Distillation Tray With Variable Diameter Holes and Weirs

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Solution Overview

Problem

Distillation columns with perforated trays experience fouling issues due to rust and debris, leading to physical dislodgment and prolonged downtimes for cleaning, especially in high liquid loading processes, making tray design and maintenance challenging.

Innovation Solution

Designing trays without downcomers, featuring through holes of different diameters separated by weirs, allowing liquid to flow to lower trays while preventing vapor from passing upwards, which simplifies fabrication, reduces fouling, and enhances cleaning efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional trays with downcomers are used, then liquid flow guidance is achieved, but fouling by rust and debris occurs leading to physical dislodgment and prolonged downtimes

Engineering Contradiction:

Improvetray operational reliabilityVSAvoidfouling by rust and debris

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes downcomers from the tray structure entirely. By extracting this component that accumulates rust and debris, the invention eliminates the primary fouling location while maintaining liquid flow guidance through alternative means (tray geometry and weir design).

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent creates different regions on the tray with different through-hole diameters. Small diameter holes (0.25-0.5 inches) are positioned in regions where vapor passage is needed, while large diameter holes (0.75-1.5 inches) are positioned in regions for liquid flow. This local differentiation optimizes both vapor-liquid contact and flow guidance without downcomers.

Inventive Principle:

Principle #3Local quality

2Productivity

If trays are designed for high liquid loading processes, then distillation capacity is improved, but fouling imposes rate limitation and cleaning becomes complex

Engineering Contradiction:

Improvedistillation capacityVSAvoidtray structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the tray into distinct regions with different functions: regions with small through holes for vapor passage, regions with large through holes for liquid flow, and weir structures for liquid level control. This segmentation allows high liquid loading capacity while maintaining simplicity in each individual component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using downcomers to guide liquid flow (conventional approach), the patent inverts the approach by using tray geometry, weir heights, and hole diameter variations to achieve liquid guidance. Liquid flows through the plate itself rather than through separate downcomer conduits.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If through holes with different diameters are used, then liquid flow control is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveliquid flow controlVSAvoidtray fabrication ease

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent changes the parameter of hole diameter across different tray regions to control liquid and vapor flow. By varying this single parameter (hole size) rather than changing structural complexity, the patent achieves improved flow control while maintaining relative manufacturing simplicity through standard drilling operations.

Inventive Principle:

Principle #35Parameter changes

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 trays operate similarly to conventional trays with downcomers, reducing complexity and cost, extending their lifespan, and minimizing downtime for maintenance, while being less prone to fouling by rust and debris.

Implementation Method 1

liquid may pass in one direction through the first set of through holes while vapor passes in an opposite direction

Methodology Applied

Scientific EffectTwo-phase flow: Two-Phase Flow

Implementation Method 2

liquid may pass in one direction through the second set of through holes (e.g., those with larger diameter), but the liquid may pass with higher volume and pressure such that vapor is substantially blocked

Methodology Applied

Scientific EffectFlow separation based on phase properties: Two-Phase Flow

Implementation Method 3

The weir is configured to prevent liquid from leaving one region until the liquid level rises above the height of the weir

Methodology Applied

Scientific EffectHydraulic barrier:

Data Source

PatentUS12017165B2Distillation tray having through holes with different diameters

Publication Date: 2024.06.25 SABIC GLOBAL TECHNOLOGIES BV

AI summary

This disclosure describes one or more trays for use in distillation columns. The trays include a plate having a plurality of through holes that extend between a first surface of the plate and a second surface of the plate. The plurality of through holes include a first set of through holes each having substantially a first diameter and a second set of through holes each having substantially a second diameter that is different from the first diameter. The trays also include a weir coupled to the plate and extending from the first surface. The weir is positioned between the first set of through holes and the second set of through holes.