Experimental and simulation studies for reaction enhancement of catalytic CF4 hydrolysis by consecutive HF removal using a multi†stage catalyst†adsorbent reactor

In this paper, a multi†stage catalyst†adsorbent reactor consisting of a series of catalyst and adsorbent beds is proposed for an effective tetrafluoromethane (CF4) abatement and conversion of corrosive hydrogen fluoride (HF) to CaF2, a useful chemical. Experimentally, enhanced CF4 conversions were observed in multi†stage catalyst†adsorbent reactors compared to a zero†stage reactor (catalyst bed only) confirming sorption†enhanced CF4 hydrolysis due to selective removal of HF during reaction. In addition, some useful design guidelines to select the number of stages and a proper time to replace adsorbents are presented. To develop a process simulation model to represent experimental data, Aspen HYSYS®, a commercial process simulator, was used providing a proper model to match experimental data quite reasonably. Based on experimental and simulative studies, a three†or four†stage catalyst†adsorbent reactor is recommended for CF4 abatement considering both reactor performance and capital/operating expenditures. © 2017 Society of Chemical Industry and John Wiley & Sons, Ltd.