CFD Simulation and Structural Optimization of a Thermal Catalytic Degradation Reactor for Sulfur Hexafluoride
Sulfur hexafluoride (SF6), widely used as an insulating gas in high-voltage electrical equipment, possesses a global warming potential (GWP) 25,200 times that of CO2, necessitating efficient degradation technologies. This study employed computational fluid dynamics (CFD) to simulate the thermal catalytic degradation of SF6 in a fixed-bed reactor, integrating models for porous media, heat transfer, turbulence, and chemical kinetics. The simulations revealed significant radial non-uniformities in pressure, velocity, temperature, and species concentration distributions, with temperature identified as the dominant factor influencing degradation efficiency. Radial temperature gradients caused uneven reaction rates, with degradation rates near the wall substantially exceeding those at the central axis, thereby reducing overall SF6 conversion. To address this, structural optimizations were implemented, including reducing the reactor tube diameter and incorporating inert porous media with high thermal conductivity at both ends of the catalytic section. These modifications enhanced radial heat transfer, homogenized the temperature field, and improved the uniformity of reaction rates and species concentrations. Parametric studies on inlet gas velocity showed that both excessively low and high flow rates were detrimental: low velocities led to underutilization of the downstream catalyst and increased energy consumption, while high velocities deteriorated heat transfer and exacerbated radial temperature gradients. The optimal inlet velocity range was determined to be 0.4–0.8 m/s for a reactor tube inner diameter of 10 mm, balancing catalyst utilization, energy consumption, and degradation efficiency. This research provides data-driven guidance for the design and scale-up of SF6 catalytic degradation reactors.