Cross-Channel Packing Microstructure for Low-Pressure Mass Transfer
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Solution Overview
Problem
Existing structured packing elements face a trade-off between high mass transfer efficiency and capacity, with high specific area leading to increased pressure drop and potential flooding, limiting their performance and increasing operational costs.
Innovation Solution
A structured cross-channel packing element with layers made of sheets having overlapping openings, a grid thickness less than 1.0 mm, and a ratio of grid thickness to sheet material thickness of at most 5.0, allowing for improved mass transfer efficiency and reduced pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high specific area is used to increase mass transfer efficiency, then mass transfer efficiency is improved, but pressure drop increases and capacity is limited
Solution Approach 1:
The patent changes the geometric parameters of the packing element by reducing the grid thickness to less than 1.0 mm and controlling the ratio of grid thickness to sheet material thickness to be at most 5.0. This parameter optimization allows achieving high mass transfer efficiency while maintaining lower pressure drop and higher capacity
Solution Approach 2:
The patent introduces overlapping openings in the sheet layers, creating a three-dimensional interlocking structure. This dimensional change allows the packing element to maintain high specific area for mass transfer while the overlapping geometry reduces flow resistance and pressure drop
2Productivity
If high specific area is used to increase mass transfer efficiency, then mass transfer efficiency is improved, but capacity is reduced due to flooding
Solution Approach 1:
By optimizing the grid thickness parameter to be less than 1.0 mm and the ratio of grid thickness to sheet material thickness to be at most 5.0, the patent enables the packing element to handle higher flow rates without flooding, thus increasing capacity while maintaining mass transfer efficiency
Solution Approach 2:
The overlapping openings create a three-dimensional structure that increases the effective flow paths and reduces flow resistance, allowing higher capacity operation without compromising mass transfer efficiency
3Productivity
If conventional structured packing elements are used, then mass transfer can occur, but operational costs increase due to higher pressure drop
Solution Approach 1:
The patent reduces the grid thickness parameter to less than 1.0 mm and controls the grid thickness to sheet material thickness ratio to be at most 5.0, which significantly lowers the pressure drop and associated energy consumption, thereby reducing operational costs while maintaining mass transfer capability
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 higher mass transfer efficiency at higher capacities with significantly lower pressure drop, reducing capital and operational costs by enabling shorter and smaller mass transfer columns.
Implementation Method 1
the structured packings elements are typically operated in counter-current flow
Implementation Method 2
The pressure gradient is required to overcome the flow resistance. In the typical case of counter-current mass transfer, the average flow direction of the light phase is from bottom to top of the structured packing element
Implementation Method 3
the heavier phase that trickles down along the surface of the layer and spreads
Implementation Method 4
an efficient heat and mass transfer between the phases is established at the interface
Implementation Method 5
These channels positively influence the flows of the gas phase and of the liquid phase within the packing and facilitate the mass transfer between the phases
Implementation Method 6
the gas phase and the liquid phase are brought into contact in the channels of the structured packing element and the mass transfer as well as the heat transfer between the phases is thus facilitated
Data Source
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AI summary
The present invention relates to a structured cross-channel packing element for a column for mass transfer and/or heat exchange between a heavy and a light fluid phase, wherein A structured cross-channel packing element for a column for mass transfer and/or heat exchange between a heavy and a light fluid phase, wherein the structured cross-channel packing element comprises at least two adjacent layers made of sheets each comprising openings, which are surrounded and separated from each other by separating elements, wherein at least two of the at least two layers are arranged parallel and in touching contact with each other so that an open space extending from one end to the opposite end of the at least two layers is provided between them so that at least one of the heavy and the light fluid phase may flow through it, wherein neighboring opening in the sheet of at least one layer overlap with each other so that each cross-sectional plane of the at least one layer comprises at least one opening s, wherein the ratio between the average grid thickness g of at least one layer and the sheet material thickness s is at most 5.0, and wherein the average grid thickness g of at least one layer is less than 1.0 mm.