Curved Structured Packing Sheets for Uniform Liquid Distribution
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Solution Overview
Problem
Existing structured packing layers in mass transfer columns face challenges with liquid maldistribution and reduced efficiency due to inclined grooves and premature liquid buildup at interfaces, leading to increased pressure drop and reduced capacity, especially at higher liquid loads.
Innovation Solution
The structured packing sheets feature a grid of indented and raised structures with microchannels and a curved geometry in the corrugations, particularly in the lower edge region, to enhance liquid spreading and reduce pressure drop by optimizing flow direction transitions between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If surface texturing with grooves is used to enhance liquid spreading, then mass transfer efficiency is improved, but liquid maldistribution occurs when the packing sheet is not level
Solution Approach 1:
The patent applies different surface texturing patterns in different regions of the packing sheet. Specifically, the first surface texturing pattern is applied to a first region while a second surface texturing pattern is applied to a second region, allowing each region to optimize for its specific function while collectively solving the liquid distribution problem across the entire sheet.
2Productivity
If higher specific surface area is used to maximize heat and mass transfer, then transfer performance is improved, but pressure drop increases
Solution Approach 1:
The patent modifies geometric parameters of the packing structure, specifically the corrugation angle and the configuration of surface texturing patterns, to optimize the balance between surface area and pressure drop. By carefully selecting and adjusting these parameters, the packing achieves high transfer performance while maintaining acceptable pressure characteristics.
3Productivity
If uniform grid of indented and raised structures is used to improve liquid spreading, then mass transfer efficiency increases, but liquid buildup occurs at interfaces between layers
Solution Approach 1:
The patent applies different surface texturing patterns in different regions of the packing sheet. Specifically, the first surface texturing pattern is applied to a first region while a second surface texturing pattern is applied to a second region, allowing each region to optimize for its specific function while collectively solving the liquid distribution problem across the entire sheet.
4Ease of manufacture
If corrugations with constant inclination angle are used to simplify manufacturing, then manufacturing ease is improved, but liquid flow direction changes abruptly at layer interfaces
Solution Approach 1:
The patent introduces curved transition regions at the interfaces between packing layers. Instead of abrupt angular changes, the corrugations are designed with curved profiles that smoothly guide liquid flow from one layer to the next, reducing turbulence and improving flow distribution while maintaining manufacturing feasibility.
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 innovative design improves mass transfer efficiency and reduces pressure drop by promoting uniform liquid distribution and minimizing liquid buildup, resulting in enhanced performance across various flow rates.
Implementation Method 1
liquid that travels along the grooves will preferentially flow in one direction
Implementation Method 2
a curve is formed in the geometry of the corrugations in the lower edge region such that an inclination angle of the corrugations in relation to the lower edge gradually increases from the bulk region through the lower edge region
Implementation Method 3
The surface texturing facilitates the spreading of the liquid phase across the surface of the structured packing sheets
Implementation Method 4
The indented structures on one face of the structured packing sheet form the raised structures on the opposite face
Implementation Method 5
the rate and/or degree of mass and heat transferred between the two phases is enhanced
Implementation Method 6
contact a gas-phase stream with a liquid-phase stream
Data Source
AI summary
A corrugated structured packing sheet has the combination of corrugations that include a curve formed in the geometry of the corrugations in the lower edge region of the structured packing sheet and a surface texturing on opposite faces of the structured packing sheet that are in the form of a grid of indented and raised structures. Each indented structure is separated from some or all of adjacent ones of the indented structures by the raised structures. The raised structures form rows of peaks and interconnecting saddles. Microchannels extend along adjacent ones of the indented structures and the interconnecting saddles. The surface texturing caused an unexpected performance improvement when used with the curved geometry of the corrugations in the lower edge region.