Patent Abstract:
In some aspects, an apparatus is provided for abating perfluorocarbons (PFCs) in a controlled decomposition oxidation (CDO) thermal reaction chamber. The apparatus includes (1) a cartridge insertable into the thermal reaction chamber having gas-permeable first and second ends and including a catalyst material; and (2) thermally-conductive fixtures positioned within the cartridge. Numerous other aspects are provided.

Full Description:
[0001]     The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/772,317, filed Feb. 11, 2006 and entitled “METHODS AND APPARATUS FOR PFC ABATEMENT USING A CDO CHAMBER”, (Attorney Docket No. 10910/L) and U.S. Provisional Patent Application Ser. No. 60/865,347, filed Nov. 10, 2006 entitled “METHODS AND APPARATUS FOR PFC ABATEMENT USING A CDO CHAMBER”, (Attorney Docket No. 10910/L2), each of which is hereby incorporated herein by reference in its entirety for all purposes. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to semiconductor device manufacturing, and more specifically to methods and apparatus for PFC abatement using a CDO chamber.  
       BACKGROUND OF THE INVENTION  
       [0003]     Many of the processes used during semiconductor device manufacturing, such as metal and dielectric etch processes, produce undesirable by-products including perfluorocompounds (PFCs) or by-products that may decompose to form PFCs. Cleaning processes used to remove materials accumulated on chamber components of deposition chambers, such as chemical or physical vapor deposition chambers, also may produce PFCs. Methods and apparatus for abating such PFCs are desirable.  
       SUMMARY OF THE INVENTION  
       [0004]     In some aspects, a method is provided for abating perfluorocarbons (PFCs) in a gaseous waste abatement system having a pre-installed controlled decomposition oxidation (CDO) thermal reaction chamber that includes (1) providing a catalyst bed within the CDO thermal reaction chamber; and (2) introducing a gaseous waste stream into the CDO thermal reaction chamber so as to expose the gaseous waste stream to the catalyst bed.  
         [0005]     In certain aspects, a system is provided for abating perfluorocarbons (PFCs) from a gaseous waste stream that includes (1) a wet scrubber adapted to scrub a gaseous waste stream and having an outlet adapted to discharge a scrubbed gaseous waste stream; and (2) a controlled decomposition oxidation (CDO) system. The CDO system includes a CDO thermal reaction chamber that includes (a) an inlet coupled to the outlet of the wet scrubber; (b) a catalyst bed adapted to abate PFCs within the CDO thermal reaction chamber; and (c) an outlet.  
         [0006]     In some other aspects, a method is provided for abating perfluorocarbons (PFCs) in a gaseous waste abatement system having a controlled decomposition oxidation (CDO) thermal reaction chamber that includes (1) providing a catalyst bed within the CDO thermal reaction chamber; (2) conveying a gaseous waste stream past a heat exchanger into an inlet of the CDO thermal reaction chamber and to the catalyst bed; (3) filtering the gaseous waste stream through the catalyst bed, the filtered gaseous waste stream being heated in the catalyst bed; and (4) recirculating the heated gaseous waste stream from the catalyst bed to the heat exchanger.  
         [0007]     In at least one aspect, a controlled decomposition oxidation (CDO) system is provided for abating perfluorocarbons (PFCs) that includes (1) an upstream portion including a first conduit adapted to convey a gaseous waste stream; (2) a thermal reaction chamber having an inlet coupled to the first conduit, a catalyst bed adapted to abate PFCs, and an outlet; and (3) a downstream portion including a second conduit having a first end coupled to the outlet of the thermal reaction chamber and having a portion, downstream from the first end, positioned proximate to the first conduit. The second conduit is adapted to convey a gaseous waste stream heated within the thermal reaction chamber to enable a transfer of heat energy from the second conduit to the first conduit so as to pre-heat the gaseous waste stream in the first conduit.  
         [0008]     In some other aspects, a system is provided for abating perfluorocarbons (PFCs) that includes (1) an upstream portion including a first conduit adapted to convey a gaseous waste stream and a heating device coupled to the first conduit and adapted to pre-heat the gaseous waste stream; and (2) a thermal reaction chamber including an inlet coupled to the first conduit and a catalyst bed adapted to abate PFCs in the gaseous waste stream entering the thermal reaction chamber from the first conduit.  
         [0009]     In certain other aspects, a system is provided for abating perfluorocarbons (PFCs) within a gaseous waste stream that includes (1) a first conduit adapted to convey the gaseous waste stream and having an outlet; (2) a heat exchanger positioned in the first conduit proximate to the outlet; (3) a thermal reaction chamber including an inlet coupled to the outlet of the first conduit, a catalyst bed having a catalyst material positioned within the thermal reaction chamber adapted to abate PFCs within the gaseous waste stream; and (4) a second conduit having a first end coupled to the catalyst bed and a second end coupled to the heat exchanger.  
         [0010]     In yet other aspects, a system is provided for abating perfluorocarbons (PFCs) within a gaseous waste stream that includes (1) a first conduit adapted to convey the gaseous waste stream and having an outlet; (2) a thermal reaction chamber including an inlet coupled to the outlet of the first conduit, a catalyst bed having a catalyst material positioned within the chamber and adapted to abate PFCs within the gaseous waste stream, and an outlet positioned opposite the inlet; and (3) a second conduit having a first end coupled to the catalyst bed and a second end that extends into the first conduit.  
         [0011]     In still other aspects, an apparatus is provided for abating perfluorocarbons (PFCs) in a controlled decomposition oxidation (CDO) thermal reaction chamber. The apparatus includes (1) a cartridge insertable into the thermal reaction chamber having gas-permeable first and second ends and including a catalyst material; and (2) thermally-conductive fixtures positioned within the cartridge.  
         [0012]     In yet other aspects, an apparatus is provided for abating perfluorocarbons (PFCs) in a controlled decomposition oxidation thermal reaction chamber. The apparatus includes a cartridge insertable into the thermal reaction chamber having gas-permeable first and second ends and including a catalyst material.  
         [0013]     In at least another aspect, an apparatus is provided for abating perfluorocarbons (PFCs) in a controlled decomposition oxidation (CDO) thermal reaction chamber that includes an annular catalyst bed embedded in the thermal reaction chamber having an outer porous liner and an inner porous liner, the inner porous liner positioned within a central region of the thermal reaction chamber so as to define an inner plenum. A gaseous waste stream introduced into the thermal reaction chamber may flow through the outer porous liner through the catalyst bed and into the inner plenum.  
         [0014]     In additional aspects, an apparatus is provided for abating perfluorocarbons (PFCs) in a gaseous waste stream that includes (1) a controlled decomposition oxidation (CDO) thermal reaction chamber having an inlet adapted to receive the gaseous waste stream; and (2) a catalyst bed including a catalyst material positioned within the CDO thermal reaction chamber so as to expose the gaseous waste stream to the catalyst material. Numerous other aspects are provided.  
         [0015]     Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]      FIG. 1A  is a schematic diagram of a PFC abatement system according to at least one embodiment of the invention.  
         [0017]      FIG. 1B  is a schematic diagram of a first alternative embodiment of the PFC abatement system of  FIG. 1A  provided in accordance with the present invention.  
         [0018]      FIG. 1C  is a schematic diagram of a second alternative embodiment of the PFC abatement system of  FIG. 1A  provided in accordance with the present invention.  
         [0019]      FIG. 2  is a top schematic view of an exemplary embodiment of the wet scrubber depicted in  FIG. 1A .  
         [0020]      FIG. 3  is a cross-sectional view of the wet scrubber of  FIG. 2 .  
         [0021]      FIG. 4  is a cross-sectional view of an alternative embodiment of the wet scrubber of  FIG. 3 .  
         [0022]      FIG. 5  is a partial perspective view of a CDO chamber that may be used as a catalyst bed in accordance with the present invention.  
         [0023]      FIG. 6  is a top view of an exemplary embodiment of the catalyst cartridge of  FIG. 5 .  
         [0024]      FIGS. 7A and 7B  are a top view and a side view, respectively, of an exemplary reduced-pressure-drop catalyst bed provided in accordance with the present invention.  
         [0025]      FIG. 8  illustrates a schematic view of a first apparatus for heating a catalyst bed provided in accordance with the present invention.  
         [0026]      FIG. 9  illustrates a schematic view of a second apparatus for heating a catalyst bed provided in accordance with the present invention.  
         [0027]      FIG. 10  illustrates a schematic view of a third apparatus for heating a catalyst bed provided in accordance with the present invention.  
         [0028]      FIG. 11  illustrates a schematic view of a fourth apparatus for heating a catalyst bed provided in accordance with the present invention.  
         [0029]      FIG. 12  is a schematic diagram of an exemplary cross heat exchanger that may be used in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0030]     The present invention provides methods and apparatus for PFC abatement. In one or more embodiments of the invention, an existing controlled decomposition oxidation (CDO) chamber used to oxidize toxic materials such as acids, acid gases, hydrides, flammable gasses, etc., may be modified and/or retrofitted to abate PFCs. Use of existing, on-site abatement equipment such as a CDO chamber to abate PFCs can result in a significant cost savings when compared to the expense of installing a new, conventional PFC abatement system.  
         [0031]     Exemplary processes that may be abated in accordance with the invention include metal and dielectric etch processes, cleaning processes for chemical vapor deposition, physical vapor deposition or other deposition processes, or the like. Exemplary PFCs that may be abated include CF 4 , C 2 F 6 , C 4 F 8 , C 3 F 8 , CHF 3 , CH 3 F, CH 2 F 2 , SF 6 , by-products of NF 3  cleaning, etc. Other processes may be abated, as may other PFCs.  
       System Overview  
       [0032]      FIG. 1A  is a schematic diagram of a first exemplary PFC abatement system  100   a  according to at least one embodiment of the invention. The abatement system  100   a  includes a wet scrubber  102 , which is fed water (e.g., from house water, a pump, a high pressure pump  104 , etc.). Gaseous waste streams from one or more process chambers are directed (e.g., exhausted) into wet scrubber  102 . In  FIG. 1A , a single process tool  106  is shown that includes four process chambers (as indicated by exhaust lines  108   a - d ), each being exhausted into the water scrubber  102 . It is understood that water scrubber  102  may receive gaseous waste streams from any number of process tools and/or process chambers (e.g., 1, 2, 3, 4, 5, 6, etc.).  
         [0033]     Wet scrubber  102  employs a water mist to remove or diminish the presence of one or more contaminants (e.g., SiF 4 ) from the gaseous waste streams. Preferably, SiF 4  may be reduced to a concentration of approximately less than one part per million. Greater or lesser concentrations of SiF 4  may be achieved.  
         [0034]     The processed gaseous waste streams are then directed from wet scrubber  102  to a first packed bed chamber  110  via conduit  112 . Contaminants and/or particulates separated from the gaseous waste streams (e.g., HCl, HF, SiO 2  suspended in water, etc.) at the wet scrubber  102  may be directed to a sump  114  via a branch or extension  116  of conduit  112 . These separated contaminants may be removed by any other appropriate means. Additionally, some amount of the processed gaseous waste stream may be directed to the sump  114  without detriment to the abatement system  100   a.    
         [0035]     The first packed bed chamber  110  may remove water, contaminants, and/or particulates from the gaseous waste streams. The separated water, contaminants, and/or particulates may be directed to the sump  114  as described above. After passing through the first packed bed chamber  110 , the gaseous waste streams may be directed through a blower  118  into a catalyst bed  120 . As will be described further below, the catalyst bed  120  interacts with the gaseous waste streams to abate PFCs.  
         [0036]     PFC abated gaseous waste streams are directed from the catalyst bed  120  to a second packed bed chamber  122  via conduit  124 . While in transit from catalyst bed  120  to second packed bed chamber  122 , the abated gaseous waste streams may be cooled by water spray nozzles  126  and/or other means in conduit  124 . Water, contaminants, and/or particulates separated from the abated gaseous waste stream in the catalyst bed  120 , the conduit  124 , and/or the second packed bed chamber  122  are directed to the sump  114  via a branch or extension  128  of conduit  124 . After passing through second packed bed chamber  122  the abated gaseous waste streams may be fed to a house exhaust system  130  (shown in phantom) and/or further abatement chambers (not shown).  
         [0037]     Water, contaminants, and/or particulates separated from the gaseous waste stream and directed into sump  114  via extensions  116  and  128  may pass, along with any other fluid in sump  114  to an acid waste neutralization system  132 . In at least one embodiment, water from the sump  114  may be filtered and recirculated via a recirculation pump  134  to the second packed bed chamber  122  and/or to any other suitable location within the abatement system  100   a.    
         [0038]      FIG. 1B  is a schematic diagram of a first alternative embodiment of the PFC abatement system  100   a  of  FIG. 1A , referred to as PFC abatement system  100   b . The PFC abatement system  100   b  is similar to the PFC abatement system  100   a  of  FIG. 1A , but includes a cross heat exchanger  160  or other recuperator for preheating a gas stream before entry into the catalyst bed  120 . Such pre-heating of the gas stream may assist in heating the catalyst used in the catalyst bed  120 . The cross heat exchanger  160  employs the gas stream output from the catalyst bed  120 , which is heated by the heaters  144  and/or exothermic abatement processes performed within the catalyst bed  120 , to pre-heat a gas stream before it enters the catalyst bed  120 . Any suitable heat exchanger or recuperator may be used. Exemplary cross heat exchangers are described below with reference to  FIGS. 8-12 .  
         [0039]     Additionally or alternatively, the PFC abatement system  100   b  may include a pre-heater  162 , such as an electric or other suitable heater, for pre-heating a gas stream before it enters the catalyst bed  120 . If both a heat exchanger and a pre-heater are employed, a smaller pre-heater may be used.  
         [0040]      FIG. 1C  is a schematic diagram of a second alternative embodiment of the PFC abatement system  100   a  of  FIG. 1A , referred to as PFC abatement system  100   c . The PFC abatement system  100   c  is similar to the PFC abatement system  100   a  of  FIG. 1A , but may employ a fuel source to pre-heat gas before entry into the catalyst bed  120 . A cross heat exchanger, recuperator and/or pre-heater also may be used.  
         [0041]     The byproducts of hydrocarbon combustion are water vapor and CO 2 . Using a fuel source such as natural gas, LPG, methane or the like to heat the gas stream before the gas stream contacts the catalyst in the catalyst bed  120  may add hydrogen in the form of water vapor, and provide a lower cost of operation than the use of electricity for heating. The heating of the gas stream with the fuel also destroys some PFCs that are easier to abate by temperature alone, and/or leaves PFCs with lower numbers of carbon atoms (rendering the PFCs easier to destroy by catalysts).  
         [0042]     With reference to  FIG. 1C , the system  100   c  includes a fuel source  170  for adding a fuel such as natural gas to the gas stream to be abated, along with excess air (e.g., in a combustion region or chamber  172 ). The fuel/air mixture is ignited either with an electric spark, a hot surface ignitor such as a hot metal surface, or a standing pilot  174 . Alternatively excess air may be added, and then fuel, possibly with a premix of some air, to insure a stable flame without the formation of soot.  
       Exemplary System Components  
       [0000]     Wet Scrubber  
         [0043]     As stated above, the wet scrubber  102  is adapted to use a water mist to remove contaminants, such as SiF 4 , from the gaseous waste stream(s) output by the process tool  106 . For example, a plurality of high pressure nozzles may be used to create a mist within the wet scrubber  102 . Exemplary embodiments of the wet scrubber  102  are described below with reference to  FIGS. 2-4 .  
         [0044]      FIG. 2  is a top perspective view of an exemplary embodiment of the wet scrubber  102  depicted in FIGS.  1 A-C; and  FIG. 3  is a cross-sectional view of the wet scrubber of  FIG. 2 . In the embodiment of  FIGS. 2-3 , wet scrubber  102  includes a set of concentrically nested tubes (e.g., an outer tube  202  and an inner tube  204 ). The outer tube  202  and inner tube  204  define an inner cavity  206  through which gaseous waste streams from one or more process tools and/or process chambers may pass. Water and/or other gases and/or fluids may be directed through outer tube  202  and inner tube  204  and dispensed radially into the inner cavity  206  via spray nozzles  208   a - h . Though depicted in  FIG. 2  as four columns of nozzles spaced equally apart on both outer tube  202  and inner tube  204 , it is understood that any number and/or arrangement of spray nozzles  208   a - h  may be utilized.  
         [0045]     With reference to  FIG. 2 , the wet scrubber  102  includes four inlets/conduits  210   a - d , each adapted to receive a gaseous waste stream from a process chamber  212   a - d  (shown in phantom). In general, the wet scrubber  102  may include any number of inlets/conduits, and each inlet/conduit may be coupled to one or more process chambers and/or process tools. Also, a single process chamber may be coupled to more than one of the inlets/conduits  210   a - d.    
         [0046]     In the embodiment of  FIGS. 2-3 , the inlet/conduits  210   a - d  are arranged so that each inlet/conduit  210   a - d  directs a gaseous waste stream approximately tangentially along a first inner surface  302  (and/or a second inner surface  304 ) of the water scrubber  102 . Such an arrangement increases the residence time of gaseous waste streams within the wet scrubber  102  thereby increasing the effectiveness of any water scrubbing process performed therein. Other inlet/conduit configurations may be used.  
         [0047]     Outer tube  202  and inner tube  204  may be constructed of plastic or other materials and may be lined with plastic and/or other materials to prevent deposition of particles in the gaseous waste streams. Inner cavity  206  may be sealable such that inlets to the inner cavity  206  are confined to spray nozzles  208   a - h  and inlet/conduits  210   a - d  and outlets from the inner cavity  206  are confined to one or more conduits  112  (FIGS.  1 A-C). In at least one embodiment, outer tube  202  may be of a conical shape having a smaller diameter at its bottom. This shaping may promote efficient run-off of water and prevent particulates and other unwanted debris from accumulating within inner cavity  206 . In an exemplary embodiment, the inner cavity  206  of wet scrubber  102  may have a volume of approximately 5-10 liters, although any larger or smaller sizes may be used.  
         [0048]     Water and/or other gases and/or fluids may be directed through outer tube  202  and inner tube  204  and dispensed radially into the inner cavity  206  via spray nozzles  208   a - h . Spray nozzles  208   a - h  may be atomizer type spray nozzles and may dispense a high pressure mist of water droplets. In some embodiments, spray nozzles  208   a - h  may dispense water droplets of a diameter of about 10 to 100 microns, and more preferably about 50 microns or less. Larger and/or smaller water droplet sizes may be dispensed. In at least one embodiment of the wet scrubber  102 , atomizing water nozzles are employed to produce drops of about a 10 to 100 micron diameter so as to create an approximately 0.1 to 5 second, and preferably about 2.5 to 5 second, contact time between water particles and the gaseous waste stream(s). Spray nozzles  208   a - h  and/or other water dispensers may also direct a water curtain along the first and second inner surfaces  302  and  304  of the inner cavity  206  to prevent deposition of particulates on these surfaces.  
         [0049]      FIG. 4  is a cross-sectional view of an alternative embodiment of the wet scrubber  102  of  FIG. 3 . In the embodiment of  FIG. 4 , water droplets dispensed by spray nozzles  208   a - h  may be electrostatically enhanced. For example, biasing electrodes may charge water droplets dispensed by spray nozzles  208   a - h  to prevent the water droplets from coalescing. A positive or negative charge may be applied to water droplets by coupling a first charger  402   a  (e.g., a DC voltage supply) to the outer tube  202  and the same or a second charger  402   b  to the inner tube  204  of the wet scrubber  102 . As all water droplets have the same charge, the droplets repel each other, preventing and/or minimizing coalescence. The voltage applied to the inner/outer tubes may range from about 100 to 5000 volts, although larger or smaller voltages may be used.  
         [0050]     A metal or otherwise conducting grid  404  may be positioned near the bottom of wet scrubber  102  to collect the charged water droplets. For example, as water droplets fall onto the grid  404 , the droplets will be collected by the grid and lose their charge, allowing the droplets to coalesce and fall through conduit  112  into sump  114 . The grid  404  may be grounded, floating or charged to an opposite polarity relative to the droplets. The grid  404  may be constructed of wire mesh or any other suitable material. In some embodiments, the grid  404  may be additionally and/or alternatively positioned before and/or after first packed bed chamber  110 . Other systems and/or methods to control water droplet size, direction of travel, and/or formation may be employed in wet scrubber  102 . For example, in addition to or in place of the grid  404 , a bottom or outlet of the wet scrubber  102  may be grounded, floating or charged (as indicated by reference numeral  406 ) to an opposite polarity relative to the droplets.  
         [0000]     First Packed Bed Chamber  
         [0051]     Referring again to FIGS.  1 A-C, the first packed bed chamber  110  or “demister” removes any “fog” in gaseous waste streams received from the wet scrubber  102 . In some embodiments, the first packed bed chamber  110  may include a packed bed of beads, barrels, or other shapes formed from ceramic, metal alloy, polypropylene, and/or any other suitable material. A plurality of nozzles  136  near an outlet of the first packed bed chamber  110  create a stream or rainfall of water that flows (via gravity) down the packed bed to the sump  114 . In this manner, mist introduced to the gaseous waste stream(s) by the wet scrubber  102  is removed. The nozzles  136  may operate continuously or intermittently.  
         [0052]     In some embodiments, the first packed bed chamber  110  may be a sealable tube arranged such that gaseous waste streams are directed via conduit  112  into a lower end of the packed bed chamber. As stated, the first packed bed chamber  110  may be packed (e.g., filled or partially filled) with material for trapping, removing, and/or abating liquid water, water vapor, chemicals, and/or particulates in gaseous waste streams. Exemplary packing materials may include polypropylene, metal alloys, polymers, alumina, ceramics, etc., that are barrel-shaped, ring-shaped, bead-shaped and/or otherwise shaped. Other shapes and/or materials may be used (e.g., such as for high temperature or corrosive applications). The first packed bed chamber  110  may, in some embodiments, have an interior volume of approximately between four and eight liters. Packed bed chambers of larger or smaller volumes may be employed, as appropriate.  
         [0053]     Note that a gaseous waste stream may be flowed in a counter-current and/or optionally a co-current manner through the packing with and/or against the flow of water. Air may be injected to provide direct cooling and promote reduction of the humidity of the exiting gaseous waste stream.  
         [0000]     Pressure Regulator  
         [0054]     Blower  118  may be constructed of plastic or other corrosion resistant materials, and may be attached directly to the first packed bed chamber  110 , the catalyst bed  120 , or indirectly to either or both of these units via appropriate conduits (as shown in FIGS.  1 A-C). The blower  118  may serve to apply positive pressure to the catalyst bed  120 . In some embodiments, the pressure applied may be approximately five in. W.C., although more or less pressure may be applied as appropriate. In the same or alternative embodiments, the blower  118  may be controllable in real time to maintain an approximately constant pressure within the system  100 , especially within the catalyst bed  120 , as will be discussed below.  
         [0055]     In an alternative embodiment, the blower  118  may be replaced by a passive device, such as an eductor or another pressure regulator. Use of such a passive device may reduce operating expenses. In such an embodiment, the eductor may take in a small amount of high pressure CDA (“Clean Dry Air”) that is mixed with the gaseous waste stream from the first packed bed chamber  110 . This increases the flow rate of the gaseous waste stream sent to the catalyst bed  120 .  
         [0056]     In some embodiments, it may be desirable to track and/or control pressure and/or flow in the abatement system  100 . For example, pressure in the abatement system  100  may be measured by one or more pressure indicators  138   a - c . Pressure indicators  138   a - c  may measure pressure at the first packed bed chamber  110  outlet, the catalyst bed  120  inlet, and/or immediately before passing to house exhaust  130 , respectively. These locations may be utilized to determine pressure in and/or pressure drop across the catalyst bed  120 . Additional pressure indicators may be located wherever it is desirable to track and/or control pressure in the abatement system  100 .  
         [0057]     The pressure indicators  138   a - c  may detect clogging in the second packed bed chamber  122  and the catalyst bed  120 . Also, the pressure indicators  138   a - c  may allow balancing of the pressure at the first packed bed chamber  110  outlet and the catalyst bed  120  outlet. This balancing may prevent water from being drawn from the sump  114  into the first packed bed chamber  110  and/or into the catalyst bed  120  should a large pressure differential be created across these components. Pressure indicators  138   a - c  may be any sensors capable of detecting pressure or differential pressure such as slant manometers, orifice plates, diaphragms, etc. Blower  118  may also be equipped with a damper and/or pressure switch to assist control of pressure within the abatement system  110 .  
         [0058]     Flow into blower  118  (or an eductor) may be controlled by a flow regulator  140 . Flow regulator  140  may be any device capable of controlling gas and/or liquid flow such as a mass flow controller.  
         [0059]     A controller  142  may be connected to and capable of receiving information from and/or transmitting command signals to blower  118 , pressure indicators  138   a - c , and/or flow regulator  140 . For example, the controller  142  may adjust (e.g., in real time) the pressure in the abatement system  100 , such as the pressure drop across catalyst bed  120 . In some embodiments, the controller  142  may control the speed of the blower  118  to regulate pressure, or control the flow rate of CDA, compressed air, or other motive into an eductor to regulate pressure. Controller  142  may be a computer, microcontroller or any other appropriate hardware and/or software.  
         [0000]     Catalyst Bed  
         [0060]     The catalyst bed  120  may, in some embodiments, be formed from a conventional thermal oxidation and/or combustion chamber. For example, the catalyst bed  120  (and the second packed bed  122 ) may be a retrofitted CDO chamber  143 , such as a retrofitted version of the EcoSys CDO863 manufactured by Metron Technology, Inc. of San Jose, Calif. Such a CDO chamber  143  is generally cylindrical and includes heaters  144  adapted to heat an inner cavity  146  of the chamber (defined by a liner  148 ) during thermal oxidation processes. In an exemplary embodiment, the catalyst bed  120  may have an interior volume of approximately 4.7 to 6.4 liters, although larger or smaller volumes may be used.  
         [0061]     It will be understood that the abatement system  100  may use a catalyst bed  120  that is not formed from a retrofitted CDO chamber. However, use of existing, on-site abatement equipment such as a CDO chamber that is retrofitted to abate PFCs can result in a significant cost savings when compared to the expense of installing an entirely new PFC abatement system.  
         [0062]      FIG. 5  is a partial perspective view of a CDO chamber  502  that may be used as the catalyst bed  120  in accordance with the present invention. The CDO chamber  502  may be a cylindrical, tubular or other shape. To allow the CDO chamber  502  to abate PFCs, the CDO chamber  502  is filled with a catalyst (e.g., as the CDO chamber  502  typically cannot be heated to a sufficient temperature to directly abate PFCs). In some embodiments, the interior of the CDO chamber  502  and/or catalyst bed  120  may be lined with and/or constructed of corrosion resistant metals or ceramics (e.g., Inconel™ or Hastelloy™, nickel, yttria doped alumina, titania with alumina, etc.) and/or other corrosion resistant materials with high thermal conductivity.  
         [0063]     A catalyst may be directly placed into the CDO chamber  502  (filling or partially filling the CDO chamber  502 ). In an alternative embodiment, a removable and/or readily serviceable catalyst cartridge  504  that is prefilled with a catalyst may be inserted into the CDO chamber  502 . The catalyst cartridge  504  may also be of a cylindrical or tubular shape, and in some embodiments capped on each end by screens  506  or other porous structures that allow gaseous waste streams to travel through the catalyst trapped by the screens  506 .  
         [0064]     As stated, the catalyst may aid in the reaction and/or destruction of components of gaseous waste streams by lowering the reaction temperature for the abatement of PFCs. Destruction of PFCs may require reaction temperatures in the range of approximately 950° C. to approximately 1300° C. Use of a catalyst may lower a reaction temperature for PFCs to approximately 500° C. in some embodiments.  
         [0065]     Exemplary catalysts may include: ceramics; calcium magnesium; barium or strontium oxide; hydroxide; carbonate; nitrate; phosphates of aluminum, boron, alkali earth metal, titanium, zirconium, lanthanum, cerium, yttrium, rare earth metal, vanadium, niobium, chromium, manganese, iron, cobalt and/or nickel; metals of groups 4 to 14 of the periodic table; iron oxide; alumina; zirconia; titania; silica; vanadium oxide; tungsten oxide; tin oxide; platinum; palladium; rhodium; gamma alumina; cobalt oxide; and/or cerium. Other catalysts may be used. In one particular embodiment, inverse spinel crystal structure manganese may be used. Reaction catalysts may be formed or be of any appropriate shape (e.g., rings, beads, barrels, honeycomb, etc.).  
         [0066]      FIG. 6  is a top view of an exemplary embodiment of the cartridge  504 . With reference to  FIG. 6 , to control temperature of the catalyst and/or within the catalyst bed  120 , the heaters  144  (FIGS.  1 A-C) may be employed. The heaters  144  may be cylindrical so as to conform to the shape of outer chamber  502  and provide heat to the liner  148  and the catalyst bed  120 . To allow more uniform heating across the catalyst bed, thermal fins  602   a - h  may be provided within the cartridge  504 . The thermal fins  602   a - h  may be constructed of metal or another thermally conductive material, run the vertical length of the heaters  144 , and/or may be arranged radially toward the center of catalyst bed  120 . Heat thereby may be more uniformly transferred from the heaters  144  to the catalyst bed  120 . Other numbers of thermal fins or other types of thermal conduction mechanisms may be employed. The cartridge  504  may be formed from the same or a different material than the thermal fins  602   a - h.    
         [0067]     In some embodiments, the catalyst bed  120  may be double contained by use of an outer shell (not shown) such that gaseous waste streams may not escape abatement system  100  at the catalyst bed  120 . In the same or other embodiments, the catalyst bed  120  may have additional exhaust to remove some portion of a gaseous waste stream.  
         [0068]     As another example, the catalytic bed  120  may include a catalytic surface that catalyzes a reaction for reducing the hazardous gas content in gaseous waste streams. For example, PFCs, as well as residual halogens (e.g., fluorine), HAPs and/or VOCs, may be abated via a reaction between a gaseous waste stream and a catalyst present in the catalytic bed  120 .  
         [0069]     The catalytic surface of the catalyst bed  120  may be, for example, a structure made from catalytic material or supporting a finely divided catalyst, a bed of foam or pellets, or a coating on a wall or component of the catalytic bed  120 . For example, the catalytic surfaces may comprise surfaces of a support structure comprising a honeycomb member with the catalyst embedded therein to form a high surface area member over and through which the effluent passes as it flows from an inlet to an outlet of the catalyst bed  120 . The catalytic surfaces may be on, for example, a structure comprising a ceramic material, such as cordierite, Al 2 O 3 , alumina-silica, alumina-titania, mullite, silicon carbide, silicon nitride, zeolite, and their equivalents; or may comprise a coating of materials, such as ZrO 2 , Al 2 O 3 , TiO 2  or combinations of these and other oxides. The catalytic surfaces may also be impregnated with catalytic metals, such as Mn, Pt, Pd, Rh, Cu, Ni, Co, Ag, Mo, W, V, La or combinations thereof or other materials known to enhance catalytic activity.  
         [0070]     In general, decreasing the size of the grains or other structure of the catalyst in the catalyst bed  120  may increase the surface area and effectiveness of the catalyst. However, such size reduction may also increase the pressure drop of gas flowing through the catalyst bed  120 .  
         [0071]     In some embodiments, a vacuum generator (not shown, such as a vacuum pump) may be employed at or near the end of the catalyst bed  120  to compensate for any pressure drop produced by the catalyst bed  120 . In the same or other embodiments, pressure drop through the catalyst bed  120  may be reduced by the geometry of the catalyst bed  120 . For example,  FIGS. 7A and 7B  are a top view and a side view, respectively, of an exemplary reduced-pressure-drop catalyst bed  700  provided in accordance with the present invention that may be used in any of the abatement systems described herein.  
         [0072]     With reference to  FIGS. 7A and 7B , the catalyst bed  700  includes a reactor chamber  702  having an annular plenum  704  along the length of the reactor chamber  702  outside of catalyst material  706  of the catalyst bed  700 , and an inner plenum  708  that extends through a central region of the reactor chamber  702  and catalyst material  706 .  
         [0073]     The outer plenum  704  may be formed, for example, by positioning an outer porous liner  710  within the reactor chamber  702  and spaced from an inner surface of the reactor chamber  702  so as to define the outer plenum  704 . The inner plenum  708  may be formed from an inner porous liner  712  positioned within a central region of the reactor chamber  702  so as to define the inner plenum  708 . The outer and inner liners  710 ,  712  contain the catalyst material  706  within the reactor chamber  702 . In the embodiment shown, the outer and inner liners  710 ,  712  may be formed from porous tubes, sheets or cylinders, such as porous ceramic, perforated metal, etc., tubes, sheets or cylinders. Other materials and/or shapes may be used.  
         [0074]     In operation, a gaseous waste stream to be abated flows into the outer plenum  704  of the catalyst bed  700  (arrow  714   a  in  FIG. 7B ) and may flow freely along the length of the reactor chamber  702  (arrows  714   b  in  FIG. 7B ). Due to the porous nature of the outer liner  710 , the gaseous waste stream travels radially through the outer liner  710  (arrows  714   c  in  FIG. 7B ), through the catalyst material  706 , through the inner liner  712  and into the inner plenum  708  (arrows  714   d  in  FIG. 7B ) as shown. The gaseous waste stream then exits the catalyst bed  700 .  
         [0075]     The geometry of the catalyst bed  700  significantly enhances and/or maximizes the cross sectional area of catalyst material  706  that contacts the gaseous waste stream, while significantly reducing and/or minimizing pressure drop across the catalyst bed  700 . It will be understood that gas flow direction may be reversed. For example, a gaseous waste stream may enter the catalyst bed  700  from the inner plenum  708  and travel through the inner liner  712 , through the catalyst material  706 , through the outer liner  710  and into the outer plenum  704  where it exits the catalyst bed  700 .  
         [0076]     In at least one embodiment, the reactivity of the catalyst in the catalyst bed  700  (or any other catalyst bed described herein) may be enhanced with electromagnetic radiation. For example, pulsed microwaves may be applied to a catalyst bed so as to cause a polarizability catastrophe to a catalyst surface that enhances catalytic reactivity. U.S. Pat. No. 6,190,507, which is hereby incorporated by reference herein in its entirety, describes the use of short burst, high-power microwave fields to increase the reactivity of the surface of a catalyst. In one embodiment, microsecond bursts of about 5 GHz microwaves with about 40 psec rise times may be employed.  
         [0077]     Most catalytic PFC abatement systems utilize a granular or pellet form of catalyst or catalyst support. These pack tightly and typically exhibit high pressure drop.  
         [0078]     In some embodiments of the invention, porous yttrium doped, zirconia stabilized alumina may be employed as a high surface area catalyst support to significantly reduce the pressure drop in the catalytic bed  120 . Such as support is capable of withstanding a corrosive high temperature environment without breaking down. A catalytic support may be fabricated in various different shapes. For example, a support may be fabricated in cylinders, disks or other suitable shapes that fit within the inner cavity of the catalyst bed  120 . The vertical dimension of the catalyst bed  120  may be filled by stacking these cylindrical or disk-shaped catalyst supports. If the catalytic bed  120  becomes plugged, the plugging generally is confined to the upper portions of the bed, and may be resolved by simply replacing only the top catalyst cylinders or disks as needed.  
         [0079]     PFCs require high temperatures for complete destruction, especially CF4 which requires temperatures in excess of about 1100° C. These high temperatures may be difficult to achieve with electrically heated systems. Using catalysts specific for PFCs allows PFC destruction temperatures to be reduced, in some embodiments, to between about 500-800° C.  
         [0080]     PFC catalysts typically require water, or a source of hydrogen and oxygen to keep from being deactivated. In some embodiments, the water may be provided by a pre-scrubber before the catalyst bed  120 , such as by the wet scrubber  102  and/or the first packed bed chamber  110 .  
         [0081]     The gas stream may be heated before contacting the catalyst within the catalyst bed  120 , such as via a recuperator and/or heater as previously described with reference to  FIG. 1B .  
         [0082]      FIG. 8  illustrates a schematic view of a first apparatus  800  for heating a catalyst bed, such as the catalyst bed  120 ,  700  of  FIGS. 1A-7B , provided in accordance with the present invention. With reference to  FIG. 8 , the first apparatus  800  includes a heat exchanger  802  inside of a reactor pipe  804  adapted to convey a waste stream (e.g., process by-products) entering in the direction shown by an arrow  806 . The reactor pipe  804  may also have an abatement bed  808 , such as a catalyst bed, in a portion of the reactor pipe  804 . In this embodiment, the abatement bed  808  may be disposed about an inner pipe  810 . As shown in  FIG. 8 , the inner pipe  810  may be coupled to the heat exchanger  802 . The heat exchanger  802  may also be coupled to an exhaust pipe  812  through a wall of the reactor pipe  804  at an interface  814 . The exhaust pipe  812  may be coupled to a quench  816 . For example, the quench  816  may be the second packed bed chamber  122  of FIGS.  1 A-C. The quench  816  may be coupled to a waste pipe  818  adapted to dispose of the treated waste stream (e.g., to the sump  114  of FIGS.  1 A-C).  
         [0083]     The first apparatus  800  may also include a reactor heater  820  and an insulator  822  disposed about the reactor pipe  804 . As shown in  FIG. 8 , the reactor heater  820  and the insulator  822  are depicted in cross section views. A waste stream heater  824  may be disposed inside the reactor pipe  804 . The waste stream heater  824  may be coupled to a power supply  826 .  
         [0084]     The heat exchanger  802  may be a coiled pipe of a steel alloy such as a Nickel-based alloy, for example Inconel 600 or 625™ available from Inco Corporation in Huntington, W.V., although any suitable shape and/or material may be employed. For example, although a coil shape may be employed in the present embodiment, in the same or alternative embodiments a multi-fin shape may be used. Also, the material may be any suitable material adapted to carry a waste stream and transfer heat between a region inside the heat exchanger  802  and a region outside the heat exchanger  802 . In some embodiments, the waste stream temperature may be about 800 to about 900 degrees Celsius although higher or lower temperatures may be present.  
         [0085]     Similarly, the reactor pipe  804 , the inner pipe  810 , the exhaust pipe  812 , and the waste pipe  818  may be formed from Inconel 600 or 625™, although any suitable material may be used. For example, in some embodiments a less expensive stainless steel alloy may be employed in the exhaust pipe  812  when the properties (e.g., corrosiveness, temperature, etc.) of the waste stream are not detrimental to the stainless steel. Although the reactor pipe  804 , the inner pipe  810 , the exhaust pipe  812 , and the waste pipe  818  may be round pipes, in general, any suitable shape and/or sizes may be employed. The temperature of the waste stream carried by the reactor pipe  804 , the inner pipe  810 , the exhaust pipe  812 , and the waste pipe  818  may range from about room temperature to about 900 degrees Celsius although higher or lower temperatures may be present.  
         [0086]     The reactor heater  820  may be a ceramic heater from, for example, the ceramic heater product line available from Watlow Corporation in St. Louis, Mo., although any suitable heater may be employed. The ceramic portion of the reactor heater  820  may provide some insulation. To provide additional insulation, the insulator  822  or any suitable insulation may be provided. The insulator  822  may also prevent injuries to operators and/or damage to equipment. As shown in  FIG. 8 , the insulator  822  may be wrapped around the reactor heater  820  although any suitable configuration of the reactor heater  820  and the insulator  822  may be employed to heat the reactor pipe  804  and the waste stream.  
         [0087]     The waste stream heater  824  may be an electric heating device although any suitable heating device may be employed. As shown in  FIG. 8 , the waste stream heater  824  may have a portion inside the reactor pipe  804  so as to contact the waste stream inside the reactor pipe  804 . Although  FIG. 8  depicts the waste stream heater  824  as a rod, other configurations may be employed in the same or alternative embodiments. The waste stream heater  824  may be at a temperature that is higher than the temperature of the waste stream. Accordingly, the waste stream heater  824  may heat the waste stream around the waste stream heater  824  to a desired temperature. The waste stream heater  824  may heat the waste stream by using electricity supplied by the power supply  826  although any suitable power source may be employed.  
         [0088]     In operation, the waste stream may enter the reactor pipe  804  as depicted by the arrow  806 , and flow about the outer surface of the heat exchanger  802 . As will be explained below, the heat exchanger  802  may be at a temperature that is greater than the temperature of the waste stream. Accordingly, heat is transferred from the heat exchanger  802  to the waste stream to heat the waste stream. The waste stream may flow past the heat exchanger  802  and the waste stream heater  824 . The waste stream heater  824  may be at a temperature higher than the heat exchanger  802  although any suitable temperature may be employed. The waste stream heater  824  may heat the waste stream to a desired temperature (e.g., for abatement). Subsequently, the waste stream may filter through the abatement bed  808  (e.g., catalyst bed  120 ,  700  of  FIGS. 1A-7B ). During this filtering the waste stream may react (e.g., chemically, physically, etc.) with the abatement bed  808  so as to change the chemical composition of the waste stream to a more desirable chemical composition. The reaction may occur at an elevated temperature.  
         [0089]     Note that, as shown in  FIG. 8 , the waste stream is heated by the heat exchanger  802  prior to being heated by the waste stream heater  824 . Accordingly, the heat exchanger  802  may use the heat retained in the waste stream after the reaction with the abatement bed  808  to preheat the incoming waste stream.  
         [0090]     After filtering through the abatement bed  808 , the waste stream may flow through the inner pipe  810  into the heat exchanger  802 . Because the waste stream may cool during the filtering, it may be at a temperature that is slightly less than the abatement temperature. However, the temperature of the waste stream after abatement is generally higher than the temperature of the entering waste stream. Accordingly, as discussed above, the heat exchanger  802  may heat the incoming waste stream. The abated waste stream may flow through the heat exchanger  802  and the exhaust pipe  812  towards the quench  816  (e.g., second packed bed chamber  122  of FIGS.  1 A-C). The quench  816  may further cool and/or abate chemistries in the waste stream. Subsequently, the waste pipe  818  may dispose of the waste stream (e.g., to the sump  114  of FIGS.  1 A-C).  
         [0091]      FIG. 9  illustrates a schematic view of a second apparatus  900  for heating a catalyst bed, such as the catalyst bed  120 ,  700  of  FIGS. 1A-7B , provided in accordance with the present invention. With reference to  FIG. 9 , the second apparatus  900  may include an abatement bed  808 ′ (e.g., a catalyst bed) that may be similar to the abatement bed  808  of the first apparatus  800 . As shown in  FIG. 9 , the second abatement bed  808 ′ is present inside the inner pipe  810 .  
         [0092]     In operation, the waste stream may flow as described above with reference to  FIG. 8 . The waste stream flows through the second abatement bed  808 ′ along a path that is longer than as described with reference to  FIG. 8 . Accordingly, the waste stream may have greater reaction and/or residence times with the second abatement bed  808 ′. Accordingly, the chemical composition of the waste stream may be abated more extensively.  
         [0093]      FIG. 10  illustrates a schematic view of a third apparatus  1000  for heating a catalyst bed, such as the catalyst bed  120 ,  700  of  FIGS. 1A-7B , provided in accordance with the present invention. With reference to  FIG. 10 , the third apparatus  1000  may include an external pipe  1002  coupled to the reactor pipe  804  and the heat exchanger  802 . The third apparatus  1000  may also include some components of the second apparatus  900 . Note that the quench  816  is coupled to the reactor pipe  804 . As shown in  FIG. 10 , a portion of the external pipe  1002  may be disposed outside the reactor pipe  804  and between the insulator  822  and the reactor heater  820  although any suitable configuration may be employed. For example, in alternative embodiments, the external pipe  1002  may be disposed between the reactor heater  820  and the reactor pipe  804 . The external pipe  1002  may be similar to the inner pipe  810  described above with reference to  FIG. 8 . For example, the external pipe  1002  may be made of a nickel-alloy such as Inconel™ or another suitable material.  
         [0094]     In operation, a waste stream may travel through the reactor pipe  804 , through the abatement bed  808  and enter the external pipe  1002  at an elevated temperature. The abated waste stream may be conveyed by the external pipe  1002  between the reactor heater  820  and the insulator  822 , thereby heating or preserving the temperature of the waste stream in the external pipe  1002 . Subsequently, similar to the first apparatus  800  and the second apparatus  900 , the abated waste stream may flow into the heat exchanger  802  to heat the heat exchanger  802  to a temperature higher than the temperature of the incoming waste stream. Accordingly, the heat exchanger  802  may preheat the incoming waste stream as described above with reference to  FIGS. 8 and 9 .  
         [0095]      FIG. 11  illustrates a schematic view of a fourth apparatus  1100  for heating a catalyst bed, such as the catalyst bed  120 ,  700  of  FIGS. 1A-7B , provided in accordance with the present invention. With reference to  FIG. 11 , the fourth apparatus  1100  may include a pipe  1102  in addition to some of the components described above with reference to  FIG. 8 . The pipe  1102  may be disposed in the abatement bed  808  inside the reactor pipe  804 . As shown in  FIG. 11 , the pipe  1102  is disposed approximately center in the abatement bed  808  although any suitable location may be employed. A portion of the pipe  1102  extends beyond the abatement bed  808  into a region of the reactor pipe  804  in proximity to where the waste stream enters the reactor pipe  804 .  
         [0096]     The pipe  1102  may be a heat pipe although any suitable device may be employed. For example, the pipe  1102  may be a hollow heat pipe with a heat pipe fluid disposed inside the heat pipe. The heat pipe fluid may include a working fluid such as reduced pressure water, acetone, solvents, ammonia, etc., although any suitable fluid may be employed. The pipe  1102  may be similar to the material of the inner pipe  810  described above with reference to  FIG. 8  although any suitable material may be employed. In  FIG. 11 , the pipe  1102  is a cylinder, although any suitable shape may be employed.  
         [0097]     In operation, a first region of the pipe  1102  in the reactor heater  820  may increase to an abatement temperature (e.g., a temperature of the waste stream within the abatement bed  808 , which may be, for example, a catalyst bed). Consequently, the heat pipe fluid may raise in temperature throughout the heat pipe  1102 . For example, a portion of the heat pipe fluid may become gaseous and rise to a second region in proximity to where an incoming waste stream enters the reactor pipe  804 . Because the heat pipe fluid is at a temperature greater than the temperature of the incoming waste stream, the heat pipe may transfer heat to the waste stream. The temperature of the incoming waste stream may increase, and the heat pipe fluid may condense back to a liquid form and flow back to the first region.  
         [0098]      FIG. 12  is a schematic diagram of an exemplary cross heat exchanger  1200  that may be used for the heat exchanger  160  of  FIG. 1B . Such a heat exchanger is similar to those described in previously incorporated U.S. Pat. No. 6,824,748.  
         [0099]     With reference to  FIG. 12 , a gaseous waste stream to be abated (e.g., within the catalytic bed  120  of  FIG. 1B ) enters the cross heat exchanger  1200  at a first inlet  1202 , and is dispersed into a first set of multiple channels  1204 . An abated gas stream (e.g., catalytic bed  120 ) enters the heat exchanger at a second inlet  1206  and is dispersed into a second set of multiple channels  1208  which are adjacent and capable of transferring heat to the first multiple channels  1204  that carry the gaseous waste stream to be abated. Heat from the abated gas stream thereby is transferred to the gaseous waste stream to be abated. An insulating material  1210  may surround the heat exchanger  1200  to prevent the loss of heat to the atmosphere and to increase the efficiency of the heat exchanger  1200 . The heat exchanger  1200  may be made of a corrosion resistant material such as a nickel-based alloy (e.g., Inconel®), or another suitable material.  
         [0100]     Other types and/or number of heat exchangers may be used. For example, concentric tube heat exchangers in which hot gas flows within an inner tube and cold gas flows within an outer tube (or vice versa) may be employed, as may gas-to-gas heat exchangers.  
         [0000]     Second Packed Bed Chamber  
         [0101]     In some embodiments, the second packed bed chamber  122  may be of similar design and/or construction to the first packed bed chamber  110 , discussed above. In at least one embodiment, the second packed bed chamber  122  may be part of the EcoSys CDO863 manufactured by Metron Technology, Inc. of San Jose, Calif. Other packed bed chambers may be used.  
         [0102]     Referring again to FIGS.  1 A-C, the second packed bed chamber  122  primarily removes acids and/or other undesirable by products of the PFC abatement that occurs in the catalyst bed  120 . In some embodiments, the second packed bed chamber  122  may include a packed bed of beads, barrels and/or other shapes (not shown) formed from a corrosion resistant material such as ceramic or any other suitable material. A plurality of nozzles  150  near an outlet of the second packed bed chamber  122  create a stream or rainfall of water that flows (via gravity) down the packed bed to the sump  114 . In this manner, acids (e.g., HF) and/or other components introduced to the gaseous waste stream(s) by the catalyst bed  120  are removed. The nozzles  150  may operate continuously or intermittently.  
       Exemplary System Operation  
       [0103]     In operation, gaseous waste streams from one or more process chambers (e.g., metal and/or dielectric etch chambers) are exhausted via exhaust lines  108   a - d  to wet scrubber  102 . Water passed through high pressure pump  104  is atomized (e.g., pressed into droplets approximately 50 microns in size) and/or electrically charged at spray nozzles  208   a - h . The gaseous waste streams are swirled around inner cavity  206  of wet scrubber  102  and through the fog of electrically charged water droplets, which react with the gaseous waste streams to remove and suspend in-water pollutants (e.g., SiF 4 ) that may harm downstream abatement equipment. Tangential insertion of the gaseous waste streams, as shown in  FIG. 2 , increases the residence time of the gaseous waste streams in wet scrubber  102 . In an exemplary embodiment, the gaseous waste streams have a minimum residence time of at least approximately 0.1 seconds. Preferably, the residence time is approximately 2.5-5 seconds or more. Other residence times may be used as appropriate.  
         [0104]     As water droplets contact grid  404 , the water, SiF 4 , and any other materials suspended in the water may flow out of water scrubber  102 , through conduit  112  and branch  116  to sump  114 . The unaffected portions of the gaseous waste streams may also flow through conduit  112  and then upward into the first packed bed chamber  110 .  
         [0105]     The first packed bed chamber  110  removes water (mist), contaminants, and/or particulates from the gaseous waste streams. The separated water, contaminants, and/or particulates may be directed to the sump  114  as described above. After passing through the first packed bed chamber  110 , the gaseous waste streams may be directed to the blower  118  or an eductor (not shown). At this location within the abatement system  100 , the gaseous waste streams primarily comprise a mixture of PFCs, nitrogen, non-soluble gases, and water vapor with acids, readily soluble by-products, particles, etc., from the process tool  106  removed.  
         [0106]     When an eductor is employed in place of the blower  118 , CDA, compressed air or another suitable gas may be added to the gaseous waste streams to affect pressure on the catalyst bed  120 , and/or enhance, improve the efficiency of, and/or enable a reaction within the catalyst bed  120 . When the blower  118  is employed, blower speed may be adjusted to achieve these objectives.  
         [0107]     In the catalyst bed  120 , the gaseous waste streams may be combusted, thermally oxidized, and/or otherwise reacted to abate PFCs (e.g., by converting PFCs to HF or other scrubbable by-products). After passing through the catalyst bed  120 , the reacted gaseous waste streams are passed into conduit  124  through spray nozzles  126  to remove particulates and other contaminants generated by the catalyst bed  120 . Particulates and other contaminants removed from the gaseous waste streams by spray nozzle water may be flowed with the water into the sump  114  via conduit  124  and branch  128 .  
         [0108]     The remaining gaseous waste streams may be flowed upwardly through the second packed bed chamber  122 . Acids and/or particulates and contaminants thereby may be removed from the gaseous waste streams using the second packed bed chamber  122 . Water from the sump  114  may be recirculated into the second packed bed scrubber  122 .  
         [0109]     Though not explicitly diagrammed in  FIG. 1 , it is understood that water that flows to high pressure pump  104  may also be flowed directly to first packed bed chamber  110 , catalyst bed  120 , water sprayers  126 , the second packed bed chamber  122  and/or any water inlet and/or sprayer in the abatement system  100 . Similarly water from sump  114 , in some embodiments, may be recirculated to any desired location such as to the wet scrubber  102 , the first packed bed chamber  110 , the water sprayers  126 , the second packed bed chamber  122 , etc.  
         [0110]     Gaseous waste streams may be passed to the house exhaust  130  for further abatement or exhaust after processing in the second packed bed chamber  122 .  
         [0111]     The foregoing description discloses only exemplary embodiments of the invention. Modifications of the above disclosed apparatus and method which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. For instance, to enhance PFC abatement, gaseous waste streams may be pre-heated before entering the catalyst bed  120 . For example, hot nitrogen may be introduced to the gaseous waste streams near the inlet of the catalyst bed  120 . Oxygen, air or enriched oxygen similarly may be injected into the gaseous waste streams near the inlet of the catalyst bed  120  to enhance abatement.  
         [0112]     As stated, an eductor or air amplifier may be used in place of the blower  118 . Additionally or alternatively, a blower, eductor or air amplifier may be used at the output of the second packed bed chamber  122  to affect, control and/or regulate pressure within the abatement system  100 .  
         [0113]     In some embodiments, the abatement system  100   a - c  may be used to abate hazardous air pollutants (HAPs) and/or volatile organic compounds (VOCs). The abatement system  100   a - c  may also include means for controlling pH at a desired location, such as near the recirculation pump  134  (e.g., using a port (not shown) for caustic injection).  
         [0114]     Any number of scrubbers may be used before and/or after the catalyst bed  120  (e.g., 1, 2, 3, 4, etc.). Other types and/or number of heat exchangers may be used. For example, concentric tube heat exchangers in which hot gas flows within an inner tube and cold gas flows within an outer tube (or vice versa) may be employed, as may gas-to-gas heat exchangers.  
         [0115]     In some embodiments, the catalytic bed  120  may be insulated and/or water-tight. The scrubbers may be co-current, counter-current, or a combination of the same. Other configurations may be used. An additional water heat exchanger may be used (e.g., for cooling recirculated water from the scrubbers).  
         [0116]     In some embodiments, a blower or eductor (described above) may be positioned after the catalyst bed  120  and/or after the second packed bed chamber  122 .  
         [0117]     In some embodiments, a vacuum source, pump, or other vacuum generator  123  ( FIG. 1C ) may be employed at or near the end of the catalyst bed  120  to compensate for any pressure drop produced by the catalyst bed  120 .  
         [0118]     Any of the catalysts described herein may be formed or be of any appropriate shape (e.g., rings, beads, barrels, honeycomb as indicated, for example, by reference numeral  716  in  FIG. 7A , or the like).  
         [0119]     The catalytic surface of the catalyst bed  120  may be, for example, a structure made from catalytic material or supporting a finely divided catalyst, a bed of foam or pellets, or a coating on a wall or component of the catalytic bed  120 . For example, the catalytic surfaces may comprise surfaces of a support structure comprising a honeycomb member (e.g., as indicated, for example, by reference numeral  716  in  FIG. 7A ) with the catalyst embedded therein to form a high surface area member over and through which the effluent passes as it flows from an inlet to an outlet of the catalyst bed  120 .  
         [0120]     In at least one embodiment, the reactivity of the catalyst in the catalyst bed  700  (or any other catalyst bed described herein) may be enhanced with electromagnetic radiation (e.g., from an electromagnetic radiation source  720 ). Note that any suitable location for a radiation source may be used.  
         [0121]     Accordingly, while the present invention has been disclosed in connection with exemplary embodiments thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention, as defined by the following claims.

Technology Classification (CPC): 2