Bulk Filler Structure with Corrugated Angles for Mass Transfer
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Solution Overview
Problem
Existing bulk fillers in rectifying tower equipment face challenges of large pressure drop, small flux, and low mass-transfer efficiency, leading to increased tower height and manufacturing difficulties, which complicates meeting separation requirements and stability needs.
Innovation Solution
An efficient mass-transfer separation bulk filler structure with a corrugated angle group, bell-mouth shape, and multilayer structure formed by coiling a silk screen or sheet, featuring a large specific surface area, low liquid holdup, and high void ratio, designed to reduce pressure drop and enhance mass-transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing bulk filler structures are used, then the separation requirements can be met, but the pressure drop is large and the flux is small
Solution Approach 1:
The bulk filler body is segmented into multiple layers with different structural characteristics. Each layer has specific corrugated angle groups with different angles, creating a gradient structure that optimizes flow distribution and reduces pressure drop while maintaining separation efficiency.
Solution Approach 2:
The bell-mouth shape at the lower portion of the bulk filler body provides a curved, streamlined entrance that reduces flow resistance and pressure drop. The corrugated surfaces also create curved flow paths that enhance mixing and mass transfer while maintaining smooth flow.
2Productivity
If existing bulk filler structures are used, then the separation process can operate, but the mass-transfer efficiency is low
Solution Approach 1:
Different regions of the bulk filler body have different local structures - the corrugated angle groups have varying angles in different layers, creating localized zones with different flow and mass transfer characteristics. This optimizes mass transfer efficiency in specific regions without uniformly increasing complexity throughout the entire structure.
Solution Approach 2:
The invention transitions from simple planar structures to three-dimensional corrugated structures with angle groups. The multilayer arrangement adds a vertical dimension to the mass transfer process, creating more extensive gas-liquid contact surfaces and improving overall mass-transfer efficiency.
3Productivity
If the tower height is increased to meet separation requirements, then the separation efficiency improves, but the manufacturing and installation difficulty increases
Solution Approach 1:
The invention changes key structural parameters - introducing corrugated angle groups with specific angles (60°-120°), bell-mouth shape dimensions, and multilayer configurations. These parameter optimizations improve separation efficiency within a compact height, avoiding the need for excessively tall towers that would be difficult to manufacture and install.
4Productivity
If the specific surface area is increased to improve mass transfer, then the mass-transfer coefficient improves, but the pressure drop increases
Solution Approach 1:
The corrugated structures create dynamic flow patterns that enhance mass transfer. The alternating angle groups generate turbulent mixing and varying flow velocities that improve gas-liquid contact efficiency without requiring excessive surface area, thereby avoiding large pressure drops.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves improved mass-transfer coefficients, separation efficiency, stability, and reduced manufacturing costs by minimizing pressure drop and increasing the surface area for gas-liquid interaction, while ensuring flow smoothness and extending the service life of the bulk filler.
Implementation Method 1
the corrugated angles of different angles which are alternately arranged to increase the disturbance and reduce the double-membrane thickness of the vapor and liquid phase mass-transfer resistance
Implementation Method 2
reduce the double-membrane thickness of the vapor and liquid phase mass-transfer resistance, thereby improving the mass-transfer coefficient and the separation efficiency
Data Source
AI summary
The present invention discloses an efficient mass-transfer separation bulk filler structure, which includes a bulk filler body with closely-fit multilayer structures, wherein an annular wall surface of the bulk, filler body has a corrugated angle group. A lower portion of the bulk filler body is of a bell-mouth shape. Three passages with a same sectional area are formed inside the bulk filler body. The present invention has the characteristics of small pressure drop, large specific surface area, low liquid holdup and large void ratio. The annular wall surface is provided with the corrugated angle group to increase the disturbance and reduce a double-membrane thickness of vapor and liquid phase mass-transfer resistance, thereby improving the mass-transfer coefficient and separation efficiency. Meanwhile, by adopting the bell-mouth shape, the stability and natural stacking regularity of the bulk filler can be improved.