Extraction Tower Vertical Plates Redistributor Plug Flow
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Solution Overview
Problem
In extraction towers, especially those without external power, axial back-mixing of the continuous phase is severe when there is a small density difference between phases and high viscosity, leading to reduced production capacity and separation efficiency.
Innovation Solution
The introduction of a redistributor and vertical plates within the extraction tower's structure to improve the flow state of the liquid phase, eliminating axial back-mixing and converting the continuous phase flow into a plug flow, thereby enhancing separation efficiency and production capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If packing structure improvements are implemented, then mass transfer effects are improved, but axial back-mixing of continuous phase remains severe
Solution Approach 1:
The extraction tower is segmented into multiple sections by dividing the packing layer into upper, middle, and lower portions. Redistributors are strategically placed at the interfaces between these sections to control and redirect the continuous phase flow, preventing axial back-mixing while maintaining mass transfer efficiency in each segment.
Solution Approach 2:
Redistributors serve as intermediary devices between the packing layers. These redistributors intercept and redirect the continuous phase that would otherwise back-mix axially, acting as a mediator that maintains the beneficial mass transfer effects of the packing while eliminating the harmful back-mixing.
2Productivity
If redistributors and vertical plates are added, then axial back-mixing is eliminated and plug flow is achieved, but device complexity increases
Solution Approach 1:
Vertical plates are placed locally within the packing layers rather than throughout the entire tower. This localized approach achieves the goal of eliminating axial back-mixing and promoting plug flow in critical regions while minimizing the overall structural complexity and number of components required.
Solution Approach 2:
Vertical plates are introduced as a vertical dimension element within the horizontal packing structure. This dimensional addition creates flow pathways that guide the continuous phase vertically, transforming the flow pattern from axial back-mixing to plug flow without requiring complete reconstruction of the existing packing system.
3Ease of operation
If packing structure is optimized for smooth continuous phase flow, then mass transfer is improved, but axial back-mixing worsens
Solution Approach 1:
Redistributors are positioned upstream within the packing structure to preliminarily redirect the continuous phase before it can engage in axial back-mixing. This preliminary action ensures that the continuous phase flows smoothly through the packing for mass transfer while being preemptively guided away from back-mixing pathways.
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 use of redistributors and vertical plates simplifies the extraction tower's structure and significantly increases separation efficiency and production capacity by preventing axial back-mixing and promoting a plug flow, breaking the dependency on packing structure improvements for efficiency gains.
Implementation Method 1
the packing can prevent the continuous phase from axially back-mixing and facilitates crushing, gathering and re-dispersing of the dispersed phase by providing a surface area to improve the effects of the mass transfer
Implementation Method 2
the redistributors can eliminate an axial back-mixing of the continuous phase... so that the flow state of the liquid phase can be improved, i.e. a flow state of the continuous phase within the extraction tower is converted into a substantial plug flow
Implementation Method 3
under an action of gravity, a dispersed phase in manner of liquid droplet group counter-current-wise contacts with a continuous phase due to a density difference
Implementation Method 4
a dispersed phase in manner of liquid droplet group counter-current-wise contacts with a continuous phase due to a density difference
Data Source
AI summary
An extraction tower includes a housing defining a light phase outlet at a top thereof, a heavy phase inlet at an upper portion thereof, a light phase inlet at a lower portion thereof and a heavy phase outlet at a bottom thereof; a heavy phase distributor disposed in the housing and communicated with the heavy phase inlet; a light phase distributor disposed in the housing and communicated with the light phase inlet; a packing layer disposed in the housing and located between the heavy phase distributor and the light phase distributor; and at least one layer of vertical plates disposed in at least one of the packing layers, each layer of the vertical plates comprising at least two vertical plates parallel or cross to each other, each vertical plate disposed in an axial direction.