Structured packing elements, structured packing layers and absorption columns

Abstract

This invention provides a structured packing element, a structured packing layer, and an absorption tower, including a corrugated plate. The corrugated plate includes alternating crests and troughs, multiple crest through-holes evenly spaced along the crests, and multiple trough through-holes evenly spaced along the troughs. The crest and trough through-holes are staggered along a predetermined direction on the corrugated plate. These through-holes periodically block the liquid film flowing along the surface of the corrugated plate, causing the liquid film to redistribute on the surface of the corrugated plate to increase the wetting area. By controlling the arrangement of the crest and trough through-holes, this invention ensures that as the liquid film flows along the surface of the corrugated plate, it is periodically blocked by each through-hole, forcing it to redistribute to the surrounding area, significantly increasing the effective wetting area and improving the mass transfer efficiency of the structured packing.

Description

Technical Field

[0001] This invention relates to the field of packing technology, and in particular to a structured packing element, a structured packing layer, and an absorption tower. Background Technology

[0002] Carbon dioxide capture, utilization, and storage (CCUS), as a cutting-edge technology with the potential for large-scale greenhouse gas emission reduction, provides crucial support for the low-carbon utilization of fossil energy and is one of the core technological pathways for addressing climate change and controlling greenhouse gas emissions. Among various CO2 capture processes, chemical absorption has become the mainstream choice for industrial applications due to its high technological maturity and reliable capture efficiency. The absorption tower is the core equipment of the CO2 capture system, and its interior typically uses structured packing as the gas-liquid contact element, with corrugated metal structured packing being the most widely used. This type of packing has advantages such as high porosity, large nominal specific surface area, and low pressure drop, which can effectively enhance gas-liquid mass transfer and improve the CO2 absorption rate. However, current design and optimization of structured packings remain significantly insufficient. Key geometric parameters of structured packings, including aperture spacing, corrugation angle, pleat angle, and porosity, are often selected in engineering practice based on recommended values ​​from design manuals or experience with similar products. This leads to common technical problems in gas-liquid mass transfer processes, such as insufficient interfacial area, uneven liquid wetting, and unreasonable liquid holdup, severely restricting the improvement of mass transfer efficiency. Consequently, the actual performance of structured packings falls far short of their theoretical potential. Therefore, effectively improving the mass transfer efficiency of structured packings has become a critical technical challenge that urgently needs to be addressed. Summary of the Invention

[0003] In order to overcome the above-mentioned defects of the prior art, the technical problem to be solved by the embodiments of the present invention is to provide a structured packing element, a structured packing layer and an absorption tower, which can effectively improve the mass transfer efficiency of structured packing.

[0004] The above-mentioned objective of the present invention can be achieved by the following technical solution: the present invention provides a structured packing element, comprising: The corrugated plate includes alternating crests and troughs, a plurality of crest through holes equally spaced along the crests, and a plurality of trough through holes equally spaced along the troughs. The crest through holes and trough through holes are staggered on the corrugated plate in a predetermined direction. The crest through holes and trough through holes are used to periodically block the liquid film flowing along the surface of the corrugated plate, so as to redistribute the liquid film on the surface of the corrugated plate to increase the wetting area.

[0005] In a preferred embodiment of the present invention, the angle between the preset direction and the corrugation tilt direction of the corrugated plate is α, where 70°≤α≤110°.

[0006] In a preferred embodiment of the present invention, the preset direction is perpendicular to the corrugation tilt angle direction of the corrugated plate, and α=90°.

[0007] In a preferred embodiment of the present invention, the corrugated plate includes a corrugated surface located between adjacent crests and troughs, and a plurality of corrugated surface through holes equally spaced along the corrugated surface. Along the preset direction, adjacent crest through holes and trough through holes form a set of through hole units. Along the corrugation angle direction of the corrugated plate, the corrugated surface within the range between two adjacent sets of through hole units forms a corrugated surface unit. Each corrugated surface unit is provided with one corrugated surface through hole. The distance between the corrugated surface through hole and the center of the corrugated surface unit does not exceed a first preset value. The corrugated surface through hole is used to form a liquid redistribution node between the crest through hole and the trough through hole, so that the liquid film flowing along the corrugated surface is intercepted by the corrugated surface through hole when it flows through the corrugated surface through hole and generates lateral spreading to cover the unwetted area in the middle of the corrugated surface.

[0008] In a preferred embodiment of the present invention, the distance between the midpoint of the line connecting the wavefront through-hole and the adjacent wave crest through-hole and wave trough through-hole does not exceed 3 mm.

[0009] In a preferred embodiment of the present invention, the diameter of the crest through-hole is 3mm-5mm; and / or, the diameter of the trough through-hole is 3mm-5mm; and / or, the diameter of the wave surface through-hole is 3mm-5mm.

[0010] In a preferred embodiment of the present invention, the crest through-hole, the trough through-hole, and the wave surface through-hole have the same diameter.

[0011] In a preferred embodiment of the present invention, the diameters of the crest through-hole, the trough through-hole, and the wave surface through-hole are all 4 mm.

[0012] In a preferred embodiment of the present invention, the opening spacing of the crest through hole, the trough through hole and the wave surface through hole is 9mm-12mm.

[0013] In a preferred embodiment of the present invention, the opening spacing of the crest through hole, the trough through hole and the wave surface through hole is 10 mm.

[0014] In a preferred embodiment of the present invention, the vertical distance between adjacent peaks and troughs is 7mm-9mm.

[0015] In a preferred embodiment of the present invention, the vertical distance between adjacent peaks and troughs is 8 mm.

[0016] In a preferred embodiment of the present invention, the corrugation angle of the corrugated plate is 30°-60°.

[0017] In a preferred embodiment of the present invention, the corrugation angle of the corrugated plate is 30° or 45°.

[0018] In a preferred embodiment of the present invention, the folding angle of the corrugated plate is 70°-110°.

[0019] In a preferred embodiment of the present invention, the fold angle of the corrugated plate is 90°.

[0020] In a preferred embodiment of the present invention, the perforation rate of the corrugated plate is 10%-15%.

[0021] In a preferred embodiment of the present invention, the shape of the corrugated plate is one of the following: rectangle, parallelogram, isosceles trapezoid, circle, ellipse, and triangle.

[0022] The present invention also provides a structured packing layer, comprising a plurality of the aforementioned structured packing elements stacked together.

[0023] In a preferred embodiment of the present invention, the nominal specific surface area of ​​the structured filler layer is one of 250 m² / m³, 350 m² / m³, 500 m² / m³, or 750 m² / m³.

[0024] The present invention also provides an absorption tower, including a tower body and the aforementioned structured packing layer disposed within the tower body.

[0025] The technical solution of the present invention has the following significant beneficial effects: The structured packing element of this invention, by equally spaced crest holes on the crests and equally spaced trough holes on the troughs, and by arranging the crest and trough holes alternately in a predetermined direction, ensures that as the liquid film flows along the surface of the corrugated plate, it is periodically blocked by each hole, preventing it from continuing to flow down the original groove and forcing it to redistribute to the surrounding area. Because the holes are equally spaced along the corrugation extension direction, the liquid film experiences uniform and continuous periodic blocking along its flow path. This repeatedly cuts and guides the liquid, which was originally concentrated in the grooves, to the unwetted areas on both sides of the corrugated surface, fundamentally and effectively suppressing liquid film channeling and significantly increasing the effective wetting area.

[0026] Furthermore, this invention utilizes the periodic blocking and redistribution of the liquid film through crest and trough through-holes, forcibly and repeatedly spreading the liquid film on the surface of the corrugated plate. The liquid distribution changes from the "linear" or "narrow band" distribution concentrated in the grooves of traditional packings to a uniform "area" distribution covering the crests, surfaces, and troughs, effectively improving the uniformity of liquid distribution on the corrugated plate surface. Simultaneously, because the liquid film is evenly spread rather than concentrated in localized areas, the liquid holdup tends to be balanced, avoiding both increased pressure drop due to excessively high local liquid holdup and insufficient mass transfer due to excessively low local liquid holdup.

[0027] Furthermore, this invention, through the periodic blocking effect of the wave crest and trough through-holes on the liquid film, not only achieves spatial redistribution of the liquid film, but also causes the surface layer of the liquid film to break and rebuild as it flows through each through-hole. That is, the original aged surface layer in contact with the gas is cut and destroyed by the through-hole opening, and the fresh liquid below is exposed to the surface to form a new gas-liquid interface. This achieves passive surface renewal of the liquid film, keeps the mass transfer interface between the gas and liquid phases highly active, and thus effectively enhances the gas-liquid mass transfer process and improves the mass transfer efficiency of structured packing. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of the invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely illustrative to aid in understanding the invention and do not specifically limit the shapes and proportions of the components. Those skilled in the art, guided by the teachings of this invention, can select various possible shapes and proportions to implement the invention according to specific circumstances.

[0030] Figure 1 This is a top view schematic diagram of an embodiment of the structured packing element described in this invention; Figure 2 for Figure 1 A partial side view of a structured packing element is shown. Figure 3 This is a graph showing the effect of the corrugation tilt angle on the interface area ratio obtained by CFD simulation of this invention. Figure 4 This is a graph showing the effect of the corrugation angle on the wetting rate obtained by CFD simulation according to the present invention. Figure 5This is a graph showing the effect of the corrugation angle on the liquid holdup obtained by CFD simulation in this invention. Figure 6 This is a graph showing the effect of the aperture spacing on the interface area ratio obtained by CFD simulation of this invention. Figure 7 This is a graph showing the effect of the aperture spacing on the wetting rate obtained by CFD simulation according to the present invention. Figure 8 This is a graph showing the effect of the orifice spacing on the liquid holdup obtained by CFD simulation of this invention. Figure 9 This is a graph showing the effect of the wrinkle angle on the interface area ratio obtained by CFD simulation of this invention. Figure 10 This is a graph showing the effect of the fold angle on the wetting rate obtained by CFD simulation in this invention. Figure 11 This is a graph showing the effect of the fold angle on the liquid holding rate obtained by CFD simulation in this invention. Figure 12 This is a top view schematic diagram of the distribution of the wetting area on the surface of the structured packing element described in this invention; Figure 13 This is a top view schematic diagram of a conventional structured packing element; Figure 14 This is a top view schematic diagram of the surface wetting area distribution of a conventional structured packing element.

[0031] The reference numerals in the above figures are as follows: 100. Corrugated plate body; 110. Corrugated peak; 111. Corrugated peak through-hole; 120. Valley; 121. Valley through hole; 130. Wave-shaped surface; 131. Wave-shaped through hole. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Implementation Method 1

[0034] Please refer to the following: Figure 1 and Figure 2As shown, an embodiment of the present invention provides a structured packing element, which includes a corrugated plate 100. The corrugated plate 100 includes alternating crests 110 and troughs 120, a plurality of crest through holes 111 equally spaced along the crests 110, and a plurality of trough through holes 121 equally spaced along the troughs 120. The crest through holes 111 and trough through holes 121 are staggered on the corrugated plate 100 along a predetermined direction. The crest through holes 111 and trough through holes 121 are used to periodically block the liquid film flowing along the surface of the corrugated plate 100, so that the liquid film is redistributed on the surface of the corrugated plate 100 to increase the wetting area.

[0035] In traditional structured packings, when liquid flows along the grooves on the surface of the corrugated plate 100, it tends to form continuously developing channels, resulting in a large area of ​​the corrugated surface 130 not being effectively covered by the liquid film, and the effective wetting area is much lower than the nominal specific surface area of ​​the packing.

[0036] This invention creates equally spaced crest through-holes 111 on the crests 110 and equally spaced trough through-holes 121 on the troughs 120, with the crest through-holes 111 and trough through-holes 121 arranged alternately in a predetermined direction. This causes the liquid film to be periodically blocked by each through-hole as it flows along the surface of the corrugated plate 100, preventing it from continuing to flow down the original groove and forcing it to redistribute to the surrounding area. Because the through-holes are equally spaced along the corrugation extension direction, the liquid film is subjected to uniform and continuous periodic blocking along the flow path. This causes the liquid originally concentrated in the groove to be repeatedly cut and guided to the unwetted areas on both sides of the corrugated surface 130, fundamentally and effectively suppressing liquid film channeling and significantly increasing the effective wetting area.

[0037] Traditional structured packings suffer from uneven liquid distribution, which can lead to excessively high or low local liquid holdup: the pressure drop in high liquid holdup zones increases sharply, and may even induce flooding risk; while in low liquid holdup zones, the mass transfer driving force is insufficient and the packing surface remains idle.

[0038] This invention utilizes the periodic blocking and redistribution of the liquid film through the crest through-holes 111 and trough through-holes 121, forcibly and repeatedly spreading the liquid film on the surface of the corrugated plate 100. The liquid distribution changes from the "linear" or "narrow band" distribution concentrated in the grooves of traditional packings to a "planar" uniform distribution covering the crests 110, wave surfaces 130, and troughs 120, effectively improving the uniformity of liquid distribution on the surface of the corrugated plate 100. Simultaneously, because the liquid film is evenly spread rather than concentrated in localized areas, the liquid holdup tends to be balanced, avoiding both increased pressure drop due to excessively high local liquid holdup and insufficient mass transfer due to excessively low local liquid holdup.

[0039] During gas-liquid mass transfer, the CO2 concentration on the surface of the liquid film increases rapidly after contact with the gas, forming an aging interface layer with high mass transfer resistance. If this interface layer cannot be renewed in time, the mass transfer driving force will continue to decay.

[0040] This invention utilizes the periodic blocking effect of the wave crest through-hole 111 and wave trough through-hole 121 on the liquid film. This not only achieves spatial redistribution of the liquid film but also causes the surface layer of the liquid film to break and rebuild as it flows through each through-hole. That is, the original aged surface layer in contact with the gas is cut and destroyed by the through-hole opening, and the fresh liquid underneath is exposed to the surface to form a new gas-liquid interface. This achieves passive surface renewal of the liquid film, keeping the mass transfer interface between the gas and liquid phases highly active. This effectively enhances the gas-liquid mass transfer process and improves the mass transfer efficiency of structured packing.

[0041] In an embodiment of the present invention, the angle between the preset direction and the corrugation angle direction of the corrugated plate 100 is α, where 70°≤α≤110°. By limiting α to 70°≤α≤110°, the arrangement direction of the crest holes 111 and trough holes 121 forms a nearly perpendicular intersection angle with the corrugation angle direction. At this angle, the crest holes 111 and trough holes 121 have sufficient projection components in the direction perpendicular to the corrugation angle, so that when the liquid film is redistributed after flowing through the crest holes 111, it can smoothly enter the adjacent trough holes 121 under the drive of gravity, forming a flow path through the corrugated plate 100. This forces the liquid film to spread laterally to the unwetted areas on both sides perpendicular to the corrugation angle direction, thereby effectively suppressing channeling, increasing the effective wetting area, and improving mass transfer efficiency.

[0042] If α is less than 70° or greater than 110°, the arrangement direction of the crest through-hole 111 and the trough through-hole 121 tends to be parallel to the direction of the corrugation angle. The projection components of the crest through-hole 111 and the trough through-hole 121 in the direction perpendicular to the corrugation angle are insufficient, the flow path is partially blocked, the liquid film is difficult to be effectively cut laterally, and the periodic blocking effect is weakened.

[0043] Designers can adjust the specific value of α according to usage needs, and no specific restrictions are imposed here. Preferably, the preset direction is perpendicular to the corrugation angle direction of the corrugated plate 100, and α=90°.

[0044] When α = 90°, the line connecting the crest through-hole 111 and the trough through-hole 121 is perpendicular to the corrugation angle. At this angle, the blocking effect is strongest and the spreading is most uniform. After passing through the through-holes, the liquid film can reach the surface of the adjacent corrugated plate 100 via the shortest path, resulting in the smoothest inter-plate flow and the best surface renewal effect. This forms a stable and efficient periodic blocking and surface renewal mechanism, which helps to maximize mass transfer efficiency.

[0045] In embodiments of the present invention, such as Figure 1 In the embodiment shown, the corrugated plate 100 includes a corrugated surface 130 located between adjacent crests 110 and troughs 120, and a plurality of corrugated surface through holes 131 equally spaced along the corrugated surface 130. Along the preset direction, adjacent crest through holes and trough through holes form a group of through hole units. Along the corrugation tilt direction of the corrugated plate, the corrugated surface within the range of two adjacent groups of through hole units forms a corrugated surface unit. Each corrugated surface unit is provided with one corrugated surface through hole. The distance between the corrugated surface through hole and the center of the corrugated surface unit does not exceed a first preset value. The corrugated surface through holes 131 are used to form liquid redistribution nodes between crest through holes 111 and trough through holes 121, so that the liquid film flowing along the corrugated surface 130 is intercepted by the corrugated surface through holes 131 when it flows through the corrugated surface through holes 131 and generates lateral spreading to cover the unwetted area in the middle of the corrugated surface 130.

[0046] By further opening wavefront through-holes 131 in the middle of the wavefront 130 and arranging each wavefront through-hole 131 within each wavefront unit, the liquid film flowing along the wavefront 130 is intercepted when passing through the wavefront through-holes 131 and forced to spread laterally to cover the unwetted area in the middle of the wavefront 130. The wavefront through-holes 131, acting as liquid redistribution nodes, work in conjunction with the crest through-holes 111 and trough through-holes 121 to ensure more complete liquid film coverage in the crest 110, wavefront 130, and trough 120 regions. This effectively solves the technical problem of dry zones easily forming in the middle region of the wavefront 130 in traditional packing materials, further increasing the effective gas-liquid contact area and improving the mass transfer efficiency of structured packing materials.

[0047] Designers can adjust the specific value of the first preset value according to usage needs, and no specific restrictions are imposed here. Preferably, the first preset value is 3mm. That is, the corrugated through hole 131 is located within a circular area with a radius of 3mm centered on the center of the corrugated unit.

[0048] In one feasible embodiment, the distance between the wavefront through-hole 131 and the center of the wavefront unit is 0, that is, the wavefront through-hole 131 is located at the center of the wavefront unit.

[0049] In another feasible embodiment, the distance between the wavefront through-hole 131 and the center of the wavefront unit is 1 mm. That is, the wavefront through-hole 131 is located on a circle with a radius of 1 mm centered at the center of the wavefront unit.

[0050] In another feasible embodiment, the distance between the wavefront through-hole 131 and the center of the wavefront unit is 3 mm. That is, the wavefront through-hole 131 is located on a circle with a radius of 3 mm centered at the center of the wavefront unit.

[0051] By controlling the distance between the wavefront through-hole 131 and the center of the wavefront unit, it is ensured that the wavefront through-hole 131 can trap the liquid film in the middle of the wavefront 130, so that the liquid film is effectively blocked and evenly spread laterally to both sides when it flows through the wavefront through-hole 131, thereby maximizing the coverage of the unwetted area in the middle of the wavefront 130.

[0052] If the first preset value exceeds 3mm, the wave surface through-hole 131 may be too close to the side of the wave crest 110 or wave trough 120, causing the liquid film to deviate from the center at the interception position in the middle of the wave surface 130, significantly reducing the symmetry and coverage of the lateral spread, and failing to effectively cover the unwetted area in the middle of the wave surface 130.

[0053] In embodiments of the present invention, designers may adjust the aperture sizes of the crest through-hole 111, trough through-hole 121, and wave surface through-hole 131 according to usage needs, without making specific limitations.

[0054] Preferred, such as Figure 1 In the illustrated embodiment, the diameter of the crest through-hole 111 is 3mm-5mm; and / or, the diameter of the trough through-hole 121 is 3mm-5mm; and / or, the diameter of the wave surface through-hole 131 is 3mm-5mm.

[0055] If the aperture is less than 3mm, the surface tension of the liquid film is significantly enhanced, making it difficult for the liquid film to pass through the hole smoothly. This can easily lead to blockage or accumulation of the liquid film at the orifice, which in turn disrupts the uniformity of the liquid film distribution.

[0056] If the aperture is greater than 5 mm, the blocking effect of the through hole on the liquid film is weakened. When the aperture is too large, the liquid film can partially pass through the through hole without being fully cut, and the periodic blocking effect decreases. At the same time, the large through hole area leads to the loss of effective mass transfer area.

[0057] Therefore, by limiting the aperture of the crest through-hole 111, trough through-hole 121 and wave surface through-hole 131 to 3mm-5mm, the present invention can ensure that the liquid film is effectively blocked and redistributed while avoiding liquid film blockage and excessive loss of effective area, so as to achieve the optimal balance between the blocking efficiency of the through-hole and the structural strength of the packing.

[0058] More preferably, the through-holes at the crests 111, troughs 121, and corrugated surfaces 131 have the same diameter. By setting the diameters of the through-holes at the crests 111, troughs 121, and corrugated surfaces 131 to the same size, it is convenient to use punching dies of the same specification for processing, simplifying the manufacturing process, reducing manufacturing costs, and ensuring the consistency of the liquid film blocking effect of the through-holes in each region, avoiding uneven liquid film distribution caused by differences in hole diameter.

[0059] In one specific embodiment, the diameters of the crest through-hole 111, trough through-hole 121, and wavefront through-hole 131 are all 4 mm. By setting the through-hole diameter to 4 mm, a value verified by CFD simulation within the range of 3 mm to 5 mm is found to be optimal. This ensures that the liquid film can pass smoothly through the through-hole without clogging, while also ensuring that the through-hole has sufficient blocking and redistribution effect on the liquid film. Simultaneously, it avoids excessively large opening areas that would occupy the effective mass transfer area of ​​the packing.

[0060] In embodiments of the present invention, such as Figure 1 In the embodiments shown, the opening spacing L1 of the crest through-hole 111 is 9mm-12mm; and / or, the opening spacing L2 of the trough through-hole 121 is 9mm-12mm; and / or, the opening spacing L3 of the wave surface through-hole 131 is 9mm-12mm.

[0061] Preferred, such as Figure 1 In the embodiment shown, the opening spacing of the crest through-hole 111, the trough through-hole 121, and the wave surface through-hole 131 is 9mm-12mm.

[0062] If the spacing between openings is less than 9mm, the number of through holes is too large, and the opening ratio is too high, resulting in excessive loss of the effective mass transfer area of ​​the packing. Furthermore, the liquid film redistribution distance between adjacent through holes is too short, and the liquid film is blocked again by the next through hole before it can fully spread, which reduces the redistribution efficiency.

[0063] If the spacing between openings is greater than 12mm, the interval between adjacent openings is too long. The channel formed by the liquid film after flowing through one opening has already developed sufficiently before reaching the next opening, thus weakening the effect of periodic blocking.

[0064] Therefore, by limiting the aperture spacing to 9mm-12mm, the present invention enables the liquid film to be blocked again by the next aperture after being blocked and redistributed by one aperture, before a stable channel flow is formed, thereby achieving the best periodic blocking effect.

[0065] Designers can adjust the specific size of the opening spacing according to the usage requirements, and no specific restrictions are imposed here. Preferably, the opening spacing of the crest through hole 111, the trough through hole 121, and the corrugated surface through hole 131 is 10mm.

[0066] By setting the aperture spacing to 10mm, the interfacial area ratio and wetting rate corresponding to this aperture spacing are optimal in the simulation results, which can maximize the mass transfer efficiency while ensuring a high interfacial area ratio and a high wetting rate.

[0067] In embodiments of the present invention, such as Figure 2In the embodiment shown, the vertical distance H between adjacent crests 110 and troughs 120 is 7mm-9mm. That is, the wave height of the corrugated plate 100 of the present invention is 7mm-9mm.

[0068] If the wave height is less than 7 mm, the ripples are too gentle, the liquid film has insufficient driving force to flow on the wave surface 130, the liquid film velocity is slow, the liquid holdup is too high, and it is easy to cause an increase in pressure drop.

[0069] If the wave height is greater than 9 mm, the ripples are too steep, the liquid film velocity is too fast, the residence time of the liquid film on the wave surface 130 is shortened, the mass transfer contact time is insufficient, and the turning resistance of the liquid film at the wave crest 110 and wave trough 120 increases, making it easy for liquid to accumulate at the turning point.

[0070] Therefore, by limiting the wave height to 7mm-9mm, the present invention can maintain a suitable flow rate and residence time of the liquid film on the wave surface 130, taking into account both mass transfer efficiency and operating pressure drop.

[0071] Designers can adjust the vertical distance between adjacent crests 110 and troughs 120 according to usage requirements, without specific limitations. Preferably, the vertical distance H between adjacent crests 110 and troughs 120 is 8mm.

[0072] By setting the vertical distance H between the peak 110 and the trough 120 to 8 mm, the wave height is verified to be the optimal value in the range of 7 mm to 9 mm through simulation. This achieves the best balance between the liquid film flow rate and the liquid holdup, allowing the liquid film to have sufficient mass transfer contact time while maintaining a low pressure drop.

[0073] In embodiments of the present invention, such as Figure 1 In the embodiment shown, the corrugation angle α of the corrugated plate 100 is 30°-60°.

[0074] If the ripple angle α is less than 30°, the ripples are too gentle, the driving force for the liquid film to flow along the ripple direction is insufficient, the liquid film flow rate is slow, the liquid holdup is too high, and the pressure drop increases significantly.

[0075] If the ripple angle α is greater than 60°, the ripples are too steep, the liquid film flows too fast under the action of gravity, the gas-liquid contact time is shortened, the mass transfer is insufficient, and the flow stability of the liquid film at the turning points of the 110° crest and 120° trough becomes worse, making it easy for the liquid film to rupture and splash.

[0076] Therefore, by limiting the corrugation angle α to 30°-60°, this invention can achieve a suitable liquid holdup and sufficient mass transfer contact time while ensuring stable liquid film flow, thus balancing mass transfer efficiency and operating pressure drop.

[0077] Designers can adjust the specific size of the corrugation angle according to the usage requirements, and no specific restrictions are imposed here.

[0078] In one feasible embodiment, the corrugation angle α of the corrugated plate 100 is 30°. That is, the corrugation angle type is an X-shaped small angle, which has a smaller angle, smoother liquid film flow, and more significant improvement in wetting uniformity.

[0079] In another feasible embodiment, the corrugation angle α of the corrugated plate 100 is 45°. That is, the corrugation angle type is Y-shaped, which has a larger angle, faster liquid film flow rate, and more significant surface renewal effect. By setting the corrugation angle to 45°, simulation verification shows that at this angle, the liquid holdup is moderate, the liquid film flow is stable, and the mass transfer efficiency and pressure drop achieve the best balance.

[0080] In embodiments of the present invention, such as Figure 2 In the illustrated embodiment, the corrugation angle b of the corrugated plate 100 is 70°-110°. If the corrugation angle b is less than 70° or greater than 110°, the interfacial area ratio decreases significantly, making it difficult to obtain sufficient gas-liquid contact area. Therefore, by setting the corrugation angle b to 70°-110°, the present invention can maintain the interfacial area ratio at a high level, providing sufficient phase interface area for gas-liquid mass transfer.

[0081] Designers can adjust the specific size of the fold angle b of the corrugated plate 100 according to usage requirements, without specific limitations. Preferably, the fold angle b of the corrugated plate 100 is 90°. By setting the fold angle to 90°, simulation verification shows that the interface area ratio reaches its maximum value and the overall mass transfer effect is optimal at this angle.

[0082] In embodiments of the present invention, the perforation ratio of the corrugated plate 100 is 10%-15%. By limiting the perforation ratio to 10%-15%, this range is determined by the combination of the aforementioned pore diameter of 3mm-5mm and pore spacing of 9mm-12mm. Within this perforation ratio range, the through-holes provide sufficient channels for blocking and redistribution of the liquid film without causing excessive loss of the effective mass transfer area of ​​the packing due to excessive perforations, thus ensuring that the mechanical strength of the packing meets the requirements for stacking and load-bearing capacity.

[0083] In embodiments of the present invention, designers may adjust the specific shape of the corrugated plate 100 according to usage needs, and no specific limitations are imposed here. For example, the shape of the corrugated plate 100 may be one of a rectangle, parallelogram, isosceles trapezoid, circle, ellipse, or triangle.

[0084] Of course, in other feasible embodiments, the specific shape of the corrugated plate 100 can also be adjusted according to the specific needs of use, so as to flexibly select and stack according to the cross-sectional shape of the absorption tower, form a regular packing layer that completely covers the cross-section of the tower, and avoid large gaps between the packing and the tower wall that could lead to gas-liquid short circuit.

[0085] To ensure high mass transfer efficiency of structured packing, this invention optimizes for high interfacial area ratio, high wetting rate, and moderate liquid holdup. The determination of the aforementioned opening method and parameters is based on three-dimensional CFD numerical simulation of falling film flow within a representative unit of the packing, with different liquid loads q applied. L For example, 20m 3 / m 2 h, 60 m 3 / m 2 h, 100 m 3 / m 2 h, the optimal combination is obtained through comparative analysis of multiple sets of parameters, and the relevant simulation results are as follows: Figures 3 to 11 As shown.

[0086] Figure 3 , Figure 4 and Figure 5 The effect of corrugation angle on interfacial area ratio, wetting rate, and liquid holdup is demonstrated. The effect of corrugation angle on interfacial area ratio and wetting rate is not significant, but the liquid holdup gradually decreases with increasing corrugation angle. To obtain a suitable liquid holdup, balancing mass transfer efficiency and operating pressure drop, this invention selects 45° as the optimal corrugation angle.

[0087] Figure 6 , Figure 7 and Figure 8 The effect of orifice spacing on interfacial area ratio, wetting rate, and liquid retention is demonstrated. Orifice spacing has a relatively small impact on liquid retention; interfacial area ratio gradually decreases as orifice spacing increases; while wetting rate shows a trend of first increasing and then decreasing. Considering both high interfacial area ratio and high wetting rate, this invention selects an orifice spacing of 10 mm, corresponding to an orifice ratio of 14.07%.

[0088] Figure 9 , Figure 10 and Figure 11 The effect of the fold angle on the interfacial area ratio, wetting rate, and liquid retention rate is demonstrated. The interfacial area ratio first increases and then decreases with increasing fold angle, reaching its maximum value at 90°. At higher spray densities, both the wetting rate and liquid retention rate show a monotonically decreasing trend with increasing fold angle. To obtain a higher interfacial area ratio, better wetting effect, and moderate liquid retention rate, this invention selects a fold angle of 90°.

[0089] Please refer to the following: Figures 12 to 14 As shown, Figure 12 The figure shows the distribution of the wetted area on the surface of the structured packing element of the present invention. The unwetted area is blue and the liquid-wetted area is red. Figure 13 The image shows a top view of a conventional structured packing element. Figure 14 The image shows the surface wetting region distribution of this conventional structured packing element. (The image is presented in the original text.) Figure 12 and Figure 14 As can be seen from the comparison, the liquid wetting zone (red area) under the open-hole method proposed in this invention is more uniform and regular than that of conventional structured packing. This improves the random and disordered liquid flow on the packing surface into an ordered flow, and effectively increases the total gas-liquid mass transfer area.

[0090] Through the synergistic optimization of the above-mentioned perforated structure and key geometric parameters, the structured packing element provided by this invention effectively increases the interfacial area ratio of gas-liquid two-phase contact, improves the wetting uniformity of the packing surface, and achieves a moderate liquid holdup rate. This avoids problems such as increased mass transfer resistance due to excessive liquid holdup and insufficient contact due to excessive liquid holdup, and significantly enhances the gas-liquid mass transfer process. Compared with traditional structured packing, the mass transfer efficiency such as CO2 absorption can be improved by more than 15%, which is significantly better than the prior art.

[0091] Furthermore, the opening method and geometric parameters in this invention are all clearly quantifiable values ​​with reasonable parameter ranges. They do not require complex processing techniques and can be mass-produced using existing structured packing production equipment, making production costs controllable. At the same time, the optimized structure does not increase the amount of material used, and while ensuring improved mass transfer performance, it controls manufacturing costs, making it highly valuable for industrial applications and promising for widespread adoption.

[0092] Implementation Method 2

[0093] An embodiment of the present invention provides a structured packing layer comprising a plurality of structured packing elements as described in Embodiment 1, stacked together. The specific structure and beneficial effects of the structured packing elements are the same as those described in Embodiment 1, and will not be repeated here.

[0094] This invention stacks multiple structured packing elements layer by layer, with the corrugation directions of adjacent structured packing elements forming a certain angle. This causes the gas to continuously change its flow direction during its ascent, increasing the gas-liquid contact effect. Simultaneously, the liquid in the upper layer of structured packing elements passes through the crest through-holes 111, trough through-holes 121, and corrugated surface through-holes 131 and falls onto the surface of the lower layer of structured packing elements, achieving continuous redistribution of the liquid phase and surface renewal, maintaining a high mass transfer efficiency throughout the entire structured packing layer.

[0095] Designers can adjust the included angle between adjacent structured packing elements as needed, without specific limitations. For example, the included angle between adjacent structured packing elements can be 45°-90°. Preferably, the included angle between adjacent structured packing elements is 90°.

[0096] The opening method and geometric layout of the crest through-hole 111 and trough through-hole 121 proposed in this invention can be applied to any type of structured packing with a nominal specific surface area, and has good versatility and adaptability.

[0097] In an embodiment of the present invention, the nominal specific surface area of ​​the structured filler layer is one of 250 m² / m³, 350 m² / m³, 500 m² / m³, or 750 m² / m³.

[0098] Specifically, when the corrugated plate body 100 has a corrugation angle of 30°, the specifications of the structured filler layer are 250X, 350X, 500X, and 750X. When the corrugated plate body 100 has a corrugation angle of 45°, the specifications of the structured filler layer are 250Y, 350Y, 500Y, and 750Y.

[0099] Implementation Method 3

[0100] An embodiment of the present invention provides an absorption tower, which includes a tower body and a structured packing layer disposed within the tower body as described in Embodiment 2. The specific structure and beneficial effects of the structured packing layer are the same as those described in Embodiment 2, and will not be repeated here.

[0101] All articles and references disclosed herein, including patent applications and publications, are incorporated herein by reference for various purposes. The term “substantially constitutes…” used to describe a combination should include the identified element, component, part, or step, as well as other elements, components, parts, or steps that do not substantially affect the essential novelty of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, components, parts, or steps herein also contemplates embodiments substantially constituted by such elements, components, parts, or steps. The use of the term “may” herein is intended to indicate that any described attribute included by “may” is optional. Multiple elements, components, parts, or steps can be provided by a single integrated element, component, part, or step. Alternatively, a single integrated element, component, part, or step can be divided into multiple separate elements, components, parts, or steps. The use of “a” or “an” to describe an element, component, part, or step is not intended to exclude other elements, components, parts, or steps.

[0102] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made according to the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A structured packing element, characterized in that, include: A corrugated plate body includes alternating crests and troughs, a corrugated surface located between adjacent crests and troughs, a plurality of crest through holes equally spaced along the crests, a plurality of trough through holes equally spaced along the troughs, and a plurality of corrugated surface through holes equally spaced along the corrugated surface. The crest through holes and the trough through holes are staggered on the corrugated plate body in a predetermined direction. The crest through holes and the trough through holes are used to periodically block the liquid film flowing along the surface of the corrugated plate body, so as to redistribute the liquid film on the surface of the corrugated plate body to increase the wetting area. Along the preset direction, adjacent crest holes and trough holes form a set of through-hole units. Along the corrugation angle direction of the corrugated plate, the corrugated surface within the range of two adjacent sets of through-hole units forms a corrugated surface unit. Each corrugated surface unit is provided with one corrugated surface through-hole. The distance between the corrugated surface through-hole and the center of the corrugated surface unit does not exceed a first preset value. The corrugated surface through-hole is used to form a liquid redistribution node between the crest holes and the trough holes, so that the liquid film flowing along the corrugated surface is intercepted by the corrugated surface through-hole when it flows through the corrugated surface through-hole and generates lateral spreading to cover the unwetted area in the middle of the corrugated surface.

2. The structured packing element as described in claim 1, characterized in that, The angle between the preset direction and the corrugated tilt direction of the corrugated plate is α, where 70°≤α≤110°.

3. The structured packing element as described in claim 2, characterized in that, The preset direction is perpendicular to the corrugation angle direction of the corrugated plate, α=90°.

4. The structured packing element as described in claim 1, characterized in that, The first preset value is 3mm.

5. The structured packing element as described in claim 1, characterized in that, The diameter of the crest through-hole is 3mm-5mm; and / or, the diameter of the trough through-hole is 3mm-5mm; and / or, the diameter of the wave surface through-hole is 3mm-5mm.

6. The structured packing element as described in claim 5, characterized in that, The crest through-hole, the trough through-hole, and the wave surface through-hole have the same diameter.

7. The structured packing element as described in claim 6, characterized in that, The diameters of the crest through-hole, the trough through-hole, and the wave surface through-hole are all 4 mm.

8. The structured packing element as described in claim 1, characterized in that, The spacing between the openings of the crest through-hole, the trough through-hole, and the wave surface through-hole is 9mm-12mm.

9. The structured packing element as described in claim 8, characterized in that, The spacing between the openings of the crest through-hole, the trough through-hole, and the wave surface through-hole is 10 mm.

10. The structured packing element as claimed in claim 1, characterized in that, The vertical distance between adjacent peaks and troughs is 7mm-9mm.

11. The structured packing element as described in claim 10, characterized in that, The vertical distance between adjacent peaks and troughs is 8 mm.

12. The structured packing element as described in claim 1, characterized in that, The corrugated angle of the corrugated plate is 30°-60°.

13. The structured packing element as described in claim 12, characterized in that, The corrugated angle of the corrugated plate is 30° or 45°.

14. The structured packing element as claimed in claim 1, characterized in that, The fold angle of the corrugated plate is 70°-110°.

15. The structured packing element as described in claim 14, characterized in that, The corrugated plate has a fold angle of 90°.

16. The structured packing element as claimed in claim 1, characterized in that, The perforation rate of the corrugated plate is 10%-15%.

17. The structured packing element as claimed in claim 1, characterized in that, The shape of the corrugated plate is one of the following: rectangle, parallelogram, isosceles trapezoid, circle, ellipse, or triangle.

18. A structured packing layer, characterized in that, It includes a plurality of structured packing elements arranged in a stacked manner as described in any one of claims 1 to 17.

19. An absorption tower, characterized in that, It includes a tower body and a structured packing layer as described in claim 18 disposed within the tower body.

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