Plant and process for efficiently producing structured cross-channel packing elements

Abstract

The present invention relates to a plant for producing structured cross-channel packing elements for columns for mass transfer and / or heat exchange between a heavy fluid phase and a light fluid phase, the structured cross-channel packing element having at least two adjacent layers made of expanded metal sheets each having openings, the openings being surrounded by and separated from one another by separating elements, the expanded metal sheets having periodic deformations, at least two of the at least two layers being arranged parallel to and in contact with one another in the longitudinal direction of the packing element, so that an open space is provided between the at least two layers, extending from one end to the opposite end of the at least two layers, so that at least one of the heavy and light fluid phases can flow therethrough. The plant comprises: a) a drawing machine for cutting and drawing metal sheets into expanded metal sheets; b) optionally a calibration machine for rolling the expanded metal sheets produced in the drawing machine (a) to a desired thickness; c) a sheet storage unit; d) a forming machine for shaping the expanded metal sheets produced in the drawing machine and optionally rolled in the optional calibration machine into expanded metal sheets with periodic deformed portions; and e) a stacking machine for stacking the expanded metal sheets with periodic deformed portions into structured cross-channel packing elements, wherein the sheet storage unit is embodied to directly receive the expanded metal sheets produced in the drawing machine and optionally rolled in the optional calibration machine and to release the expanded metal sheets directly to the forming machine.

Description

[Technical Field]

[0001] The present invention relates to a plant and process for efficiently producing structured cross-channel packing elements for columns for mass transfer and / or heat exchange between heavy and light fluid phases. [Background technology]

[0002] Structured packing elements are used in mass transfer columns, such as in fractional distillation columns, distillation columns, absorption columns, extraction columns, or flue gas scrubbers. Structured packing elements function to improve mass transfer and / or heat transfer between at least two fluid phases of different densities, and are typically operated in counterflow. In distillation and absorption applications, the light phase is a gas or vapor and the heavy phase is a condensate or liquid, whereas in extraction processes, both phases are liquids with different densities. Structured packing elements have multiple different layers, each of which provides surface area for the heavier phase. The heavier phase flows and diffuses slowly downward along the surface of the layers. In addition, there are empty spaces between the different layers of the structured packing element, which are filled with the light phase (e.g., vapor or gas in distillation), and these empty spaces provide a path for the ascending light phase, during which the light phase is moved by a pressure gradient. The pressure gradient is necessary to overcome flow resistance. In a common example of counterflow mass transfer, the mean flow direction of the light phase is from the bottom to the top of the structured packing element, and therefore opposite to the mean flow direction of the heavy phase. By allowing one heavy phase to diffuse on the surface of the structured packing element, an interface is created between at least two phases, and as a result, efficient heat transfer and mass transfer between the phases are established at the interface. There may also be applications using two or more heavy phases. One example is extractive distillation.

[0003] Mass transfer columns typically have multiple beds of structured packing elements. Dispersers are usually positioned at the top of each bed to uniformly distribute the heavy phase across the cross-section of the bed, leaving sufficient space for the light phase to ascend through it. In addition, grid-like holding devices and collection devices are often positioned below each bed, with the grid structure holding the bed in place and the collection device collecting the heavy phase as it slowly flows downward from the bed, while leaving sufficient space within the collection device for the light phase to ascend.

[0004] A common type of structured packing element is the so-called cross-channel corrugated sheet packing, which is assembled from, for example, multiple corrugated sheets, with the sheets parallel to and in contact with each other. Typically, the corrugated metal sheets are fastened to each other by multiple rods that penetrate the corrugated sheets perpendicular to the longitudinal section of the corrugated sheets, and the rods are fastened to the first and last corrugated sheets by washers and nuts, or by bending the rods. Each corrugated sheet has multiple periodic deformation sections, such as alternating crests and valleys, and adjacent corrugated sheets are oriented so that the corrugations of these adjacent corrugated sheets intersect in a cross shape with the corrugations of corrugated sheets extending diagonally to the vertical or longitudinal direction, thereby forming a continuously traversing inclined channel. These channels have a positive effect on the flow of the gas and liquid phases within the packing and promote mass transfer between the phases. In other words, the gas and liquid phases are brought into contact within the channels of the structured packing element, and therefore mass transfer and even heat transfer between the phases are promoted. More specifically, the ascending gas comes into contact with the liquid present on the surface of the sheet and forms a channel as it flows downward through the mass transfer column. During this contact, components abundant in the gas are transferred into the liquid and vice versa. This means that efficient mass transfer is taking place. These packings are disclosed, for example, in DE1253673, CA1270751, and U.S. Patent No. 6,206,349(B1).

[0005] The amount of mass transfer per unit time is proportional to the area of ​​the interface between the gas and the liquid, and the interface area increases as the portion of the surface of the packing element's layer that is wetted by the liquid increases. Cross-channel corrugated sheet packing made of wire mesh is known to have good wetting properties thanks to the good diffusion of the biphase on the surface of the corrugated sheet due to the capillary force of the wire mesh, and therefore (thanks to this good wetting properties) high mass transfer efficiency. However, mesh of metal wire is an expensive material. An alternative proposal to facilitate the diffusion of the biphase on the surface of the layer (instead of using wire mesh or very precise corrugated expanded metal sheets as the material for structured packing elements) is to provide a porous layer and another surface texture, as disclosed in U.S. Patent No. 4,296,050, GB1,569,828, U.S. Patent No. 4,981,621, and EP3003550A1, etc. In addition, CN88200252U proposes providing cross-channel corrugated sheet packing made of expanded metal sheets, i.e., perforated layers having a high porosity, i.e., a large quotient when the total area of ​​openings in the layer is divided by the sheet area of ​​the layer. Another unique advantage of such cross-channel corrugated sheet packing made of expanded metal sheets is that these sheet packings are relatively efficient.

[0006] Typically, cross-channel corrugated sheet packing made from expanded metal sheets is produced by forming corrugated sheets from expanded metal sheets obtained from suppliers, cutting these corrugated sheets to the desired size, and stacking them to form structured packing elements. The expanded metal sheets themselves are usually produced by suppliers by cutting and stretching metal sheets almost simultaneously. However, producing cross-channel corrugated sheet packing using expanded metal sheets obtained from suppliers incurs transportation costs. Furthermore, for transportation and further processing, the expanded metal sheets need to be wound under tension onto a sleeve made, for example, cardboard. However, because each expanded metal sheet has a structured surface, the expanded metal sheets cannot be wound precisely "edge-on-edge". Rather, individual expanded metal sheets placed on top of each other will shift relative to each other, creating tension within the coil, which negatively affects further processing. Furthermore, if a single sheet shifts, at least a portion of it will protrude from the sleeve, causing the protruding portion to easily deform during transport. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] DE1253673 [Patent Document 2] CA1270751 [Patent Document 3] U.S. Patent No. 6,206,349(B1) [Patent Document 4] U.S. Patent No. 4,296,050 [Patent Document 5] GB1,569,828 [Patent Document 6] U.S. Patent No. 4,981,621 [Patent Document 7] EP3003550A1 [Patent Document 8] CN88200252U [Overview of the project] [Problems that the invention aims to solve]

[0008] In view of the above, the fundamental objective of the present invention is to provide a plant and process for the rapid and cost-effective production of structured cross-channel packing elements for columns for mass transfer and / or heat exchange between heavy and light fluid phases, overcoming the drawbacks mentioned above. [Means for solving the problem]

[0009] According to the present invention, this objective is achieved by providing a plant for producing structured cross-channel packing elements for columns for mass transfer and / or heat exchange between a heavy fluid phase and a light fluid phase, wherein the structured cross-channel packing element has at least two adjacent layers made of expanded metal sheets, each having an opening, the openings being surrounded by separation elements and separated from each other by these separation elements, the expanded metal sheets having a periodic deformation portion, and at least two of the at least two layers being arranged parallel to and in contact with each other in the longitudinal direction of the packing element, resulting in an open space being provided between these at least two layers extending from one end to the opposite end of the at least two layers, thereby allowing at least one of the heavy phase and the light fluid phase to flow through it, and the plant: a) A stretching machine for cutting and stretching metal sheets to make expanded metal sheets, b) An optional calibration machine for rolling the expanded metal sheet produced in the stretching machine (a) to a desired thickness, c) Sheet storage unit, d) A forming machine for forming an expanded metal sheet produced in a stretching machine and optionally rolled in an optionally calibrating machine into an expanded metal sheet having a periodic deformation portion, e) A stacking machine for stacking expanded metal sheets having periodic deformation sections to form structured cross-channel packing elements. It has, The sheet storage unit is embodied to directly receive expanded metal sheets produced in a stretching machine and optionally rolled in an optional calibration machine, and to directly release the expanded metal sheets to a forming machine.

[0010] By providing a sheet storage unit between the stretching machine and the forming machine, the different speeds of the stretching machine and the forming machine can be compensated for or mitigated, respectively, and as a result, structured cross-channel packing elements can nevertheless be produced in a semi-continuous process. More specifically, the stretching machine and the forming machine operate in a stroke-type or hub-type manner, respectively, and the length of the sheet transported in one stroke of the stretching machine is the product of the width of the separating element and the stretching coefficient, and the metal sheet is stretched in the stretching machine by this stretching coefficient, while the length of the sheet transported in one stroke of the forming machine is the quotient obtained by dividing the distance between two adjacent periodic deformation portions of the sheet by the cosine of angle α, thereby the corrugation is inclined at an angle α with respect to the longitudinal direction. For example, in the case of an expanded metal sheet having a distance of 20 mm between two adjacent periodic deformation sections, an angle α of 45°, and a stretching coefficient of 1.25, the length of the sheet transported in one stroke of the stretching machine is 2.5 mm, compared to the length of the sheet transported in one stroke of the forming machine, which is 28.3 mm. Therefore, an expanded metal sheet prepared in a stretching machine and rolled in an optional calibration machine cannot be directly transported into a forming machine.

[0011] Another unique advantage of the present invention is that it allows the expanded metal sheet to maintain its orientation as it is produced in the stretching machine and released from the stretching machine before being fed into the forming machine. In other words, the plant of the present invention allows the expanded metal sheet to be transported into the forming machine in the stretching direction. This is particularly advantageous for the following reasons: after production, i.e., after cutting and stretching of the metal plate, the resulting expanded metal sheet is no longer flat and has a structured surface. This is the result of deformation, strain, bending, or bouncing of individual separation elements, as well as the relative deformation of the separation elements to other parts, e.g., inclination. The expanded metal sheet has a flat flank on the stretching direction side and a steep flank on the opposite direction side, as shown in Figure 7. Therefore, by transporting the expanded metal sheet into the forming machine in the stretching direction, the expanded metal sheet is transported so that its flat flank side enters the forming machine. However, in the conventional technique, the expanded metal sheet is first wrapped around a sleeve, and then unwound from the sleeve, thereby forcibly reversing the direction of transport of the expanded metal sheet. Consequently, in the conventional technique, the expanded metal sheet is transported so that its steep flank side enters the forming machine, which hinders the transport of the expanded metal sheet. Furthermore, this has the disadvantage that the expanded metal sheet may become immobile, thereby causing forming errors, i.e., undesirable deformations, and that the steep flank causes the forming tool to wear down more strongly and quickly than a flat flank.

[0012] The sheet storage unit is embodied to directly receive an expanded metal sheet produced in a stretching machine and optionally rolled in an optional calibration machine and directly release the expanded metal sheet to a forming machine. This feature means that when the plant does not have a calibration machine, the sheet storage unit is embodied to directly receive the expanded metal sheet produced in the stretching machine from the stretching machine, and when the plant has a calibration machine, the sheet storage unit is embodied to directly receive the rolled expanded metal sheet produced in the stretching machine and rolled by calibration from the calibration machine.

[0013] The longitudinal direction of the structured packing element is the average direction of the structured packing element during its operation, such as in a column for mass transfer and / or heat exchange, such as in a rectification column, when the light phase ascends and the heavy phase descends. Due to the interaction with the shape of the structured packing element, the light phase may be split into a plurality of streams having different directions as a whole, but the average direction of the light phase coincides with the longitudinal direction, which is usually close to the vertical direction.

[0014] Normally, the stretching machine operates in a stroke manner at a first stroke frequency, that is, it is operable to operate in such a manner, and the forming machine operates in a stroke manner at a second stroke frequency, that is, it is operable to operate in such a manner, and the first stroke frequency is higher than the second stroke frequency.

[0015] As described above, the stretching machine is operable to release an expanded metal sheet of a first length during each stroke, and the forming machine is operable to release an expanded metal sheet of a second length having periodic deformation portions during each stroke, and usually, the first length is shorter than the second length.

[0016] More specifically, the stretching machine usually has a higher stroke frequency than the forming machine, but transfers an expanded metal sheet of a shorter length than the forming machine during one stroke. Therefore, when the stroke of the forming machine is started, the forming machine requires a sheet length longer than that transferred by the stretching machine per given time interval, whereas after the end of the stroke of the forming machine, until the next stroke of the forming machine is started, the stretching machine still releases the sheet length not required by the forming machine at this time. According to the present invention, the different material requirements of the stretching machine and the forming machine in different stroke cycles of both machines are compensated or alleviated by the sheet storage unit respectively.

[0017] Without applying tension and / or pressure such as that generated when winding an expanded metal sheet around a sleeve made of, for example, cardboard, and thus without deforming the expanded metal sheet, the sheet storage unit can store, in a short time, i.e., in less than one minute, the expanded metal sheet produced in the stretching machine and optionally rolled in an optional calibration machine, as long as it can. In other words, the sheet storage unit, according to the present invention, means any machine that enables temporarily storing the expanded metal sheet produced in the stretching machine and optionally the calibration machine before transferring it into the forming machine, which aims to disconnect the stretching machine and the forming machine so as to enable balancing the respective differences in the release speed or feed speed of the stretching machine and the forming machine without requiring stopping either or both of the stretching machine and the forming machine.

[0018] Preferably, the sheet storage unit has at least two orientation-changing means designed to change the orientation of the expanded metal sheet produced in the stretching machine for temporary storage in the sheet storage unit.

[0019] According to one variant of this embodiment, at least one, and preferably all, of the at least two orientation means are movable to allow for a change in the distance between the at least two orientation means. This makes it possible to load the expanded metal sheets produced by the stretching machine and optionally rolled in the optionally selected calibration machine into the sheet storage unit during the time interval between two strokes of the forming machine by simply increasing the distance between the at least two orientation means in proportion to the excess sheet length received from the stretching machine or calibration machine, respectively, that is not required by the forming machine at this point. Furthermore, this makes it possible to remove the sheet storage unit from the expanded metal sheets stored inside during the time interval between one stroke of the forming machine by simply decreasing the distance between the at least two orientation means in proportion to the excess sheet length required by the forming machine that exceeds the sheet length received from the stretching machine or calibration machine, respectively, at this point.

[0020] Preferably, the sheet storage unit has at least two orientation rollers, and at least one, or preferably all, of these at least two orientation rollers is movable to allow a change in the distance between at least two orientation rollers. Again, this allows expanded metal sheets produced by the stretching machine and optionally rolled in an optionally selected calibration machine to be loaded into the sheet storage unit during the time interval between two strokes of the forming machine by simply increasing the distance between the rollers in proportion to the excess sheet length received from each stretching machine or calibration machine that is not required by the forming machine at this point. Furthermore, this allows the sheet storage unit to be removed from the expanded metal sheets stored inside during the time interval between one stroke of the forming machine by simply decreasing the distance between the rollers in proportion to the excess sheet length required by the forming machine that exceeds the sheet length received from each stretching machine or calibration machine at this point.

[0021] Specifically, good results are obtained when the sheet storage unit has at least four, more preferably at least six, and most preferably at least eight orientation rollers. Regardless of the number of orientation rollers, one or more, and preferably all, of the orientation rollers are movable preferably vertically, horizontally, and / or in any other direction, so that the distance between at least two of the rollers, and preferably between each pair of rollers, can be changed vertically, horizontally, and / or in any other direction. This results in each sheet storage unit having a very high capacity for expanded metal sheets, while requiring only a relatively small area.

[0022] According to another variation of this embodiment of the present invention, not all of the reversing rollers are movable; rather, only one reversing roller, or two or more but not all of the reversing rollers, are movable.

[0023] According to yet another variation of this embodiment of the present invention, the sheet storage unit has at least two orientation changing means, at least one orientation roller and at least one orientation plate, wherein at least one orientation roller is movable and preferably at least one orientation plate is curved. If the storage unit has two or more orientation rollers, only one orientation roller, some of the orientation rollers, or all of the orientation rollers may be movable. Furthermore, none of the at least one orientation plate may be movable, one or more orientation plates may be movable, or all of the orientation plates may be movable. The sheet storage unit of this embodiment may have at least two, at least four, or at least six orientation rollers and at least two, at least four, or at least six orientation plates. The orientation plate is embodied to change the orientation of the expanded metal sheet from an upstream orientation means to a downstream orientation means, or, in the case of the furthest downstream orientation means, from the upstream orientation means to the forming machine, or, in the case of the furthest upstream orientation means, from the upstream stretching machine or an optional calibration machine to the downstream orientation means. This is preferably achieved by each curved portion of the orientation plate. The total distance of the expanded metal sheet within the sheet storage unit is then adjusted by at least one movable orientation roller and / or at least one orientation means, if present.

[0024] According to yet another variation of this embodiment of the present invention, the sheet storage unit has at least two orientation means, but no orientation rollers, and at least two, preferably at least four, more preferably at least six, and most preferably at least eight orientation plates. At least one, two or more, or all of the orientation plates may be movable so as to allow a change in the distance between at least two orientation plates. Preferably, at least one orientation plate is curved. The operating principle is the same as in the embodiment having movable orientation rollers.

[0025] According to yet another variation of this embodiment of the present invention, the sheet storage unit has at least two orientation means, but no orientation rollers, and has at least two, preferably at least four, more preferably at least six, and most preferably at least eight orientation plates, and none of the at least two orientation means are movable, i.e., all of the orientation means are fixed. Preferably, at least one orientation plate is curved. In this example, the storage of the expanded metal sheet is carried out such that the expanded metal sheet is pushed into the space between the orientation means for storage in the sheet storage unit by pushing the expanded metal sheet on the upstream orientation plate more quickly than pulling the expanded metal sheet on the downstream orientation plate so that a longer length of the expanded metal sheet exists in the storage unit. When the storage unit is removed, the expanded metal sheet is pulled on the downstream orientation plate more quickly than it is pushed on the upstream orientation plate, resulting in a shorter length of the expanded metal sheet being present in the storage unit.

[0026] Any conventional stretching machine can be used in this invention, insofar as it is suitable for producing expanded metal sheets from metal sheets. Typically, the stretching machine has at least one knife for cutting and stretching the metal sheet in the same stroke of the stretching machine as the metal sheet is fed through the stretching machine using a pressure-induced slitting and stretching process. More specifically, the slits created by the knife allow the metal to be stretched to create uniform openings. To ensure a consistent pattern, the stretching machine is programmed and operated manually or automatically based on the programming used when feeding the metal through it.

[0027] As described above, a calibration machine may or may not be included in the plant. However, preferably the plant has a calibration machine. Any conventional calibration machine can be used in the present invention, insofar as it is suitable for rolling the expanded metal sheet to the desired thickness. If present, the calibration machine is located between the stretching machine and the sheet storage unit. Preferably the calibration machine has at least two rollers through which the expanded metal sheet is fed and pressure is applied, thereby rolling the expanded metal sheet to the desired thickness.

[0028] Furthermore, any conventional forming machine can be used in the present invention, insofar as it is suitable for forming an expanded metal sheet having a periodic deformation portion. Preferably, the forming machine has one or more first forming units for pleating the expanded metal sheet, a device for continuously advancing the expanded metal sheet to one or more first forming units, and at least one device for removing the pleated expanded metal sheet.

[0029] In a further development of the idea of ​​the present invention, it is proposed that the forming machine further comprises one or more second forming units for reshaping a pleated expanded metal sheet, wherein the forming machine has a pair of rollers that do not have an outline for reshaping in the intermediate zone but have an outline for reshaping in the terminal zone. This makes it possible to bend the periodic deformation portions within the terminal portions of the expanded metal sheet of the structured packing element relative to the periodic deformation portions of the central portion located between the terminal portions. Thus, the peaks and valleys of the expanded metal sheet in this embodiment do not extend linearly. Preferably, the periodic deformation portions are bent within the terminal portions of the expanded metal sheet so as to extend at least substantially vertically. Substantially vertical means that the peaks and valleys at the lower and upper edges of the expanded metal sheet do not slope more than 10°, preferably more than 5°, and more preferably more than 2° with respect to the vertical. This reduces the flow resistance in the terminal zones of the structured packing element relative to the flow resistance of the zones located between the terminal zones, thereby reducing the pressure loss of the structured packing element.

[0030] Alternatively, the forming machine may have a lower tool element and an upper tool element, each of which has a front and a rear side. The lower tool element has a first base element and a first finger element protruding from the first base element, the first finger element forming a first ridge for forming the peaks of a wave in the sheet, and the upper tool element has a second base element and a second finger element protruding from the second base element, the second finger element forming a second ridge for forming the valleys of a wave in the sheet. The first ridge is positioned opposite the second ridge, and the first ridge is positioned diagonally from the second ridge, thereby enabling engagement of the first finger element and the second finger element at the engagement position. Each of the first and second ridges has a main portion and an end portion, and the angle between each of the first and second ridges in the main portion and the corresponding front side is at least partially different from the angle between each of the first and second ridges in the end portion and the corresponding front side. Furthermore, a space may be provided between the first finger element and the nearby second finger element in the engagement position. This space is defined in the plane into which the sheet enters the shaping tool. Thus, this space is an empty space. When the upper and lower tool elements are in their engagement positions, this empty space exists between the main portion and the end portion. Thus, the sheet is in contact with the upper and lower tool elements only at the ridges of the finger elements forming its apex, thus the peaks. Between the ridges of the first and second finger elements, the sheet is not in contact with either finger element and can be freely formed in the space between the two adjacent apex portions.

[0031] Furthermore, any conventional stacking machine can be used in the present invention, insofar as it is suitable for stacking expanded metal sheets having periodic deformation portions on top of each other to form a structured cross-channel packing element. Preferably, the stacking machine has one or more rotary cutting wheels for cutting expanded metal sheets having periodic deformation portions to a desired size, and a stacking unit for stacking the cut expanded metal sheets having periodic deformation portions to form a structured cross-channel packing element.

[0032] Another aspect of the present invention is a process for producing a structured cross-channel packing element for a column for mass transfer and / or heat exchange between a heavy fluid phase and a light fluid phase, wherein the structured cross-channel packing element has at least two adjacent layers made of expanded metal sheets, each having an opening, the openings being surrounded by a separation element and separated from each other by this separation element, the expanded metal sheets having a periodic deformation portion, and at least two of the at least two layers being arranged parallel to and in contact with each other in the longitudinal direction of the packing element, thereby providing an open space between these at least two layers extending from one end to the opposite end of the at least two layers, thereby allowing at least one of the heavy phase and the light fluid phase to flow through it, the process comprising the following steps: a) Steps of cutting and stretching a metal sheet in order to make an expanded metal sheet, b) Optionally, roll the expanded metal sheet produced in step (a) to the desired thickness. c) A step of sending the expanded metal sheet produced in step (a), or optionally produced in step (b), directly to a sheet storage unit. d) A step of directly transferring the expanded metal sheet from the sheet storage unit to the forming machine, e) The step of forming an expanded metal sheet in a forming machine to obtain an expanded metal sheet having a periodic deformation portion, and f) Step of stacking expanded metal sheets having periodic deformation portions, formed in step (e), to form a structured cross-channel packing element. Includes.

[0033] According to a particularly preferred embodiment of the present invention, the process is carried out within the plant mentioned above.

[0034] Specifically, good results are obtained when the metal sheet is stretched in step (a) by a stretching coefficient between 1.0 and greater than 1.5, preferably between 1.1 and 1.5, and more preferably between 1.2 and 1.35.

[0035] Preferably, in step (a), a metal sheet having a sheet material thickness of 0.05 mm to 0.50 mm, preferably 0.08 mm to 0.2 mm, and most preferably 0.09 mm to 0.15 mm is used. The sheet material thickness refers to the thickness of the material that constitutes or forms the layer. According to the present invention, since the layer is made of an expanded metal sheet, the sheet material thickness is the sheet thickness. If the sheet thickness varies across the area of ​​the layer, the sheet material thickness is the thickness measured, for example, by a micrometer screw at one of the outer edges of the sheet material thickness.

[0036] The present invention is not particularly limited with respect to the material of the expanded metal sheet of the structured packing element. For example, the expanded metal sheet may be made of stainless steel or a composite selected from the group consisting of aluminum, copper, titanium, zirconium, and alloys.

[0037] As described above, after production, i.e., after cutting and stretching the metal plate, the resulting expanded metal sheet is no longer flat. This is a result of deformation, strain, bending, or bouncing of individual separation elements, as well as the relative deformation of the separation elements to other parts, e.g., inclination. Other characteristic parts, such as burrs, may arise from the drilling process and thus may contribute to the thickness. The resulting dimensions of the expanded metal sheet are called the grid thickness and can be several times greater than the layer material thickness. Preferably, an optional step (b) is performed, and the expanded metal sheet is rolled in step (b) to a grid thickness of 1.0 mm to 1.4 mm, preferably 1.1 mm to 1.3 mm, and more preferably 1.15 mm to 1.25 mm.

[0038] As described above, the task of the sheet storage unit is to temporarily store expanded metal sheets to compensate for the different stroke cycles of the stretching machine and the forming machine. More specifically, during the time interval between two strokes of the forming machine, the sheet storage unit will be loaded with expanded metal sheets produced by the stretching machine and an optional calibration machine, and conversely, during the time interval between strokes of the forming machine, the sheet storage unit will be removed from the expanded metal sheets stored inside. In practice, it is sufficient for the sheet storage unit to store the expanded metal sheets for a short time, i.e., less than one minute. Therefore, preferably the sheet storage unit has at least two, more preferably at least four, even more preferably at least six, and most preferably at least eight orientation rollers, all of which are movable so as to allow the distance between at least two of the orientation rollers to be changed. Particularly preferably, all of the orientation rollers are vertically movable so as to allow the distance between each of two of the rollers to be changed vertically. For example, a sheet storage unit has an upper roller fixed at a specific height and a lower roller, and the upper and lower rollers have weight to maintain a dense state of the expanded metal sheet that is alternately guided by the upper and lower rollers. Preferably, during the stroke of the stretching machine, the rollers of the sheet storage unit are moved to increase the distance between the rollers, and conversely, during the stroke of the forming machine, the rollers of the sheet storage unit are moved to decrease the distance between the rollers.

[0039] The present invention is not particularly limited with respect to the type of periodic deformation portion of the expanded metal sheet, insofar as it enables the formation of a structured cross-channel packing element for a column for mass transfer and / or heat exchange between a heavy fluid phase and a light fluid phase by stacking a plurality of sheets on top of each other. According to the present invention, the final structured packing element has at least two layers of expanded metal sheets arranged parallel to each other in the longitudinal direction. The parallel arrangement of the two layers means, according to the present invention, that one of the layers is inclined with respect to the other layer by an angle of up to + / -20°, preferably up to + / -10°, more preferably up to + / -5°, and even more preferably up to + / -2°, and most preferably no inclination with respect to the other layer.

[0040] According to a particularly preferred embodiment of the present invention, the expanded metal sheet is formed in step (e) to be an expanded metal sheet having a corrugated shape with a plurality of alternating peaks and valleys as periodic deformation portions, wherein the angles of each peak and each valley with respect to the longitudinal direction are 10° to 60°, more preferably 20° to 50°, and more preferably 25° to 47°.

[0041] Preferably, the peaks and valleys are bent at the end portions of the expanded metal sheet relative to the peaks and valleys of the central portion located between the end portions, resulting in a reduction in the flow resistance within the end zones of the structured packing element relative to the flow resistance of the zones located between the end zones. Instead of providing such bends and different heights at both end portions, these may be present in only one of these end zones. As described above, this makes it possible to reduce the pressure loss of the packing element of a structured cross-channel for a column for mass transfer and / or heat exchange between the heavy and light fluid phases formed from the respective layers.

[0042] According to another particularly preferred embodiment of the present invention, the expanded metal sheet is formed in step (e) to be an expanded metal sheet having waves with a square, triangular, or sinusoidal cross-section, with crests and valleys as periodic deformation portions, wherein the angles of each crest and each valley with respect to the longitudinal direction are 10° to 60°, preferably 20° to 50°, and most preferably 25° to 47°.

[0043] Regardless of the morphology of the periodic deformation portions, the distance between two adjacent periodic deformation portions of the expanded metal sheet is preferably 5 mm to 30 mm, more preferably 10 mm to 30 mm, even more preferably 15 mm to 25 mm, and most preferably 28 mm to 22 mm, such as approximately 20 mm. The distance between the uppermost points of two adjacent periodic deformation portions of a single expanded metal sheet is preferably between 5 mm and 12.5 mm, and more preferably between 6.5 mm and 11.5 mm, depending on the surface area.

[0044] In a further development of the present invention, an expanded metal sheet having a periodic deformation portion, formed in step (e), is cut and stacked in step (f) to form a structured cross-channel packing element, wherein the layers of the structured cross-channel packing element are oriented such that the periodic deformation portions of these adjacent layers intersect in a crosswise manner with the periodic deformation portions of layers extending obliquely to the longitudinal direction, and at least 50%, preferably at least 75%, and most preferably all layers are in contact with each of the adjacent layers at the intersection points between the periodic deformation portions of one layer and the periodic deformation portions of the adjacent layer, and the open space between at least two layers is defined by the periodic deformation portions. The longitudinal direction of the structured cross-channel packing element is the direction from the top area to the bottom area of ​​the structured cross-channel packing element when incorporated into a mass transfer and / or heat exchange column, that is, the longitudinal direction is the direction from the top to the bottom of the mass transfer and / or heat exchange column. In other words, this is the intended flow direction for gravity-driven heavier phases during the operation of the structured cross-channel packing elements and the columns of mass transfer and / or heat exchange. More specifically, the longitudinal direction of the structured cross-channel packing elements may be determined as follows: the structured cross-channel packing elements are positioned on a horizontal area, and as a result, layers of structured cross-channel packing elements positioned parallel to each other and in contact with each other extend vertically, and as a result, open spaces (or channels enclosed and thus defined by the periodic deformation portions of the layers) extending from one end of the layers to the other extend from the top to the bottom of the structured cross-channel packing elements. Therefore, the longitudinal direction is the direction from the top to the bottom of the structured cross-channel packing elements arranged in this manner, that is, in other words: a heavy phase, such as water, falling onto the top of the structured cross-channel packing elements arranged in this manner flows downward along the open space by gravity, and the longitudinal direction is the mean flow direction of the heavy phase.

[0045] Preferably, the angle of each periodic deformation portion with respect to the longitudinal direction is from 10° to 60°, preferably from 20° to 50°, more preferably from 25° to 47°, and the periodic deformation portions of adjacent expanded metal sheets are preferably oriented in opposite directions.

[0046] Specifically, when at least 50%, preferably at least 75%, more preferably at least 80%, still more preferably at least 90%, still more preferably at least 95%, and most preferably all, of the maximum distances between at least two layers of the packing elements of the structured cross-channels, measured in a plane perpendicular to the longitudinal direction, are from 8 mm to 80 mm, preferably from 12 mm to 51 mm, and most preferably from 16 mm to 30 mm, good results are obtained.

[0047] Accordingly, it is preferable that the layer width is from 4 mm to 40 mm, more preferably from 6 mm to 25.5 mm, and most preferably from 8 mm to 15 mm.

[0048] Furthermore, it is preferable that the packing elements produced in step (f) have a height from 100 mm to 300 mm, preferably from 150 mm to 250 mm.

[0049] Specifically, the specific surface area of the structured packing elements produced in step (f) is from 60 m 2 / m 3 to 750 m 2 / m 3 , preferably from 120 m 2 / m 3 to 500 m 2 / m 3 , and most preferably from 200 m 2 / m 3 to 450 m 2 / m 3 ; good results are obtained.

[0050] As described above, the expanded metal sheets forming the structured cross-channel packing elements each have openings surrounded by and separated from each other by these separating elements. In other words, the expanded metal sheets form a grid. Preferably, the stretching in step (a) is carried out such that the layers of expanded metal sheets of the final structured cross-channel packing elements have the following characteristics: Preferably, the ratio between the average width of at least one separating element between adjacent openings and the sheet material thickness is at least 15, and more preferably at least 18. The openings preferably have a lenticular or trapezoidal shape and thus have a shorter inherent length and a longer inherent length, where the shorter inherent length of the opening is the maximum dimension of the opening in the stretching direction of the expanded metal sheet, and the longer inherent length of the opening is the maximum dimension of the opening in the direction perpendicular to the stretching direction of the expanded metal sheet. The stretching direction of the expanded metal sheet is the direction along which the sheet metal is stretched during the production of the expanded metal sheet. Preferably, at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably all of the opening has a shorter inherent length of 1.0 mm to 4.0 mm, preferably 2.0 mm to 3.0 mm, and a longer inherent length of 2.0 mm to 8.0 mm, preferably 2.5 mm to 7.0 mm, and most preferably 3.0 mm to 6.0 mm.

[0051] The distance between adjacent openings in the stretching direction of the expanded metal sheet is different from the distance between adjacent openings in a direction perpendicular to the stretching direction of the expanded metal sheet. Hereafter, the distance between a first opening and a second opening adjacent to each other in the stretching direction of the expanded metal sheet will also be referred to as u2, and will be abbreviated as u2. In contrast, the distance between the first opening and a third opening adjacent to the first opening in a direction perpendicular to the stretching direction of the expanded metal sheet will also be referred to as u1, and will be abbreviated as u1. Preferably, the ratio of distance u2 to distance u1 is at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, most preferably 0.4 to 0.7, more preferably 0.45 to 0.70, and most preferably 0.49 to 0.55 for all openings. In addition, preferably, the distance u2 is at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, most preferably 2mm to 8mm, more preferably 3mm to 7mm, and most preferably 4mm to 6mm in all openings. In contrast, the distance u1 is preferably at least 50%, more preferably at least 75%, even more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, most preferably 7.5mm to 15mm, and most preferably 9mm to 11mm in all openings.

[0052] According to another specific embodiment of the present invention, the average width of all separation elements between adjacent openings is at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably between 70% and 125% of the average hydraulic diameter of the adjacent openings. More preferably, the average width of all separation elements between adjacent openings is at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably between 75% and 100% of the average hydraulic diameter d of the adjacent openings. More preferably, the average width of all separation elements between adjacent openings is at least 50%, preferably at least 75%, more preferably at least 80%, even more preferably at least 90%, even more preferably at least 95%, and most preferably between 1.5 mm and 4.0 mm, even more preferably 1.6 mm and 3.5 mm, and most preferably 1.8 mm and 3.0 mm. In addition, preferably, at least 50%, preferably at least 75%, more preferably at least 80%, more preferably at least 90%, and most preferably at least 95% of the openings in at least two layers, and most preferably all hydraulic diameters, are between 1.25 mm and 5.0 mm, more preferably 2.0 mm and 4.0 mm, and most preferably 2.2 mm and 3.5 mm.

[0053] Furthermore, preferably, the ratio of the maximum distance D between at least two layers and the average width b of the separating elements, measured in a plane perpendicular to the longitudinal direction, is at least 5, preferably at least 75%, more preferably at least 8, even more preferably at least 90%, even more preferably at least 95%, and most preferably all, is at least 5.

[0054] The parameters u2 (the distance between two adjacent openings in the stretching direction of the expanded metal sheet) and b (the average width of the separation element) can be used to calculate the stretch coefficient of the expanded metal sheet. More specifically, the stretch coefficient of the expanded metal sheet is defined as u2 / 2b. The reciprocal of this stretch clearly indicates the material savings that can be achieved compared to a solid metal sheet.

[0055] According to a particularly preferred embodiment of the present invention, the porosity of all layers of the structured cross-channel packing element, i.e., the quotient obtained by dividing the total area of ​​openings in the layer by the sheet area of ​​the layer, is between 20% and 38%.

[0056] Next, with reference to the attached drawings, a specific embodiment of the present invention will be described as an example. [Brief explanation of the drawing]

[0057] [Figure 1] This is a schematic diagram showing a plant according to one embodiment of the present invention. [Figure 2a] This is a schematic diagram showing a sheet storage unit for a plant according to one embodiment of the present invention. [Figure 2a] This is a schematic diagram showing a sheet storage unit for a plant according to one embodiment of the present invention. [Figure 2b] This is a schematic diagram showing a sheet storage unit for a plant according to another embodiment of the present invention. [Figure 2c] This is a schematic diagram showing a sheet storage unit for a plant according to another embodiment of the present invention. [Figure 2d] This is a schematic diagram showing a sheet storage unit in a plant according to another embodiment of the present invention at two different stages. [Figure 2e] This is a schematic diagram showing a sheet storage unit in a plant according to another embodiment of the present invention at two different stages. [Figure 3]This is a schematic side view showing a mass transfer column having multiple structured cross-channel packing elements produced using a process according to one embodiment of the present invention. [Figure 4a] This is an exploded view showing a portion of a sheet of structured cross-channel packing elements produced using a process according to one embodiment of the present invention. [Figure 4b] Figure 4a is a schematic side view showing the structured cross-channel packing elements. [Figure 4c] Figure 4a shows two layers of structured cross-channel packing elements. [Figure 5] This is a partial diagram showing a corrugated sheet of a structured cross-channel packing element produced using a process according to another embodiment of the present invention. [Figure 6a] This is a schematic diagram illustrating various embodiments of a grid structure of expanded metal sheets with layers of structured cross-channel packing elements produced using the process according to the present invention. [Figure 6b] This is a schematic diagram illustrating various embodiments of a grid structure of expanded metal sheets with layers of structured cross-channel packing elements produced using the process according to the present invention. [Figure 6c] This is a schematic diagram illustrating various embodiments of a grid structure of expanded metal sheets with layers of structured cross-channel packing elements produced using the process according to the present invention. [Figure 6d] This is a schematic diagram illustrating various embodiments of a grid structure of expanded metal sheets with layers of structured cross-channel packing elements produced using the process according to the present invention. [Figure 6e] This is a schematic diagram illustrating various embodiments of a grid structure of expanded metal sheets with layers of structured cross-channel packing elements produced using the process according to the present invention. [Figure 6f]This is a schematic diagram illustrating various embodiments of a grid structure of expanded metal sheets with layers of structured cross-channel packing elements produced using the process according to the present invention. [Figure 7a] This is a schematic diagram showing another embodiment of a grid structure of expanded metal sheets of layers of structured cross-channel packing elements produced using the process according to the present invention. [Figure 7b] This is a cutout diagram along line AA in Figure 7a. [Modes for carrying out the invention]

[0058] Figure 1 schematically shows a plant 10 for producing structured cross-channel packing elements for a column for mass transfer and / or heat exchange between a heavy fluid phase and a light fluid phase, according to one embodiment of the present invention. The plant 10 comprises, from its upstream end to its downstream end, a decoiler 12, a stretching machine 14 for cutting and stretching metal sheets to make expanded metal sheets, a calibration machine 16 for rolling the expanded metal sheets produced in the stretching machine to a desired thickness, a sheet storage unit 18, a forming machine 20 for forming the rolled expanded metal sheets produced in the calibration machine to make expanded metal sheets with periodic deformation portions, and a stacking machine 22 for stacking the expanded metal sheets with periodic deformation portions to make structured cross-channel packing elements. The decoiler 12 is a sleeve, and the metal sheets are wound around this sleeve. During the operation of plant 10, the metal sheet is removed from the decoyler 12 and sent into the stretching machine 14, which has at least one knife for cutting (or slitting, respectively) and stretching the metal sheet in the same stroke of the stretching machine as the metal sheet is fed through the stretching machine, with the aim of producing an expanded metal sheet. More specifically, the slits created by the knife allow the metal to be stretched to create a uniform opening. To ensure a consistent pattern, the stretching machine 14 is manually programmed or operated as the metal is fed through. The stretching machine 14 operates in a stroke manner, and the length of the expanded metal sheet transported in one stroke of the stretching machine 14 is the product of the width of the separation element and the stretching coefficient. The expanded metal sheet produced in the stretching machine 14 is guided into a calibration machine 16 having at least two rollers, through which the expanded metal sheet is fed and pressure is applied, thereby rolling the expanded metal sheet to the desired thickness or grid thickness.

[0059] The produced rolled expanded metal sheets are guided from the calibration machine 16 into the sheet storage unit 18, and the expanded metal sheets are then transferred directly from the sheet storage unit 18 into the forming machine 20. Preferably, the sheet storage unit 18 has at least two, more preferably at least four, even more preferably at least six, and most preferably at least eight orientation rollers, all of which are movable to allow for a change in the distance between these orientation rollers. A specific embodiment of such a sheet storage unit 18 is shown in Figure 2.

[0060] The forming machine 20 preferably has a device for continuously advancing the rolled expanded metal sheet to one or more first forming units for pleating the rolled expanded metal sheet, for the purpose of producing an expanded metal sheet having periodic deformation portions, and at least one device for removing the pleated expanded metal sheet. The expanded metal sheet having periodic deformation portions is then guided into a stacking machine 22, which preferably has one or more rotary cutting wheels for cutting the rolled expanded metal sheet having periodic deformation portions to a desired size, and stacking units for stacking the cut rolled expanded metal sheet having periodic deformation portions to form a structured cross-channel packing element. Due to cutting and stacking, the stacking machine 22 operates discontinuously. The forming machine 20 needs to be stopped during cutting and stacking in the stacking machine 22. Therefore, the forming machine 20 also operates in a stroke-type manner, and the length of the expanded metal sheet transported in one stroke of the forming machine is the quotient obtained by dividing the distance between two adjacent periodic deformation portions of the sheet by the cosine of angle α, where the waveform is inclined at angle α with respect to the longitudinal direction. For example, in the case of an expanded metal sheet with a distance of 20 mm between two adjacent periodic deformation portions, an angle α of 45°, and a stretching coefficient of 1.25, the length of the sheet transported in one stroke of the stretching machine is 2.5 mm, compared to the length of the sheet transported in one stroke of the forming machine, which is 28.3 mm. Therefore, an expanded metal sheet prepared in the stretching machine and rolled in the calibration machine cannot be directly transported into the forming machine.

[0061] More specifically, the stretching machine 14 typically has a higher stroke frequency than the forming machine 20, but transports shorter lengths of expanded metal sheets in a single stroke than the forming machine 20. Therefore, when the stroke of the forming machine 20 begins, the forming machine 20 requires a longer sheet length per given time interval than the stretching machine 14 transports during that time interval, while the stretching machine 14 still transports sheet lengths that are not required by the forming machine 20 after the end of the stroke of the forming machine 20 and until the next stroke of the forming machine 20 begins. According to the present invention, the different material requirements of the stretching machine 14 and the forming machine 20 in different stroke cycles of both machines are compensated for or mitigated, respectively, by the sheet storage unit 18. The movable rollers of the sheet storage unit 18 allow the rolled expanded metal sheets produced by the stretching machine 14 and the calibration machine 16 to be loaded into the sheet storage unit 18 during the time interval between two strokes of the forming machine 20 by simply increasing the distance between the rollers in proportion to the excess sheet length received from the calibration machine 16 that is not required by the forming machine 20 at this point. Furthermore, the movable rollers allow the sheet storage unit 18 to be removed from the rolled expanded metal sheets stored inside during the time interval between one stroke of the forming machine 20 by simply decreasing the distance between the rollers in proportion to the excess sheet length required by the forming machine 20 that exceeds the sheet length received from the calibration machine 16 at this point.

[0062] As shown in Figure 1, the sheet storage unit 18 is implemented to directly receive the rolled expanded metal sheets produced in the calibration machine 16 and directly release the rolled expanded metal sheets to the forming machine 20.

[0063] Figure 2a is a schematic diagram of a sheet storage unit 18 of a plant 10 according to one embodiment of the present invention. The sheet storage unit 18 has six immovable rollers 23, 23', 23'', 23''' and fourteen vertically movable rollers 24, 24', 24'', 24''''. Thereafter, the distance between individual movable rollers 24, 24', 24'', 24'''' can be adjusted as needed, thereby allowing the total distance between the upstreammost movable roller 24 and the downstreammost movable roller 24'''' to be adjusted as needed. The total distance between the upstreammost movable roller 24 and the downstreammost movable roller 24''' defines the length of rolled expanded metal sheets stored in the storage unit 18 at a given time. If it is necessary to preserve a more rolled expanded metal sheet, the total distance between the upstream movable roller 24 and the downstream movable roller 24''' is increased, while if the forming machine 20 is performing a stroke, the total distance between the upstream movable roller 24 and the downstream movable roller 24''' is decreased.

[0064] Figure 2b is a schematic diagram of a sheet storage unit 18 of plant 10 according to another embodiment of the present invention. The sheet storage unit 18 has six immovable rollers 23, 23', 23'', 23''' and two horizontally movable rollers 24, 24'. Thereafter, the distance between individual movable rollers 24, 24' can be adjusted as needed, thereby allowing the total distance between the uppermost movable roller 24 and the downstreammost movable roller 24' and, consequently, the overall length of the expanded metal sheets in the storage unit 18 to be adjusted as needed.

[0065] Figure 2c is a schematic diagram of a sheet storage unit 18 of plant 10 according to another embodiment of the present invention. The sheet storage unit 18 has four immovable rollers 23, 23', 23'', 23''', two immovable curved reorientation plates 25, 25', and one vertically movable roller 24. Thereafter, the total distance from the first reorientation plate 25 to the second reorientation plate 25 via the movable roller 24, and thus the overall length of the expanded metal sheets in the storage unit 18, can be adjusted as needed.

[0066] Figures 2b and 2e are schematic diagrams of a sheet storage unit 18 of a plant 10 according to another embodiment of the present invention at two different stages. The sheet storage unit 18 has four immovable rollers 23, 23', 23'', 23''' and two immovable curved reorienting plates 25, 25'. This allows the overall length of the expanded metal sheet between the two reorienting plates 25, 25' to be changed. More specifically, the storage of the expanded metal sheet is carried out such that the expanded metal sheet 18 is pushed into the space between the reorienting means 25, 25' for storage in the sheet storage unit 18 by pushing the expanded metal sheet on the upstream reorienting plate 25 more quickly than pulling the expanded metal sheet on the downstream reorienting plate 25' to allow a longer length of the expanded metal sheet to be present in the storage unit 18 and positioned on the floor 27 as shown in Figure 2d. When the storage unit 18 is removed, the expanded metal sheet is pulled more quickly on the downstream orientation plate 52' than it is pushed on the upstream orientation plate 52, resulting in a shorter length of the expanded metal sheet being present within the storage unit 18, as shown in Figure 2e.

[0067] Figure 3 is a schematic diagram of a mass transfer column 26, and more specifically, a distillation column 26 having structured packing elements produced according to the process of the present invention (the transparent interior in the figure is for illustrative purposes only). Also for illustrative purposes, a layered grid structure is not shown in Figure 3 but is shown only in Figures 6 and 7. The distillation column 26 has a plurality of structured cross-channel packing elements 28 arranged in the form of two beds 30, 30'. Above each of the two beds 30, 30', dispersers 32, 32' are positioned to uniformly disperse the liquid across the cross-section of the bed, leaving sufficient space for vapor to ascend through them. Below each bed 30, 30', a grid-like holding device 34 and a collection device 36 are positioned, the grid-like holding device 34 holding the bed 30 in place, and the collection device 36 collecting the liquid slowly flowing downward from the bed 30, while leaving sufficient empty space within the collection device for vapor to ascend.

[0068] During the operation of the distillation column 26, the gas rises from bottom to top as the light phase, while the liquid descends from top to bottom of the distillation column 26 in a counterflow. More specifically, the liquid is dispersed substantially homogeneously across the cross-section of the bed 30 by the disperser 32 and flows slowly downward along the surface of the layers of structured cross-channel packing elements 28. Spaces are provided between the different layers of structured cross-channel packing elements 28, and these spaces are filled with gas, which provides a path for the rising gas, during which time the gas is moved by a pressure gradient. By allowing the liquid to diffuse on the surface of the layers of structured cross-channel packing elements 28, a large interface is created between the two phases to establish efficient heat transfer and mass transfer between the liquid and gas at the interface. At the bottom of the bed 30, the liquid is collected in the collection device 36 and guided downward through the pipe 38 to the disperser 32' above the second bed 30'.

[0069] Figures 4a to 4c show a structured cross-channel packing element 28 of the so-called cross-channel corrugated sheet packing type. For illustrative purposes, the layered grid structure is not shown in Figure 4 but is shown only in Figures 6 and 7. The structured cross-channel packing element 28 is assembled from multiple corrugated sheets 40, 40', which are parallel to each other and in contact with each other. Each of the corrugated sheets 40, 40' is a grid, as described above and will be further described later in Figure 7. In the lower right of Figure 4c, the grid structure which is part of the corrugated sheet 40 is schematically shown. As can be understood from the above specification, all of the corrugated sheets 40, 40' are actually composed of such grids. This is not shown in Figures 4a to 4c for illustrative purposes only. In this embodiment, the corrugated sheets 40 and 40' are made from expanded sheet material, that is, the corrugated sheets 40 and 40' are prepared by cutting and stretching a thin metal plate and then deforming the expanded sheet metal into corrugated sheets 40 and 40'.

[0070] The corrugated metal sheets 40, 40' are fastened to each other by a plurality of rods (not shown) that penetrate the corrugated sheets 40, 40' perpendicular to the longitudinal sections of the corrugated sheets 40, 40', and the rods are fastened to the first and last corrugated sheets by washers and nuts, by bending the rods, or by any other means (not shown). Each corrugated sheet 40, 40' has a plurality of alternating crests 42 and valleys 44, and adjacent corrugated sheets 40, 40' are oriented so that the waves 42, 44 of adjacent corrugated sheets 40, 40' intersect in a cross shape with the waves 42, 44 of corrugated sheets 40, 40' that extend diagonally with the longitudinal direction, thereby forming a continuously traversing inclined channel 46. More specifically, the angle α of each crest 42 and each valley 44 with respect to the longitudinal direction is 10° to 60°, preferably 20° to 50°, and most preferably 25° to 47°, such that the crests 42 and valleys 44 of adjacent layers 40, 40' are oriented in opposite directions. The channels 46 define the maximum distance D between adjacent corrugated sheets 40, 40', which is, for example, 20 mm. These channels 46 have a positive effect on the flow of the gas and liquid phases within the structured cross-channel packing element 28, promoting mass transfer between the phases. That is, the gas and liquid phases are brought into contact within the channels 46 of the structured cross-channel packing element 28, thus promoting mass transfer and even heat transfer between the phases. More specifically, the ascending gas defines the channels 46 as it flows downward through the mass transfer column, coming into contact with the liquid present on the surface of the corrugated sheets 40, 40'. Overall, the light phases flow through the open spaces or channels 46, and there is no bypass flow through the openings in the grid of the corrugated sheets 40, 40' of the structured cross-channel packing element 28. This leads to particularly efficient mass transfer and energy transfer between the light and heavy phases. Furthermore, the cross-crossing configuration of channels 46 leads to optimal phase dispersion from left to right.

[0071] Figure 5 shows a partial view of a corrugated sheet 40 of a structured cross-channel packing element according to an alternative embodiment. The corrugated sheet 40 of the structured cross-channel packing element in Figure 5 is similar to the corrugated sheets 40, 40' shown in Figures 4a to 4c. However, the corrugated sheet 40 of the structured cross-channel packing element in Figure 5 does not have linearly extending peaks and valleys, but the peaks 42, 42' and valleys of the corrugated sheets 40, 40' are bent within the terminal portions 48, 48' and thus extend substantially vertically within the terminal portions 48, 48' of the corrugated sheets 40, 40'. In Figure 5, the solid lines depict the corrugated peaks 26 in the face of the corrugated sheet 40 presented to the viewer, while the dashed line 42' depicts the appearance of the corrugated valleys in the corresponding face of the corrugated sheet 40' immediately behind this face. By bending the terminal portions 48, 48' of the corrugated sheets 40, 40' so that they extend substantially vertically within the terminal portions 48, 48' of the corrugated sheets 40, 40', the flow resistance of the terminal portions 48, 48' of the corrugated sheets 40, 40' is reduced compared to the flow resistance of the portions located between the terminal portions 48, 48' of the corrugated sheets 40, 40'. This leads to a reduction in the pressure loss of the packing element of the structured cross channel.

[0072] Figures 6a to 6f are schematic diagrams of various embodiments of grids 56 forming layers 50 of structured cross-channel packing elements produced according to the present invention, suitable for use in structured cross-channel packing elements as shown in any of Figures 4a to 4c and 5. The grid 56 of the layer 50 of structured cross-channel packing elements shown in Figure 6a has openings 58 having a quadrilateral cross section, the openings 58 being surrounded by separation elements 60 and separated from each other by separation elements 42. The separation elements 60 are thin strips having an average width b of, for example, 2 mm, and the separation elements 60 completely surround the openings 58. The lengths of two sides a1 and a2 of the openings 58 are selected to obtain openings 58 having a suitable hydraulic diameter d of, for example, 3 mm. As is known in the art, the hydraulic diameter d can be calculated according to the formula 4A / P, where A is the cross-sectional area of ​​the openings 40 and P is the perimeter of the openings 58. Grids 56 having openings 58 of various geometries and separating elements 60 of various geometries are shown in Figures 6b to 6f. The openings 58 of the grids 56 in Figures 6b and 6c are quadrilaterals, in contrast to the openings 58 of the grids 56 in Figure 6d which are irregular, and the openings 58 of the grids 56 in Figures 6e and 6f which are elliptical.

[0073] Figure 7a shows a schematic diagram of another embodiment of a grid structure of expanded metal sheets in layers of structured cross-channel packing elements produced using the process according to the present invention. The expanded metal sheets are grids 56 having substantially trapezoidal openings 58 separated from each other by separation elements 60. Thus, the openings have shorter and longer inherent lengths, with the shorter inherent length of the openings 58 being the maximum dimension of the openings 58 in the stretching direction SD of the expanded metal sheets, and the longer inherent length of the openings 58 being the maximum dimension of the openings 58 in a direction perpendicular to the stretching direction SD of the expanded metal sheets. As shown in Figure 7b, a cutaway diagram along line AA in Figure 7a, the expanded metal sheets are no longer flat and have a structured surface. This is a result of deformation, strain, bending, or bouncing of the individual separation elements, as well as the relative deformation of the separation elements to other parts, e.g., inclination. More specifically, the expanded metal sheets have flat flanks on the stretching direction SD side and relatively steep flanks on the opposite side. The present invention enables the transport of an expanded metal sheet in the stretching direction SD, that is, the transport of the expanded metal sheet so that its flat flank side is placed into the forming machine 20. [Explanation of Symbols]

[0074] 10. Plant for producing structured cross-channel packing elements 12 Decoys 14 Stretching Machine 16 Calibration Machine 18 Sheet Storage Unit 20 Forming Machines 22 Stacking machine 23, 23', 23'', 23'''' Immovable rollers of the sheet storage unit 24, 24', 24'', 24'''' Orientation change means / movable roller for sheet storage unit 25, 25' Seat storage unit orientation changing means / orientation changing plate 26 Mass transfer columns / distillation columns 27th floor 28 Structured cross-channel packing elements 30, 30' structured packing element bed 32, 32' dispersion device 34 Retaining devices 36 Collection device 38 pipes 40, 40' waveform sheet 42-layered mountain 42' Mountains of the adjacent layer 44 Valley 46 channels / available space 48, 48' End of waveform sheet 50, 50' layer 56 grid 58 grid openings 60 grid separation elements A Cross-sectional area of ​​the opening a1 Side length of the opening Length of the second side of opening a2 b. Average width of the separating element d Average hydraulic diameter of the opening D. The maximum distance between at least two adjacent layers / wavesheets. P Circumference of the opening SD Expanded Metal Sheet Stretching Direction V is usually the longitudinal direction, which is vertical. α The angle of each peak and each valley with respect to the longitudinal direction.

Claims

1. A plant (10) for producing structured cross-channel packing elements (28) for a column (26) for mass transfer and / or heat exchange between a heavy fluid phase and a light fluid phase, wherein the structured cross-channel packing elements (28) have at least two adjacent layers (50, 50') made of expanded metal sheets each having an opening (58), the openings (58) being surrounded by a separation element (60) and separated from each other by the separation element (60), and the expanded metal sheets undergoing periodic deformation Having portions (42, 42', 44), at least two of the at least two layers (50, 50') are arranged parallel to and in contact with each other in the longitudinal direction (V) of the packing element (28), and as a result, an open space (46) is provided between the at least two layers (50, 50') extending from one end of the at least two layers (50, 50') to the opposite end, and as a result, at least one of the heavy phase and the light fluid phase can flow through there, and the plant: a) A stretching machine (14) having at least one knife for cutting a metal sheet and forming a slit in the metal sheet, the stretching machine (14) for stretching the metal sheet to form an expanded metal sheet having the opening (58), b) Optionally, a calibration machine (16) for rolling the expanded metal sheet produced in the stretching machine (14) to a desired thickness, c) Sheet storage unit (18), d) A forming machine (20) for forming the expanded metal sheet produced in the stretching machine and optionally rolled in the optional calibration machine (16) to make an expanded metal sheet having periodic deformation portions (42, 42', 44), e) A stacking machine (22) comprising one or more rotary cutting wheels for cutting the expanded metal sheet having the periodic deformation portions (42, 42', 44) to a desired size, and a stacking unit for stacking the cut expanded metal sheets to form a structured cross-channel packing element (28) It has, The sheet storage unit (18) is embodied to directly receive the expanded metal sheet produced in the stretching machine and optionally rolled in the optional calibration machine (16), and to directly release the expanded metal sheet to the forming machine (20). Plant (10).

2. The plant (10) according to claim 1, wherein the stretching machine (14) is operable to operate in a stroke manner at a first stroke frequency, and the forming machine (16) is operable to operate in a stroke manner at a second stroke frequency, and the first stroke frequency is higher than the second stroke frequency.

3. The plant (10) according to claim 1 or 2, wherein the sheet storage unit (18) has at least two orientation changing means (24, 24', 24'', 24''', 25, 25').

4. The plant (10) according to claim 3, wherein the sheet storage unit (18) has at least two, preferably at least four, more preferably at least six, and most preferably at least eight curved orientation changing plates (25, 25') that are not movable, as orientation changing means (24, 24', 24'', 24''', 25, 25').

5. The plant (10) according to claim 3, wherein the sheet storage unit (18) has at least two, preferably at least four, more preferably at least six, and most preferably at least eight curved orientation plates (25, 25') as orientation changing means (24, 24', 24'', 24''', 25, 25'), and at least one, and preferably all, of the orientation plates from the curved orientation plates (25, 25') are movable to allow a change in the distance between at least two of the orientation changing means (25, 25').

6. The plant (10) according to any one of claims 3 to 5, wherein the sheet storage unit (18) has at least two, preferably at least four, more preferably at least six, and most preferably at least eight orientation rollers (24, 24', 24'', 24'') as orientation changing means (24, 24', 24'', 24''), and at least one, and preferably all, of the orientation rollers (24, 24', 24'', 24'') are movable to allow a change in the distance between at least two orientation changing means (24, 24', 24'', 24'', 25, 25'').

7. The plant (10) according to any one of claims 1 to 6, wherein the forming machine (20) comprises one or more first forming units for pleating the expanded metal sheet, a device for continuously advancing the expanded metal sheet to the one or more first forming units, and at least one device for removing the pleated expanded metal sheet.

8. A process for producing a structured cross-channel packing element (28) for a column (26) for mass transfer and / or heat exchange between a heavy fluid phase and a light fluid phase, wherein the structured cross-channel packing element (28) has at least two adjacent layers (50, 50') made of expanded metal sheets, each having an opening (58), the openings (58) being surrounded by a separation element (60) and separated from each other by the separation element (60), and the expanded metal sheets having a periodic deformation portion (42 The packing element (28) has layers 42', 44), and at least two of the at least two layers (50, 50') are arranged parallel to and in contact with each other in the longitudinal direction (V) of the packing element (28), and as a result, an open space (46) is provided between the at least two layers (50, 50') extending from one end of the at least two layers (50, 50') to the opposite end, and as a result, at least one of the heavy phase and the light fluid phase can flow through there, and the process is as follows: a) Cutting a metal sheet to form a slit in the metal sheet, stretching the metal sheet to make an expanded metal sheet having the opening (58), b) A step of optionally rolling the expanded metal sheet produced in step (a) to obtain a desired thickness, c) A step of directly sending the expanded metal sheet produced in step a) or optionally produced in step (b) to a sheet storage unit (18), d) A step of directly transferring the expanded metal sheet from the sheet storage unit (18) to the forming machine (20), e) the step of forming the expanded metal sheet in the forming machine (20) to make an expanded metal sheet having periodic deformation portions (42, 42', 44), and f) Cutting the expanded metal sheet having the periodic deformation portions (42, 42', 44) formed in step (e) to a desired size, and stacking the cut expanded metal sheets to form a structured cross-channel packing element (28), including, process.

9. The process according to claim 8, wherein the process is carried out in a plant according to any one of claims 1 to 7.

10. The process according to claim 9, wherein in step (a), the metal sheet is stretched by a stretching coefficient greater than 1.0 to 1.5, preferably between 1.1 and 1.5, and more preferably between 1.2 and 1.

35.

11. The process according to claim 9 or 10, wherein step (b) is carried out, and the expanded metal sheet is rolled in step (b) to a grid thickness of 1.0 mm to 1.4 mm, preferably 1.1 mm to 1.3 mm, and more preferably 1.15 mm to 1.25 mm.

12. The process according to any one of claims 9 to 11, wherein the sheet storage unit (18) comprises at least two rollers (24, 24', 24'', 24'''), and during the stroke of the stretching machine (14), the rollers (24, 24', 24'', 24''') of the sheet storage unit (18) are moved to increase the distance between the rollers (24, 24', 24'', 24'''), while during the stroke of the forming machine (20), the rollers of the sheet storage unit (18) are moved to decrease the distance between the rollers (24, 24', 24'', 24''').

13. The process according to any one of claims 8 to 12, wherein the expanded metal sheet is formed in step (e) to be an expanded metal sheet having a corrugated shape with a plurality of alternating peaks (42, 42') and valleys (44) as periodic deformation portions (42, 42', 44), the angle (α) of each of the peaks (42, 42') and each of the valleys (44) with respect to the longitudinal direction (V) is from 10° to 60°, more preferably from 20° to 50°, and more preferably from 25° to 47°.

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