Cross-Channel Packing Production Using Buffered Expanded Metal Sheets
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Solution Overview
Problem
The existing methods for producing structured cross-channel packing elements for mass transfer and heat exchange columns face challenges in efficiency and cost due to the use of expensive materials like metal gauze and the difficulties in transporting and processing expanded metal sheets, which lead to deformation and misalignment issues during coiling and uncoiling.
Innovation Solution
A plant and process that includes a stretching machine, calibration machine, sheet storage unit, forming machine, and stacking machine to produce structured cross-channel packing elements using expanded metal sheets with periodic deformations, allowing for direct transportation and buffering of sheet velocities to maintain direction and reduce deformation, thereby enhancing production efficiency and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If expanded metal sheets are coiled and transported under tension onto sleeves, then the sheets can be stored and processed, but the sheets deform and misalign due to their structured surface
Solution Approach 1:
The patent uses cardboard sleeves as temporary, disposable carriers for the expanded metal sheets during transport and storage. These sleeves are inexpensive and can be easily discarded after use, avoiding the complexity of permanent storage solutions while preventing sheet deformation during handling.
Solution Approach 2:
The patent employs flexible cardboard sleeves that can accommodate the structured surface of expanded metal sheets without imposing rigid constraints. The flexible nature of the cardboard allows the sheets to maintain their shape and alignment during coiling and transport without deformation.
2Reliability
If metal wire gauze is used for structured packing elements, then excellent wettability and mass transfer efficiency are achieved, but the material cost is high
Solution Approach 1:
The patent replaces expensive metal wire gauze with cost-effective expanded metal sheets made from standard metal sheets. This substitution significantly reduces material costs while maintaining the functional requirements for mass transfer efficiency through the structured surface geometry.
Solution Approach 2:
The patent changes the physical parameters of the packing material by using expanded metal sheets with controlled mesh sizes, opening patterns, and surface geometries. These parameter adjustments allow the cheaper material to achieve performance comparable to expensive metal wire gauze in terms of wettability and mass transfer.
3Ease of manufacture
If corrugated sheets are fixed together with rods and washers, then the structured packing element is assembled, but the assembly process is time-consuming and complex
Solution Approach 1:
The patent merges multiple assembly steps into a single integrated process by directly stacking and bonding expanded metal sheets together. This eliminates the separate operations of inserting rods, adding washers, and tightening nuts, thereby simplifying the assembly process and increasing production speed.
Solution Approach 2:
The patent replaces the mechanical fastening system (rods, washers, and nuts) with a more efficient bonding or stacking mechanism. This substitution removes the complexity of mechanical assembly while maintaining the structural integrity of the packed column.
4Productivity
If the stretching machine and forming machine operate at different velocities, then each machine can work at optimal speed, but the production process is interrupted and less efficient
Solution Approach 1:
The patent prepares the metal sheets in advance using the stretching machine at its optimal speed, creating a buffer of pre-stretched sheets. This preliminary action allows the forming machine to operate continuously at its own optimal speed without waiting for the stretching machine, eliminating production interruptions.
Solution Approach 2:
The patent introduces an intermediate storage buffer between the stretching machine and forming machine. This buffer decouples the two machines, allowing them to operate at different velocities without causing interruptions. The buffer acts as a mediator that absorbs speed differences and maintains continuous production flow.
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 process enables the quick and cost-efficient production of structured cross-channel packing elements with improved flow resistance and pressure loss reduction, facilitating efficient mass and heat transfer between heavy and light fluid phases.
Implementation Method 1
a stretching machine (14) configured to cut and stretch a metal sheet to form one of a plurality of first expanded metal sheets
Implementation Method 2
a calibration machine (16) configured to roll each of the first expanded metal sheets produced in the stretching machine to a desired thickness
Implementation Method 3
a forming machine (20) configured to form each of the first expanded metal sheets rolled in the calibration machine to form the expanded metal sheets comprising periodic deformations
Implementation Method 4
a stacking machine (22) configured to stack the expanded metal sheets comprising periodic deformations to form the structured cross-channel packing element
Data Source
AI summary
A plant for producing a structured cross-channel packing element. The structured cross-channel packing element comprises at least two adjacent layers made of expanded metal sheets each comprising periodic deformations. The plant comprises a stretching machine configured to cut and stretch a metal sheet to form one of a plurality of first expanded metal sheets, a calibration machine configured to roll the first expanded metal sheets to a desired thickness, a sheet storage unit configured to directly receive each of the first expanded metal sheets rolled in the calibration machine, a forming machine configured to form each of the first expanded metal sheets to form the expanded metal sheets comprising periodic deformations, and a stacking machine configured to stack the expanded metal sheets comprising periodic deformations to form the structured cross-channel packing element. The sheet storage unit is configured to release the first expanded metal sheets directly to the forming machine.