional reactive gas. According to this embodiment, the enclosure may comprise a first opening which is in communication with a first controlling device configured to introduce gas into said enclosure. The first controlling device may allow to inject the inert gas and optionally the additional reactive gas into the enclosure. The first controlling device may comprise for example one or more tanks in which inert gas and additional reactive gas are stored under compressed gas or liquid form, and an expander for generating a flow of gas from the tank.

According to another embodiment, the enclosure may comprise a second opening that is in communication with a second controlling device configured to create a depression in the enclosure through said second opening. The second controlling device may be for example a pressure regulating device such as a vacuum pump.

Advantageously, by regulating the pressure inside the enclosure using the second controlling device, the pressure inside the enclosure may be maintained at a low pressure so as to maintain the plasma flow at a non-equilibrium state, said low pressure ranging from 0.1 to 10000 Pa, preferably from 0.5 to 5 000, preferably from 1 to 3 500, preferably from 1 to 2 500 Pa, preferably from 10 to 1 500 Pa, and more preferably from 300 to 900 Pa. According to a further embodiment, the reactor may comprise a third controlling device which may be a plasma generator. The plasma generator may generate the plasma by heating the gas present within the enclosure or by submitting said gas to a magnetic field. According to a preferred embodiment, the plasma may be generated by submitting said gas to microwaves, to an electric or to an electromagnetic field.

When the plasma is generated by submitting said gas to an electromagnetic field, the third controlling device may be a radiofrequency generator. The radiofrequency generator may be connected, for example, to a coil arrangement or device comprising inductive wires surrounding the enclosure. Preferably, the coil arrangement or device is placed around a portion of the enclosure which may be located between the first opening and the second opening. According to this preferred embodiment, the radiofrequency generator may generate a non-equilibrium plasma from the gas present in the enclosure by applying a power to the radiofrequency generator ranging from 50 to 6000 W, preferably from 50 to 3000 W, and more preferably from 50 to 2000W. More particularly, the plasma generator generates a non-equilibrium plasma flow from the gas flow present in the enclosure.

The plasma generator may generate a non-equilibrium plasma possessing one, two or three of the following physical features, or the four following physical features: a power ranging from 50 to 6000 W, preferably from 50 to 3000 W, more preferably from 50 to 300 W, and more preferably from 50 to 200 W; the power of the plasma may be measured by measuring the temperature of the plasma using for example a thermal cameras or calorimetry; an intensity below 1A, preferably ranging from 0,02 A to 1 A, preferably from 0,06 A to 0,8 A, preferably from 0,1 A to 0,7 A, and more preferably from 0,2 A to 0,6 A; the intensity of the plasma may be measured using for example an oscilloscope or an ammeter on the electrodes of the generator; a voltage ranging from 100 V to 6 kV, preferably from 150 V to 2 kV, preferably from 180 V to 1 kV, and more preferably from 200 V to 500 V; the voltage of the plasma may be measured using for example an oscilloscope or voltmeter on the electrodes of the generator ; a frequency ranging from 10 MHz to 45 MHz, preferably 10 MHz to 42 MHz, and more preferably 15 MHz to 40 MHz; the frequency of the plasma may be measure using for example an oscilloscope on the electrodes of the generator.

The physical features of the non-equilibrium plasma allow to have a plasma reactive enough to generate reactive species from the gas present into the enclosure and gentle enough to avoid deterioration/degradation of the compounds of interest present in the composition.

According to still another embodiment, the composition may be placed on a support and the reactor may comprise a temperature regulating device configured to regulate the temperature of said composition by controlling the temperature of said support. According to a preferred embodiment, the support may be a crucible, preferably a carbon crucible. Still according to a preferred embodiment, the temperature of the support may be controlled.

According to an embodiment, the reactor may comprise a fourth controlling device allowing to control the temperature of the support, preferably the crucible. According to this embodiment, the temperature of the support may be heated or cooled by means of a heat exchanger, for example a circuit of heat transfer fluid which may be in contact with the support or may surround said support.

When the support is heated, the fourth controlling device may be a resistance heating/heat resistor which may be in contact with the support or may surround said support.

According to a preferred embodiment, when the support is heated, the fourth controlling device may be an electromagnetic induction generator. The electromagnetic induction may be applied for example on the support using a coil arrangement or device surrounding the enclosure, said coil arrangement or device being connected to an electromagnetic induction generator.

According to another embodiment, the non-equilibrium plasma flow may circulate between the first and the second openings under the action of the depression created through the second opening. The support is located between the first and the second openings so as to be fully exposed to the non-equilibrium plasma flow.

According to still another embodiment, the enclosure may comprise a porous material (as previously described) configured to capture at least one compound contained in the non-equilibrium plasma flow. Preferably, the porous material may be placed between the support for the composition and the second opening of the enclosure so as to be crossed by the non-equilibrium plasma flow.

According to a preferred embodiment, the reactor may be used to perform the process of treatment of a composition previously described.

FIGURES

Other features and advantages will become apparent during the course of the following description given solely by way of nonlimiting example and made with reference to the attached drawing, in which:

- Figure 1 is a schematic view of a reactor for treating a composition with a plasma.

As depicted in Figure 1, the reactor 1 comprises an enclosure 2 which is cylindrical and made of quartz. The enclosure is transparent to allow an operator placed outside the enclosure to visually monitor the inside of the enclosure 2 when a process is performed inside said enclosure 2, such a process may be the previously described process for treating a composition or a the previously described process for capturing a compound.

In operation, the enclosure 2 is vertically oriented as shown in Figure 1. In other possible embodiments, the enclosure may have other forms, preferably elongated. Other materials than quartz may alternatively be used for the enclosure to the extent that said materials are able to withstand a reduced pressure.

At a first end 3, the enclosure 2 comprises a first opening 4 which is in communication with a first tank 6 containing an inert gas and a second tank 8 containing an additional reactive gas.

The reactor 1 comprises a first regulating valve 6' allowing to regulate the flow rate of inert gas to be introduced into the enclosure 2 through the first opening 4. The reactor 1 also comprises a second regulating valve 8' allowing to regulate the flow rate of additional reactive gas to be introduced into the enclosure 2 through the first opening 4.

At a second end 5, opposite to the first end 3, the enclosure comprises a second opening 10 which is in communication with a vacuum pump 12. The vacuum pump 12 allows to reduce the pressure inside the enclosure by means of a third regulating valve 12'.

The injection of inert gas, and optionally of additional reactive gas, into enclosure 2 while the vacuum pump is functioning/operating allows to generate an inner flow of gas 11 (inert gas and optionally additional reactive gas) between the first opening 4 and the second opening 10.

The reactor 1 also comprises a radiofrequency generator 14 operating at 40 MHz or at a lower frequency and at a power of 500 to 6000 W. The radiofrequency generator 14 is connected to a coil arrangement or device comprising here inductive wires 16 which are connected to a power supply 17. The inductive wires 16 surround an external portion of the enclosure that is located downstream the first opening along the gas flow 11.

The radiofrequency generator 14 is configured to apply an electromagnetic field on the flow of gas 11 by means of inductive wires 16 in order to generate a plasma flow 13 having a power ranging from 50 to 600 W. In the case where the vacuum pump 12 maintains a pressure that is lower than 10 000 Pa, and preferably lower than 5 000 Pa, the plasma flow 13 is maintained at a non-equilibrium state.

According to other possible embodiments, the plasma flow may be generated by any other type of generator such as electromagnetic field generator or microwaves generator.

The reactor 1 also comprises a carbon crucible 18 located inside the enclosure 2 and on which a composition 20 (comprising a first and a second compound) to be treated with a plasma may be placed. The carbon crucible 18 is maintained by means of a leg 22 in alumina. The leg 22 is fixed to the inner side of the enclosure 2 and for example rests against the second end 5 that forms here the bottom of the enclosure. The carbon crucible 18 is located downstream the coil arrangement or device 16 so as to receive the generated plasma flow 13.

The reactor also comprises an electromagnetic induction generator 26 functioning at a frequency of 15-35 kHz and able to provide a power ranging from 1 kW to 6 kW. The electromagnetic induction generator 26 is connected to a coil arrangement or device 28 located outside a portion of the enclosure 2 that surrounds the crucible 18. The electromagnetic induction generator 26 allows to heat the crucible 18 and thus the composition 20 at a desired temperature.

According to other possible embodiments, the crucible may be heated or cooled by means of a heat exchanger, or heated by one or more heating element(s), for example heating wire(s), heating resistance(s) and the like.

A carbon felt 24, e.g. in the form of a cylinder, surrounds the carbon crucible 18, and is placed within the enclosure so as to fill in the volume located between the carbon crucible 18 and the wall of the enclosure 2.

When, for example, the process for treating composition 20 is ongoing, the plasma flow 13 comes into contact with composition 20, which allows to extract the first compound therefrom. In particular, the non-equilibrium plasma flow 13 conveys the first compound in a gaseous state. The non-equilibrium plasma flow 13 carrying the gaseous first compound forms a resulting non-equilibrium plasma flow 13' that cross the carbon felt 24.

Due to its composition, the carbon felt 24 is not heated by the non equilibrium plasma flow 13' or by the electromagnetic induction generator 26 heating the crucible 18. Therefore, the carbon felt 24 allows to capture the first compound (which was previously extracted from composition 20 in a gaseous state) in a liquid or solid state.

This change in state of the first compound is due to the temperature of the carbon felt which is lower than the condensation point or lower than the solidification point of the first compound.

The captured first compound may then be recovered by the process previously described.

As represented in Figure 1, the controlling devices 6, 8, 14, 26 and 12 are external to the enclosure and may be removably connected thereto.

EXEMPLES

The plasma generator is a radiofrequency generator which operates at a frequency of 40 MHz and with an electric power ranging from 500 to 6000 W to generate a plasma discharge ranging from 50 to 600 W.

The electromagnetic induction generator functions at a frequency ranging from 15-35 kHz and is able to provide a power ranging from 1 kW to 6 kW.

The support is a carbon crucible having a density of 2.05 g/cm ³ and the carbon felt has a porosity of 88 ± 2 %.

Example 1

2 g of a composition A comprising 70 % by weight of copper (Cu) as first compound and 30 % by weight of tin (Sn) as second compound over the total weight of the composition was placed on the crucible. The vacuum pump was started to reduce the pressure within the enclosure and argon (Ar) as inert gas was introduced into the enclosure with a flow rate of 300 mLymin. The pressure at this stage was of 800 Pa.

The electromagnetic induction generator was started at a power of 2 kW for 400 seconds (s) allowing to heat the support, and thus the composition, at a temperature of 1080°C at which the composition was melted. At this stage, the pressure inside the enclosure was of 1200 Pa and was maintained at this value until the end of the process.

Then, the radiofrequency generator was started at a power of 2000 W (2kV, 1A) and at a frequency of 40 MHz and oxygen (O2) as additional reactive gas was introduced into the enclosure at a flow rate of 100 mLymin during 20 s. A non-equilibrium plasma flow having a power of 200 W was generated comprising reactive species (generated from argon (Ar)) and additional reactive species (generated from the oxygen (O2)).

Instantaneously, the carbon felt was covered with a white powder of tin oxide (SnC ) which is a derivative of the first compound.

All the controlling devices were then stopped and the carbon felt was removed from the enclosure and weighed. The weight of the white powder contained in the carbon felt was of 23 mg. Analysis by X-ray diffraction XRD) showed that the extracted compound comprised 93 % by weight of tin oxide (SnC ) and 7 % by weight of copper (Cu), over the total weight of the extracted compound.

In this example, the process for treating the composition was stopped before the end of the process. However, the process could have been extended to extract the totally of tin under the form of tin oxide (SnCb).

Example 2

An ingot of 2 g of tin (Sn) as first compound was placed on the crucible and a tablet of 1 g of copper chloride (CuCh) as second compound was placed below said tablet. The vacuum pump was started to reduce the pressure within the enclosure and argon (Ar) as inert gas was introduced into the enclosure with a flow rate of 300 mb/min. The pressure at this stage was of 800 Pa and was maintained at this value until the end of the process.

Then, the radiofrequency generator was started at a power of 2000 W (2k V, 1A) and at a frequency of 40 MHz to generate a non-equilibrium plasma flow at 200W comprising reactive species (generated from argon (Ar)).

In this example, the temperature of the crucible was not modified and the composition was therefore at the temperature of the non-equilibrium plasma flow which is lower than 400°C at the end of the treatment.

The composition was therefore treated with the non-equilibrium plasma flow and after 300 s, the tin (Sn) was melted and the copper chloride (CuCb) was embedded into it.

After 40 more seconds, the first and the second compounds were allowed to react together, and the carbon felt was covered with a white powder of tin chloride (SnCh) which is a derivative of the first compound.

All the controlling devices were then stopped and the carbon felt was removed from the enclosure and weighed. The weight of the white powder was of 45 mg. Analysis using Energy-dispersive X-ray spectroscopy (EDX) showed that the extracted compound comprised 90 % by weight of tin chlorine (SnCI2) and 10 % by weight of copper (Cu + CuCI) over the total weight of the extracted compound.

Example 3

A composition of eight used condensators comprising an organic fraction, a ceramic fraction, and a metallic fraction was placed on the crucible.

The composition was first submitted to a preparation step to remove the organic fraction by pyrolysis and without using any plasma flow. The vacuum pump was started to reduce the pressure within the enclosure and argon (Ar) as inert gas was introduced into the enclosure with a flow rate of 300 mLymin. The pressure at this stage was of 530 Pa.

The electromagnetic induction generator was started at a power of 1 kW for 120 seconds (s) allowing to heat the condensator and thus to realize the pyrolysis of the organic fraction which were extracted from the composition under gaseous (CHx, COx) and oil form. After 120 second the pressure has increased to 1100 Pa.

After this preparation step, the crucible contained the ceramic fraction and the metallic fraction. Both fractions were crushed and separated by magnetism.

EDX analysis showed that:

- the crushed ceramic fraction contained mainly silicon (Si + S1O2), carbon (C), tantalum (Ta° + Ta ₂ 0s) and manganese (Mn° + MnO + MnC ), under the form of oxides or metals, and

- the crushed metallic fraction contained mainly iron (Fe), copper (Cu), tin (Sn) and a small amount of silver (Ag), under the form of metals.

In this example, only the crushed metallic fraction was not treated by plasma.

The crushed ceramic fraction was sieved to eliminate silica (S1O2), carbon (C) and to recover a composition comprising manganese (MnO + Mn0 ₂ ) as first compound and a mixture of tantalum (Ta° + Ta ₂ 0s) as second compound. This composition was then submitted to the treatment with non equilibrium plasma.

The composition was placed on the crucible.

The vacuum pump was started to reduce the pressure within the enclosure and argon (Ar) as inert gas was introduced into the enclosure with a flow rate of 300 mLymin. The pressure at this stage was of 750 Pa.

The electromagnetic induction generator was started at a power of 1 kW for 300 seconds (s) allowing to heat the crucible, and thus the composition, at a temperature of at most 850°C. The pressure at this stage was of 1200 Pa and was maintained at this value until the end of the process.

Then, the radiofrequency generator was started at a power of 2000 W (2k V, 1A) and at a frequency of 40 MHz and hydrogen (H2) as additional reactive gas was introduced into the enclosure at a flow rate of 120 mL/min during 120 s. A non-equilibrium plasma flow of 200 W was then generated comprising reactive species (generated from argon (Ar)) and additional reactive species (generated from hydrogen (H ₂ )).

The process allowed to extract the totality of manganese (first compound) which was captured by the carbon felt under the form of Mn° + Mn0 ₂ . The second compound which was reduced by the non-equilibrium plasma flow, i.e. tantalum under his metallic form, was recovered in the crucible at a purity of 99,2 % by weight, the rest being 0.8 % by weight of Mn° over the total weight of the second compound.

Example 4

A composition comprising 500 mg of a sulfur (S) powder (average diameter of 1 pm) as first compound and 200 mg of a tantalum oxide (Ta ₂ Os) powder (average diameter of 200 nm) as second compound was placed in the crucible.

The vacuum pump was started to reduce the pressure within the enclosure and argon (Ar) as inert gas was introduced into the enclosure with a flow rate of 300 mb/min. The pressure at this stage was of 400 Pa.

The electromagnetic induction generator was started at a power of 1 kW for 30 seconds (s) allowing to heat the support, and thus the composition, at a temperature of 500°C. The pressure at this stage was of 750 Pa.

After 30 s of operation at the same pressure, the sulfur was totally extracted and the carbon felt was covered with a yellow powder of sulfur (S) and the operating parameters were maintained for 10 more seconds. Then, the electromagnetic induction and the radiofrequency generator were stopped. At this stage, the second compound remained in the crucible under its initial form of tantalum oxide (Ta20s) (white powder) and the temperature of the crucible is about 400 °C (i.e. at the temperature of the non-equilibrium plasma used to extract the sulfur (S)).

The flow rate of argon (Ar) was then maintained allowing to decrease the temperature of the crucible, and thus the temperature of the composition, at 250 °C after 1 min. The pressure at this stage was of 630 Pa.

Then, the radiofrequency generator was started at a power of 180 W (0.3kV - 0.6A) and a frequency of 40 MHz and hydrogen (H2) as additional reactive gas was introduced into the enclosure at a flow rate of 50 mL/min during 2 min. A non-equilibrium plasma flow was thus generated at 700 Pa comprising reactive species (generated from argon (Ar)) and additional reactive species (generated from the hydrogen (H ₂ )).

The temperature of the crucible then increased with a rate of 30°C / min.

After 2 min the tantalum oxide (Ta ₂ 0s) powder was covered with tantalum (under its metal form), the reduction being performed thanks to the additional reactive species of hydrogen generated from hydrogen (H ₂ ).

The process was stopped and a mixture of 91% by weight of tantalum oxide (Ta205) and 9% by weight of tantalum metal (Ta) over the total weight of the mixture was obtained in the crucible. The powder of tantalum oxide (Ta205) initially white turned grey due to the formation of tantalum metal (Ta). The process may have been pursued to obtain only tantalum metal (Ta) on the crucible.

Example 5

In this example, a special carbon crucible equipped with an internal circuit of heat transfer fluid (air or water for example) was used. This internal cooling channel allowed to cool the crucible during the process.

The same composition of example 4 was placed in the crucible. The sulfur was extracted according to the process described in example 4 and at the end of the sulfur, extraction, the temperature of the crucible is about 400 °C (i.e. at the temperature of the non-equilibrium plasma used to extract the sulfur (S)).

The flow rate of argon (Ar) was then maintained allowing to decrease the temperature of the crucible. To further decrease the temperature of the crucible, a circulation of air was set up in the circuit of heat transfer during 2 min, and then a circulation of water was set up and maintain until the end of the process. The temperature of the crucible was thus stabilized at 25°C and maintained at this value until the end of the process.

Then, the radiofrequency generator was started at a power of 180 W (0.3 kV - 0.6 A) and at a frequency of 40 MHz and hydrogen (H2) as additional reactive gas was introduced into the enclosure at a flow rate of 50 mL/min during 2 min. A non-equilibrium plasma flow at 580 Pa was thus generated comprising reactive species (generated from argon (Ar)) and additional reactive species (generated from the hydrogen (H ₂ )).

After 2 min the tantalum oxide (Ta ₂ 05) powder was covered with tantalum (under its metal form), the reduction being performed thanks to the additional reactive species generated from hydrogen (H ₂ ). At the end of the process, a mixture of 87% by weight of tantalum oxide (Ta ₂ Os) and 13% by weight of tantalum metal (Ta°) over the total weight of the mixture was obtained in the crucible. The powder of tantalum oxide (Ta ₂ Os) initially white turned dark grey due to the formation of tantalum metal in a larger amount than in example 4.

Examples 4 and 5 allows to show that the process of treating the composition performed using a crucible which may be heated or cooled, may advantageously applied to thermal sensitive compounds. In the process of reduction of tantalum oxide (Ta ₂ Os) to form tantalum metal (Ta°), which is thermal sensitive, the yield was improved by cooling the crucible. Example 6

The plasma generator used in this example is a radiofrequency generator which operates at a frequency of 4.5 MHz and with an electric power ranging from 24 to 60 kW to generate a plasma discharge ranging from 12 to 30 kW.

The induction generator functions at a frequency ranging from 15-35 kHz and is able to provide a power ranging from 1 kW to 6 kW.

A composition comprising 3g of dielectrics from recycling capacitors was placed on a crucible. The composition contains 14.37% by weight of oxygen (O), 2.38% by weight of carbon (C), 64.13% by weight of tantalum (Ta), 19.04% by weight of manganese (Mn) and 0.08 % by weight of impurities over the total weight of the composition (determined by electron microscopy/energy dispersive X-ray spectroscopy (SEM/EDX)).

The vacuum pump was started to reduce the pressure at 2000 Pa within the enclosure and argon (Ar) as inert gas was introduced into the enclosure with a flow rate of 3000 L/min.

Then the radiofrequency generator was started at a power of 36 kW and the argon flow rate was increased to 50 L/min and the pressure at this stage was of 1 bar. Under these conditions, a thermal plasma having a power of 18 kW was formed and the temperature of the carbon crucible was measured by a pyrometer at 1210°C.

The electromagnetic induction generator was started at a power of 2 kW to heat the crucible which was also heated by the thermal plasma. The resulting temperature of the crucible, and thus of the composition was then of 1400°C.

The high temperature of the thermal plasma allowed to extract manganese (under the form of Mn° + MnC ) which was captured in a solid form by the carbon felt.

A flow of 250 ml/min of hydrogen as reactive gas was then injected into the enclosure allowing to reduce tantalum oxide (Ta20s) into tantalum (Ta). At the end of the process, 1.9g of tantalum (Ta) was obtained in the crucible with a purity of 99% (analyzed by SEM/EDX), and carbon and oxygen were eliminated under ChU and gaseous H2O forms.