Structured cross-channel filler element with reduced material requirement.

Abstract

STRUCTURED CROSSCHANNEL FILLING ELEMENT WITH REDUCED MATERIAL REQUIREMENT. The present invention relates to a structured crosschannel filling element for a column for mass transfer and / or heat exchange between a heavy and a light fluid phase, wherein the structured crosschannel filling element comprises at least two adjacent layers made of expanded metal sheets, each comprising openings, which are surrounded and separated from each other by separation elements, wherein at least two of the at least two layers are arranged in the longitudinal direction of the filling element parallel and in tactile contact with each other so that an open space extending from one end to the opposite end of the at least two layers is provided between them so that at least one of the heavy and light fluid phases can flow through it.wherein the ratio between the average width of at least 50% of the separation elements between adjacent openings and the thickness of the sheet material is at least 15, wherein the ratio between the maximum distance between at least two of the at least two layers measured in the plane that is perpendicular to the longitudinal direction and the average width of the separation elements is at least 4, and wherein the ratio between the distance between two openings that are in the direction perpendicular to the stretching direction of the expanded metal sheet adjacent to a separation element and the average width of that separation element is 4 to 6 for at least 50% of all separation elements.

Description

1 / 71 “STRUCTURED CROSS-CHANNEL FILLING ELEMENT WITH REDUCED MATERIAL REQUIREMENT

[0001] The present invention relates to a structured cross-channel packing element for a column for mass transfer and / or heat exchange between a heavy fluid phase and a light fluid phase.

[0002] Structured packing elements are used in mass transfer columns, such as fractionation columns, distillation columns, absorption columns, extraction columns, or flue gas strippers. Structured packing elements serve to enhance mass transfer and / or heat transfer between at least two fluid phases of different densities, where the structured packing elements are typically operated in countercurrent flow. While in distillation and absorption applications, the light phase is a gas or vapor and the heavy phase is a condensate or liquid, in extraction processes, both phases are liquids with different densities. Structured packing elements comprise a plurality of different layers, each of which provides a surface area for the heavier phase that flows along the surface of the layer and spreads out.Furthermore, between the different layers of the structured packing elements, open spaces are provided, which are filled with the light phase (e.g., vapor or gas in distillation) and provide a path for the light phase to ascend, while being driven by a pressure gradient. The pressure gradient is required. Petition 870220037181, dated 04 / 29 / 2022, page 7 / 94 2 / 71 to overcome flow resistance. In the typical case of countercurrent mass transfer, the average flow direction of the light phase is from the bottom to the top of the structured packing element and, therefore, opposite to the average flow direction of the heavy phase. By allowing a heavy phase to spread on the surface of the structured packing element, an interface is created between at least the two phases so that efficient heat and mass transfer between the phases is established at the interface. There may also be applications with more than one heavy phase. An example is extractive distillation.

[0003] A mass transfer column typically comprises several beds of structured packing elements. Typically, a distributor is arranged at the top of each bed to evenly distribute the heavy phase over the cross-section of the bed, while leaving sufficient space for the light phase to ascend through it. In addition, a grid-like containment device and a collector are often arranged below each bed, wherein the grid-like structure holds the bed in its position and the collector collects the heavy phase that flows from the bed, while sufficient open space is left in the collector for the light phase to ascend.

[0004] A common type of structured filler elements is the so-called cross-channel corrugated sheet filler, which is assembled from a plurality of, for example, corrugated sheets, which are arranged parallel and in tactile contact with each other. Typically, the corrugated metal sheets are fastened together by means of several rods that penetrate the corrugated sheets. Petition 870220037181, dated 04 / 29 / 2022, page 8 / 94 3 / 71 perpendicular to the longitudinal section of the corrugated sheets, wherein the rods are fixed to the first and last corrugated sheets by means of a washer and nut or by bending the rod. Each corrugated sheet comprises a plurality of periodic deformations, such as alternately oriented peaks and valleys, wherein adjacent corrugated sheets are oriented so that the corrugations of adjacent corrugated sheets crosswise with the corrugations of corrugated sheets that extend obliquely to the vertical or longitudinal direction, thus forming continuously intersecting inclined channels. These channels positively influence the gaseous and liquid phase flows within the packing and facilitate mass transfer between the phases.In other words, the gaseous and liquid phases are brought into contact within the channels of the structured packing element, and mass transfer as well as heat transfer between the phases is thus facilitated. More specifically, the ascending gas comes into contact with the liquid, which is present on the surface of the laminations that form the channels, as it flows downwards through the mass transfer column. During this contact, a component enriched in the gas can transfer to the liquid and vice versa; this means that efficient mass transfer can occur. Such packings are described, for example, in documents DE 1,253,673, CA 1270751 and US 6,206,349 B1.

[0005] The amount of mass transfer per unit time is proportional to the area of ​​the interface between the gas and the liquid, where the interface area becomes larger with Petition 870220037181, dated 04 / 29 / 2022, page 9 / 94 4 / 71 The increase in the portion of the surface of the filler element layers that is wetted by the liquid. Cross-channel corrugated sheet fillers made of metallic gauze are known to have excellent wettability thanks to good spreading of the heavy phase over the surface of the corrugated sheets due to the capillary force of the metallic gauze and thus – due to the excellent wettability – a high mass transfer efficiency. Examples of such structured fillers are the Sulzer BX and CY type fillers, which were first introduced in the 1960s. Another example of such a structured filler is described in document EP 1 477 224 A1. Meanwhile, metallic wire gauze is an expensive material. For this reason, an attempt was made to replace the gauze material with a corrugated metallic sheet with a large number of small openings. An example is the commercially available Montz-Pak Type BSH.During mass transfer column operation, the openings in this packing are filled with the heavy phase due to capillary action. The wettability of such relatively finely structured corrugated metal sheets is worse than that of metal gauze-based packings, and sheet production is still relatively expensive, partly due to the slow production process associated with the fine structure.

[0006] As presented above, it is important for high mass transfer efficiency that the surface of the structured filler element is well covered by liquid, since failure results in waste. Petition 870220037181, dated 04 / 29 / 2022, page 10 / 94 5 / 71 of filler material, considering that the light phase is not in much contact with the heavy phase, which could be due to the physical area of ​​the filler. Alternative suggestions to promote the spreading of the heavy phase over the surface of the layers – instead of using metallic or corrugated gauze, very thin expanded metal sheets as material for the structured filler element – ​​are to provide the layers with perforations and other surface textures, as described in documents US 4,296,050, GB 1,569,828, US 4,981,621 and EP 3,003,550 A1.

[0007] In order to further enhance the use of the surface of the structured filler element, it has already been proposed in document DE 38 18917 C1 and in document CN 882 00252 U to provide cross-channel corrugated sheet fillers made of perforated layers that have a high void space fraction, i.e., a high ratio of the total area of ​​the openings in the layer divided by the sheet area of ​​the layer.More specifically, document DE 38 18917 C1 discloses structured infill elements made of sheet metal layers comprising openings, which are separated from each other by separating elements. The edges of the openings are provided with protruding rims, wherein the rims of adjacent openings are extending alternately upwards from the upper side of the surface and downwards from the lower side of the surface of the sheet metal layers. Furthermore, document DE 38 18917 C1 teaches that the openings of the layers should be 3 to 7 times larger than the width of the separating elements located between adjacent openings. This results in a structured infill element made of open metal sheets. Petition 870220037181, dated 04 / 29 / 2022, page 11 / 94 6 / 71 with a very high void space fraction on the order of 50% or more. Document CN 882 00252 U discloses a structured infill element made of perforated sheets that have a thickness of 0.1 to 0.5 mm. The openings have a rhomboid shape, where the width of the openings is between 2 and 3 mm and where the percentage of open area in the sheet, that is, the void space fraction, is 40% to 50%. Thus, both prior art documents teach how to provide structural infill elements comprising sheet layers that preferably have high void space fractions of more than 40% and preferably of about 50%. In contrast, classic structured infill elements have drastically lower void space fractions of at most 10%.

[0008] Structured filler elements based on a different principle than cross-channel corrugated sheet fillers are, for example, described in documents EP 0 069 241 A1, US 4,304,738 and EP 0 250 061 A1. The layers of these structured filler elements consist of expanded sheet metal, where the layers assume a certain layer width due to the expansion process. However, in contrast to cross-channel corrugated sheet fillers, the layers of these structured filler elements are not corrugated and do not deform except for the deformation that arises with the expansion process. This limits the open space for upward vapor. Therefore, the mass transfer efficiency is not ideal, due to the fact that the open space between the layers does not provide a well-defined path that conducts upward vapor in a way that promotes a Petition 870220037181, dated 04 / 29 / 2022, page 12 / 94 7 / 71 homogeneous distribution over the entire cross-sectional plane of the structured packing element. It would be desirable to impose a certain direction on the vapor by means of an additional degree of freedom when defining the packing shape.

[0009] In addition to high mass transfer efficiency, capacity is an important aspect for a structured packing element. As the flow rates of the light and heavy phases in a structured packing element increase, the pressure drop in the structured packing element increases. At a certain pressure drop, gravity is not strong enough to counteract the friction between the two phases, and the heavy or liquid phase, respectively, is trapped in the light or gaseous phase, respectively, and thus no longer descends along the structured packing element. At this point, mass transfer is interrupted, and this situation is called flooding.This flooding point determines the capacity of a structured packing element; that is, the capacity of a structured packing element is characterized by pairs of maximum countercurrent flow rates beyond which an increase in each of the two flow rates leads to flooding. The flooding point refers to a characteristic pressure drop, which is generally on the order of 10 mbar per meter of packing height.

[0010] It would be ideal if a structured filler element had excellent mass transfer efficiency as well as excellent capacity, due to the fact that this would allow reducing the diameter and / or the Petition 870220037181, dated 04 / 29 / 2022, page 13 / 94 8 / 71 mass transfer column height at a given capacity would, by means of this, minimize investment costs for the mass transfer column. However, these two characteristics depend on opposing trends regarding specific area and other geometric parameters. More specifically, a high specific area, that is, a high quotient of the geometric area of ​​the structured packing element divided by the volume it occupies, leads to intense contact between the light and heavy phases, due to the fact that a respective structured packing element has a high mass transfer efficiency, which is commonly expressed in terms of the number of theoretical stages per meter of NTSM packing height.However, a structured packing element with a high specific area is characterized by high resistance to flow for the light phase, due to the fact that a respective structured packing element has - at a given light phase flow rate - a greater pressure drop per packing height and thus a lower capacity than a packing with a lower specific area.

[0011] In view of the foregoing, the underlying objective of the present invention is to provide an economical multi-purpose structured filler element that has superior mass transfer efficiency at a given capacity or greater capacity at a given mass transfer efficiency or lower weight at a given mass transfer efficiency, respectively.

[0012] According to the present invention, this objective Petition 870220037181, dated 04 / 29 / 2022, page 14 / 94 9 / 71 is satisfied by providing a structured cross-channel packing element for a column for mass transfer and / or heat exchange between a heavy and a light fluid phase, wherein the structured cross-channel packing element comprises at least two adjacent layers made of expanded metal sheets, each comprising openings, which are surrounded and separated from each other by separation elements, wherein at least two of the at least two layers are arranged in the longitudinal direction of the packing element parallel and in touch with each other so that an open space extending from one end to the opposite end of the at least two layers is provided between them so that at least one of the heavy and light fluid phases can flow through it.wherein the ratio between the average width of at least one, and preferably at least 50%, of the separation elements between adjacent openings and the thickness of the sheet material is at least 15; wherein the ratio between the maximum distance between at least two of the at least two layers measured in the plane that is perpendicular to the longitudinal direction and the average width of the separation elements is at least 4; and wherein the ratio between the distance between two openings that are in the direction perpendicular to the stretching direction of the expanded metal sheet adjacent to a separation element and the average width of that separation element is preferably, for at least 50%, 4 to 6 separation elements; wherein the distance between two openings is measured by determining the distance between the outermost point of one, Petition 870220037181, dated 04 / 29 / 2022, p. 15 / 94 10 / 71 side of the margin of one of the openings in the direction perpendicular to the direction of stretching of the expanded metal sheet and the outermost point of the same side of the margin of an adjacent opening in the same direction of the expanded metal sheet, wherein the longitudinal direction of the filler element is as defined in the descriptive report, wherein the direction of stretching of the expanded metal sheet is the direction that is perpendicular to the longitudinal direction of the structured cross-channel filler element, and wherein the average width of a separating element is determined by dividing the separating element into individual sections i=1, 2, 3... n each holding a section length di, wherein for each of the sections, the shortest distance bi between adjacent margins within the sections is measured and the sum of the products di-bi is divided by the sum of di to produce the average width b of the separating element.

[0013] This solution is based on the surprising finding that mass transfer efficiency at a given capacity can be significantly improved if the average width of the separation elements between adjacent openings is relatively large compared to the openings (namely, the ratio of the distance between two openings that are in the direction perpendicular to the direction of stretching (which is the direction perpendicular to the longitudinal direction) of the expanded metal sheet adjacent to a separation element and the average width of that separation element is 4 to 6) and significantly wider than the thickness of the sheet material (namely, by 15 times or more). This was in Petition 870220037181, dated 04 / 29 / 2022, p. 16 / 94 11 / 71 This particular finding is unexpected because it contradicts the teachings of documents DE 38 18917 C1 and CN 882 00252 U. The two prior art documents imply that a free film suspension between the separating elements contributes twice to the mass transfer area and thus suggest further minimizing the width of the separating elements and removing even more of the physical area. In view of this, it was even more surprising that, by adjusting the aforementioned parameters as described above, the mass transfer efficiency at a given capacity is significantly improved.

[0014] A significant additional advantage of the structured filler element according to the present invention is that it does not actually rely on the use of expensive layer material. Preferably, the layers are simply produced from expanded metal sheets, i.e., by cutting and stretching a thin metal sheet and then, in a second step, deforming the expanded metal sheet into, for example, corrugated sheets. In this way, an economical raw material is used and the required amount of material of this economical raw material is further reduced by stretching it. However, the present invention provides an economical multi-purpose structured cross-channel filler element that has superior mass transfer efficiency at a given capacity or superior capacity at a given mass transfer efficiency, respectively.

[0015] The longitudinal direction of the filler element Petition 870220037181, dated 04 / 29 / 2022, p. 17 / 94 12 / 71 of a structured cross-channel packing element is the direction from the top to the bottom of the packed element when incorporated into a mass transfer and / or heat exchange column; that is, the longitudinal direction is the top to bottom direction of the mass transfer and / or heat exchange column. In other words, this is the intended gravity-driven flow direction of the heavier phase during the operation of the packed element and the mass transfer and / or heat exchange column, respectively.More specifically, the longitudinal direction of the structured cross-channel filler element can be determined as follows: The structured cross-channel filler element is placed in a horizontal area so that the layers of the structured cross-channel filler element that are arranged in parallel and in touch with each other extend in the vertical direction and so that the open spaces (or channels, respectively, that are surrounded and thus defined by the periodic deformations of the layers) that extend from one end to the opposite end of the layers extend from the top to the bottom of the structured cross-channel filler element.The longitudinal direction is, therefore, the direction from the top to the bottom of the structured cross-channel filling element thus arranged, or - in other words: Heavy phase, for example, water, which is poured over the top of the structured cross-channel filling element thus arranged flows gravity-driven downwards along the open spaces, in that direction. Petition 870220037181, dated 04 / 29 / 2022, page 18 / 94 13 / 71 longitudinal is the average flow direction of the heavy phase.

[0016] The maximum distance (subsequently also referred to as or abbreviated as D) is closely related to the layer width (subsequently also referred to as or abbreviated as W), which is the extent of a single layer measured in the aforementioned plane. The value of W is typically around half of D. The open space between the two layers is obtained thanks to the layer width W. The maximum distance D between two adjacent layers of the structured filler element measured in the plane that is perpendicular to the longitudinal direction denotes, according to the present invention, the distance between the layers, if the distance between the layers is constant over all surfaces of the adjacent layers, as in the case of two parallel flat sheets.If the distance between layers is not constant over all surfaces of adjacent layers, that is, if the distance between different surface portions of the layers differs, the maximum distance D between the two adjacent layers is the distance between those surface portions of both layers where the distance in the plane perpendicular to the longitudinal direction between both layers is maximum. More specifically, the maximum distance D between two adjacent layers of the structured filler element measured in the plane perpendicular to the longitudinal direction denotes, according to the present invention, the distance between the two most distant points A and B, such that point A is in the first layer and point B is in the second layer. Two parallel planes are defined, one comprising point A, the other point B. These two parallel planes are oriented. Petition 870220037181, dated 04 / 29 / 2022, p. 19 / 94 14 / 71 essentially parallel to the orientation of the two layers. The distance D is defined as the distance between these two parallel planes.

[0017] According to the present invention, the structured filling element comprises at least two layers that are arranged longitudinally parallel to each other. The parallel arrangement of two layers means, according to the present invention, that one of the layers is inclined at an angle of at most + / - 20°, preferably at most + / - 10°, more preferably at most + / - 5°, even more preferably at most + / - 2° in relation to the other layer and is most preferably not actually inclined in relation to the other layer.

[0018] Furthermore, according to the present invention, the ratio between the average width of at least 50% of the separation elements between adjacent openings and the thickness of the blade material is at least 15. This means that for at least 50% of the separation elements, the ratio between the average width of the respective separation element and the thickness of the blade material is at least 15. Preferably, the ratio between the average width of at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably of all separation elements between adjacent openings and the thickness of the blade material is at least 15.

[0019] The thickness of blade material means according to the thickness of the material that constitutes or forms the Petition 870220037181, dated 04 / 29 / 2022, p. 20 / 94 15 / 71 layer, respectively. Once, according to the present invention, the layer is made of an expanded metal sheet, the thickness of the sheet material is the thickness of the sheet. If the sheet thickness varies by the area of ​​the layer, the thickness of the sheet material is the thickness of the sheet measured at one of the outer edges of the sheet material thickness by means of, for example, a micrometer screw. For example, the thickness of the material forming the layer is measured at at least two, preferably at least three, and more preferably at least five locations on one or more of the outer edges with the micrometer screw, before the values ​​obtained are summed and weighted by dividing the sum by the number of measurements.Good results are obtained, for example, when the thickness is measured at 2 to 20, preferably 2 to 10, more preferably 3 to 10, and most preferably 5 to 10 locations on one or more of the outer edges of the layer with the micrometer screw, wherein the different locations are approximately 3 cm apart along the outer edge. A micrometer screw is a known measuring device comprising a fixed and a movable measuring area, wherein the movable measuring area is adjustable with a fine screw. Both measuring areas can come into contact or touch, respectively, if the movable measuring area is fully moved into the fixed measuring area. Both measuring areas are flat and circular, wherein the diameter of both measuring areas is preferably 5 to 6 mm.

[0020] The average width (subsequently also referred to as or abbreviated as “b”) of a separating element is Petition 870220037181, dated 04 / 29 / 2022, page 21 / 94 16 / 71 determined according to the present invention by measuring the distance between the two adjacent parallel edges of the separating element, if the separating element has a uniform width. If the separating element does not have a uniform width, the average width b of a separating element is determined by dividing the separating element into individual sections i=1, 2, 3 ... n each having a section length di. For each of the sections, the shortest distance bi between the adjacent edges within the sections is measured. The sum of the products di-bi divided by the sum of di yields the average width b of the separating element. The greater the non-uniformity of the separating element, the more and shorter sections need to be chosen. Preferably, the number n of individual sections i taken for measurement per separating element is 1 to 1000, more preferably 5 to 100 and most preferably 5 to 20, as well as 8 to 15.For example, 5 sections are selected per cm of a separation element.

[0021] Preferably, the average width b of a separating element is determined in a top view or in a plan view of one of the openings that are adjacent to the separating element. This is advantageously achieved by taking a photographic image of an opening. A top view of an opening is obtained by taking a photograph of the opening after flattening the respective expanded metal sheet by placing the expanded metal sheet on a flat surface, placing a plate on top of the expanded metal sheet, and then pressing the plate down with sufficiently low pressure just to flatten it. Petition 870220037181, dated 04 / 29 / 2022, p. 22 / 94 17 / 71 Expanded metal sheet is used to remove periodic deformations, but without altering the geometry and dimensions of the separating elements and openings, i.e., without altering the geometry and dimensions of the expanded metal sheet grid structure. The plan view of an opening is made on the expanded metal sheet in its form as used in the structured cross-channel filler element, i.e., without having flattened or otherwise mechanically processed it. More specifically, the plan view of an opening is taken along the normal geometric axis of the plane defined by the adjacent edges of the opening. In some cases, such a plane is not well defined. In this case, the most suitable view is obtained by trial and error. Several images, such as at least five images or preferably at least 10 images, from various angles are taken. The image that makes the opening appear larger is then considered as the plan view of the opening.A reference length z can be used to determine lengths and sizes in plan view as well as top view. This is best achieved by identifying or marking a certain distance z on the actual object in the vicinity of the opening and measuring its length. The ratio between the effective length z' of this distance in plan view or top view, respectively, and the distance z measured on the actual object is used to scale all other distances that are measured in plan view. For example, the actual length of a segment width is obtained by bi = bi' · (z / z'), where the prepared variables denote the lengths measured in plan view or top view, respectively, and the unprepared variables . Petition 870220037181, dated 04 / 29 / 2022, page 23 / 94 18 / 71 actual length.

[0022] According to the present invention, the hydraulic diameter d of an opening is calculated using the formula 4 A / P, where A is the cross-sectional area of ​​the opening and P is the perimeter of the same opening. The cross-sectional area of ​​the opening can be determined by using basic measurements (such as shape length and height) and a basic geometric formula (known from Euclidean geometry), if the shape of the opening is simple, for example, a triangle, rectangle, quadrilateral, planar trapezoid or similar. Preferably, the area is determined from a top view or a plan view of the opening. Complex shapes can be approximated and subdivided into a number j=1, 2, 3 ... m of simple shapes that have an area Aj. The area of ​​these shapes can again be calculated using basic measurements and a basic geometric formula. The area A of the opening is obtained by summing all the areas Aj determined in the opening. The more complex the shape of the opening, the more subdivision is required. Preferably, the number m of individual simple shape sections j taken for measurement is 1 to 1000, preferably 5 to 100, more preferably 5 to 20, as well as 8 to 15. As before, the actual lengths are determined based on the ratio z / z' defined above.

[0023] The perimeter of a simple opening can be determined using basic measurements and a basic geometric formula. In the most general case, the plan view or top view of the opening is used. The perimeter of the opening is subdivided into a number of k=1, 2, 3 ... K straight lines. Petition 870220037181, dated 04 / 29 / 2022, page 24 / 94 19 / 71 individual Pk lines that best approximate the opening and represent it by a closed polygon. By summing the lengths of these straight lines, the perimeter P is obtained. Again, the lengths need to be translated into real lengths using the ratio z / z' as defined above.

[0024] Numerical image processing methods can be used to determine the average width b, the area A of an opening, and its perimeter P. In this case, the basic unit is determined by the size of a pixel. To translate lengths and areas to a pixel basis, the ratio z / z' needs to be defined in an appropriate way, as explained above, for example. Gray values ​​can be used to identify pixels that belong to a separation element and others that belong to the opening. Areas can be calculated directly by summing the pixels and multiplying the sum by the actual area of ​​a pixel (relative to the actual object). When determining the width bi or length di of a segment, trigonometric rules need to be applied if the width orientation is not parallel to the sides of the pixels.

[0025] Further details on measurement methods and illustrative examples are given below along with the figures.

[0026] According to the present invention, the layers of the structured cross-channel filler element are made of expanded metal sheets, which are produced by expanding a sheet metal, i.e., by cutting and stretching a sheet metal. Therefore, the resulting openings are typically of an essentially Petition 870220037181, dated 04 / 29 / 2022, page 25 / 94 20 / 71 elliptical, lenticular, trapezoidal, or rhomboid, and usually of an essentially lenticular or trapezoidal shape. Thus, as schematically shown in the figures and as described in further detail below, each expanded metal sheet is, in fact, a grid comprising openings, wherein each opening is surrounded by separating elements that each have a width b, wherein the separating elements of adjacent openings are connected to each other at junction points. The hydraulic diameter is generally unknown, but can be determined as shown above or calculated from commonly used characteristic dimensions as explained below. Expanded sheets are typically characterized by the dimensions of their openings and the (average) widths of the separating elements b.The openings, which are usually essentially lenticular or trapezoidal in shape, thus have a shorter and a longer characteristic length, wherein the shorter characteristic length (subsequently also referred to or abbreviated as “e2”) of an opening is the maximum dimension of the opening in the direction of stretching of the expanded metal sheet and the longer characteristic length (subsequently also referred to or abbreviated as “e1”) of an opening is the maximum dimension of the opening in the direction perpendicular to the direction of stretching of the expanded metal sheet. The direction of stretching of the expanded metal sheet is the direction along which the metal of the sheet was stretched during the production of the expanded metal sheet. More specifically, the direction of stretching is, according to the present invention, the direction. Petition 870220037181, dated 04 / 29 / 2022, p. 26 / 94 21 / 71 which is perpendicular to the longitudinal direction of the structured cross-channel filler element. Thus, the direction that is perpendicular to the stretching direction is the longitudinal direction of the structured cross-channel filler element. The (average) widths of the separating elements and the characteristic lengths of the openings determine the distances between adjacent openings. The distance between openings that are adjacent in the stretching direction of the expanded metal sheet differs from the distance between openings that are adjacent in the direction perpendicular to the stretching direction of the expanded metal sheet.Subsequently, the distance between a first opening and a second opening that are in the direction of stretching of the expanded metal sheet adjacent to each other is also referred to or abbreviated as u2, while the distance between the first opening and a third opening that is in the direction perpendicular to the direction of stretching of the expanded metal sheet adjacent to the first opening is also referred to or abbreviated as u1. These distances u1 and u2 can be measured as explained in detail below with reference to the figures. The following equations could be used to determine the hydraulic diameter (subsequently also referred to or abbreviated as d) of the respective opening if the openings are approximately rhomboid in shape: e1= u1- b V (1 + u12 / u22) e2 = Θ1 · U2 / Ui d = e1 · e2 / V (e12+ e22)

[0027] If the ratio of e2 / e1 is around 0.5 or below, as is realistic for expanded metal sheets, the Petition 870220037181, dated 04 / 29 / 2022, page 27 / 94 22 / 71 The following simplified equations for e1 and e2 can be used to determine the hydraulic diameter d of the respective opening: e1 = u1 - b · u1 / u2 e2 = u2 - b

[0028] Additionally, the expanded metal sheet can be characterized by means of the stretch factor, which is defined as u2 / 2b. The inverse of the stretch is a good indication of the material savings that can be achieved compared to a solid metal sheet. More details on these dimensions with an illustrative example are given further below along with the figures.

[0029] According to the present invention, the filler element is a structured cross-channel filler element. Consequently, it is preferable that at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably all of the at least two layers are made of expanded metal sheets and comprise periodic deformations, wherein the layers are oriented so that the periodic deformations of adjacent layers intersect crosswise with the periodic deformations of layers extending obliquely with respect to the longitudinal direction. At least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably each Petition 870220037181, dated 04 / 29 / 2022, page 28 / 94 23 / 71 one of the layers comes into contact with each of the adjacent layers at points of intersection between the periodic deformations of the layer and those of the adjacent corrugated layers, and wherein the open space between at least two layers is defined by the periodic deformations. Preferably, the distance between the uppermost points of two adjacent periodic deformations of a layer is, depending on the surface area, between 10 and 25 mm and more preferably between 13 and 23 mm.

[0030] Good results are achieved, in particular, when the stretching factor of the expanded metal sheet of at least two layers is between 1.1 and 1.5 and more preferably between 1.2 and 1.35.

[0031] According to the present invention, the distance u1 is measured by determining the distance between the outermost point on one side of the margin of one of the openings in the direction perpendicular to the stretching direction of the expanded metal sheet and the outermost point on the same side of the margin of an adjacent opening in the same direction of the expanded metal sheet. For example, if a photographic image of a top view or plan view of a layer of the structured cross-channel filler element is made, where the stretching direction is shown in the vertical direction of the photographic image and the direction perpendicular to the stretching direction is shown in the horizontal direction of the photographic image, the distance u1 can be determined as the distance between the outermost point on the left side of the margin of one opening and the outermost point on the left side of the margin of an opening that is adjacent to the opening in the same direction as the opening. Petition 870220037181, dated 04 / 29 / 2022, page 29 / 94 24 / 71 expanded metal sheet.

[0032] In order to determine the distance u1 particularly precisely, the distance between the outermost point of one side of the margin of an opening in the direction perpendicular to the direction of stretching of the expanded metal sheet and the outermost point of the same side of the margin of the fifth or nth opening adjacent to it arranged in the direction perpendicular to the direction of stretching of the expanded metal sheet can be measured and divided by four or (n-1).

[0033] Even more preferably, the distance u1 is determined by measuring the distance between the outermost point of one side of the margin of an opening in the direction perpendicular to the direction of stretching of the expanded metal sheet and the outermost point of the same side of the margin of the tenth opening adjacent to it, arranged in the direction perpendicular to the direction of stretching of the expanded metal sheet, which can be measured and divided by nine.

[0034] According to the present invention, the ratio between the distance u1 between two openings that are perpendicular to the direction of stretching of the expanded metal sheet adjacent to a separating element and the average width of that separating element is at least 50% for all separating elements 4 to 6. Good results are particularly achieved when the ratio between the distance u1 and the average width b is at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably for all separating elements 4 to 6, preferably Petition 870220037181, dated 04 / 29 / 2022, p. 30 / 94 25 / 71 4.5 to 5.5, and more preferably 4.9 to 5.1.

[0035] In a further development of the idea of ​​the present invention, the distance u1 is preferably at least 50%, more preferably at least %, even more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably for all openings 5 ​​to 20 mm. More preferably, the distance u1 is preferably at least 50%, more preferably at least %, even more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably for all openings 7.5 to 15 mm and most preferably 9 to 11 mm.

[0036] According to a further particular embodiment of the present invention, the ratio between the distance u2 between a first opening and a second opening that is in the direction of stretching of the adjacent expanded metal sheet and the distance u1 between the first opening and a third opening that is in the direction perpendicular to the direction of stretching of the adjacent expanded metal sheet is 0.4 to 0.7, wherein the distance u2 is measured by determining the distance between the outermost point of one side of the margin of the first opening in the direction of stretching of the expanded metal sheet and the outermost point of the same side of the margin of the second adjacent opening that is adjacent in the direction of stretching of the expanded metal sheet, and wherein the distance u1 is measured as described above. Petition 870220037181, dated 04 / 29 / 2022, page 31 / 94 26 / 71

[0037] Similar to the determination of distance u1, distance u2 is preferably measured by determining the distance between the outermost point on one side of the margin of the first opening in the direction of stretching of the expanded metal sheet and the outermost point on the same side of the margin of the fifth or tenth (n-th) opening adjacent to it, arranged in the direction of stretching of the expanded metal sheet, and by dividing the distance by four or nine (n-1), respectively.

[0038] Good results are particularly achieved when the ratio between distance u2 and distance u1 is at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably for all openings 0.4 to 0.7, most preferably 0.45 to 0.70 and with maximum preference 0.49 to 0.55.

[0039] Furthermore, it is preferable that the distance u2s be at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably for all openings 2 to 8 mm, more preferably 3 to 7 mm, and most preferably 4 to 6 mm.

[0040] According to a further particular embodiment of the present invention, the average width b of at least one separation element between adjacent openings is between 70% and 125% of the average hydraulic diameter d of the adjacent openings. Petition 870220037181, dated 04 / 29 / 2022, p. 32 / 94 27 / 71

[0041] In a further development of the idea of ​​the present invention, it is suggested that the average width b of at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably of all separation elements between adjacent openings be between 70% and 125% of the average hydraulic diameter d of the adjacent openings. More preferably, the average width b of at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably of all separation elements between adjacent openings be between 75% and 100% of the average hydraulic diameter d of the adjacent openings.

[0042] In order to achieve an ideal spreading of the heavy phase in the surface layer, it is preferable that the average width b of at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably of all separation elements between adjacent openings is 1.5 to 4.0 mm. More preferably, the average width b of at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably of all separation elements between adjacent openings is 1.6 to 3.5 mm, and most preferably 1.8 to 3.0 mm. Petition 870220037181, dated 04 / 29 / 2022, p. 33 / 94 28 / 71

[0043] According to the present invention, the ratio between the average width b of at least 50% of the separation elements between adjacent openings and the thickness of the layer material (subsequently also referred to or abbreviated as s) is at least 15. Particularly good results are obtained when the ratio between the average width b of at least 50% of the separation elements between adjacent openings and the thickness of the layer material is at least 18. Preferably, the ratio between the average width of at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95% and most preferably of all separation elements between adjacent openings and the thickness of the blade material is at least 18.

[0044] According to the present invention, the ratio between the maximum distance D between at least two adjacent layers of at least two layers measured in the plane that is perpendicular to the longitudinal direction and the average width b of the separating elements is at least 4. This means that the ratio between the maximum distance D between at least two adjacent layers of at least two layers measured in the plane that is perpendicular to the longitudinal direction and the average width b of at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably of all separating elements is at least 4.

[0045] Good particular results are obtained when the ratio between the maximum distance measured on the plane that is Petition 870220037181, dated 04 / 29 / 2022, p. 34 / 94 29 / 71 perpendicular to the longitudinal direction and the average width of the separation elements between at least 50%, preferably between at least 75%, more preferably between at least 80%, even more preferably between at least 90%, still more preferably between at least 95% and with maximum preference between all at least two layers is at least 4.

[0046] Furthermore, it is preferable that the ratio between the maximum distance D between at least 50%, preferably between at least 75%, more preferably between at least 80%, even more preferably between at least 90%, still more preferably between at least 95% and most preferably between all at least two layers measured in the plane that is perpendicular to the longitudinal direction and the average width b of the separation elements be at least 5 and more preferably at least 8.

[0047] In a further development of the idea of ​​the present invention, it is suggested that the ratio of the maximum distance D between at least 50%, preferably between at least 75%, more preferably between at least 80%, even more preferably between at least 90%, still more preferably between at least 95% and most preferably between all of the at least two layers measured in the plane that is perpendicular to the longitudinal direction and the average width b of the separating elements be 4 to 15, preferably 5 to 13 and most preferably 8 to 12.

[0048] Good results are obtained, in particular, if the maximum distance D is at least 50%, preferably at least 75%, more preferably at least 80%, and even more preferably at least Petition 870220037181, dated 04 / 29 / 2022, p. 35 / 94 30 / 71%, with even greater preference between at least 95% and with maximum preference between all of the at least two layers measured in the plane that is perpendicular to the longitudinal direction, is 8 to 80 mm, preferably 12 to 51 mm and with maximum preference 16 to 30 mm. Consequently, it is preferable that the layer width W be 4 to 40 mm, more preferably 6 to 25.5 mm and with maximum preference 8 to 15 mm.

[0049] According to a particular preferred embodiment of the present invention, for at least one of the at least two layers, the ratio of the total area of ​​the openings in the layer divided by the blade area of ​​the layer, that is, the fraction of empty space in the layer, is between 20% and 38%. The blade area AS of a layer is, according to the present invention, the sum of the physical area of ​​all separation elements measured only on one side and the total area of ​​the openings enclosed by the separation elements. The total area of ​​the openings is simply the sum of the areas A (cross-section) of the openings. Additionally, the blade area AS of a structured filler element is the sum of the blade areas of the layers included in the structured filler element. As presented above, the fraction of empty space in the filler layer is the ratio of the total area of ​​the openings in that layer divided by the blade area of ​​that layer.

[0050] Preferably, for at least 50%, more preferably for at least 75%, even more preferably for at least 80%, even more preferably for at least 90%, even more preferably for at least 95%, and most preferably Petition 870220037181, dated 04 / 29 / 2022, page 36 / 94 31 / 71 for all of at least two layers, the fraction of empty space in the layer is between 20% and 38%. This allows the advantages of the present invention to be obtained at a particularly high rate.

[0051] Additionally, it is preferable that for at least 50%, more preferably for at least 75%, even more preferably for at least 80%, even more preferably for at least 90%, even more preferably for at least 95%, and most preferably for all of the at least two layers, the void space fraction of the layer is between 25% and 35%, and most preferably between 28% and 32%. This leads to particularly excellent wetting of the layers of the structured filler element according to the present invention.

[0052] Particularly good results are obtained if the grid structure of the expanded metal sheets is uniform, that is, when all or at least most of the openings and separating elements are identical or at least highly similar to each other. In view of this, it is preferable that at least 50%, more preferably at least 75%, even more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably all the openings of each of the at least two layers have a hydraulic diameter d, which is between 50 and 150%, preferably between 70 and 130%, more preferably between 80 and 120%, and most preferably between 90 and 110% of the average hydraulic diameter d of all the openings.

[0053] It is preferable that the hydraulic diameter d of Petition 870220037181, dated 04 / 29 / 2022, page 37 / 94 32 / 71 at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably all openings of each of the at least two layers should be 1.25 to 5.0 mm. Even more preferably, the hydraulic diameter d should be at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably all openings of each of the at least two layers should be 2.0 to 4.0 mm, most preferably 2.2 to 3.5 mm.

[0054] According to an alternative embodiment of the present invention, at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably all of the openings have a shorter characteristic length e2 of 1.0 to 4.0 mm and preferably 2.0 to 3.0 mm and a longer characteristic length e1 of 2.0 to 8.0 mm, preferably 2.5 to 7.0 mm and most preferably 3.0 to 6.0 mm. As presented above, the shorter characteristic length e2 of an opening is the maximum dimension of the opening in the direction of stretching of the expanded metal sheet, and the longer characteristic length e1 of an opening is the maximum dimension of the opening in the direction perpendicular to the direction of stretching of the expanded metal sheet.

[0055] In a further development of the idea of Petition 870220037181, dated 04 / 29 / 2022, p. 38 / 94 33 / 71 of the present invention, it is suggested that the ratio between the shortest characteristic length e2 of an opening and the longest characteristic length e1 of the same opening be at least 50%, preferably at least 75%, more preferably at least %, even more preferably at least 90%, even more preferably at least 95%, and most preferably for all openings 0.4 to 0.7, preferably 0.45 to 0.6, and most preferably 0.49 to 0.55. As presented above, the shortest characteristic length e2 of an opening is the maximum dimension of the opening in the direction of stretching of the expanded metal sheet, and the longest characteristic length e1 of an opening is the maximum dimension of the opening in the direction perpendicular to the direction of stretching of the expanded metal sheet.

[0056] The present invention is not particularly limited with respect to the material of the expanded metal sheets of the structured filler element. For example, the expanded metal sheets may be made of stainless steel or a composite selected from the group consisting of aluminum, copper, titanium, zirconium and alloys.

[0057] Preferably, the material thickness of The thickness of each expanded metal sheet is s = 0.05 to 0.50 mm, more preferably s = 0.09 to 0.15 mm, and with

[0058] Usually at least 50%, more preferably at least 75%, even more preferably at least 80%, even more preferably at least 90%, even more preferably with more Petition 870220037181, dated 04 / 29 / 2022, page 39 / 94 34 / 71 preferably at least 95% and most preferably all of the openings in the layers of the structured filler element have an essentially elliptical, lenticular or trapezoidal cross-section.

[0059] After production, i.e., cutting and stretching of a metal plate, the resulting expanded metal sheet is no longer flat. This is the result of deformation, distortion, bending, or folding of individual separating elements and a relative deformation of separating elements compared to others, for example, by tilting. Other features such as burrs may have resulted from a punching process and therefore contribute to the thickness. The resulting dimension of the expanded metal sheet is called the grid thickness (subsequently also referred to or abbreviated as “g”) and may be identical to the thickness of the layer material (which is the case if the expanded sheet is flat, due to the fact that it was flattened by rolling) or up to several times greater than the thickness of the layer material. The grid thickness is typically on the order of magnitude of the width b of the separating element and should not be much greater than the width b.Therefore, the ratio of grid thickness g to average width b of the separation elements ranges from more than 0 to approximately 1.2, more preferably from 0.4 to 1 and most preferably from 0.5 to 0.8. The grid thickness g is significantly smaller than the maximum distance D between two adjacent layers measured in the perpendicular plane of the longitudinal direction.

[0060] It is additionally preferred that the ratio between the Petition 870220037181, dated 04 / 29 / 2022, p. 40 / 94 35 / 71 average grid thickness g of each layer and the thickness of the blade material s is at least 6.

[0061] Good results are achieved, in particular, when the average grid thickness g of each layer (32, 32') is 1.0 to 1.4 mm, preferably 1.1 to 1.3 mm and more preferably 1.15 to 1.25 mm.

[0062] The grate can also be flattened by pressing a plate on top of it as described above.

[0063] Another embodiment of the present invention comprises laminating the expanded metal sheet for the purpose of providing an expanded metal sheet with a textured surface. More specifically, each of the periodic deformations, such as corrugations in particular, may have a flow surface including a patterned front comprising a plurality of protrusions and depressions that define continuously crossing capillary channels. The protrusions may be arranged in a contiguous relationship with adjacent protrusions and may have side walls that define channels between them and a patterned back identical to the front and that defines continuously crossing capillary channels, as described, for example, in document EP 0190435 B1. The protrusions may have a similar height range as the g-grid thickness without any additional treatment.

[0064] Preferably, the ratio of the maximum distance D to the grid thickness g (i.e., D / g) is at least 3.

[0065] Good results are obtained, in particular, when the ratio between the maximum distance D between each adjacent of at least two layers measured in the plane that is perpendicular to the longitudinal direction and the diameter Petition 870220037181, dated 04 / 29 / 2022, p. 41 / 94 36 / 71 average hydraulic d of the openings is at most 15.

[0066] Expanded metal sheets provide, as shown in figure 7c, a rough and a smooth side. Preferably, the single layers of the structured cross-channel filler element are arranged so that, on the rough side of the layer, an adjacent layer is arranged with its rough side and that, on the smooth side of the layer, an adjacent layer is arranged with its smooth side.

[0067] In a further development of the idea of ​​the present invention, it is suggested that at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least %, still more preferably at least 95%, and most preferably all of the at least two layers comprise periodic deformations, wherein the open space between the at least two layers is defined by the periodic deformations. It is particularly preferred that all layers of the structured filler element of the present invention comprise such periodic deformations, i.e., that the structured filler element of the present invention does not include any planar layers. Preferably, the angle (subsequently also referred to or abbreviated as α) between each of the periodic deformations with respect to the longitudinal direction is 10° to 60°, more preferably 20° to 50° and with maximum preference 25° to 47°, wherein periodic deformations of adjacent layers are preferably oriented in opposite directions.

[0068] For example, periodic deformations can be Petition 870220037181, dated 04 / 29 / 2022, p. 42 / 94 37 / 71 corrugations comprising a plurality of alternately oriented peaks and valleys, wherein the peaks of one layer come into contact with the valleys of an adjacent layer and the valleys of one layer come into contact with the peaks of an adjacent layer, wherein the adjacent layers are oriented so that the peaks and valleys of the adjacent layers intersect in a cross-sectional manner with the peaks and valleys of the layers that extend obliquely with respect to the longitudinal direction.Therefore, it is preferable that at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95%, and most preferably all of the at least two layers comprise periodic deformations, wherein the periodic deformations of the cross-filling element are corrugations comprising a plurality of alternately oriented peaks and valleys, wherein the peaks of one layer come into contact with the valleys of an adjacent layer and the valleys of one layer come into contact with the peaks of an adjacent layer, wherein the adjacent layers are oriented so that the peaks and valleys of the adjacent layers intersect in a cross-sectional manner with the peaks and valleys of the layers extending obliquely with respect to the longitudinal direction.Obviously, it is also possible that not all peaks of a layer come into contact with one or more valleys of an adjacent layer, but preferably that some of the peaks of a layer come into contact with one or more valleys of an adjacent layer and vice versa. However, between two adjacent layers there must be at least three points of contact. Petition 870220037181, dated 04 / 29 / 2022, p. 43 / 94 38 / 71 present. Preferably, in 30 to 90% and more preferably in 50 to 80% of locations, where peaks and valleys of adjacent layers are opposite each other, no touch contact is present, wherein, in the remaining locations, the respective peaks and valleys of adjacent layers touch.

[0069] Good results are obtained, in particular, in this modality, when the angle α between each of the peaks and each of the valleys in relation to the longitudinal direction is 10° to 60°, preferably 20° to 50° and with maximum preference 25° to 47°, where the peaks and valleys of adjacent layers are preferably oriented in opposite directions. This allows a uniform distribution of the light phase over at least one direction of the cross-section of the structured filler element. The angles should not be too large to minimize pressure drop and maximize capacity.

[0070] In order to reduce the pressure loss of the structured filler element, a further development of the idea of ​​the present invention proposes that the peaks and valleys be bent at the terminal portions of the layers relative to the peaks and valleys of the central portion that is disposed between the terminal portions, so that the flow resistance in the terminal zones of the structured filler element is reduced relative to that of the zone disposed between the terminal zones. Consequently, the peaks and valleys of the layers in this embodiment do not extend linearly. Preferably, the peaks and valleys are bent at the terminal portions of the layers in order to extend at least essentially by Petition 870220037181, dated 04 / 29 / 2022, page 44 / 94 39 / 71 vertical mode. Essentially vertical means that the peaks and valleys are not inclined at the lower and upper edges of the layers by more than 10°; preferably not more than 5° and more preferably not more than 2° in relation to the vertical direction. The terminal zones are the uppermost and lowermost zones of the layers that extend from the upper and lower edges of the layers 30%, preferably 25% and more preferably 20% or less along the blade length, which is the direction along the longitudinal direction of the layer. Each of the terminal zones may have peaks and valleys with a height different from that of the central zone, which is the zone of the layer between the two terminal zones. Instead of providing such bends or different heights in both terminal zones, they may only be present in one of the terminal zones.

[0071] According to an alternative embodiment of the present invention, the periodic deformations are waves that have a square, a triangle, a sinusoidal cross-section or a meander-like shape comprising peaks and valleys, wherein the peaks of one layer come into contact with the valleys of an adjacent layer, and the valleys of one layer come into contact with the peaks of another adjacent layer, wherein the adjacent layers are oriented so that the peaks and valleys of the adjacent layers intersect in a cross manner with the peaks and valleys of the layers that extend obliquely with respect to the longitudinal direction.

[0072] Good results are obtained, in particular, in this modality, when the angle α between each of the peaks and each of the valleys in relation to the longitudinal direction is 10° a Petition 870220037181, dated 04 / 29 / 2022, p. 45 / 94 40 / 71 60°, preferably 20° to 50° and with maximum preference 25° to 47°, where the peaks and valleys of adjacent layers are preferably oriented in opposite directions. This allows for a uniform distribution of the lightweight phase over at least one direction of the cross-section of the structured infill element.

[0073] The present invention is not particularly limited with respect to the number of layers contained therein. The number of layers in a filler element depends on the diameter of the mass transfer column and the specific area required aM for mass transfer. When more surface area is required, i.e., when the specific area is greater, more layers will be present, and the maximum distance D will be smaller, consequently. Although the structured filler element is generally cylindrical in shape with a round cross-section, there may also be cross-sections of other shapes, for example, rectangular, depending on the shape of the mass and / or heat transfer column. If the column has a large diameter, the element is commonly subdivided into segments or tiles to reduce weight and to allow for installation in parts.

[0074] Good particular combinations of mass transfer efficiency and capacity are obtained when the structured filling element according to the present invention has a specific area aM of 60 to 750 m2 / m3, 120 to 500 m2 / m3 and most preferably 200 to 450 m2 / m3.

[0075] The specific area aM is defined as the geometric area AM of the structured infill element divided by the volume VM that the infill element Petition 870220037181, dated 04 / 29 / 2022, page 46 / 94 41 / 71 structured occupies. The geometric area AM of the structured infill element is the sum of the geometric area of ​​all layers comprised in the element, where the geometric area of ​​a layer adds both sides of the layer as if there were no openings or holes. In other words, the geometric area is approximately obtained by multiplying the sheet area AS of the infill layers by two due to the fact that both sides of the layers count towards the geometric area.

[0076] The AS sheet area of ​​a structured fill layer is obtained by adding both the area of ​​the openings in the layer and the physical area AP of the layer. AP considers only the surface that is physically present. Holes or openings do not contribute to the value. The AS sheet area of ​​the structured fill element is obtained by summing the sheet area of ​​all the layers included in it.

[0077] The physical area AP of a structured fill layer is the sum of the surface area measured on a selected side of all separation elements included in the structured fill layer. The edges of layer material thickness s do not contribute to this area. The physical area AP of the fill is the sum of the physical area of ​​all layers comprised within it.

[0078] In addition to the definitions aM, AM, AS and AP for areas, the expressions surface and “surface area” are used in a more qualitative or intuitive way in the description of the present invention.

[0079] Preferably, the structured filling element has a height of 100 to 300 mm and Petition 870220037181, dated 04 / 29 / 2022, page 47 / 94 42 / 71 preferably 150 to 250 mm.

[0080] According to a further aspect, the present invention relates to a mass transfer column comprising at least one structured filler element as described above.

[0081] Preferably, the mass transfer column comprises 1 to 10, more preferably 2 to 8, and most preferably 2 to 4 beds, wherein each bed comprises at least one structured packing element as described above. Preferably, a bed comprises 2 to 20, more preferably 4 to 15, and most preferably 6 to 10 structured packing elements. In order to achieve a very good gas distribution in the bed, two adjacent structured packing elements are rotated along the geometric axis of the column, which is generally parallel to the longitudinal direction. The angle of rotation is around 50 to 120°, more preferably 70° to 110°, and most preferably 80° to 100°.

[0082] Furthermore, it is preferable that the mass transfer column comprise a distributor above each of the structured packing element beds in order to allow it to at least essentially distribute the heavy phase homogeneously during the operation of the mass transfer column over the cross-section of the structured packing element bed.

[0083] According to a further preferred embodiment of the present invention, it is proposed that the mass transfer column comprises, below the bottom of each structured packing element bed, a collector, which allows the heavy phase that flows down to be collected. Petition 870220037181, dated 04 / 29 / 2022, page 48 / 94 43 / 71 surfaces of the layers of the structured filler elements during the operation of the mass transfer column.

[0084] Specific embodiments according to the present invention are subsequently described with reference to the accompanying drawings and by way of example. Fig. 1 is a schematic side view of a mass transfer column including several cross-channel filler elements structured according to an embodiment of the present invention. Fig. 2a is an exploded view of a portion of the blades of a cross-channel filler element structured according to an embodiment of the present invention. Fig. 2b is a schematic side view of the cross-channel filler element shown in Figure 2a. Fig. 2c shows two layers of the cross-channel filler element shown in Figure 2a. Fig. 3 is a fragmented view of a cross-channel filler element structured according to another embodiment of the present invention. Figs.Figures 4a-f are schematic views of different embodiments of the grid structure of the expanded metal sheets of the cross-channel filling element layers structured according to the present invention. Petition 870220037181, dated 04 / 29 / 2022, p. 49 / 94 44 / 71 Figures 5a-b are schematic views illustrating the determination of the average width of a separation element and the average hydraulic diameter of an opening. Figure 6 illustrates the determination of the minimum deformed portion of a structured cross-channel filler element made of corrugated layers. Figure 7a is a schematic top view of an expanded metal sheet of a layer of a structured cross-channel filler element according to another example of the present invention. Figures 7b-c are schematic views along planes A and B, respectively, of Figure 7a. Figure 8 is a schematic plan view of an expanded metal sheet of a layer of a structured cross-channel filler element shown in Figure 7. Figure 9 shows schematic cross-sectional views of a filler layer to illustrate the definitions of areas AP (Figure 9b), AS (Figure 9c), AM, VM, and aM (Figure 9d).Figure 10 shows the efficiency curves obtained in Example 1 and Comparative Example 1 for a distillation column inlet pressure of 960 mbar. Figure 11 shows the efficiency curves obtained in Example 1 and Comparative Example 1 for a distillation column inlet pressure. Petition 870220037181, dated 04 / 29 / 2022, pp. 50 / 94 45 / 71 of 100 mbar. Figure 12 shows the pressure drops obtained in example 1 and in comparative example 1 for an inlet pressure of the distillation column. 100 mbar. Figure 13 shows the efficiency curves obtained in example 2 for a distillation and in comparative examples 2 and 3 for a column inlet pressure of 960 mbar. Figure 14 shows the efficiency curves obtained in example 2 for a distillation and in comparative examples 2 and 3 for a column inlet pressure of 100 mbar. Figure 15 shows the pressure drops obtained in example 2 for a distillation and in comparative examples 2 and 3 for a column inlet pressure of 100 mbar. distillation at 100 mbar.

[0085] Figure 1 shows a schematic side view of a mass transfer column 10 and more specifically a distillation column 10 according to an embodiment of the present invention (the transparent interior of the figure is for illustrative purposes only). Also for illustrative purposes, the grid structure of the layers is not shown in Figure 1, but only in Figure 4. The distillation column 10 comprises a plurality of structured cross-channel packing elements 12, which are arranged in the form of two beds 14, 14'. Above each of the two beds 14, 14', a distributor 16, 16' is arranged to evenly distribute the liquid over the cross-section of the bed. Petition 870220037181, dated 04 / 29 / 2022, pp. 51 / 94 46 / 71 while leaving sufficient space for the vapor to ascend through it. Below each bed 14, 14', a containment device similar to grid 18 and a collector 20 are arranged, wherein the containment device similar to grid 18 holds bed 14 in its position and the collector 20 collects the liquid that flows from bed 14, while sufficient open space is left in the collector for the vapor to ascend.

[0086] During the operation of the distillation column 10, the gas ascends as the light phase from the bottom to the top, while the liquid as the heavy phase descends countercurrently from the top to the bottom of the distillation column 10. More specifically, the liquid is distributed essentially homogeneously by the distributor 16 over the cross-section of the bed 14 and flows along the surfaces of the layers of the structured cross-channel packing elements 12. Between the different layers of the structured cross-channel packing elements 12, open spaces are provided, which are filled with gas and provide a path for the gas to ascend, while being driven by a pressure gradient.By allowing the liquid to spread over the surface of the layers of the structured cross-channel packing elements 12, a large interface is created between the two phases so that efficient heat and mass transfer between the liquid and the gas is established at the interface. At the bottom of bed 14, the liquid is collected in collector 20 and guided through tube 22 below to distributor 16' above the second bed 14'.

[0087] Figures 2a to 2c show an element of Petition 870220037181, dated 04 / 29 / 2022, page 52 / 94 47 / 71 Structured cross-channel filler 12 of the so-called cross-channel corrugated sheet filler type. For illustrative purposes, the grid structure of the layers is not shown in Figure 2, but only in Figure 4. The structured cross-channel filler element 12 is assembled from a plurality of corrugated sheets 24, 24', which are parallel and in touch contact with each other. Each of the corrugated sheets 24, 24' is a grid as described above and as described in further detail below according to Figure 4. In the bottom right of Figure 2c, the grid structure of a portion of the corrugated sheet 24 is schematically indicated. As is understood from the descriptive report above, in fact all the corrugated sheets 24, 24' consist of such grids, which is not shown in Figures 2a to 2c only for illustrative reasons.In this embodiment, the corrugated sheets 24, 24' are made of expanded sheet material, that is, they are prepared by cutting and stretching a thin metal plate and then deforming the expanded sheet metal into corrugated sheets 24, 24'.

[0088] The corrugated metal sheets 24, 24' are fastened together by means of several rods (not shown) that penetrate the corrugated sheets 24, 24' perpendicular to the longitudinal section of the corrugated sheets 24, 24', wherein the rods are fastened to the first and last corrugated sheet by means of a washer and a nut or by bending the rods or by any other means (not shown). Each corrugated sheet 24, 24' comprises a plurality of alternately oriented peaks 26 and valleys 28, wherein the adjacent corrugated sheets 24, 24' Petition 870220037181, dated April 29, 2022, pp. 53-94 48 / 71 are oriented so that the corrugations 26, 28 of the adjacent corrugated sheets 24, 24' intersect in a cross-sectional manner with the corrugations 26, 28 of the corrugated sheets 24, 24' that extend obliquely in relation to the longitudinal direction, thus forming inclined channels 30 that continuously intersect each other. More specifically, the angle α between each of the peaks 26 and each of the valleys 28 in relation to the longitudinal direction V is 10° to 60°, preferably 20° to 50° and with maximum preference 25° to 47°, wherein the peaks 26 and valleys 28 of adjacent layers 32, 32' or 24, 24', respectively, are oriented in opposite directions. The 30 channels define a maximum distance D between adjacent corrugated sheets 24, 24', such as, for example, 20 mm. These 30 channels positively influence the gas and liquid phase flows within the structured cross-channel packing element 12 and facilitate mass transfer between the phases.That is, the gas phase and the liquid phase are brought into contact in the channels 30 of the structured cross-channel packing element 12, and mass transfer as well as heat transfer between the phases are thus facilitated. More specifically, the ascending gas comes into contact with the liquid, which is present on the surface of the corrugated sheets 24, 24' that define the channels 30, as it flows down through the mass transfer column. However, the light phase flows through the open space or channels 30, respectively, without a diversion flow through the openings 40 of the grid 38 of the layers 32, 32' of the structured cross-channel packing element 12. Petition 870220037181, dated 04 / 29 / 2022, pp. 54 / 94 49 / 71 This leads to particularly efficient mass and energy transfer between the light and heavy phases. Furthermore, the crossover mode of the 30 channels leads to an ideal distribution of the phases from left to right.

[0089] Figure 3 shows a fragmented view of a structured cross-channel filler element according to an alternative embodiment. The structured cross-channel filler element of Figure 3 is similar to that shown in Figures 2a to 2c, except that the corrugated sheets 24, 24' do not comprise linearly extending peaks and valleys, but that the peaks 26, 26' and the valleys of the corrugated sheets 24, 24' are flexed at the terminal portions 33, 33' in order to extend into the terminal portions 33, 33' of the corrugated sheets 24, 24' essentially in the vertical direction. In Figure 3, the solid lines depict the peaks 26 of the corrugations on the face of the corrugated sheet 24 shown to the observer, while the flashing lines 26' depict the peaks of the corrugations on the corresponding face of the corrugated sheet 24' immediately through an observer.By flexing the terminal portions or zones 33, 33', respectively, in order to extend the terminal portions 33, 33' of the corrugated sheets 24, 24' essentially in the vertical direction, the flow resistance of the terminal portions 33, 33' of the corrugated sheets 24, 24' is reduced compared to the flow resistance of the portions located between the terminal portions 33, 33' of the corrugated sheets 24, 24'. This leads to a reduced pressure loss of the structured cross-channel filling element. The terminal zones are the zones. Petition 870220037181, dated 04 / 29 / 2022, pp. 55 / 94 50 / 71 uppermost and lowermost 33, 33' of the corrugated sheets 24, 24' extending from the upper and lower edges of the corrugated sheets 24, 24' 30%, preferably 25% and more preferably 20% or less along the length of the corrugated sheets 24, 24', which is the direction along the longitudinal direction of the corrugated sheets 24, 24'. Each of the terminal zones 33, 33' may have peaks 26, 26' and valleys with a height different from that of the central zone, which is the zone of the layer between the two terminal zones 33, 33'. Such features as different height or bending may be present in both terminal zones 33, 33' of the corrugated sheets 24, 24' only.

[0090] Figures 4a to 4f are schematic views of different embodiments of the grid 38 forming the layers 32 of the structured cross-channel filler element 12 according to the present invention, which are, for example, suitable for use in a structured cross-channel filler element as shown in any of Figures 2a to 2c and 3. The grid 38 of layer 32 of the structured cross-channel filler element shown in Figure 4a comprises openings 40 with a quadrilateral cross-section, wherein the openings 40 are surrounded and separated from each other by separating elements 42. The separating elements 42 are thin strips with an average width b of, for example, 2 mm, wherein the separating elements 42 completely surround the openings 40. The two lateral lengths a1, a2 of the openings 40 are selected for the purpose of resulting in an opening 40 with a suitable hydraulic diameter d of, for example, 3 mm. Petition 870220037181, dated April 29, 2022, pp. 56-94 51 / 71 mm. As is known in the field, the hydraulic diameter d can be calculated according to the formula 4 A / P, where A is the cross-sectional area of ​​the opening 40 and P is the perimeter of the opening 40.

[0091] Grade 38 is simply produced from expanded sheet material, that is, by cutting and stretching a thin metal plate and then deforming the expanded sheet metal into the desired shape, such as for a corrugated sheet.

[0092] Grids 38 with a geometry different from the openings 40 and a geometry different from the separation elements 42 are shown in figures 4b to 4f. The openings 40 in the grids 38 in figures 2b and 2c are quadrilateral, while the openings 40 in the grid 38 in figure 2d are irregular and the openings 40 in the grids 38 in figures 2e and 2f are ellipsoids. They can also be lenticular in shape.

[0093] Subsequently, the determination of the width b of a separating element 42 and the hydraulic diameter d of an opening 40 of the grid 38 of a structured filler element according to the present invention is described with reference to Figures 5a and 5b. First, several plan views of one of the openings 40, 40' of the structured filler element 12 are made by taking three photographic images 44a, 44b, 44c of the opening 40 at different angles. The photographic images 44a, 44b, 44c of the plan views of the opening 40 are taken along the geometric axis normal to the plane defined by the adjacent edges 48, 48' of the separating element 42. The photographic image 44b that makes the opening 40 larger is then, Petition 870220037181, dated 04 / 29 / 2022, pp. 57 / 94 52 / 71 is adopted as the plan view of opening 40. A reference length z is used to determine lengths and size in the plan view. This is achieved by identifying or marking a certain distance z on the actual object in the vicinity of opening 40 and measuring its length. The ratio between the effective length z' of this distance in the plan view and the apparent distance z measured on the actual object is used to scale all other distances that are measured in the plan view.

[0094] To determine the width b of a separating element 42, the separating element 42 in the plan view is divided into individual sections 46 designated i=1, 2, 3 ... n each having a section length di. For each of the sections, the shortest distance bi between adjacent edges 48, 48' within the sections 46 is measured. The sum of the products di-bi divided by the sum of di multiplied with the coefficient z / z' yields the average width b of the separating element 42.

[0095] The hydraulic diameter of opening 40 is calculated using the formula 4 A / P, where A is the cross-sectional area of ​​opening 40 and P is the perimeter of the same opening 40. The cross-sectional area of ​​opening 40 is subdivided into a number j=1, 2, 3 ... m of sections 50, each having a simple shape. The area of ​​each section 50 is designated as Aj and is calculated using basic measurements and a basic geometric formula. The area A of opening 40 is obtained by summing all the areas Aj determined in opening 40.

[0096] The perimeter P of the 40' opening is determined by subdividing the perimeter P of the 40' opening into a number of k=1, 2, 3 ... K individual straight lines Pk that Petition 870220037181, dated 04 / 29 / 2022, pp. 58 / 94 53 / 71 best approximates the 40' opening and represents it by a closed polygon. By summing the lengths of these straight lines Pk, the perimeter P is obtained. Again, the lengths need to be translated into real lengths using the ratio z / z' as defined above.

[0097] Figure 6 illustrates the determination of the minimum deformed portion of a structured filler element made of corrugated sheets 24, 24' as layers 32, 32'. As presented above, in preferred embodiments of the present invention, the layers 32, 32' of the structured filler element 12 are made of expanded sheet metal, that is, by cutting and stretching a thin metal plate and then deforming the expanded sheet metal into, for example, corrugated sheets 24, 24'. After this processing, the openings and separation elements are similarly distorted and / or stretched around the peaks 26 and valleys 28 of the corrugations of the corrugated sheets 24, 24'.

[0098] However, the sloping flanks, which are defined by the approximately straight portion of the grid connecting the peaks 26 and the valleys 28, include openings and separation elements of almost unchanged size, due to the fact that the deformation is less pronounced there. Therefore, it is preferable according to the present invention to measure the dimensions only in the portion of the layer that is least deformed, which is designated as a “minimum deformed portion” of the corrugated sheets 24, 24'. This “minimum deformed portion” is defined as follows: The corrugated sheet has an average layer width W. This average layer width is determined by the amplitude of the larger part Petition 870220037181, dated 04 / 29 / 2022, page 59 / 94 54 / 71 of the peaks 26 and valleys 28 of layer 24. An upper and a lower plane, represented by two dashed lines in the figure below, are sketched to touch most of the peaks 26 and valleys 28 of the layer. The distance between these two dashed lines is called the average layer width W, and it is typically about half the maximum distance D. The value W is very often a constant value, but it can vary in the more general case, considering that the two planes do not need to be parallel and a fill element can contain layers of different widths. A third central plane 52 is defined, which is placed in such a way that, from each point on this central plane 52, the distance measured to the upper and lower planes is identical.The minimum deformed portion of the corrugated layer 24, which must be considered when determining the characteristic dimensions of the grid, is delimited by an upper and a lower limiting plane 54, 54', which are positioned at ±20%, more preferably ±30% and most preferably ±40% of W around the central plane 52. The openings and separation elements in this minimum deformed portion, that is, the openings and separation elements found between these two limiting planes 54, 54', are analyzed when determining parameters such as average hydraulic diameter of the orifices and average widths of the separation elements. According to an embodiment of the present patent application, for at least 90% of the orifices between the limiting planes, the following is valid: Each opening with its surrounding system of separation elements must have the same appearance and identical hydraulic diameter d. Petition 870220037181, dated 04 / 29 / 2022, pp. 60 / 94 55 / 71 surrounding separation elements must on average have the same width b. A structured infill layer that fulfills this requirement is considered a layer made of a uniform grid.

[0099] The above observations are also valid for layers of any different shape. They are not limited to corrugated layers.

[0100] Fig. 7a is a schematic top view of a single-layer expanded metal sheet of a structured cross-channel filler element according to another example of the present invention. The top view was made by taking a photographic image of the expanded metal sheet after flattening the expanded metal sheet by arranging the expanded metal sheet on a flat surface, placing a plate on top of the expanded metal sheet, and then pressing a plate on top of the expanded metal sheet downwards with sufficiently low pressure for the sole purpose of flattening the expanded metal sheet, without altering the geometry and dimensions of the separating elements and openings. The expanded metal sheet comprises openings 40, 40', 40'', 40''' which have an essentially trapezoidal shape, which are separated from each other by the separating elements 42.Consequently, the 40, 40', 40'' openings have a shorter characteristic length e2 and a longer characteristic length e1, wherein the shorter characteristic length e2 of a 40, 40', 40'' opening is the maximum dimension of the opening in the SD stretching direction of the expanded metal sheet and the longer characteristic length e1 of a 40, 40', 40'' opening. Petition 870220037181, dated 04 / 29 / 2022, pp. 61 / 94 56 / 71 is the maximum dimension of the opening in the direction perpendicular to the SD stretching direction of the expanded metal sheet. The SD stretching direction of the expanded metal sheet is the direction along which the sheet metal was stretched during the production of the expanded metal sheet. For example, the longest characteristic length e1 of openings 40, 40', 40'' is determined by measuring the distance between the outermost left point and the outermost right point of the edge of the 40'' opening in the direction perpendicular to the SD stretching direction of the expanded metal sheet, while the shortest characteristic length e2 of openings 40, 40', 40'' can be determined by measuring the distance between the uppermost point and the lowermost point of the edge of the 40 opening.In order to determine the characteristic lengths e1 and e2 with particular precision, their dimensions can be measured for at least 5 different openings 40, 40', 40'' and more preferably for at least 10 different openings 40, 40', 40'' and then by dividing the sum of the measured values ​​by five or ten, respectively.

[0101] The distance u1 between two openings 40, 40', 40''' that are perpendicular to the SD stretching direction of the expanded metal sheet, adjacent to each other and separated by a separating element 42, is determined by measuring the distance between the outermost point on one side of the edge of opening 40 and the outermost point on the same side of the edge of opening 40''' that are adjacent perpendicular to the SD stretching direction of the expanded metal sheet. In Figure 7a, the distance u1 is determined by measuring the distance Petition 870220037181, dated April 29, 2022, pp. 62-94 57 / 71 between the outermost point on the left side of the margin of opening 40 and the outermost point on the left side of the margin of opening 40'' that is adjacent in the direction perpendicular to the SD stretching direction of the expanded metal sheet. Furthermore, the distance u2 between two openings 40, 40' that are in the SD stretching direction of the expanded metal sheet adjacent to each other and separated by a separating element 42 is determined by measuring the distance between the outermost point on one side of the margin of opening 40 in the SD stretching direction of the expanded metal sheet and the outermost point on the same side of the margin of opening 40' that is adjacent in the SD stretching direction of the expanded metal sheet.In Figure 7a, the distance u2 is determined by measuring the distance between the uppermost point of the upper side of the margin of the 40° opening in the SD stretching direction of the expanded metal sheet and the uppermost point of the upper side of the margin of the adjacent 40° opening in the SD stretching direction of the expanded metal sheet. In order to determine the distance u1 particularly precisely, the distance u1 can be determined by measuring the distance between the outermost point of one side of the margin of a 40° opening in the direction perpendicular to the stretching direction of the expanded metal sheet and the outermost point of the same side of the margin of the fifth or tenth adjacent opening in the same direction of the expanded metal sheet, and by dividing the distance by four or nine, respectively. Similarly, the distance u2 can be determined by measuring the distance between the outermost point of one side of the margin of the 40° opening in the direction perpendicular to the stretching direction of the expanded metal sheet. Petition 870220037181, dated April 29, 2022, pp. 63-94 58 / 71 direction of stretching of the expanded metal sheet and the outermost point on the same side of the margin of the fifth or tenth opening adjacent to it, arranged in the direction of stretching of the expanded metal sheet and by dividing the distance by four or nine, respectively.

[0102] Again, the dimensions determined in the photographic image can be transformed into real lengths through the use of the z / z' coefficient as defined above.

[0103] From the aforementioned values, the area of ​​the openings 40, 40', 40'', 40''' and the perimeter length P can be obtained by the following equations if the openings are exactly rhomboid in shape: A = er eg / 2 P = 2^V(e12+ e22)

[0104] Additionally, the expanded metal sheet can be characterized by means of the stretching factor, which is defined as fs= u2 / 2b.

[0105] Figs. 7b and 7c are schematic views along planes A of Fig. 7a and B of Fig. 7b, respectively. As shown in these figures, the expanded metal sheet resulting from the production process, i.e., by cutting and stretching a metal plate, is no longer flat. This is the result of deformation, distortion, bending or folding of individual separating elements and a relative deformation of separating elements compared to others, for example, by tilting. Other features such as burrs may have resulted from a punching process and therefore contribute to the thickness. The resulting dimension of the expanded metal sheet is the thickness of the grid and may be identical to the thickness of the material. Petition 870220037181, dated April 29, 2022, pp. 64-94 59 / 71 layer (which is the case if the expanded sheet is flat, due to the fact that it was flattened by lamination) or even several times greater than the thickness of the layer material. Another embodiment of the present invention comprises laminating the expanded metal sheet for the purpose of providing an expanded metal sheet with a textured surface. More specifically, each of the periodic deformations, such as corrugations in particular, may have a flow surface including a patterned front including a plurality of protrusions and depressions that define continuously crossing capillary channels. The protrusions may be arranged in a contiguous relationship with adjacent protrusions and may have side walls that define channels between them and a patterned back identical to the front and that defines continuously crossing capillary channels, as described, for example, in document EP 0190435 B1.The protrusions can have a similar height range as the grid thickness g without any additional treatment. The grid thickness is typically on the order of magnitude of the width b of the separation element and should not be much greater than the width b. Therefore, the ratio of grid thickness g to average width b of the separation elements is in the maximum preferred range of 0.5 to 0.8. The grid thickness g is significantly less than the maximum distance D between two adjacent layers measured in the perpendicular plane of the longitudinal direction.

[0106] Fig. 8 is a schematic plan view of the expanded metal sheet of a layer of the structured cross-channel filler element shown in Fig. 7. Petition 870220037181, dated April 29, 2022, pp. 65-94 60 / 71 The plan view is obtained as described above.

[0107] Figure 9 shows schematic cross-sectional views of a fill layer in order to explain how to distinguish the various expressions for surface areas. Figure 9a shows a cross-section of a typical layer of the structured fill element 12. The material forming the separation elements 42 is represented by the black lines, while the white portions represent the openings 40, 40' in the layer 32, 32'. Each black portion is a cross-section through a separation element 42. The thickness of the black lines represents the thickness of layer material s. In Figures 8b to 8d, the areas in this layer are represented only by thinner lines that follow the contour of the layer. The physical area AP of a structured fill layer 32, 32' is shown in Figure 9b. It is the sum of the surface area measured on a selected side of all its separation elements 42.The edges (which typically have a width) of 48, 48' of the separation elements 42 do not contribute to this area. Preferably, AP only considers the surface that is physically present. Thus, the holes do not contribute to the value. The physical area AP of the structured infill element 12 is the sum of the physical area AP of all layers 32, 32' contained within it. Figure 9c defines the sheet area AS of an infill layer. It is obtained by adding both the area of ​​the openings in the layer and the physical area AP of the layer. The sheet area AS of the structured infill element 12 is obtained by summing the sheet area AS of all layers 32, 32' contained within it. The geometric area of ​​the layer. Petition 870220037181, dated 04 / 29 / 2022, pp. 66 / 94 61 / 71 As defined in Figure 9d, Am adds both sides of the layer if there are no 40, 40' openings or holes. In other words, the geometric area Amé is approximately obtained by multiplying the sheet area AS of the filler layers by two, due to the fact that both sides of the layers count towards the geometric area Am. The specific area aMé is defined as the geometric area Am of the structured filler element divided by the volume VM that the structured filler element occupies. Examples and Comparative Examples

[0108] The structured packing element 12 as shown in Figure 2 was tested in a distillation column. The commonly known standard procedure determines the pressure drop across the packing bed and the mass transfer efficiency using a binary mixture under full reflux conditions. EP patent Brazilian patent 995 958 B1 describes such a test with oxygen and argon at a pressure of 22 psia. US patent 6,874,769 B2 describes the testing of structured packing elements using a near-boiling binary mixture for ethylbenzene and orthoxylene. A binary mixture with similar ideal characteristics as the latter was used in the present invention, namely, monochlorobenzene (as a low boiler) and ethylbenzene (as a high boiler). Other standard near-boiling binary mixtures for evaluating the performance of distillation equipment are specified in U. Onken, W. Arlt: Recommended Test Mixtures for Distillation Columns, 2ndEd. 1990, The Institution of Chemical Engineers, Rugby, England. ISBN 0-85295-248-1.

[0109] The bottom of a distillation column was Petition 870220037181, dated 04 / 29 / 2022, pp. 67 / 94 Column 62 / 71 was filled with a sufficient quantity of the binary mixture to maintain a decent liquid level during column operation. The reboiler was started, a portion of the liquid mixture was continuously vaporized, and the vapor was lifted towards the column head. The vapor flow rate can be expressed in terms of the F-factor and is commonly determined indirectly through the energy balance in the reboiler or condenser at the column head. The condenser cooled the vapor so that it condensed back into liquid. Under preferred total reflux conditions, the entire quantity of liquid was sent back to the top of the packed bed, where it was distributed via a distributor. The distributor is typically a device comprising channels that receive the liquid and provide a uniformly spaced set of orifices through which the liquid can flow over the top packing of the structured packed bed.After flowing through the structured packed bed, the entire quantity of liquid was collected at the bottom of the column or at the bottom of the bed by means of a collector from where it was sent back to the bottom of the column. At the bottom, the liquid joined the liquid cluster from which it was vaporized again. A constant inlet pressure p was established by controlling the cooling work of the condenser in combination with a vacuum pump to remove excess inert gases.

[0110] After a certain time of operation at constant re-boiling work, a steady-state condition was reached. At this point, the pressure drop across the packed bed and the temperatures at relevant points. Petition 870220037181, dated 04 / 29 / 2022, pp. 68 / 94 63 / 71 readings were taken along the column, and top and bottom samples of the mixture were taken from the distributor at the top of the packed bed and from the collector at the bottom end of the packed bed or reservoir. Several operating points were measured by varying the heat (and cooling) work, which affects the F-factor (vapor flow) and the related liquid flow through the packed bed while the inlet pressure was kept unchanged. The same experiment was repeated for various inlet pressure settings.

[0111] The compositions of the samples were analyzed by means of calibrated gas chromatography. The top and bottom samples varied in the amount of low-boiler compound they contained. More low-boiler compound, that is, the compound with the lower boiling point, was found in the top sample than in the bottom sample. Once the binary compositions were known, the equation according to Fenske (MR Fenske, Ind. Engng. Chem. 24, p. 482, 1932) was applied to determine the number of Theoretical Stages per Meter (NTSM). Sometimes, the inverse value HETP was used, which is called the Equivalent Height of a Theoretical Plate. HETP = 1 / NTSM

[0112] A high NTSM (or a low HETP) means good mass transfer efficiency.

[0113] The F factor is defined by: F = Vg - Vpg where vg is the average velocity of the rising vapor, which can be determined from the mass flow rate through an energy balance in the reboiler. Petition 870220037181, dated 04 / 29 / 2022, pp. 69 / 94 64 / 71 The second variable, pG, is the vapor density at the relevant vapor / liquid equilibrium. Due to changes in pressure and temperature along the column, the vapor density and other physical properties of the fluids vary along the column, but relevant information is available for the binary mixture. Such variations require selecting an appropriate definition of the F-factor. This can be determined using properties valid under conditions at the top or bottom of the packed bed. Alternatively, an average value can be computed considering the variation throughout the bed. For comparison, either approach works, provided it is used for all tests.

[0114] A high F factor means a high mass flow rate in the column. The achievable F value is usually limited by the flooding that determines the capacity of a packing. Sometimes, the capacity factor c is used instead of F, which is obtained by dividing F by the square root of the density difference between the liquid and the vapor.

[0115] The pressure drop across the packed bed was another relevant result of the experiment. It was obtained as the difference between the pressure readings at the top and bottom of the packed bed after dividing by the bed height HB: ΔΡ / ΔΖ = ( ptop - pbottom ) / HB

[0116] Five types of structured filler elements were used in the examples and comparative examples, which were called P1-250, R-250, P2500, P3-500 and R-500. Although the filler elements Petition 870220037181, dated 04 / 29 / 2022, pp. 70 / 94 Structured fillers P1-250 and P2-500 were cross-channel corrugated sheet fillers made of layers according to the present invention; structured fillers P3-500, R-250, and R-500 were structured fillers not according to the present invention. More specifically, structured fillers R-250 and R-500 were known standard cross-channel corrugated sheet fillers with punched holes (leading to approximately 10% void fraction of the layers) and surface texturing as described in GB 1,569,828 and US 4,981,621, which are commercially distributed under the names Mellapak 250.Y and Mellapak 500.X. All structured fillers had a height of approximately 200 mm. The relevant parameters of the aforementioned structured fillers are summarized in Table 1. Table 1 Parameter P1-250 P2-500 P3-500 R-250 R-500 Corrugation angle α 45° 30° 30° 45° 30° Specific area aM (m2 / m3) 250 500 500 250 500 Hydraulic diameter d (mm) 2.46 2.46 1.54 Separation element width b (mm) 2 2 0.7 b / d = 81% 81% 45% Maximum distance D (mm) 22.5 13 13 22.5 13 D / b ​​= 11.3 6.5 18.6 Lateral length a1 (mm) 3.1 3.1 1.9 Longest distance u1 (mm) 10 10 5 u1 / b = 5 5 7.2 Petition 870220037181, dated 04 / 29 / 2022, pp. 71 / 94 66 / 71 Parameter P1-250 P2-500 P3-500 R-250 R-500 Shortest distance u2 (mm) 5 5 2.5 Longest diagonal e1 (mm) 5.5 5.5 3.4 Diagonal ratio β2 / β1 0.5 0.5 0.5 Grid thickness g (mm) 1.2 1.2 0.75 Layer void space fraction 30% 30% 47% 10% 10% Layer material thickness s (mm) 0.1 0.1 0.1 0.1 0.1 b / s = 20 20 7 this invention prior art prior art Example 1 and Comparative Example 1

[0117] The structured packing element according to the invention P1-250 and the reference structured packing element R-250 not according to the present invention were tested in a distillation column with a 1 m internal diameter under total reflux using monochlorobenzene and ethylbenzene at inlet pressures of p=960 mbar (near atmospheric) and ep=100 mbar. The packing beds were 4.3 m high. The efficiency curves obtained are shown in Figure 10 and Figure 11. In both cases, the structured packing element P1-250 according to the invention showed, compared to the reference structured packing element R-250, a higher mass transfer efficiency (higher NTSM) and also a slightly extended capacity, which is characterized by the F-factor, where the efficiency drops abruptly. It is noteworthy and surprising that the packing element Petition 870220037181, dated 04 / 29 / 2022, pp. 72 / 94 The 67 / 71 structured P1-250, with 30% less material usage (and 20% less physical area AP) than the reference structured R-250 filler element, achieves better mass transfer results.

[0118] The pressure drops of both structured packing elements are shown in Figure 12 and were very similar. Consequently, the P1-250 structured packing element according to the invention had a higher pressure drop at low F-factor, but the angular coefficient was lower, which gave the new packing its advantage of capacity and a lower pressure drop at high flow rates. Example 2 and Comparative Examples 2 to 3

[0119] The P2-500 structured packing element according to the invention and the reference R-500 structured packing element were tested in a column with an internal diameter of 0.25 m in full reflux using monochlorobenzene and ethylbenzene at inlet pressures of p=960 mbar and ep=100 mbar. Additionally, the P3-500 structured packing element was tested. Despite its similarity to P2-500, the P3-500 structured packing element was quite different insofar as the significant geometric parameters are defined for values ​​outside the numerical value ranges as specified in the present invention. More specifically, for the P3-500 structured packing element, the ratio of the distance u1 between adjacent openings measured perpendicular to the stretching direction and the average width of the separating elements u1 / b was 7.2 and the ratio of the average width of the separating elements to the thickness Petition 870220037181, dated April 29, 2022, pp. 73-94 The 68 / 71 layer material b / s ratio was 7, meaning both of these ratios were outside the numerical value ranges as specified in the present invention. The fill beds with P2-500 and P3-500 had a height of 2.4 m, and the fill bed with reference R-500 had a height of 2.6 m.

[0120] The efficiency curves obtained for these structured packing elements are shown in Figure 13 and Figure 14, and the pressure drops obtained for these structured packing elements in Figure 15.

[0121] The superior efficiency of the P2-500 structured packing element according to the present invention compared with the P3500 and R-500 structured packing elements (not according to the present invention) can be easily derived from Figures 13 and 14 for both an inlet pressure of 960 mbar and an inlet pressure of 100 mbar. The dispersion in mass transfer efficiency is particularly impressive at low inlet pressure. Interestingly, P3-500 has good capacity, but the efficiency is significantly lower than R-500. Both the P2-500 and P3-500 structured packing elements initially have a higher pressure drop than R-500, but as F increases, they gain an advantage, and the higher capacity of both can also be recognized in this graph. List of Numerical References and Abbreviations

[0122] Mass transfer column / distillation column Petition 870220037181, dated 04 / 29 / 2022, pp. 74 / 94 69 / 71 Structured cross-channel filler element 14' Structured filler element beds 16' Distributor Containment device Collector Pipe 24' Corrugated sheets Peak of a layer Peak of an adjacent layer Valley Channel / open space 32' Layers 33' Terminal portions of a corrugated sheet Pit Pit valley wall Grate 40', 40'', 40''' Grate opening Grate separation element 44b, 44c Photographic images of an aperture 48' taken from different angles. Section of a separating element. Edges of a section of a separating element. Section of an opening. Central plane. 54' Upper and lower limiting planes that determine the portion. Petition 870220037181, dated 04 / 29 / 2022, pp. 75 / 94 70 / 71 Minimum deformation of a structured filler element made of corrugated layers A Cross-sectional area of ​​an opening ai Lateral length of an opening a2 Second lateral length of an opening aM Specific area of ​​a filler or layer Aj Area of ​​a section of the opening AM Geometric area AP Physical area AS Blade area b Average width of separation elements bi Shortest distance between adjacent edges of a section of the separation element d Average hydraulic diameter of openings di Length of a section of the separation element ei Longest characteristic length of the opening θ2 Shortest characteristic length of the opening g Grid thickness s Layer material thickness D Maximum distance between at least Petition 870220037181, dated 04 / 29 / 2022, pp. 76 / 94 71 / 71 adjacent to at least two corrugated layers / sheets P Perimeter of an opening Pk Straight lines of perimeter sections of an opening SD Stretching direction of expanded metal sheet U1 Distance between two openings that are adjacent in the direction perpendicular to the stretching direction of the expanded metal sheet U2 Distance between two openings that are adjacent in the stretching direction of the expanded metal sheet V Longitudinal direction, which is usually the vertical direction W Average layer width of a corrugated layer or sheet z Reference length of the layer z' Reference length in plan view of a photographic image α Angle between each of the peaks and each of the valleys in relation to the longitudinal direction Petition 870220037181, dated April 29, 2022, pp. 77-94

Claims

1 / 8 CLAIMS 1. Structured cross-channel packing element (12) for a column (10) for mass transfer and / or heat exchange between a heavy and a light fluid phase, the structured cross-channel packing element (12) being characterized by comprising at least two adjacent layers (32, 32') made of expanded metal sheets, each comprising openings (40, 40', 40”, 40'”), which are surrounded and separated from each other by separation elements (42), wherein at least two of the at least two layers (32, 32') are arranged in the longitudinal direction (V) of the packing element (12) parallel and in touch contact with each other so that an open space (30) extending from one end to the opposite end of the at least two layers (32, 32') is provided between them so that at least one of the heavy and light fluid phases can flow through the same,wherein the ratio between the average width (b) of at least 50% of the separation elements (42) between adjacent openings (40, 40', 40”, 40'”) and the thickness of sheet material (s) is at least 15, wherein the ratio between the maximum distance (D) between at least two of the at least two layers (32, 32') measured in the plane that is perpendicular to the longitudinal direction (V) and the average width (b) of the separation elements (42) is at least 4, and wherein the ratio between the distance (u1) between the two openings (40, 40'”) that are in the direction perpendicular to the stretching direction of the expanded metal sheet adjacent to a separation element (42) and the average width (b) of that separation element (42) is for Petition 870220031799, dated 13 / 04 / 2022, p. 63 / 91 2 / 8 at least 50 % of all separation elements (42) 4 to 6,wherein the distance (u1) is measured by determining the distance between the outermost point of one side of the margin of an opening (40) in the direction perpendicular to the direction of stretching of the expanded metal sheet and the outermost point of the same side of the margin of an adjacent opening (40') in the same direction of the expanded metal sheet, wherein the longitudinal direction of the filler element (12) is as defined in the descriptive report, wherein the direction of stretching of the expanded metal sheet is the direction that is perpendicular to the longitudinal direction (V) of the structured cross-channel filler element (12), and wherein the average width (b) of a separating element (42) is determined by dividing the separating element (42) into individual sections i=1, 2, 3 ... n each having a section length di,wherein for each of the sections the shortest distance bi between adjacent margins within the sections is measured and the sum of the products di-bi is divided by the sum of di to produce the average width b of the separating element (42)., 2. Structured filling element (12), according to claim 1, characterized in that at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95% and most preferably all of the at least two layers (32, 32') are made of expanded metal sheets and comprise periodic deformations (26, 28, 34), wherein the layers (32, 32') are oriented so that the periodic deformations (26, 28, 34) of the layers Petition 870220031799, dated 13 / 04 / 2022, p.64 / 91 3 / 8 adjacent (32, 32') cross in a crosswise manner with the periodic deformations (26, 28, 34) of the layers (32, 32') that extend obliquely in relation to the longitudinal direction (V), where each layer (32, 32') comes into contact with each of the adjacent layers (32, 32') at points of intersection between the periodic deformations (26, 28, 34) of the layer (32, 32') and those of the adjacent layers (32, 32') and where the open space (30) between the at least two layers (32, 32') is defined by the periodic deformations (26, 28, 34).

3. Structured filling element (12), according to claim 1 or 2, characterized in that the ratio between the distance (u1) and the average width (b) of at least 75%, more preferably of at least 80%, even more preferably of at least 90%, even more preferably of at least 95% and most preferably of all separation elements (42) is 4 to 6, preferably 4.5 to 5.5 and most preferably 4.9 to 5.

1.

4. Structured filling element (12), according to any of the preceding claims, characterized in that for at least 50%, preferably for at least 75%, more preferably for at least 80%, even more preferably for at least 90%, even more preferably for at least 95% and most preferably for all openings (40, 40', 40”, 40”'), the distance (u1) is 5 to 20 mm, preferably 7.5 to 15 mm and more preferably 9 to 11 mm.

5. Structured filling element (12), in accordance with Petition 870220031799, dated 04 / 13 / 2022, page. 65 / 91 4 / 8 with any of the preceding claims, characterized in that the ratio between the distance (u2) between a first opening (40) and a second opening (40') adjacent to each other, which is in the direction of stretching, which is the direction perpendicular to the longitudinal direction (V) of the expanded metal sheet and the distance (u1) between the first opening (40) and a third opening (40”) adjacent to each other, which is in the direction perpendicular to the direction of stretching of the expanded metal sheet, is 0.4 to 0.7, wherein the distance (u2) is measured by determining the distance between the outermost point of one side of the margin of the first opening (40) in the direction of stretching of the expanded metal sheet and the outermost point of the same side of the margin of the second adjacent opening (40') which is adjacent in the direction of stretching of the expanded metal sheet,and wherein the distance (u1) is measured by determining the distance between the outermost point of one side of the margin of the first opening (40) in the direction perpendicular to the direction of stretching of the expanded metal sheet and the outermost point of the same side of the margin of the third adjacent opening (40”) in the same direction of the expanded metal sheet.

6. Structured filling element (12), according to any of the preceding claims, characterized in that for at least 50%, preferably for at least 75%, more preferably for at least 80%, even more preferably for at least 90%, even more preferably for at least 95% and most preferably for all openings (40, 40', 40”, 40”'), the ratio between distance (u2) and distance (u1) is 0.4 to 0.7, preferably 0.45 to 0.70 and more preferably 0.49 to 0.

55.

7. Structured filling element (12), according to any of the preceding claims, characterized in that for at least 50%, preferably for at least 75%, more preferably for at least 80%, even more preferably for at least 90%, even more preferably for at least 95% and most preferably for all openings (40, 40', 40”, 40'”), the distance (u2) is 2 to 8 mm, preferably 3 to 7 mm and more preferably 4 to 6 mm.

8. Structured filling element (12), according to any of the preceding claims, characterized in that the average width (b) of at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95% and most preferably of all separation elements (42) between adjacent openings (40, 40', 40”, 40'”) is 1.5 to 4 mm, preferably 1.6 to 3.5 mm and most preferably 1.8 to 3.0 mm.

9. Structured filling element (12), according to any of the preceding claims, characterized in that the ratio between the average width (b) of at least one separation element (42) between adjacent openings (40, 40', 40”, 40'”) and the thickness of the blade material(s) is at least 18.

10. Structured filling element (12), according to any of the preceding claims, characterized in that between at least 50%, preferably between at least 75%, more preferably between at least 80%, even more preferably between at least 90%, even more preferably between at least 95% and most preferably between all of the at least two layers (32, 32'), the ratio between the maximum distance (D) measured in the plane that is perpendicular to the longitudinal direction (V) and the average width (b) of the separation elements (42) is 4 to 15, preferably 5 to 13 and most preferably 8 to 12.

11. Structured filling element (12), according to any of the preceding claims, characterized in that for at least 50%, preferably for at least 75%, more preferably for at least 80%, even more preferably for at least 90% and even more preferably for at least 95% of the at least two layers (32, 32'), the ratio of the total area of ​​the openings (40, 40', 40”, 40”') divided by the blade area (AS) of the layer (32, 32') is between 20% and 38%, preferably between 25% and 35% and most preferably between 28% and 32%.

12. Structured filling element (12), according to any of the preceding claims, characterized in that at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, still more preferably at least 95% and with Petition 870220031799, dated 13 / 04 / 2022, page.68 / 91 7 / 8 most preferably all openings (40, 40', 40”, 40'”) have a shorter characteristic length (e2) of the openings (40, 40', 40”, 40'”) of 1 to 4 mm and preferably 2 to 3 mm and longer characteristic lengths (e1) of 2 to 8 mm, preferably 2.5 to 7 mm and most preferably 3 to 6 mm, wherein the shorter characteristic length (e2) of an opening (40, 40', 40”, 40'”) is the maximum dimension of the opening (40, 40', 40”, 40'”) in the direction of stretching of the expanded metal sheet and the longer characteristic length (e1) of an opening (40, 40', 40”, 40'”) is the maximum dimension of the opening (40, 40', 40”, 40'”) in the direction perpendicular to the direction of stretching of the expanded metal sheet.

13. Structured filling element (12), according to any of the preceding claims, characterized in that for at least 50%, preferably for at least 75%, more preferably for at least 80%, even more preferably for at least 90%, even more preferably for at least 95% and most preferably for all openings (40, 40', 40”, 40'”), the ratio between the shortest characteristic length (e2) of an opening (40, 40', 40”, 40”') and the longest characteristic length (e1) of the same opening (40, 40', 40”, 40'”) is 0.4 to 0.7, preferably 0.45 to 0.6 mm and most preferably 0.49 to 0.55 mm.

14. Mass transfer column characterized by comprising at least one structured filling element (12) as defined in any of the preceding claims. Petition 870220031799, dated 13 / 04 / 2022, pp. 69 / 91 8 / 8 15. Use of a structured filling element (12) as defined in any of claims 1 to 13 characterized by being for mass transfer and / or heat exchange. Petition 870220031799, dated 13 / 04 / 2022, pp. 70 / 91

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