The Corona Discharge, Its Properties and Specific Uses
The Corona Discharge, Its Properties and Specific Uses
Abstract - The main properties of corona discharges are reviewed, with emphasis
on the features which make them unique for use as non-equilibrium chemical
reactors : Their stability and ease of operation over a wide range of gases
and pressures, including atmospheric ; their sharply confined ionization regions
where hot electrons interact with cold gas, inducing reactions without back
reactions ; and their extended low field drift regions which act as gaseous
electrolytes, inducing electrochemical reactions on surfaces.
Present and future applications are discussed : Synthesis of ozone and ammonia,
promotion of flames and combustion, surface treatment, and electrical insulation
improvement.
INTRODUCTION
Gas discharges have been used for industrial chemical purposes ever since Birkeland's "electric
gun" (really a linear motor) short-circuited during a crucial demonstration in Oslo around the turn
of the century. The resulting DC arc was blown out in a gigantic fan by the magnetic field, disper-
sing the assembled dignitaries and all hopes of defense contracts. However, it also gave Birkeland
the extended but thin slab of hot plasma he needed to convert air to nitrogen oxides, by heating
a passing air flow to around 3000 K in the arc zone, with subsequent fast cooling to prevent back
reactions. Backed by the business man S. Eyde and French capital, this was the start of the Birkeland-
Eyde process and the Norsk Hydro Company that now dominate European fertilizer manufacture.
The purpose of the present paper is to question whether Birkeland would have been still more lucky
if his cannon had developed extensive electrical corona.
What are the reasons for using ionized gases as media for chemical reactions ? Some applications
use the plasma solely as a source of heat, and in these cases coronas cannot compete. Apart from
these cases, all use of ionized gases for bulk reactions or for surface treatment exploits the non -
equilibrium (non-thermal) properties of these media. Here coronas excell, as no other discharge
form has sharper internal divisions, both geographically into zones, and species-wise into electron,
ion and neutral populations of very different energy distributions.
In the following some fundamental aspects of corona discharges and their interactions with the
surroundings will be discussed briefly. A more thorough introduction to the subject will be found
in refs. 1-2. After that, we turn to some applications related to chemistry.
5
a i0cos 0
"PLANE"
z=d
-REGION
—"POINT", "ROD"
outer limit of ionization region, where
the production of electrons by ionization
just balances the loss by attachment.
In air and most other gases containing electron attaching molecules, two very different types of DC
(and low frequency AC) coronas are found
1. Unipolar conduction coronas, variously called positive glow coronas, negative Trichel pulse coronas,
and negative glow coronas, all have ionization regions that stay concentrated very close to the
active electrode. Also, at microampere currents and above, they either burn stably or, more often,
in short pulses of such high repetition rate that the ion flow in the drift region is practically conti-
nuous. The predominant ions are of the corona polarity, that is, positive ions in positive coronas
and negative ions in negative. The part of the drift region current in negative air coronas carried
by electrons is usually small below 10-20 pA total current, because of electron attachment. At
higher currents, the space charges make the electric field distribution more uniform. This, and
the higher applied voltage, sharply increase the drift region field, increasing the electron/negative
ion ratio. Note that the rapidly pulsed nature of the ionization region processes is very important
for the corrosion of the negative point electrode. This may affect the drift region and the plane
electrode by sputtering (ref. 4) or evaporation of point metal or corrosion products (refs. 5,6).
A plasma chemist may be well advised to look upon the unipolar drift region as an overgrown boun-
dary sheath connecting the ionization region (often a plasma) with the low field electrode.
2. Streamer (bipolar) conduction coronas occur at higher point-to-plane currents, especially at
positive point polarity. Under these conditions, the ionization region produces a conducting plasma
faster than the plasma can be absorbed by the point electrode. Consequently a conductive plasma
filament of some 30 pm diameter grows out of the point toards the plane, carrying the plasma
producing ionization region ahead of it with velocity around 10 m/s (values for atmospheric density
air). When this streamer hits the plane, a cathode spot is produced, the gap field is redistributed
along the plasma channel, and this channel either dies out (by electron attachment) or later converts
to a thermally ionized spark channel. A positive streamer hitting a plane cathode will subject
it to a pulsed glow discharge treatment, bombarding it with positive ions of energies that may
exceed 100 eV (measured at 10 kPa air by retarding potential analysis of extracted positive ions.
Scaling laws predict no change with increase in pressure). This is in sharp contrast to the mainly
thermal energy ion influx to the plane in unipolar current coronas.
Note that both corona forms may coexist : A 50 pA positive corona might consist of 20 pA continuous
unipolar current, diffusely distributed over the plane (see below), with 30 pA of streamers, repetitive
at 10 kHz, hitting the plane just opposite the point (ref. 7).
Nearly a century of observations all agree that the unipolar current density in positive and negative
point-to-plane coronas is distributed over the plane according to the so-called Warburg law (refs.8-1 1)
(0) = j0 cos50 (1)
j0 1/(2.d) (2)
with tg 0 = r/d and where I is the total corona current and d the gap length. The field and ion
flow lines are somewhat, but not much, pushed apart by space charge repulsion. The observed distri-
butions j (0) usually fall quite abruptly to zero around 0 65°, due to the fact that ions drift
along the field lines and that field lines ending outside 0 65° usually originate on the point surface
outside the ionization region. The Warburg distribution is sketched in Fig. 1.
In point-to-plane unipolar current coronas, as well as in wire-cylinder or wire-plane ones, space
charge fields will tend to make the total field increasingly uniform at increasing currents. It can
be shown (ref. 12) that the unipolar current I at a given voltage U0 cannot exceed the saturation
limit
I
sat 2pc 0 U2/d
o (3)
where p is the ion mobility and = 8.85 pF/m the permittivity. For ions in air at atmospheric
density, this gives
Isat (pA) 4 U2o (kV2) / d (mm). (4)
If currents above this are observed, they are either partly bipolar (Eqs. (3) and (4) invalid) or electron-
carried (p for electrons must be used).
The space charge dominated currents driven by high potentials (in the 5-10 kV range) make corona
discharges nearly perfect galvanostatic ion and electron current generators, on the macroscopic
level.
An important feature of the point-to-plane coronas is the so-called electric wind.As the charged
particle flow in atmospheric density coronas is completely viscous (collision dominated), virtually
all momentum and energy extracted by the ions from the electric field are transferred to the
neutral gas molecules. A fairly strong, axial gas jet results (refs. 13,14), often employed to blow
out candles in demonstration experiments and to carry ions to grammophone records for removal
of excess surface charge. However, this jet also transmits up to half the discharge power to the
plane (ref. 15), in the form of heat and of chemically very potent excited atoms and molecules.
Our electrochemical view of the point-to-plane corona discharge may be summarized by Fig. 2,
illustrating schematically the various reaction regions and channels in the corona gas and on the
surrounding conducting and non-conducting surfaces. The importance of synergy between the neutral,
activated species and the charged species will be further discussed below.
Electrochemical
U-
Fig. 2. Schematic diagram illustrating the
., main reaction regions and reaction channels
High fielffjgh field, primary of a corona electrochemical reactor (ref. 16).
ft e1ectrode I production regwn
reactor — ___________________ Two intermixed streams of energetic parti-
cles emerge from the ionization region
where they are produced : Neutral, activated
species, carried by the electric wind, and
charged species, carried by the electric
field. The activated neutrals interact with
the gas, the neutral (insulated or insulating)
surfaces, and the low field electrode.
Charged particles interact with the gas and
with the low field electrode. The low densi-
ties preclude significant interaction between
the two streams and their reaction products,
except at the low field electrode surface,
where important synergetic effects appear.
and in potential) the positive ion will absorb energy and momentum from the electric field, and
transfertheimto thegas and to the plane electrode. Further, the ion might attach to or react with
neutral constituents of the gas, and thus cause a transport of these to the plane. The relative
importance of these effects can be estimated as follows
** Total electric energy input per ion W = U.q = 10 keV
tg = = /2 I mgng/q n E
:Ht =n
H20
V/4 = 4.4.1025 molecules/m2s 2.lOJHi (8)
This shows that charge, not chemical species nor energy, is the important quantity that unipolar
corona ions transport to the passive electrode. Chemical species, excitation energy and thermal
energyareprimarily transported by the electric wind. All corona corrosion phenomena must be viewed
in the light of these facts.
_p__ Finally, let us consider how the above picture changes when a substantial part of the corona
current is carried as bipolar, repetitive, non-sparking streamers.
Firstly, the ionization region in front of the streamer head is not overly different from a stationary
ionization region, except for its rapid movement through the gas. Secondly, the residual streamer
channel behind the head is a true, collision dominated cold plasma, but not so dense as to make
charged particle collisions of great importance (ref. 17). The total number of ions in that channel,
and the field in which they move, are also comparable to what is found in a non-streamer drift
region. Thus the ion energy balance should be not very different from inside a unipolar conduction
corona. The main difference, then, is the transient presence of free electrons in the channel, of
energies sufficient to excite and dissociate neutrals, even in a positive corona. In air and CO
most of the free electrons will disappear by dissociative attachment, forming chemically importan
neutrals
e+ 02 O+ 0 (9)
e+ C02÷ O + CO (10)
voltage probe for a time A tb during which the measured potential V falls iV. In Fig. 3b each
short vertical line represents a registration of the fall tV during phase b, plotted at an abscissa
value equal to the summed charge Q = LQ received during all the phases a. The hysteresis-like
curve shapes are obtained by reversing the corona polarity, thus subjecting the samples first to
anodic oxidation in a negative corona, then to cathodic reduction in a positive corona, and again
to anodic oxidation in the negative corona.
After each change in polarity the gold surface rapidly reaches a stationary state, in contrast to
oxidizable metals, such as copper or nickel. The potential difference between the oxidation and
reduction plateaus ( 'u1.3 V), and the equivalent capacitance of the layer ( 4OO pF/cm2) are
comparable to voltametrically measured values for gold in aqueous acid solutions (refs. 26,27).
C:2
WV)
o
10 20 3 4Q
01 ts)
0.3 a) b)
With less noble electrodes than gold, another similarity to aqueous electrochemistry appears
Corona corrosion, uniform or pitting. Negative coronas in air of more than 10-20 % relative humidity
will rapidly form a semi-liquid layer on anodic metal surfaces, containing water and NOx ions
from the air as well as dissolved impurities. Powered by the corona ion current, this layer seems
to behave like any other aqueous electrolytic cell, as illustrated by Fig. 4. For instance, with alumi-
nium as the anode, pronounced pitting occurS.Under dry conditions, on the other hand, negative
air coronas cause only uniform anodic passivation of this metal, building up surface layers charged
to several hundred volts. Positive coronas do not seem to pit aluminium.
Chemical synthesis
Many chemical products can be synthetized by corona discharges, but ozone is so far the only
one of industrial importance. It is used for the treatment of water, preserving its natural taste
and avoiding the smell of chlorine, and for other applications utilizing its large oxidation power.
for instance in textile and paper industries.
The streamer type coronas used for ozone generation generally use air or oxygen filled short gaps
where one of the electrodes is covered with an insulating layer in order to prevent streamer-arc
transition. The relevant features of these so-called silent discharges for ozone production are
- High energy electrons, providing a high yield of atomic oxygen for the main reaction
O + 02 + M -- 03 + M where M is a molecule, often oxygen, carrying away the excess energy;
- Low gas temperature, necessary to avoid thermal dissociation of the ozone molecules already
produced;
- High working pressure, around atmospheric.
Research is still needed to improve both chemical and energy yields, still too low ( 2 % and
6 % respectively in dried air). Progress might be obtained by different ways
- There is no clear evidence that a unipolar conduction current does not flow in the silent discharge
considered, in parallel with the streamers. This should be reduced to a minimum, as mentioned
earlier. For this, an externally pulsed discharge could bring improvements, but entails the use of
more complex power supplies. Work is proceeding along these lines (refs. 28,29).
- Ozone is produced via excited and atomic oxygen, and oxygen dissociation can be catalyzed in
several ways. Addition of SF6 (ref. 30) or He (ref. 29) to air, or surface catalysis (refs. 31,32),
all seem to involve excitatiOn of nitrogen molecules, which in turn can dissociate and
excite oxygen with high efficiency (ref.33).
The catalytic effect of selected surfaces in production of activated nitrogen in coronas might
also be used for chemical synthesis of other products, as ammonia (ref. 31). Yields for production
of nitrogen oxides are still much too small for industrial exploitation, however.
..
LIQUID PHASE
r_iIitiI
Cu Al
N__ ELECTROLYTE .
_ CORROSION1
if
/ Al203, n(H20)
Al (0(03 , n(H20)
\
PRODUCTS I
Al (!X)3)3 , n(H20)
GAS PHASE etc...
AIR +H20
Fig. 4. Schematic representation of the pitting activity of negative ions, leading to compa-
rable effects on aluminium anodes in an electrolyte and in a gaseous plasma
(ref. 24).
Surface treatment
Coronas are widely used as chemical reactors for surface treatment. Their oxidation and reduction
effects, Dassivating or corroding, have already been mentioned in the section dealing with the
electrochemical behavior of the discharge. Depending on the material to be treated and the desired
surface prooerties, the oDtimal corona gas composition, discharge parameters and operating procedure
may be very different.
An industrially very important application is the surface treatment of polymers, in particular to
increase their wettability and their adhesivity to ease printing, painting, sealing, coating, etc.
This is achieved simply by corona discharges in ambient air. Discharge products transfer their
activation energy to the polymer by breaking chains and creating radicals. These will rapidly react
with the further impinging oarticles, with the environment, and even with gas coming from the
bulk material. Polar bonds and hydrogen bonds formed in this way will increase the polymers sur-
face energy. The bonds most frequently encountered are C - 0, C = 0, C - 0 - O, C - OOH (ref. 34)
and, in smaller amounts, NH, NO, NO2, NO (ref. 35). The effect of the corona treatment increase
with time and current until a saturation stJe is reached (ref. 36) (Fig. 5); then oxidation processes
are counterbalanced by decarboxilation processes, as revealed by ejection of GO, CO2 and H2
molecules emitted from the surface (ref. 37). The chemical changes in the surface are often accom-
panied by changes in the structure, generally with a loss of crystallinity (ref. 35), that must be
ascribed to the large number of short chains remaining on the surface. Other corona induced pheno-
mena which may contribute to or affect the surface evolution are
- Density variations, for instance a decrease induced by oxygen grafting or an increase due to
cross-linking by active nitrogen, causing surface deformation or change in porosity
- Migration phenomena, changing the surface topography
- Sputtering phenomena, localized at the impact point of streamers.
If gap length of an air or oxygen corona is reduced so that the drift region becomes very small,
the oxygen grafted on polymers rapidly diminish (ref. 36) (Fig. 6a) due to increased etching. How-
ever, the induced surface energy (wettability, etc) is not reduced (Fig. 6b), even if the mechanisms
involved must have changed.
The efficiency of a corona surface treatment also depends on polarity. Negative coronas generally
appear to be less efficient than positive coronas, both for oxidation and etching. Contributing factors
are that the energy delivered to the surface by charge neutralization is lower for negative ions
than for positive ones and that the streamers generated in positive coronas submit the surface
to concentrated bursts of high energy ions.
A [0/C]
0.1
0
0 10 20
A [0/C] y (dyne/cm)
45
0.3
40
0.2
35
0.1
d(mm) T dim)
0
0 1 2 3 4 0 2 4 6 8
(a) (b)
Fig. 6. Variation of the amount of oxygen fixed at the surface of polyethylene terephtalate
films (curve a) and of surface energy (curve b) as a function of gap length (ref. 36).
The use of coronas to improve the wettability and adhesivity of polymer and other surfaces is
well established. However, more recent work shows that coronas also may be used to reduce these
quantities, typically by surface polymerization induced by coronas in fluorinated gases of pressures
up to atmospheric. For instance, good results have been obtained on paper and textile materials
by corona treatment in a C2 H2 F2 atmosphere (ref. 38).
Finally, let us note that coronas have bactericidal effects. Exposure to air coronas will stop the
growth of bacteria cultures, as recently demonstrated on Escherichia Coli.
REFERENCES
1. R.S. Sigmond and N. Goldman, in Electrical breakdown and discharges in gases, NATO ASI
series, B89b, E .E. Kunhardt and L.H. Luessen (eds), Plenum Press, New York (1983).
2. A. Goldman and J. Amouroux, in Electrical breakdown and discharges in gases, NATO ASI
series, B89b, E.E. Kunhardt and L.H. Luessen (eds), Plenum Press, New York (1983).
3. M. Goldman and R.S. Sigmond, IEEE Trans.Electr.Ins. EI-17, 90 (1982).
4. G. Buchet and A. Goldman, in Proc. 1stInt.Conf. on Gas Discharges, p.L159, lEE Conf.Publ.
No.70, London (1970).