Crossflow Structured Packing with Crossing Corrugations
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Solution Overview
Problem
Existing structured packings in mass transfer columns face a trade-off between maximizing mass and energy transfer and minimizing pressure drop, as increases in specific surface area often result in undesirable pressure drops, leading to increased operational and capital costs.
Innovation Solution
The structured packing module features corrugations with alternating peaks and valleys, apertures, and raised ridges, arranged in a crisscross pattern with inclination angles between 5 to 35 degrees, and specifically 10 to 20 degrees, to facilitate cross-flow and reduce pressure drop while maintaining efficiency, with apertures and ridges designed to enhance fluid distribution and contact between streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the specific surface area of structured packing is increased to maximize mass and energy transfer, then mass transfer efficiency is improved, but pressure drop increases leading to higher operational and capital costs
Solution Approach 1:
The structured packing employs corrugations with varying inclination angles (5 to 35 degrees, preferably 10 to 20 degrees) in different regions to optimize local fluid distribution and mass transfer characteristics while controlling pressure drop. The packing sheets include entry regions, exit regions, and bulk regions with different corrugation configurations to address local flow conditions
Solution Approach 2:
The packing structure utilizes three-dimensional corrugated sheets with crossing corrugations at angles to each other, creating a complex spatial configuration that maximizes surface area and fluid contact in multiple directions. This dimensional approach allows efficient mass transfer without requiring excessive surface area density that would increase pressure drop
2Area of stationary object
If corrugations are arranged in crossing relationship to form flow channels, then mass transfer surface area is increased, but pressure drop increases due to more complex flow paths
Solution Approach 1:
The corrugations are configured with specific inclination angles (5 to 35 degrees, preferably 10 to 20 degrees) relative to the horizontal axis, and adjacent packing sheets are arranged with crossing angles optimized to balance surface area provision with pressure drop control. This parameter optimization allows efficient mass transfer while minimizing flow resistance
3Productivity
If structured packing sheets are positioned in upright parallel relationship with crossing corrugations, then mass transfer contact between fluid streams is enhanced, but device complexity increases
Solution Approach 1:
The packing is divided into multiple separate packing sheets positioned in parallel, each sheet containing corrugations that can be independently configured. This segmentation allows for modular assembly and simplified manufacturing while achieving the desired complex three-dimensional flow patterns for efficient mass transfer
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
This configuration enhances mass transfer coefficients while minimizing pressure drop, demonstrated in applications like removing carbon dioxide from air, offering improved performance compared to commercial products.
Implementation Method 1
These structured packings typically comprise a plurality of structured packings sheets that are positioned in an upright, parallel relationship to each other. One type of structured packing sheet has corrugations, with the corrugations on adjacent structured packing sheets being arranged in crossing relationship to each other to form flow channels for one of the fluid streams. The other fluid stream may flow in crossing relationship, i.e., crossflow, or countercurrent flow to the fluid stream flowing along the flow channels formed by the crossing corrugations.
Implementation Method 2
Each structured packing sheet has corrugations formed of alternating peaks and valleys and corrugation sidewalls that extend between adjacent ones of the peaks and valleys, and apertures in the corrugations for allowing passage of fluid through the structured packing sheets.
Implementation Method 3
Mass transfer columns are configured to contact at least two fluid streams in order to provide product streams of specific composition and/or temperature. These structured packings typically comprise a plurality of structured packings sheets that are positioned in an upright, parallel relationship to each other. One type of structured packing sheet has corrugations, with the corrugations on adjacent structured packing sheets being arranged in crossing relationship to each other to form flow channels for one of the fluid streams. The other fluid stream may flow in crossing relationship, i.e., crossflow, or countercurrent flow to the fluid stream flowing along the flow channels formed by the crossing corrugations.
Implementation Method 4
mass transfer columns, such as those used in multicomponent absorption and distillation, are configured to contact gas and liquid phases, while other mass transfer columns, like extractors, are configured to contact two liquid phases of differing density.
Data Source
AI summary
A structured packing module for crossflow applications is provided and includes a plurality of corrugated structured packing sheets positioned in an upright, parallel relationship to each other. The corrugations of adjacent structured packing sheets are in contact with each other and extend at a crossing angle. Apertures and raised ridges may be positioned on sidewalls of the corrugations. The structured packing module may be used in a crossflow contactor, such as in a process for removing carbon dioxide from air.