FUELLKOERPER

Description

[0001] The invention relates to packing materials for use in unstructured packings, comprising a fiber-reinforced carbon flat material, a column comprising a packing comprising packing materials according to the invention, and a method for producing packing materials according to the invention.

[0002] Packing materials are used in a wide variety of chemical and / or thermal processes, especially in column packings.

[0003] In separation columns, packings define separation zones, e.g. in absorption columns, desorption columns, distillation columns or extractive distillation columns.

[0004] In reaction columns, packing materials are used in various sections of the packing. For example, packing materials are used in sections upstream or downstream of reaction zones, through which reactant or product-containing fluids flow. Here, they can serve to supply or remove heat. Packing materials are also used within reaction zones, where they are either present together with catalytically active materials, such as catalyst substrates, and dilute the catalytically active materials, or they themselves serve as catalyst supports when a catalytically active mass is attached to the packing material.

[0005] From EP2380659 A1, packing materials of the Pall ring type in the form of hollow cylinders or half-cylinders are known, in which sections of the cylinder wall are bent inwards in a web-like manner towards the cylinder axis and which are made entirely of a temperature- and chemical-resistant glass, in particular borosilicate glass. They are preferably produced by cutting and forming from glass tubes. JP S 63209744 describes that packing materials for columns can consist of different materials, e.g., porcelain, plastics, metal, or carbon. Raschig rings, Lessing rings, and Berl saddles are mentioned, among others.

[0006] JP S 63209744 proposes a filling material for a device for contacting gas with liquid, made of carbon fiber-reinforced carbon. Corrugated sheets, wire mesh, honeycomb-shaped, and similar filling materials are also described. The reinforcing carbon fiber can be selected from continuous fibers and short fibers or be used as a sheet, e.g., as a woven fabric, mat, felt, or similar material.

[0007] JP S 63209744 proposes various methods for producing the filler material described therein. If the carbon fiber is a continuous fiber, it is first impregnated with a carbonizable substance, such as phenolic resin, furan resin, pitch, or similar, and then wound around a mandrel or similar tool to form it into the desired filler shape. If the carbon fiber is a short fiber, a mixture of carbon fiber and the carbonizable material is injected, for example, into the desired filler shape. If the carbon fiber is in the form of a sheet, for example, as a woven fabric, it is impregnated with the aforementioned carbonizable substance and rolled or laminated into a desired filler shape. Carbonization at 600 to 2800 °C is then recommended. Machining is also suggested to achieve the desired shape.One example describes the production of a Raschig ring starting from a prepreg.

[0008] The filling materials and filler bodies described in the prior art, which are made from carbon fiber reinforced carbon, can only be manufactured with great effort.

[0009] The present invention is based on the objective of providing a packing element that is particularly corrosion-resistant and can be manufactured with particularly little effort and is able to withstand the usual mechanical stress requirements, i.e. in particular the static pressure that acts on the packing elements in the lower area of ​​a packing by the packing elements resting on top and the liquid flowing out.

[0010] This problem is solved by packing materials for use in unstructured packings according to claims 1 or 12, wherein the packing material comprises a fiber-reinforced carbon flat material and two strip regions of the carbon flat material separated by a cross-section merge into each other in two connection regions of the carbon flat material.

[0011] The packing materials according to the invention are suitable for use in unstructured packings, e.g., in unstructured packings that can withstand halogen-containing fluids and hydrogen halide-containing fluids even in the presence of water at temperatures above 50 °C (continuously). Unstructured packings are found, for example, in chemical process engineering equipment, particularly in columns such as absorption columns, desorption columns, distillation columns, or extractive distillation columns.

[0012] The filler materials according to the invention comprise a fiber-reinforced carbon flat material. Fiber-reinforced carbon flat materials are known to those skilled in the art in the field of carbon-based materials, e.g., from the book "Carbon Fibers and Their Composite Materials, Manufacturing Processes, Applications and Market Development" by Hubert Jäger and Tilo Hauke ​​(Verlag Moderne Industrie, 2010, ISBN 978-3-86236-001-7). The fiber-reinforced carbon flat material can be formed from a prepreg by curing and carbonization. A prepreg is a fiber tape impregnated with a matrix polymer (e.g., resin) but not yet cured, e.g., carbon fiber tape or a two-dimensional technical textile.

[0013] In the context of the present invention, a cross-section is understood to be a cut extending through the carbon flat material from one main surface to the other, wherein both ends of the cross-section are set off from the circumferential edge of the carbon flat material. The cross-section is therefore not a cut originating from an edge of the carbon flat material, nor is it a cut that divides the carbon flat material into two parts.

[0014] The average defines two band ranges that are separated by the average. The band ranges border the average.

[0015] The two band regions of the carbon flat material merge into each other at two connection regions. These connection regions link the band regions because the two ends of the cross-section are set off from the edges of the carbon flat material.

[0016] Preferably, the connecting areas are spatially separated areas of the carbon flat material that are connected via the strip areas.

[0017] In the filler body according to claim 12, the fibers can be short fibers, e.g., short carbon fibers. In the context of the present invention, "short fiber" means that the fiber is shorter than the shortest section of the strip. The length of the strip is measured along its shortest average.

[0018] The filler materials according to claims 1 or 12 may consist of continuous fibers, e.g., continuous carbon fibers. The continuous fibers extend, e.g., from one point on the circumferential edge to another point on the circumferential edge of the carbon flat material.

[0019] The fibers, e.g., carbon fibers, can be arranged irregularly or regularly. Irregularly arranged fibers are found, for example, in a nonwoven fabric. The fiber reinforcement according to the invention can be achieved, for example, by fibers arranged in a nonwoven form.

[0020] According to the solution according to claim 1 and preferably according to claim 12, at least a portion of the fibers running in at least one band region extends into both connection regions. This increases the stability of the filler elements according to the invention; in particular, tensile loads then lead even less frequently to tearing or breaking of band regions. Ultimately, greater packing heights can be achieved without significant damage to the filler elements occurring in the lower regions of the packing.

[0021] The number of cross-sections can be chosen arbitrarily. However, it is recommended not to increase the number of band sections arbitrarily and to ensure a sufficient width of the band sections to withstand the mechanical stresses occurring in packages.

[0022] The filler elements can have, for example, 1 to 35 cuts, in particular 2 to 23 cuts, preferably 2 to 15 cuts, and especially preferably 2 to 11 cuts. A particularly preferred filler element according to the invention has 3 to 7 cuts, for example, 3, 4, or 5 cuts.

[0023] It is preferred that all band regions of the carbon flat material, separated by the cross-sections, merge into each other in only two connection regions of the carbon flat material (as, for example, in the case of the carbon flat material shown in the diagram). Figs. 1A to 1C(shown filler body, which only has the connection areas marked with reference numerals 3 and 4). However, it is also possible that more than two connection areas are present (as, for example, in the one shown in Fig. 5 (shown packing material). A particularly preferred packing material has n averages and n+1 band ranges, on, where n is a number selected from 2, 3, 4, 5, 6, 7, 8, 9, 10 or 11, preferably a number selected from 3, 4 or 5, such as 4.

[0024] In preferred fillers according to the invention, the cross-section defines a first cutting edge and a second cutting edge, which merge into one another at a first and a second end of the cross-section. A section of one cutting edge is spaced apart from the other cutting edge of the same cross-section. This space can be precisely adjusted as desired by appropriately designing the press-cutting tools used in the manufacturing process. The closer the press-cutting tools interlock, the greater the space becomes. Preferably, the distance between a point on one cutting edge and the corresponding point on the other cutting edge is at least 1 / 8, and preferably at least 1 / 6, of the cutting edge length. The corresponding points of both cutting edges are the points on the flat material that were directly adjacent to one another before the cross-section was inserted and shaped in the press-cutting tool.The cut edge length is the length of one of the two equally long cut edges.

[0025] If the fill material has at least two cross-sections, two cutting edges of adjacent cross-sections can define the band area, and these cutting edges are parallel to each other. The band area is then uniformly wide. "Parallel to each other" cutting edges does not mean that the cutting edges are straight overall, but rather that the course of both cutting edges can be approximated at any point along each cutting edge by a straight line where that line is tangent to the cutting edge. Corresponding lines of both cutting edges are then parallel to each other.

[0026] Preferably, the other two cutting edges of the adjacent cross-sections also run parallel to each other.

[0027] The two edges of a cross-section preferably do not run parallel to each other.

[0028] It is also preferred if the two edges of the same intersection lie in a surface obtainable by parallel translation of a curve. Preferably, the two edges of the same intersection lie in a plane.

[0029] Inventive filler bodies with parallel cutting edges and / or in which the two cutting edges of the same cross-section lie in one plane are particularly cost-effective to produce, because the press cutting tools can then have conventional, clamped metal plates of uniform thickness. Figures 3A and 3BFigure 1 shows press-cutting tools in which such metal plates are clamped with threaded rods. Since the sliding cutting edges of both press-cutting tools are edges of flat metal plates, the two cutting edges of a cross-section formed therein necessarily lie in one plane. Preferably, all cutting edges of all cross-sections of the filler lie in mutually parallel planes.

[0030] The fiber-reinforced carbon flat material (2) can comprise, for example, selected fibers including glass fibers, basalt fibers, and carbon fibers, preferably carbon fibers. Particularly preferred fiber-reinforced carbon flat materials according to the invention are carbon fiber-reinforced carbon flat materials.

[0031] The fiber-reinforced carbon flat material can comprise at least one unidirectional region in which the fibers do not cross. It can also comprise at least two unidirectional strip regions adjacent to both cut edges of the same cross-section. Preferably, the fibers in the regions adjacent to the two cut edges of the cross-section run parallel to the cut edge. With such a filler material, the cross-section can be formed essentially without cutting through the fibers. The cross-section then runs between the fibers. This results in particularly low wear on the press cutting tools, as these essentially only cut through matrix material. The filler material can therefore be manufactured even more efficiently.

[0032] A unidirectional band area can extend from one cutting edge of the band area to the other cutting edge of the same band area and from the first cutting ends of the two cuts adjacent to the band area to the second cutting ends of the two cuts adjacent to the band area.

[0033] The unidirectional area preferably extends over the entire carbon flat material.

[0034] Alternatively or additionally to one or more unidirectional regions, but necessarily according to the inventive solution of claim 12, the fiber-reinforced carbon flat material comprises at least one multidirectional region in which the fibers intersect. In this region, the fiber-reinforced carbon flat material can comprise a multidirectional fiber fabric, a fiber woven fabric, or a fiber nonwoven fabric. For example, connection regions can comprise multidirectional regions. This has the advantage that the connection regions are even more stable and the filler elements can withstand even higher mechanical loads. Nevertheless, it is then possible to form the cross-sections without having to cut any fibers.

[0035] The invention also relates to a column comprising an unstructured packing consisting of packing materials according to the invention. The column has the unstructured packing. "Unstructured" means that the packing materials are randomly oriented, as happens, for example, when the packing materials are poured into the column or into sections of the column. The packing comprises packing materials according to the invention. These can be present in a mixture with other packing materials or catalytically active materials (e.g., catalyst substrates or carrier substrates coated with catalytically active material). The packing can also consist solely of packing materials according to the invention in certain sections or throughout the entire packing.

[0036] The invention also relates to a method for producing a filler body according to the invention, wherein a fiber-reinforced starting flat material is fed into a press-cutting zone, and the starting flat material is shaped, cut and cut in the press-cutting zone in such a way that a body is formed which has a fiber-reinforced flat material and in which two strip areas of the flat material separated by a cross-section merge into each other in two connecting areas of the flat material.

[0037] In one variant of the process according to the invention, the fiber-reinforced starting flat material is already wholly or partially carbonized. The fiber-reinforced starting flat material can therefore be a fiber-reinforced carbon flat material, e.g., a carbon fiber-reinforced carbon flat material.

[0038] In another variant of the process according to the invention, the fiber-reinforced starting flat material contains non-carbonized matrix components and / or non-carbonized fiber components. Non-carbonized matrix components can comprise a resin, which may be uncured, partially cured, or fully cured, a thermoplastic, pitch, or mixtures thereof. Non-carbonized fiber components can comprise polymer-based fibers, such as, in particular, aramid, cellulose, and / or plastic fibers. Suitable carbonizable starting fibers and carbonizable matrix substances are described in "Carbon Fibers and Their Composites: Manufacturing Processes, Applications, and Market Development" by Hubert Jäger and Tilo Hauke ​​(Verlag Moderne Industrie, 2010, ISBN 978-3-86236-001-7). In this variant of the process, the body formed in the press-cutting zone is subjected to carbonization, in which the body is converted into the filler material according to the invention.Carbonization preferably takes place in the absence of oxygen and at elevated temperatures, which can range, for example, from 300 to 3000 °C. The person skilled in the art selects the temperature depending on which matrix and / or fiber substance is to be carbonized and depending on the desired properties of the filler material.

[0039] The invention also relates to the use of packing materials or a column according to the invention for the processing of fluids containing acid gas, such as hydrogen halogens and / or halogens, such as chlorine gas.

[0040] The invention is illustrated by the following figures and embodiment, without being limited thereto. Figures 1A, 1B and 1C show a filling body according to the invention with two connection areas in different perspectives. Figure 2shows an enlarged section of the filling body according to the invention, which is indicated by a rectangle in Figure 1A. Figures 3A and 3B show interlocking press cutting tools for the production of the in Figures 1A, 1B , 1C and 2 shown filler body. Figure 4 shows the stacked press cutting tools of the Figures 3A and 3B with cut-through, fiber-reinforced flat material cut into filler greens. Figure 5 shows a filling body according to the invention with three connection areas.

[0041] In Figures 1A, 1B and 1C is a filler body 1 shown for a column. The packing material consists of a fiber-reinforced carbon flat material. 2 two divided by an average 10-1 separate band sections 5, 15 of the carbon flat material 2 go into two connecting areas 3, 4 of the carbon flat material merge into one another. In Figure 1AThe transition from the band areas to the connection areas is indicated by dashed lines. In the embodiment shown in the figures, there are a total of four cross-sections. 10-1, 20-1, 30-1, 40-1 These run parallel to each other. Therefore, there are a total of five separate band sections. 5, 15, 25, 35, 45 before (n cross-sections and n+1 band ranges, where n is 4).

[0042] A part of what is in each band area 5, 15, 25, 35, 45 The continuous fibers (preferably carbon fibers) extend into both connection areas. 3, 4 into. This is in Figure 2 shown as an example of an enlarged section shown there from Figure 1A in band area 15. The area in band 15 of connection area 3 up to the connection area 4 the fibers extending inwards are in Figure 2 indicated as thin straight lines. When considering the filler material. 1From the outside, the fibers are not visible, or not visible in their full length, because they lie at least partially within the carbon matrix of the carbon flat material. Figure 2 indicates the fiber orientation within the matrix.

[0043] The in Figure 1A shown averages 10-1, 20-1, 30-1, 40-1 define each one in Figure 1B shown first cutting edge 10-2, 20-2, 30-2, 40-2 and one in Figure 1B shown second cut edge 10-3, 20-3, 30-3, 40-3. At the two intersection points of the averages 10-1, 20-1, 30-1, 40-1 The two cutting edges of each cross-section merge into one another, which is reflected in the three perspectives of the Figures 1A, 1B and 1C which is very easy to see. From the perspective of Figure 1B concealed band area 5 the two band sections 25, 45 and band area 15 covers the band area 35. The band area is also covered. 5 the cut edge 10-2 , where a double arrow d in Figure 1Bindicates that a section of this cut edge 10-2 to the other cut edge 10-3 the same average 10-1 is spaced apart.

[0044] At the in Figures 1A to 1C The filler bodies shown, according to the invention, each define two cutting edges ( 10-3 and 20-2; 20-3 and 30-2; 30-3 and 40-2 ) neighboring averages (10-1 and 20-1; 20-1 and 30-1; 20-1 and 30-1 ) a band range ( 15, 25, 35 ). The respective band range ( 15, 25, 35 ) limiting cut edges ( 10-3 and 20-2; 20-3 and 30-2; 30-3 and 40-2 ) run parallel to each other in pairs.

[0045] The other two cutting edges as well ( 10-2 and 20-3; 20-2 and 30-3; 30-2 and 40-3 ) of the neighboring averages ( 10-1 and 20-1; 20-1 and 30-1; 20-1 and 30-1 ) run parallel to each other in pairs.

[0046] From the perspective of Figure 1A It is easy to see that each of the two cutting edges ( 10-2 and 10-3; 20-2 and 20-3; 30-2 and 30-3; 40-2 and 40-3 ) of the same average ( 10-1; 20-1; 30-1; 40-1 ) lie in a plane. The planes here converge towards the viewer. Thus, the intersection edges lying in the planes each appear as a straight line segment that coincides with the corresponding intersection.

[0047] In the Figure 2 The carbon fibers do not cross in the area indicated by the straight lines. This area is therefore unidirectional. BU of the fiber-reinforced carbon flat material 2. The figures do not show that the fibers embedded in the other band areas are also parallel and extend into the connection areas. 3 and 4 run into it. The fiber-reinforced carbon flat material 2It therefore comprises several pairs of unidirectional band regions ( BU-5 and BU-15; BU-15 and BU-25; BU-25 and BU-35; BU-35 and BU-45 ), each attached to the two cutting edges ( 10-2 and 10-3; 20-2 and 20-3; 30-2 and 30-3; 40-2 and 40-3 ) of the same average (10-1; 20-1; 30-1; 40-1) adjacent.

[0048] Out of Figures 1A and 2 It becomes clear that the unidirectional bandwidth BU-15 the entire area of ​​the band 15 occupies. The unidirectional band area BU -15 extends from one cutting edge 10-3 of the band range 15 to the other cut edge 20-2 the same band range 15 and from the first intersections of the two intersections 10-1, 20-1 up to the second intersection points of the two averages 10-1, 20-1. For example, the unidirectional area BU extend across the entire flat carbon material.

[0049] Not shown in the figures, the fiber-reinforced carbon flat material 2 can, and according to the solution according to claim 12 must, comprise at least one multidirectional region in which the fibers cross each other.

[0050] The in Figures 3A and 3B The press-cutting tools shown can be used in a process according to the invention for producing the shown filler body. According to the process, a starting flat material comprising fibers and a carbonizable matrix substance is fed into a press-cutting zone. In the press-cutting zone, the Figure 3A The press cutting tool shown is an upper counterpart to the one in Figure 3B lower press cutting tool shown; as in Figure 4 shown. In the press cutting zone, the area between the tools of the Figures 3A and 3BThe starting flat material is cut and trimmed, thus transforming it into filler green compacts. These filler green compacts can then be converted into filler bodies according to the invention by carbonization.

[0051] The press-cutting tools shown here as examples each comprise 9 (3 x 3) sections, at the transitions of which cutting edges 100 run along the lower press-cutting tool. The cutting edges 100 cut the fiber-reinforced flat material in the longitudinal and transverse directions so that 9 cut filler green bodies with the desired shape are obtained.

[0052] Each of the 9 sub-areas comprises plate-like, parallel cutting projections and, between them, parallel cutting projection receptacles that engage the cutting projections of the other press-cutting tool during the press-cutting process. On the surfaces (see e.g. 105, 125 and 145 in the first part of Figure 3B as well as115 and 135 in the first sub-area of Figure 3A ) the cutting edges come into contact with the band areas 5, 15, 25, 35, 45 for lying down. The averages 10-1, 20-1, 30-1, 40-1 These are created when the plate-like cutting projections penetrate the cutting projection recesses of the other cutting tool. In this process, two cutting edges (e.g., 120-2 and 120-3 as well as 130-2 and 130-3 ) along each other and thereby force the formation of the corresponding averages (averages) 20-1 and 30-1 for those mentioned here and in Figures 3A and 3B Cutting edges marked with reference symbols 120-2, 120-3, 130-2, 130-3 ).

[0053] It is also possible to use press cutting tools that do not comprise 3 x 3 sub-areas, but larger or smaller numbers of sub-areas, e.g., only one sub-area.

[0054] Figure 5 shows a filling body according to the invention with 3 connection areas.3, 4 and 6. It is only the perspective of Figure 1 A shown.

[0055] For the sake of clarity, only selected reference symbols are shown in the figures. Reference symbol list Filler 1 Carbon flat material 2 First main surface 2-1 Second main surface 2-2 Connection area 3, 4, 6 Band area 5, 15, 25, 35, 45 Average 10-1, 20-1, 30-1, 40-1 first cutting edge 10-2, 20-2, 30-2, 40-2 second cut edge 10-3, 20-3, 30-3, 40-3 unidirectional area BU unidirectional bandwidth BU-5, BU-15 Cutting edge 100 Cutting edge 120-2, 120-3, 130-2, 130-3 Surfaces 105, 115, 125, 135, 145

Claims

1. Filling body (1) for use in unstructured packings, wherein the filling body has a fibre-reinforced carbon flat material (2), and two strip regions (5, 15) of the carbon flat material, which are separated by a cut (10-1), transition into one another in two connecting regions (3, 4) of the carbon flat material, characterized in that at least some of the fibres running in at least one strip region (5, 15) extend into both connecting regions (3, 4).

2. Filling body (1) according to claim 1, comprising n cuts and n+1 strip regions, wherein n is a number selected from 2, 3, 4, 5, 6, 7, 8, 9, 10 or 11.

3. Filling body (1) according to claim 1, wherein the cut (10-1) defines a first cut edge (10-2) and a second cut edge (10-3), which transition into one another at a first and a second cut end of the cut (10-1), and a portion of one cut edge (10-2) is spaced apart from the other cut edge (10-3) of the same cut (10-1).

4. Filling body (1) according to claim 1, wherein two cut edges (10-3, 20-2) of adjacent cuts (10-1, 20-1) delimit the strip region (15), and the cut edges (10-3, 20-2) delimiting the strip region (15) run parallel to one another.

5. Filling body (1) according to claim 4, wherein the two other cut edges (10-2, 20-3) of the adjacent cuts (10-1, 20-2) also run parallel to one another.

6. Filling body (1) according to claim 1, wherein both cut edges (10-2, 10-3) of the same cut (10-1) lie in one plane.

7. Filling body (1) according to claim 1, wherein the fibre-reinforced carbon flat material (2) comprises fibres selected from glass fibres, basalt fibres and carbon fibres.

8. Filling body (1) according to claim 1, wherein the fibre-reinforced carbon flat material (2) comprises at least one unidirectional region (BU) in which the fibres do not cross.

9. Filling body (1) according to claim 8, wherein the fibre-reinforced carbon flat material (2) comprises at least two unidirectional strip regions (BU-5, BU-15) adjacent to both cut edges (10-2, 10-3) of the same cut (10-1).

10. Filling body (1) according to claim 8, wherein a unidirectional strip region (BU-15) extends from one cut edge (10-3) of the strip region (15) to the other cut edge (20-2) of the same strip region (15) and from the first cut ends of the two cuts (10-1, 20-1) to the second cut ends of the two cuts (10-1, 20-1).

11. Filling body according to claim 8, wherein the unidirectional region (BU) extends over the entire carbon flat material (2).

12. Filling body (1) for use in unstructured packings, wherein the filling body has a fibre-reinforced carbon flat material (2), and two strip regions (5, 15) of the carbon flat material, which are separated by a cut (10-1), transition into one another in two connecting regions (3, 4) of the carbon flat material, characterized in that the fibre-reinforced carbon flat material (2) comprises at least one multidirectional region (BM) in which the fibres cross.

13. Column having an unstructured packing comprising filling bodies according to one of claims 1 to 12.

14. Method for producing a filling body according to one of claims 1 to 12, wherein a fibre-reinforced starting flat material is fed into a press-and-cutting zone, and the starting flat material is shaped, cut up and cut through in the press-and-cutting zone so as to form a body which comprises a fibre-reinforced flat material and in which two strip regions of the flat material separated by a cut transition into one another in two connecting regions of the flat material.

15. Use of filling bodies according to claims 1 to 12 or a column according to claim 13 for the processing of fluids containing sour gas and / or halogen.