Corrugated Screen Packing Assembly for CO2 Absorption With Low Pressure Drop
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Solution Overview
Problem
Existing carbon capture systems face inefficiencies in removing carbon dioxide from flue gases due to high back pressure, flooding, and fouling, especially in high gas flow rates and particulate loads.
Innovation Solution
The use of a corrugated screen packing assembly within an absorption column that induces co-current flow of flue gas and solvent, creating a froth condition with pulsing bubbles and droplets, enhancing mass transfer and minimizing resistance, while using a support ring and grid layers to facilitate assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional packing materials are used in absorption columns, then carbon dioxide absorption capacity is achieved, but high back pressure and flooding occur reducing system efficiency
Solution Approach 1:
The packing material is segmented into modular corrugated screen sections that can be individually installed through a manway opening. Each module consists of corrugated sheets arranged in specific patterns, allowing the large packing assembly to be divided into manageable segments that reduce installation complexity and pressure drop while maintaining absorption capacity.
Solution Approach 2:
The packing structure transitions from traditional random or structured packing to a corrugated screen geometry that utilizes three-dimensional wave patterns. This dimensional transformation creates optimized flow paths that reduce back pressure while maintaining sufficient surface area for carbon dioxide absorption, addressing both the productivity and pressure constraints.
2Productivity
If high gas flow rates are used to increase productivity, then carbon capture efficiency improves, but flooding and fouling increase reducing system reliability
Solution Approach 1:
The corrugated screens feature curved wave patterns rather than flat surfaces. This curvature promotes uniform gas and liquid distribution across the packing cross-section, preventing channeling and flooding even at high flow rates. The curved geometry maintains system reliability by ensuring stable operation across a wider range of gas flow conditions.
3Ease of operation
If access opening size is reduced for easier installation, then assembly simplicity improves, but difficulty in installing large packing modules increases
Solution Approach 1:
The packing system is divided into multiple modular sections that can be installed sequentially through a standard-sized manway opening. Each module is self-contained with standardized dimensions that fit through the access opening, eliminating the need for oversized openings while maintaining the ability to assemble large total packing volumes through repeated modular installation.
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 corrugated screen packing assembly enables efficient carbon dioxide absorption with minimal pressure drop, high gas flow rates, and reduced fouling, maintaining effective operation under challenging conditions.
Implementation Method 1
induces co-current flow of flue gas and solvent, creating a froth condition with pulsing bubbles and droplets
Implementation Method 2
enhancing mass transfer and minimizing resistance
Implementation Method 3
carbon dioxide absorption with minimal pressure drop
Data Source
AI summary
An absorption column includes an outer wall, a floor connected to the outer wall and a ceiling connected to the outer wall, a support ring disposed on an inner surface of the outer wall, and a corrugated screen packing module supported on the support ring. The corrugated screen packing module includes a corrugated screen layer including a plurality of corrugated structures, each of the corrugated structures being configured and dimensioned to pass through an access opening having a first area A1. The first area A1 is smaller than a second area A2 defined by the inner surface of the outer wall in a plane perpendicular to a longitudinal axis of the absorption column.