Structural filling materials

Abstract

The corrugated structured filler sheet has a combination of corrugations, including curvatures formed in the shape of the corrugations in a lower edge region of the structured filler sheet, and surface texturing on the opposing surface of the structured filler sheet in the form of a grid of dimple structures and raised structures. Each dimple structure is separated from some or all of its adjacent ones by raised structures. The raised structures form rows of peaks and interconnected saddles. Microchannels extend along adjacent ones of the dimple structures and the interconnected saddles. The surface texturing, when used in conjunction with the curved shape of the corrugations in the lower edge region, provided unexpected performance improvements.

Description

[Technical Field]

[0001] (Related Applications) This application claims priority to U.S. Provisional Patent Application No. 63 / 394,976, filed August 4, 2022, which is incorporated herein by reference in its entirety.

[0002] FIELD OF THE INVENTION The present invention relates generally to mass transfer columns, and more particularly to structured packing materials used to facilitate the transfer of mass and heat between fluids within such columns. [Background technology]

[0003] A mass transfer column is configured to contact at least two fluid streams to provide a product stream of a particular composition and / or temperature. As used herein, the term "mass transfer column" is intended to encompass columns whose primary purpose is the transfer of mass and / or heat. While some mass transfer columns, such as those utilized in multicomponent distillation and absorption applications, contact a vapor-phase stream with a liquid-phase stream, other mass transfer columns, such as extraction columns, may be designed to promote contact between two liquid phases of different densities. Mass transfer columns are often configured to contact an ascending vapor or liquid stream with a descending liquid stream, typically along multiple mass transfer surfaces disposed within the column. These transfer surfaces are generally defined by structures disposed within the column's interior volume that are configured to promote intimate contact between the two fluid phases. As a result of these mass transfer surfaces, the rate and / or extent of mass and heat transfer between the two phases is enhanced.

[0004] Structured packing is a type of mass transfer surface commonly used to improve heat and / or mass transfer performance in columns. Many different types of structured packing exist, most of which include multiple corrugated structured packing sheets positioned in an upright, parallel relationship and joined together to form a structured packing module with fluid passageways formed along the intersecting corrugations of adjacent sheets. The structured packing module may itself form a structured packing layer that fills the horizontal interior cross-section of a mass transfer column, or the packing module may be in the form of individual bricks positioned in an end-to-end parallel relationship to form the structured packing layer. Multiple structured packing layers are typically stacked on top of each other with the orientation of the sheets in one layer rotated relative to the sheets in adjacent structured packing layers.

[0005] It is generally desirable to maximize heat and / or mass transfer between the gas and liquid phases as they flow through a structured packing layer. This is typically achieved by increasing the specific surface area available for mass and energy transfer. However, fluids passing through a structured packing layer with a larger specific surface area will typically experience a higher pressure drop, which is undesirable from an operational standpoint.

[0006] One approach to improving the heat and / or mass transfer performance of structured packing without increasing the specific surface area of the structured packing layer is to use various types of surface texturing on the structured packing sheet. The surface texturing facilitates the diffusion of the liquid phase across the surface of the structured packing sheet, which then results in increased heat and / or mass transfer between the liquid and gas phases. A single type of surface texturing is typically applied to the entire surface area of the structured packing sheet.

[0007] One known type of surface texturing uses transversely extending grooves parallel to the top and bottom edges of a corrugated structured packing sheet. A potential drawback of this type of surface texturing is that if the structured packing sheet is not horizontal, the grooves will be inclined from the horizontal, causing liquid moving along the grooves to flow preferentially in one direction, leading to maldistribution of liquid and reduced mass transfer efficiency.

[0008] Another type of surface texturing, which typically has higher mass transfer efficiency than groove-type surface texturing, includes a uniform grid of depression and raised structures, where each depression structure is separated from an adjacent depression structure by a raised structure, such that depression structures on one side of the structured packing sheet form raised structures on the opposing side of the structured packing sheet, and vice versa.

[0009] The raised structures surrounding the recessed structures form rows containing ridges and interconnected saddles, and the saddle and recessed structures form rows of microchannels along which liquid preferentially flows. The rows and microchannels are inclined and intersect the top and bottom edges of the structured packing sheet at an angle. It has been found that liquid diffusion patterns can be influenced by these microchannels.

[0010] The capacity of a structured packing layer can also be limited by the behavior of the gas and liquid phases when they change flow direction at the interface between vertically adjacent structured packing layers. As a result of this change in flow direction, liquid tends to accumulate at the interface, which can cause a decrease in capacity and performance, especially at higher liquid loadings.

[0011] One approach to increasing the capacity of a structured packing layer and / or reducing the pressure drop at the interface involves modifications to the shape of the corrugations at the bottom of the structured packing layer. In one such variation, curvatures are formed in the shape of the corrugations at the bottom and optionally at the top of the structured packing layer so that the angle of the corrugations relative to the vertical axis of the mass transfer column gradually increases from the angle present in the bulk region of the structured packing layer to a larger angle at the bottom and optionally the top edge of the structured packing layer. This curved shape of the corrugations reduces premature accumulation of liquid at the interface of the structured packing layer and reduces the pressure drop that would otherwise exist at the interface. Summary of the Invention

[0012] In one aspect, the invention is directed to a structured filler module comprising a plurality of structured filler sheets positioned in an upright, parallel relationship and surface texturing on the structured filler sheets. Each structured filler sheet comprises opposing surfaces, upper and lower edges, a lower edge region adjacent the lower edge, a bulk region above the lower edge region, and corrugations formed from alternating peaks and valleys interconnected by corrugation sidewalls and extending in an oblique direction that forms an oblique angle relative to the upper and / or lower edges of the structured filler sheet. The structured filler sheets are constructed and arranged such that the corrugations of adjacent ones of the structured filler sheets intersect each other at an angle. Each structured filler sheet further includes curvatures formed in the shape of the corrugations in the lower edge region such that the angle of inclination of the corrugations relative to the lower edge gradually increases from the bulk region through the lower edge region. The surface texturing on the structured filler sheet comprises a grid of recessed and raised structures in the bulk region, each recessed structure separated from some or all of its adjacent ones by raised structures, the raised structures forming rows of ridges and interconnecting saddles, and microchannels extending along the grid and between adjacent ones of the recessed structures and the interconnecting saddles positioned between each of the adjacent ones of the recessed structures.

[0013] In another aspect, the invention is directed to a structured filler sheet comprising: opposing surfaces; upper and lower edges; a lower edge region adjacent the lower edge; a bulk region above the lower edge region; a plurality of openings extending through the structured filler sheet; corrugations formed from alternating peaks and valleys interconnected by corrugation sidewalls and extending in an oblique direction that forms an oblique angle relative to the upper and / or lower edges of the structured filler sheet; curvatures formed in the shape of the corrugations in the lower edge region such that the oblique angle of the corrugations relative to the lower edge gradually increases from the bulk region through the lower edge region; and surface texturing on the opposing surfaces. The surface texturing comprises a grid of recessed and raised structures, each recessed structure separated from some or all of its adjacent ones by raised structures, the raised structures forming rows of ridges and interconnecting saddles, and microchannels extending along the grid and between adjacent ones of the recessed structures and interconnecting saddles positioned between each of the adjacent ones of the recessed structures.

[0014] In a further aspect, the invention is directed to a structured packing sheet comprising: opposing surfaces; upper and lower edges; a lower edge region adjacent the lower edge; a bulk region above the lower edge region; a plurality of openings extending through the structured packing sheet; corrugations formed from alternating peaks and valleys interconnected by corrugation sidewalls and extending in an oblique direction that forms an oblique angle relative to the upper and / or lower edges of the structured packing sheet; curvatures formed in the shape of the corrugations in the lower edge region such that the oblique angle of the corrugations relative to the lower edge gradually increases from the bulk region through the lower edge region; and surface texturing on the opposing surfaces. The surface texturing comprises a grid of recessed and raised structures, each recessed structure separated from some or all of its adjacent ones by raised structures, the raised structures forming rows of ridges and interconnecting saddles, and microchannels extending along the grid and between adjacent ones of the recessed structures and interconnecting saddles positioned between each of the adjacent ones of the recessed structures. [Brief explanation of the drawings]

[0015] The accompanying drawings form part of the specification, and like numerals are used to refer to like elements in the various figures.

[0016] [Figure 1] FIG. 1 is a partial side view of a mass transfer column with the column shell taken in vertical section to show four layers of structured packing of the present invention positioned in a stacked arrangement within the mass transfer column. [Figure 2] FIG. 1 is a front perspective view of a corrugated structured filler sheet of the present invention forming part of a structured filler module and having openings and one embodiment of surface texturing comprising a grid of recessed and raised structures, the surface texturing being shown representatively to cover only certain portions of the sheet for ease of viewing and understanding, although in reality it may cover the entire sheet. [Figure 3] FIG. 1 is an enlarged partial view of a structured packing sheet having one embodiment of surface texturing comprising a grid of dimpled and raised structures in the form of conical peaks and valleys. [Figure 3a] FIG. 3 is a cross-sectional view taken along line 3a-3a in FIG. [Figure 3b] FIG. 3 is a cross-sectional view taken along line 3b-3b in FIG. [Figure 4] FIG. 10 is an enlarged partial view of a structured packing sheet having another embodiment of surface texturing comprising a grid of recessed and raised structures in the form of elongated ridge-like peaks and valleys. [Figure 4a] FIG. 4 is a cross-sectional view taken along line 4a-4a in FIG. [Figure 4b] FIG. 4 is a cross-sectional view taken along line 4b-4b in FIG. [Figure 5] FIG. 10 is an enlarged partial view of a structured packing sheet having yet another embodiment of surface texturing comprising a grid of dimple and ridge structures in the form of conical peaks and valleys with high saddles between rows of peaks and low saddles between rows of peaks. [Figure 5a] FIG. 5 is a cross-sectional view taken along line 5a-5a in FIG. [Figure 5b] FIG. 5 is a cross-sectional view taken along line 5b-5b of FIG. [Figure 6] FIG. 1 is a front perspective view of another embodiment of a corrugated structured packing sheet of the present invention, similar to the structured packing sheet shown in FIG. 2, but having curved corrugations in the upper edge region in addition to the curved corrugations in the lower edge region as shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0017] Referring now more particularly to the drawings, and initially to Figure 1, a mass transfer column suitable for use in mass transfer and heat exchange processes is generally designated by the numeral 10. Mass transfer column 10 includes an upright outer shell 12 that is generally cylindrical in shape, although other shapes, including polygonal, are possible and within the scope of the present invention. Shell 12 is of any suitable diameter and height and is constructed from one or more rigid materials that are desirably inert to or otherwise compatible with the fluids and conditions present during operation of mass transfer column 10.

[0018] The shell 12 of the mass transfer column 10 defines an open interior region 14 within which desired mass transfer and / or heat exchange occurs between the fluid streams. Typically, the fluid streams include one or more ascending vapor streams and one or more descending liquid streams. Alternatively, the fluid streams may include both ascending and descending liquid streams. The fluid streams travel to the mass transfer column 10 through any number of feed lines (not shown) positioned at appropriate locations along the height of the mass transfer column 10. One or more vapor streams may also be generated within the mass transfer column 10 rather than being introduced to the column 10 through feed lines.

[0019] Mass transfer column 10 also typically includes an overhead line (not shown) for removing vapor products or by-products, and an underflow branch line (not shown) for removing liquid products or by-products from mass transfer column 10. Other column components that are typically present, such as feed points, side draws, reflux lines, reboilers, condensers, vapor horns, and liquid distributors, are not illustrated in the drawings because illustration of these components is not considered necessary for an understanding of the present invention.

[0020] One or more structured packing layers 16 comprising a plurality of individual structured packing sheets 18 are positioned within the open interior region 14 and extend across the horizontal interior cross-section of the mass transfer column 10. In the illustrated embodiment, four structured packing layers 16 are arranged in vertically stacked relationship with one another, although it should be understood that more or fewer structured packing layers 16 may be provided.

[0021] In one embodiment, each layer of structured packing layer 16 is formed as a single structured packing module that extends completely across the horizontal interior cross-section of column 10. In another embodiment, each structured packing layer 16 is formed as a plurality of individual structured packing modules (not shown), referred to as bricks, that are positioned end-to-end in a side-by-side relationship to fill the horizontal interior cross-section of mass transfer column 10.

[0022] Structured packing layers 16 are each suitably supported within mass transfer column 10, such as on a support ring (not shown) secured to shell 12, on an underlying one of structured packing layers 16, or by a grid or other suitable support structure. In one embodiment, the bottom structured packing layer 16 is supported on a support structure, and the top structured packing layer 16 is stacked on top of the other and supported by the bottom structured packing layer 16.

[0023] Successive structured packing layers 16 are typically rotated relative to one another so that the individual structured packing sheets 18 in one of the packing layers 16 are positioned in a vertical plane that extends at an angle relative to the vertical plane defined by the individual structured packing sheets 18 in the adjacent packing layer(s). This rotation angle is typically 45 degrees or 90 degrees, but can be other angles if desired. The height of each structured packing element 16 may vary depending on the particular application. In one embodiment, the height is within a range of about 50 to about 400 mm.

[0024] The structured packing sheets 18 of each structured packing layer 16 are positioned in an upright, parallel relationship to one another. Each of the structured packing sheets 18 is constructed of a suitable rigid material, such as any of a variety of metals, plastics, or ceramics, having sufficient strength and thickness to withstand the processing conditions experienced within the mass transfer column 10.

[0025] 2 , each structured filler sheet 18 exhibits opposing front and back surfaces 20 and 22, opposing top and bottom edges 24 and 26, and opposing side edges 28 and 30. Each structured filler sheet 18 has a plurality of parallel corrugations 32 extending along some or all of the associated structured filler sheet 18. The corrugations 32 are formed of alternating peaks 34 and valleys 36 and corrugation sidewalls 38 extending between adjacent ones of the peaks 34 and valleys 36. The peaks 34 on the front surface 20 of each structured filler sheet 18 form valleys 36 on the opposite or back surface 22 of the structured filler sheet 18. Similarly, the valleys 36 on the front surface 20 of each structured filler sheet 18 form peaks 34 on the back surface 22 of the structured filler sheet 18.

[0026] In the illustrated embodiment, the corrugations 32 of each structured filler sheet 18 extend along the entire height and width of the structured filler sheet 18 and are generally triangular or sinusoidal in cross-section. Adjacent ones of the structured filler sheets 18 within each structured filler layer 16 are positioned in a face-to-face relationship such that the front side 20 of one of the structured filler sheets 18 faces the back side 22 of the adjacent structured filler sheet 18.

[0027] As described in more detail below, in one embodiment, such as that shown in FIG. 2 , the shape of the corrugations 32 in the lower edge region 40 adjacent the lower edge 26 of each structured filler sheet 18 differs from the shape of the corrugations 32 in the adjacent bulk region forming the remainder of the structured filler sheet 18. The lower edge region 40, in some embodiments, may span 5 to 30 percent, 5 to 25 percent, or 5 to 20 percent of the vertical distance from the lower edge 26 to the upper edge 24 of each structured filler sheet 18. In other embodiments, the lower edge region 40 may span 20 to 60 percent, 20 to 50 percent, 25 to 45 percent, or 30 to 40 percent of the distance from the lower edge 26 to the upper edge 24 of each structured filler sheet 18.

[0028] In other embodiments, such as shown in FIG. 6 , the shape of the corrugations 32 in both the lower edge region 40 and the upper edge region 42 adjacent the upper edge 24 of the structured filler sheet 18 differs from the shape of the corrugations 32 in the remaining bulk region. In the illustrated embodiment, the lower edge region 40 extends over a greater vertical distance than the upper edge region 42. For example, the lower edge region 40 can span 5 to 35 percent, 5 to 25 percent, 5 to 20 percent, or 30 to 35 percent of the distance from the lower edge 26 to the upper edge 24 of each structured filler sheet 18, while the upper edge region 42 may span 5 to 30 percent, 5 to 20 percent, 5 to 10 percent, or 20 to 25 percent. In other embodiments, the lower edge region 40 and the upper edge region 42 may span the same distance. For example, lower edge region 40 and upper edge region 42 may each span 5 to 35 percent, 5 to 25 percent, 5 to 20 percent, or 30 to 35 percent of the vertical distance from lower edge 26 to upper edge 24 of each structured filler sheet 18 .

[0029] Adjacent structured filler sheets 18 are further arranged such that the corrugations 32 of each structured filler sheet 18 extend across, or in a cross-corrugation manner, to the corrugations 32 in the adjacent sheet(s) of structured filler sheets 18. As a result of this arrangement, the corrugations 32 in each structured filler sheet 18 intersect at an angle with the corrugations 32 of each adjacent one of the structured filler sheets 18 in all or a portion of the bulk region and bottom edge region 40. In one embodiment, all of the peaks 34 of the corrugations 32 on the front side 20 of each structured filler sheet 18 contact the peaks 34 of the corrugations 32 on the back side 22 of an adjacent one of the structured filler sheets 18 in all or a portion of the bulk region and bottom edge region 40. In other embodiments, some of the peaks 34 of the corrugations 32 on the front surface 20 of a structured filler sheet 18 do not contact the peaks 34 on the back surface of an adjacent one of the structured filler sheets 18.

[0030] The peaks 34 and valleys 36 of the corrugations 22 are generally formed as curved arcs that may be defined by an apex radius. Generally, as the apex radius increases, the arc of curvature of the peaks 34 and valleys 36 increases, and conversely, for a given specific surface area, the length of the corrugation sidewalls 38 between the peaks 34 and valleys 36 decreases. The two corrugation sidewalls 38 of each corrugation 32 form an apex angle. The apex radius, apex angle, filler crimp height, and peak-to-peak 34 length are interrelated and may be varied to achieve a desired shape and specific surface area. Generally, as the crimp height decreases, the number of structured filler sheets 18 contained within each structured filler layer 16 (or module) and the associated specific surface area increase.

[0031] Corrugations 32 are inclined to form an acute angle, or, in regions near lower edge 26, to form a perpendicular angle relative to upper edge 24 and / or lower edge 26 of structured packing sheet 18. The angle of inclination may be selected to suit the requirements of the particular application in which structured packing sheet 18 is being used. In one embodiment, the angle of inclination in the bulk region may be in the range of 25 to 75 degrees. Specific examples of inclination angles are about 30 degrees, about 45 degrees, and about 60 degrees. Because upper edge 24 and lower edge 26 of structured packing sheet 18 are positioned perpendicular to the vertical axis of mass transfer column 10, corrugations 32 are also inclined relative to the vertical axis of mass transfer column 10. At each location on structured packing sheet 18, the angle of inclination of corrugations 32 relative to upper edge 24 and / or lower edge 26 of structured packing sheet 18 and the acute angle at which corrugations 32 are inclined relative to the vertical axis of mass transfer column 10 are complementary angles.

[0032] The shape of the corrugations 32 in the lower edge region 40 adjacent the lower edge 26 of the structured filler sheet 18 is modified to increase the capacity of the structured filler layer 16 and / or reduce the pressure drop as fluid flow passes through the transition zone at the interface between vertically adjacent structured filler layers 16. In one embodiment, as shown in FIG. 2 , curvatures 44 are formed in the shape of the corrugations 32 in the lower edge region 40 such that the slope angle of the corrugations 32 relative to the lower edge 26 of the structured filler sheet 18 gradually increases from the bulk region through the lower edge region 40 of the structured filler sheet 18. The slope angle of the corrugations 32 increases at the lower edge 26 of the structured filler sheet 18 to a slope angle in the range of 65-90 degrees, 75-90 degrees, or 85-90 degrees.

[0033] 6, curves 46 may be formed in the shape of the corrugations 32 in the upper edge region 42 of the structured packing sheet 18. The curves 46 in the upper edge region 42 are formed similarly to the curves 44 in the lower edge region 40.

[0034] The curvatures 44 of the shape of the corrugations 32 in the lower edge region 40 and, if present, the curvatures 46 of the shape of the corrugations 32 in the upper edge region 42, smoothly change the direction of the ascending vapor flow as it transitions between adjacent structured packing layers 16 and enters and exits the bulk region of the structured packing sheet 18. This smooth transition in vapor flow direction reduces premature accumulation of liquid at the interfaces of the structured packing layers 16 and reduces the pressure drop that would exist at the interfaces if the curved shapes were not used.

[0035] Some or all of the structured packing sheets 18 may be provided with a plurality of apertures 48 extending therethrough to facilitate vapor and liquid distribution within the structured packing layer 16. Each aperture 40 provides an open area to allow the passage of fluid through the associated packing sheet 18. The apertures 40 are typically uniformly distributed on the structured packing sheets 18. In one embodiment, an aperture 40 is provided on each structured packing sheet 18 within each structured packing layer 16.

[0036] The front surface 20 and / or back surface 22 of the structured packing sheet 18 may include one or more different types of surface texturing 49 to facilitate spreading and thereby maximize contact between ascending and descending fluid flow. In one embodiment, as shown in FIG. 3 , the surface texturing 49 includes a grid of dimple structures 50 and raised structures 52 on the front surface 20 and back surface 22 of the structured packing sheet 18. While only a few representative areas of the grid of dimple structures 50 and raised structures 52 are shown in FIG. 3 so that the corrugations 32 can be easily seen, it should be understood that the grid may cover the entire surface area of the structured packing sheet 18, or a sufficient portion thereof, to achieve the desired mass transfer efficiency. In one embodiment, the grid extends between the top edge 24 and the bottom edge 26 and between the side edges 28 and 30 to cover the entire surface area of the structured packing sheet 18. In another embodiment, the grid covers 70 to 95 percent of the total surface area of each structured packing sheet 18.

[0037] Each recessed structure 50 is separated from some or all of its adjacent recessed structures 50 by raised structures 52. The recessed structures 50 may be arranged in parallel rows and positioned in square, diamond, triangular, or other patterns. The raised structures 52 include peaks 54 and interconnecting saddles 56. The peaks 54 may be generally conical, as shown in FIGS. 3, 3a, and 3b, and 5, 5a, and 5b, or may be elongated to form a ridge shape, as shown in FIGS. 4, 4a, and 4b. Other shapes and / or configurations are possible and are within the scope of the present invention. Typically, at least some portions of the raised structures 52 on the front surface 20 are formed by at least some portions of the recessed structures 50 on the back surface 22, and vice versa. Thus, each of the cone-shaped peaks 54 may be formed by the conical end of one of the recessed structures 50 on the opposing surface 20 or 22 of the structured filler sheet 18. Similarly, each of the ridge peaks 54 may be formed by the ridge termination of one of the recessed structures 50 on the opposing surface 20 or 22 of the structured packing sheet 18 .

[0038] The surface texturing 49 includes microchannels, indicated by arrows 58, that extend along adjacent ones of the recessed structures 50 and the interconnecting saddles 56 of the raised structures 52 positioned between adjacent ones of the recessed structures 50. These microchannels 58 may intersect with the corrugation valleys 36 or extend parallel or substantially parallel to the corrugation valleys 36 to facilitate spreading of liquid over the front surface 20 and back surface 22 of the structured filler sheet 18. The orientation of the microchannels 58 relative to the top edge 24 and / or bottom edge 26 of the structured filler sheet 18, and therefore relative to the corrugation valleys 36, is selected to optimize spreading of liquid over the front surface 20 and back surface 22.

[0039] In one embodiment, some of the microchannels 58 extend in parallel relationship to the corrugation valleys 26. For example, one-third or one-half of the microchannels 58 may extend in parallel relationship to the corrugation valleys 26. In other embodiments, the microchannels 58 intersect the corrugation valleys 36 at an angle in the range of 20 to 75 degrees, which is understood to be the smallest possible intersection angle between the corrugation valleys 36 and the microchannels 52. In some embodiments, the angle may be in the range of 25 to 70 degrees or 30 to 65 degrees.

[0040] Two of the microchannels 58 extend in a crossing relationship with each other at a crossing angle in each recessed structure 50. The crossing angle in one embodiment may be in the range of 50 to 140 degrees. In other embodiments, the crossing angle may be in the range of 70 to 130 degrees or 85 to 95 degrees. The microchannels 58 may extend in a straight line as shown in FIG. 3, in a zigzag pattern as shown in FIG. 4, or in other manners as shown in FIG. 5. For example, in the embodiment of FIG. 6, the interconnecting saddles 56 of the raised structure 52 are higher between the rows of peaks 54 that form more barriers to fluid flow and lower between the rows of peaks 54 that form fewer barriers to fluid flow, resulting in more fluid flow within the microchannels 58 between the rows of peaks 54.

[0041] Comparative tests were conducted using a structured filler layer with two types of corrugations within the structured filler sheet and two types of surface texturing on the structured filler sheet. In one set of tests, the surface texturing commercially used on MONTZ-PAK™ Type B1 structured filler sheet was applied to a straight corrugated structured filler sheet and tested against the above-mentioned surface texturing 49 applied to the same type of straight structured filler sheet.

[0042] In another set of tests, surface texturing commercially used on MONTZ-PAK™ Type B1 structured filler sheet was applied to a structured filler sheet 18 having curvatures 44 in the lower region 40 and tested against the above-described surface texturing 49 applied to the same type of corrugated structured filler sheet 18 having curvatures 44 in the lower edge region 40. Generally, the surface texturing commercially used on MONTZ-PAK™ Type B1 structured filler sheet has a triangular pitch pattern and has finer, more densely packed dimple and ridge structures than the above-described surface texturing 49.

[0043] Prior to testing, it was expected that the effect of surface texturing on the performance of the structured filler layer would be independent of the shape of the corrugations in the structured filler sheet. In other words, it was expected that the performance of the surface texturing commercially used in MONTZ-PAK™ Type B1 structured filler sheet would carry over to a structured filler sheet having curvatures 44 within the corrugations 32 compared to surface texturing 49 on a straight corrugated structured filler sheet.

[0044] Surprisingly, that expectation was not supported by the comparative test data. Instead, the data showed that the surface texturing 49, when used in combination with the curvatures 44 in the corrugations 22, performed unexpectedly better than would have been predicted based on the comparative performance of the two surface textures when used with straight corrugation shapes. Thus, the comparative test data demonstrates that the surface texturing 49 performs differently depending on the shape of the corrugations on the structured filler sheet, and that improved synergistic performance is achieved by combining the surface texturing 49 with a corrugated structured filler sheet 18 having curvatures 44 in its lower edge region 40.

[0045] This unexpected performance improvement can be seen in the normalized comparative test data shown in the table below, where the straight corrugated structured filler sheet was KOCH-GLITSCH™ FLEXIPAC® 250Y structured filler sheet, the curved corrugated structured filler sheet 18 had curvatures 44 only in the lower edge region 40 and had the corrugated structure found in commercially available MONTZ-PAK™ B1-250MN structured filler, the MONTZ™ surface texturing was the surface texturing commercially used on MONTZ-PAK™ Type B1 structured filler sheet, and the KOCH-GLITSCH™ surface texturing was the surface texturing 49 described above and generally shown in Figures 3, 3a, and 3b and commercially used on KOCH-GLITSCH™ FLEXIPAC® 250Y structured filler sheet.

[0046] In the comparative test results shown in Table 1, the performance of the structured packing layer with MONTZ™ surface texturing was better than the performance of the structured packing layer with KOCH-GLITSCH™ surface texturing at 6 of 11 flow rates and was the same at 2 of 11 flow rates. This comparative performance between the two surface textures was expected to be seen when testing was also performed using a structured packing layer with curvatures 44 in the lower edge region 40. In other words, the structured packing layer with MONTZ™ surface texturing was expected to perform better than the structured packing layer with KOCH-GLITSCH™ surface texturing when the shape of the corrugations changed in the lower edge region.

[0047] Instead, as unexpectedly shown in Table 2, the structured filler layer with KOCH-GLITSCH™ surface texturing, when curvatures 44 were added to the corrugations 22 in the lower edge region 40, performed better than the structured filler layer with MONTZ™ surface texturing in 8 of 11 flow rates and identical in 2 of 11 flow rates. This performance improvement suggests that the use of surface texturing 49 in combination with curvatures 44 in the lower edge region 40 of the structured filler sheet 18 creates some kind of synergistic interaction.

[0048] [Table 1]

[0049] [Table 2]

[0050] From the foregoing, it will be seen that this invention is one well adapted to attain all of the ends and objectives hereinabove set forth, together with other advantages inherent in its construction.

[0051] It will be understood that certain features and subcombinations are of utility and may be used independently of other features and subcombinations, which are contemplated by and within the scope of the present invention.

[0052] Since many possible embodiments may be made of the present invention without departing from the scope of the present invention, it is to be understood that all matter set forth in this specification or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

Claims

1. 1. A structured packing module comprising: a plurality of structured filler sheets positioned in an upright, parallel relationship, each structured filler sheet comprising: An opposing surface; an upper edge and a lower edge; a lower edge region adjacent to the lower edge; a bulk region above the lower edge region; a plurality of apertures extending through the structured packing sheet; a plurality of structured filler sheets, the structured filler sheets comprising: corrugations interconnected by corrugation sidewalls and formed from alternating peaks and valleys extending in oblique directions that form oblique angles relative to one or both of the top and bottom edges of the structured filler sheets, the structured filler sheets being constructed and arranged such that the corrugations of adjacent ones of the structured filler sheets intersect each other at an angle; a curvature formed in the shape of the corrugations in the lower edge region such that the angle of inclination of the corrugations relative to the lower edge gradually increases from the bulk region through the lower edge region; a surface texturing on the structured packing sheet; Equipped with The surface texturing may be a grid of recessed and raised structures within the bulk region, each recessed structure separated from some or all of its adjacent ones by raised structures, the raised structures forming rows of ridges and interconnecting saddles; and microchannels extending along adjacent ones of the recessed structures and the interconnecting saddles positioned between each of the adjacent ones of the recessed structures.

2. 2. The structured packing module of claim 1, wherein the angle of inclination of the corrugations at the lower edge is in the range of 65 to 90 degrees.

3. 2. The structured filler module of claim 1, wherein the angle of inclination of the corrugations at the lower edge is in the range of 75 to 90 degrees.

4. 4. The structured filler module of claim 3, wherein the dimple structures are arranged in parallel rows, and the interconnecting saddles of the raised structures connect adjacent dimple structures in each row.

5. 5. The structured filler module of claim 4, wherein each of the peaks of the raised structures is conical in shape and is formed by the conical termination of one of the recessed structures on the opposing surface of the structured filler sheet.

6. 5. The structured filler module of claim 4, wherein each of the peaks of the raised structures is ridge-shaped and is formed by the termination of a ridge shape of one of the recessed structures on the opposing surface of the structured filler sheet.

7. 5. The structured packing module of claim 4, wherein some of said microchannels extend in parallel relationship with said corrugation valleys.

8. an upper edge region adjacent to the upper edge; and further curvatures formed in the shape of the corrugations in the upper edge region such that the angle of inclination of the corrugations relative to the upper edge gradually increases from the bulk region through the upper edge region.

9. 10. The structured filler module of claim 1, wherein the lower edge region spans 5 to 30 percent, 5 to 25 percent, 5 to 20 percent, 20 to 60 percent, 20 to 50 percent, 25 to 45 percent, or 30 to 40 percent of the distance from the lower edge to the upper edge of the structured filler sheet.

10. The structured packing module of claim 1 , wherein the plurality of openings are uniformly distributed on the structured packing sheet.

11. 1. A structured packing sheet comprising: An opposing surface; an upper edge and a lower edge; a lower edge region adjacent to the lower edge; a bulk region above the lower edge region; a plurality of apertures extending through the structured packing sheet; corrugations formed from alternating peaks and valleys interconnected by corrugation sidewalls and extending in an oblique direction that forms an oblique angle relative to one or both of the top and bottom edges of the structured packing sheet; a curvature formed in the shape of the corrugations in the lower edge region such that the angle of inclination of the corrugations relative to the lower edge gradually increases from the bulk region through the lower edge region; surface texturing on said opposing surface; Equipped with The surface texturing may be 1. A structured packing sheet comprising: a grid of recessed and raised structures, each recessed structure separated from some or all of its adjacent ones by a raised structure, the raised structures forming rows of ridges and interconnecting saddles; and microchannels extending along adjacent ones of the recessed structures and the interconnecting saddles positioned between each of the adjacent ones of the recessed structures.

12. 12. The structured packing sheet of claim 11, wherein the angle of inclination of the corrugations at the bottom edge is in the range of 65 to 90 degrees.

13. 12. The structured packing sheet of claim 11, wherein the angle of inclination of the corrugations at the bottom edge is in the range of 75 to 90 degrees.

14. 12. The structured packing sheet of claim 11, wherein the dimple structures are arranged in parallel rows, the interconnecting saddles of the raised structures connecting adjacent dimple structures in each row.

15. 12. The structured packing sheet of claim 11, wherein each of the peaks of the raised structures is conical in shape and is formed by the conical termination of one of the recessed structures on the opposing surface of the structured packing sheet.

16. 16. The structured packing sheet of claim 15, wherein each of the peaks of the raised structures is ridge-shaped and is formed by the termination of a ridge shape of one of the recessed structures on the opposing surface of the structured packing sheet.

17. 17. The structured packing sheet of claim 16, wherein some of the microchannels extend in parallel relationship with the corrugation valleys.

18. 17. The structured packing sheet of claim 16, wherein two of the microchannels extend relative to one another in each recessed structure at an intersection angle in the range of 50 to 140 degrees.

19. 12. The structured filler sheet of claim 11, wherein the bottom edge region spans 5 to 30 percent, 5 to 25 percent, 5 to 20 percent, 20 to 60 percent, 20 to 50 percent, 25 to 45 percent, or 30 to 40 percent of the distance from the bottom edge to the top edge of the structured filler sheet.

20. 1. A structured packing sheet comprising: An opposing surface; an upper edge and a lower edge; a lower edge region adjacent the lower edge, the lower edge region spanning 25 to 45 percent of the distance from the lower edge to the upper edge of the structured filler sheet; a bulk region above the lower edge region; a plurality of apertures extending through the structured packing sheet; corrugations formed from alternating peaks and valleys interconnected by corrugation sidewalls and extending in an oblique direction that forms an oblique angle relative to one or both of the top and bottom edges of the structured packing sheet; a curvature formed in the shape of the corrugations in the lower edge region such that the angle of inclination of the corrugations relative to the lower edge gradually increases from the bulk region through the lower edge region, the angle of inclination at the lower edge being in the range of 65 to 90 degrees; surface texturing on said opposing surface; Equipped with The surface texturing may be 1. A structured filler sheet comprising: a grid of recessed and raised structures, each recessed structure separated from some or all of its adjacent ones by a raised structure, the raised structures forming rows of ridges and interconnecting saddles; and microchannels extending along adjacent ones of the recessed structures and the interconnecting saddles positioned between each of the adjacent ones of the recessed structures, the recessed structures being arranged in parallel rows, the interconnecting saddles of the raised structures connecting adjacent recessed structures in each row.

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