Thin-layer high-density filler

Abstract

The utility model discloses a thin-layer high-density filler which is formed by superposing a plurality of thin-layer high-density silk screen single sheets to form a cylindrical three-dimensional space structure, all the thin-layer high-density silk screen single pieces are of a rectangular outline structure, the heights of all the thin-layer high-density silk screen single pieces are the same, and the lengths of the thin-layer high-density silk screen single pieces are gradually decreased from the silk screen single piece at the center position of the cylindrical three-dimensional space structure to the two sides along the semicircular outline. Each silk screen single piece of the thin-layer high-density packing is provided with a corrugated structure, the corrugated structures of the adjacent thin-layer high-density silk screen single pieces are arranged in a 90-degree mode, the thin-layer high-density silk screen single pieces are mutually fixed through spot welding and are connected in series through screws with different lengths, and a tension band is installed on the outer side of the thin-layer high-density packing. The filler disclosed by the utility model adopts stainless steel wires as raw materials, has the advantages of low manufacturing cost, large flux, stable performance and low metal exudation rate, and is difficult to replace in the field of heat pump rectification, high-purity electronic chemical separation, intermediate separation and isomerism separation production.

Description

Technical Field

[0001] This utility model belongs to the technical field of chemical production equipment and is applicable to mass transfer and heat transfer devices, specifically relating to a thin-layer high-density packing. Background Technology

[0002] Metal wire mesh packings are widely used in chemical, oil refining, and pharmaceutical production fields due to their advantages such as large specific surface area, low pressure drop, high mass transfer efficiency, and ease of assembly. With the development of the times, the requirements for comprehensive green development in the chemical industry and high-efficiency, energy-saving separation equipment are becoming increasingly urgent. Recently, due to the widespread adoption of heat pump distillation processes, there is an urgent need for low-pressure-drop, high-efficiency tower internals. Therefore, the research and development of novel low-pressure-drop, high-efficiency packings is a research hotspot in the chemical separation industry.

[0003] Metal wire mesh packings offer advantages such as high separation efficiency, low cost, and relatively low pressure drop, making them suitable for the separation and purification of high-end electronic chemicals. The theoretical plate number and energy consumption required for distillation separation increase exponentially with product purity. Therefore, in distillation purification, metal wire mesh packings with extremely high specific surface area are often used to improve separation efficiency, and heat pump distillation is employed to reduce energy consumption. However, conventional metal wire mesh packings, while possessing relatively high mass transfer efficiency, also exhibit high pressure drop and low processing efficiency, leading to problems such as excessively high investment in heat pump distillation processes and the inability to achieve optimal heat recovery. To address this deficiency, we propose an innovative woven packing material—thin-layer high-density packing. Utility Model Content

[0004] To address the aforementioned problems, the purpose of this invention is to provide a thin-layer high-density packing material that is easy to weave, has a simple structure, low pressure drop, and high throughput. This packing material features small mesh openings, a large specific surface area, better wettability, easier liquid film formation, lower flow pressure drop, and higher mass transfer efficiency. This invention improves upon the shortcomings of ordinary flat-woven metal wire mesh packing materials, such as excessively large mesh openings leading to high pressure drop, poor liquid wettability, and low efficiency, by employing a novel weaving method.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0006] This invention proposes a thin-layer high-density filler, which is composed of multiple thin-layer high-density wire mesh sheets stacked together to form a cylindrical three-dimensional spatial structure. All thin-layer high-density wire mesh sheets have a rectangular outline and the same height. The length decreases progressively from the center of the cylindrical three-dimensional spatial structure towards both sides along a semi-circular outline. Each wire mesh sheet of the thin-layer high-density filler is woven using a novel weaving technique and has a corrugated structure. The corrugated structures of adjacent thin-layer high-density wire mesh sheets are arranged at 90° and fixed together by a special binding method. Adjacent wire mesh sheets are fixed by spot welding, and the entire filler is connected and fixed together by multiple screws of different lengths. Hoop rings are installed on the outer side of the thin-layer high-density filler.

[0007] The thin-layer high-density wire mesh is woven using a novel weaving technique. Specifically, it involves interlacing one or more tightly bonded weft threads with one or more tightly bonded warp threads using weaving patterns such as one-skip-four, one-skip-two, and two-skip-two. Different tensile strengths are applied during the weaving process depending on the warp and weft density, generally not exceeding 8 pounds. By increasing the number of weft threads, the warp and weft density is altered, thereby lengthening the warp threads, reducing the metal bending angle, and minimizing the problem of the wire mesh thickening and increasing the aperture due to metal stress. This results in a thinner wire mesh, a three-dimensional mass transfer space, and a larger apparent specific surface area.

[0008] Furthermore, the specific methods of one-jump-four, one-jump-two, and two-jump-two are as follows:

[0009] The "one-skip-four" method treats one or more closely spaced weft or warp threads as a group. The first group of weft threads crosses the first group of warp threads, then the second to fifth groups of warp threads, repeating this process multiple times. The second group of weft threads crosses the third group of warp threads, then the fourth to seventh groups of warp threads, repeating this process multiple times. The third group of weft threads crosses the first to fourth groups of warp threads, then the fifth group of warp threads, repeating this process multiple times. The fourth group of weft threads crosses the second group of warp threads, then the third to sixth groups of warp threads, repeating this process multiple times. The fifth group of weft threads crosses the fourth group of warp threads, then the fifth to eighth groups of warp threads, repeating this process multiple times. Multiple groups of weft threads are woven in sequence, repeating the above process to ultimately produce a single sheet of "one-skip-four" thin-layer high-density filler wire mesh.

[0010] The "one-jump-two" method treats one or more closely spaced weft or warp threads as a group. The first group of weft threads crosses the first group of warp threads first, then crosses the second and third groups of warp threads, repeating this process multiple times. The second group of weft threads crosses the second group of warp threads first, then crosses the third and fourth groups of warp threads, repeating this process multiple times. The third group of weft threads crosses the first and second groups of warp threads first, then crosses the third group of warp threads, repeating this process multiple times. Multiple groups of weft threads are woven in sequence, and the above process is repeated to finally obtain a single sheet of one-jump-two thin-layer high-density filler wire mesh.

[0011] The "two-skip-two" method treats one or more closely spaced weft or warp threads as a group. The first group of weft threads crosses the first and second groups of warp threads, then the third and fourth groups of warp threads, repeating this process multiple times. The second group of weft threads crosses the second and third groups of warp threads, then the fourth and fifth groups of warp threads, repeating this process multiple times. Multiple groups of weft threads are woven in sequence, and the above process is repeated to finally obtain a single sheet of two-skip-two thin-layer high-density filler wire mesh.

[0012] Furthermore, based on the novel weaving method of thin-layer high-density wire mesh, the surface of the thin-layer high-density filler has a large number of flat strip-shaped micropores and regular patterns.

[0013] Furthermore, after the warp and weft threads of the thin-layer high-density wire mesh are woven, the bending angle of the warp and weft threads is less than 90°.

[0014] Furthermore, the special binding method refers to the use of spot welding to fix the individual pieces of the thin-layer high-density filler wire mesh together, and the filler as a whole is connected in series with multiple screws of different lengths to ensure the structural stability of the wire mesh filler.

[0015] Furthermore, the vertical tilt angle of each sheet of the thin-layer high-density wire mesh is between 0° and 90°, the height of each reel of thin-layer high-density filler is between 20mm and 500mm, and the diameter of the yarn used for weaving is between 0.08mm and 2.5mm.

[0016] Furthermore, the material of the thin-layer high-density wire mesh sheet is stainless steel wire, carbon wire, or polymer wire. Specific materials can be categorized according to the separation process application scenario, including various stainless steel wires such as 304 (0Cr19Ni9), 316 (022Cr17Ni12Mo2), and PTFE, as well as non-metallic wires such as carbon wire and polymer wire.

[0017] Furthermore, the number of thin-layer high-density wire mesh sheets can be adjusted according to production needs by changing the peak height and peak angle of the corrugated structure of the thin-layer high-density wire mesh sheet, thereby adjusting the specific surface area of ​​the thin-layer high-density filler.

[0018] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0019] (1) The new weaving process greatly reduces the internal pore size of the metal wire mesh packing, effectively avoiding the problem of gas phase passing through the mesh and liquid phase mixing due to the large pore size, which leads to increased pressure drop. Since the gas phase cannot break through the liquid film, the stable liquid film flow on the wire mesh surface greatly enhances the mass transfer efficiency of the packing.

[0020] (2) Compared with ordinary plain-woven metal wire mesh packing, thin-layer high-density packing adopts a new weaving technique. The new weaving process increases the number of weft threads by several times under the same warp count as ordinary plain-woven metal wire mesh packing, which is beneficial to the formation of liquid film on the wire mesh surface and the lateral diffusion of liquid. Furthermore, the formation of regular flow channels on the surface of the wire mesh further enables the liquid phase to be rapidly and uniformly distributed in the radial and lateral directions, enhancing the liquid renewal rate on the packing surface; thus, it is beneficial to improve the mass transfer efficiency.

[0021] (3) By adopting a new weaving process, the bending angle of the yarn is less than 90° by changing the tension and the longer span, so that the filler itself has a smaller thickness and a larger mass transfer surface area, thereby enhancing the mass transfer efficiency.

[0022] In summary, this utility model of thin-layer high-density packing is based on plain-woven metal wire mesh packing, and is manufactured through an optimized combination of weaving method, weaving density, and flat stamping process. The novel weaving technique allows the number of weft threads in the thin-layer high-density packing to be several times greater than that of plain-woven metal wire mesh packing under the same warp count. Therefore, the thin-layer high-density packing possesses advantages such as ultra-high specific surface area and three-dimensional mass transfer space. Compared to ordinary plain-woven metal wire mesh packing, the thin-layer high-density wire mesh packing features high specific surface area, high mass transfer efficiency, and low flow pressure drop. Therefore, it can be widely used in heat pump distillation energy-saving processes to reduce the pressure difference between the top and bottom of the column, thereby reducing temperature difference and compressor power, achieving better heat utilization. Furthermore, the thin-layer high-density packing is mostly woven from metal wire, and its surface has numerous flat strip-shaped micropores with excellent wettability. The high weft density greatly enhances the lateral diffusion effect of the liquid inside the packing, resulting in particularly outstanding separation performance in processes such as high-density spray distillation, with a pressure drop approximately 30%-50% lower than that of ordinary plain-woven packing. The packing material of this invention mainly uses stainless steel wire as raw material, which has the advantages of stable performance and low metal leakage rate. Therefore, it has an irreplaceable position in the fields of fine chemical industry, separation of high-purity electronic chemicals, separation of intermediates and separation of isomers and isomers. Attached Figure Description

[0023] Figure 1 The weaving method for thin-layer high-density wire mesh is mesh pattern-1 (one jump four).

[0024] Figure 2 The weaving method for thin-layer high-density wire mesh is mesh pattern-2 (one jump two).

[0025] Figure 3 The weaving method for thin-layer high-density wire mesh is mesh pattern-3 (one jump four).

[0026] Figure 4 A comparison chart of pressure drop between two types of thin-layer high-density packing and flat-woven packing at 0 spray density;

[0027] Figure 5 A comparison chart of pressure drop between two types of thin-layer high-density packing and flat-woven packing at a spray density of 10;

[0028] Figure 6 A comparison chart of pressure drop between two types of thin-layer high-density packing and flat-woven packing at a spray density of 20;

[0029] Figure 7 A comparison chart of pressure drop between two types of thin-layer high-density packing and flat-woven packing at a spray density of 30;

[0030] Figure 8 A comparison chart of pressure drop between two types of thin-layer high-density packing and flat-woven packing at a spray density of 40;

[0031] Figure 9 A comparison chart of pressure drop between two types of thin-layer high-density packing and flat-woven packing at a spray density of 50;

[0032] Figure 10 A comparison chart of pressure drop between two types of thin-layer high-density packing and flat-woven packing at a spray density of 60;

[0033] Figure 11 A comparison chart of the efficiency of two types of thin-layer high-density packing and flat-woven packing at a spray density of 10;

[0034] Figure 12 A comparison chart of the efficiency of two types of thin-layer high-density packing and flat-woven packing at a spray density of 20;

[0035] Figure 13 A comparison chart of the efficiency of two types of thin-layer high-density packing and flat-woven packing at a spray density of 30;

[0036] Figure 14 This is a comparison chart of the efficiency of two types of thin-layer high-density packing and flat-woven packing at a spray density of 40. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be described in detail below. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0038] like Figure 1-3 As shown, this utility model is a metal wire mesh filler with a three-dimensional spatial structure and high specific surface area, composed of multiple thin-layer high-density metal wire mesh sheets stacked together. The new thin-layer high-density wire mesh sheets are flattened and stamped into a corrugated shape. The intersections of the corrugated thin-layer high-density wire mesh sheets are welded together and connected in series using multiple screws of different lengths. Then, the vertically arranged thin-layer high-density metal wire mesh strips are assembled into a disc-shaped, well-organized filler. The mesh pattern of the thin-layer high-density filler is shown in [details omitted]. Figure 1-3 A hoop can be installed on the outside of the thin-layer high-density packing.

[0039] The following details the comparison between the Type B and Type Y thin-layer high-density packings and the ordinary BX500 and CY700 packings, facilitating comparison with case studies. The Type B and Type Y thin-layer high-density packings employ a novel one-skip-four weaving method, while the ordinary BX500 and CY700 packings use ordinary flat-woven metal wire mesh packing sheets. Both the Type B thin-layer high-density packing and the ordinary BX500 packing have the same peak height of 6.2±0.07mm, wave spacing of 10.2±0.07mm, corrugation angle of 30°, tooth angle of 78.9±1°, and nominal specific surface area of ​​507.9 m². 2 / m 3 The wire diameter is 0.156 mm. The porosity of type B thin-layer high-density packing is 96.83%, while that of ordinary BX500 packing is 97.64%. Type Y thin-layer high-density packing and ordinary CY700 packing share the same peak height of 4.5 ± 0.05 mm, corrugation spacing of 7.2 ± 0.05 mm, corrugation angle of 45°, tooth angle of 77.3 ± 1°, and nominal specific surface area of ​​711.4 m². 2 / m 3 The wire diameter is 0.156mm. The porosity of the Y-type thin-layer high-density packing is 95.29%, while the porosity of the ordinary CY700 packing is 95.79%. Example 1

[0040] Magnified observation of the intersections of ordinary plain-woven wire mesh filler sheets reveals that the narrower weft yarns require greater bending over a shorter distance when the warp yarns interlock. This material stress in the warp yarns leads to a thicker mesh and larger apertures. Thin-layer high-density filler mesh, using a different weaving technique, shows through magnified observation at the intersections that the wider weft yarns allow for a longer warp yarn span during interlocking, resulting in less bending. This effectively solves the problem of material stress causing the mesh to thicken and the apertures to increase. Under the same mesh count and wire diameter of 0.20 mm per unit area, comparing the surface area of ​​thin-layer high-density packing and ordinary plain woven wire mesh packing in a range of 10 mm * 10 mm, it was calculated that the surface area of ​​thin-layer high-density packing is 57.26% larger than that of ordinary plain woven wire mesh packing. Since specific surface area equals surface area divided by volume, under the same volume, the larger the surface area, the larger the specific surface area. Specific surface area is also positively correlated with mass transfer performance. Therefore, thin-layer high-density packing has the advantage of high mass transfer efficiency. Example 2

[0041] The pressure drop of wet towers was compared between type B and type Y thin-layer high-density packings and ordinary BX500 and CY700 packings at different spray densities. The packing pressure drop test was conducted in a 600 mm diameter plexiglass tower. The gas inlet device was a metal double-row blade gas distributor, the bottom packing support was a grid support, and the top liquid distribution device was a tubular liquid distributor. The experimental system was an air-water system. In the experiment, water was pumped from the bottom of the tower to the top liquid distributor via a centrifugal pump. The liquid flow rate was measured using a rotor flowmeter. The spray density of the liquid in the tower was changed by adjusting the gate valve opening. Gas was pumped into the bottom of the tower by a centrifugal fan. The gas flow rate was measured as pressure drop using an orifice plate flowmeter. The gas flow rate in the tower was controlled by adjusting the butterfly valve opening. The tower contained a total packing height of 2400 mm. After removing some end-effect-eliminating packing, the pressure-measuring packing height was 1800 mm. The packing layer pressure drop was measured using a micro differential pressure gauge and a U-tube differential pressure gauge.

[0042] The test results are as follows: Under the same test conditions, the pressure drop of type B thin-layer high-density packing is approximately 30% lower than that of ordinary BX500 packing; under the same test conditions, the pressure drop of type Y thin-layer high-density packing is approximately 50% lower than that of ordinary CY700 packing. Specific data are as follows: Figure 7-13Furthermore, the pressure drop of the type B and type Y thin-layer high-density packing varies relatively gently with the spray density. This phenomenon is because the wire mesh thickness of type B and type Y thin-layer high-density packing is about 33% thinner than that of ordinary BX500 and CY700 packing. In addition, the surface of type B and type Y thin-layer high-density packing wire mesh has multiple microchannels with liquid guiding function, thereby achieving a more perfect flow state between the gas and liquid phases and reducing the collision between the gas and liquid phases, resulting in a significant reduction in pressure drop. Example 3

[0043] The mass transfer efficiency of type B and type Y thin-layer high-density packings was compared with that of ordinary BX500 and CY700 packings using the oxygen desorption method. The oxygen desorption test was conducted using an oxygen-water system, and the change in oxygen content in the water after the system flowed through the packing was used as the rating standard for mass transfer efficiency. The test was carried out in a 600 mm diameter steel tower. The gas inlet device in the tower used a metal double-row blade gas distributor, the bottom support device of the packing used a grid support, and the liquid distribution device used a tubular liquid distributor. In the experiment, water was pumped from the bottom of the tower to the absorption tower via a centrifugal pump, and oxygen was introduced into the absorption tower through an oxygen cylinder to achieve an oxygen-enriched state. The oxygen-enriched water was then introduced into the liquid distributor. The liquid flow rate was measured using a rotor flowmeter, and the liquid flow rate was controlled by changing the gate valve opening, thereby changing the spray density of the liquid in the tower. Gas was sent into the bottom of the tower by a centrifugal fan under high pressure. The gas flow rate was measured by pressure drop using an orifice plate flowmeter, and the gas flow rate was controlled by changing the butterfly valve opening. The tower was filled with packing material with a total height of 1100 mm as test packing.

[0044] The test results are as follows: Under the same test conditions, the mass transfer performance of the type B thin-layer high-density packing is approximately 20% higher than that of the ordinary BX500 packing; under the same test conditions, the mass transfer performance of the type Y thin-layer high-density packing is approximately 30% higher than that of the ordinary CY700 packing. Specific data are as follows: Figure 11-14 This phenomenon is because type B and type Y thin-layer high-density packing wire meshes have better lateral liquid distribution capabilities than ordinary BX500 and CY700 packing wires, and contain a large number of flat strip-shaped micropores that are easier to form films and less prone to breakage, resulting in a significant increase in mass transfer efficiency.

[0045] In summary, compared with ordinary plain-woven metal wire mesh packing, the thin-layer high-density packing of this invention significantly improves the performance of the packing wire mesh structure stability, flow pressure drop, operational flexibility, and mass transfer efficiency. The parameters of the thin-layer high-density packing, such as wire diameter, crest, disc height, wave pitch, tooth angle, corrugation angle, and porosity, can be adjusted according to actual process conditions. Within the parameter range specified in the claims, this invention can produce the aforementioned beneficial effects.

[0046] The embodiments described above are only for explaining this utility model and should not be construed as limiting this utility model. Referring to the accompanying drawings, the structures, proportions, sizes, etc., shown in the drawings are only used to complement the content disclosed in the specification and are not intended to limit the conditions under which this utility model can be implemented. Therefore, they do not have substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and purposes that this utility model can produce, should still fall within the scope of the technical content disclosed in this utility model.

Claims

1. A thin-layer high-density packing material, characterized in that, The thin-layer high-density filler is composed of multiple thin-layer high-density wire mesh sheets stacked together to form a cylindrical three-dimensional spatial structure. All thin-layer high-density wire mesh sheets have a rectangular outline structure, and all thin-layer high-density wire mesh sheets have the same height. The length decreases gradually from the wire mesh sheet at the center of the cylindrical three-dimensional spatial structure to both sides along the semi-circular outline. Each wire mesh sheet of the thin-layer high-density filler has a corrugated structure, and the corrugated structures of adjacent thin-layer high-density wire mesh sheets are arranged at 90°. The thin-layer high-density wire mesh sheets are fixed to each other by spot welding and connected by screws of different lengths. Hoops are installed on the outside of the thin-layer high-density filler.

2. The thin-layer high-density packing according to claim 1, characterized in that, The thin-layer high-density wire mesh sheet is a metal wire mesh sheet woven from warp and weft threads in a one-skip-four, one-skip-two, or two-skip-two pattern.

3. The thin-layer high-density filler according to claim 2, characterized in that, The bending angle of the warp and weft threads of the thin-layer high-density wire mesh after weaving is less than 90°.

4. The thin-layer high-density filler according to claim 2, characterized in that, The surface of each sheet of the thin-layer high-density wire mesh has a large number of flat strip-shaped micropores and regular patterns.

5. A thin-layer high-density filler according to claim 2, characterized in that, The vertical tilt angle of each sheet of the thin-layer high-density wire mesh is between 0° and 90°, the height of each reel of thin-layer high-density filler is between 20mm and 500mm, and the diameter of the yarn used for weaving is between 0.08mm and 2.5mm.

Images