Self-Cleaning Mass Transfer Tray for Separation Columns

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Solution Overview

Problem

Conventional mass transfer trays in separating columns face issues with solid particle formation, which can block passage openings and reduce separation efficiency, necessitating frequent manual cleaning that is hazardous and inefficient.

Innovation Solution

A self-cleaning mass transfer tray design featuring a bottom plate with through holes and corresponding movable valves that open under gravity during cleaning, allowing liquid with small particles to flow through and reducing manual cleaning requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional mass transfer trays are used in separating columns, then mass transfer between liquid and gas phases can be achieved, but solid particles accumulate on the trays and block passage openings, reducing separation efficiency

Engineering Contradiction:

Improveseparation efficiencyVSAvoidpassage blockage

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements a self-cleaning mechanism where liquid flow automatically removes solid particles from the tray surface. The liquid transmission part is designed to allow liquid to flow over the tray and wash away accumulated solids, eliminating the need for manual cleaning and maintaining passage openings clear of blockages.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent extracts the cleaning function from the main mass transfer function by introducing a separate liquid transmission pathway dedicated to particle removal. This allows the mass transfer process to continue uninterrupted while solid particles are continuously extracted and removed from the system.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If manual cleaning of trays is performed frequently, then solid particle accumulation is removed, but worker safety is compromised due to hazardous chemicals and confined space entry

Engineering Contradiction:

Improveparticle removalVSAvoidworker safety

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system performs self-cleaning through automated liquid flow that washes particles off the trays. This eliminates the need for workers to enter confined spaces and handle hazardous chemicals manually, transferring the cleaning function to the process fluid itself.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical cleaning operations with an automated fluid-based cleaning system. Instead of workers physically scrubbing trays, liquid flow mechanically removes particles through hydrodynamic forces, substituting human labor with a mechanical-fluid system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If large diameter crossflow mass transfer trays are used, then processing capacity is increased, but liquid gradient forms from feed to outlet causing solid particle accumulation in low liquid level regions

Engineering Contradiction:

Improveprocessing capacityVSAvoidparticle accumulation

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent segments the tray into distinct functional zones: a liquid transmission part for particle removal and a gas transmission part for mass transfer. This segmentation allows liquid to be directed specifically to regions where particle accumulation occurs, addressing the liquid gradient issue while maintaining large tray diameter for high capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different properties to different regions of the tray. The liquid transmission part is designed with specific flow characteristics to target particle accumulation zones, while the gas transmission part maintains optimized properties for mass transfer. This local differentiation addresses the liquid gradient problem in specific regions without compromising overall processing capacity.

Inventive Principle:

Principle #3Local quality

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 self-cleaning tray design effectively reduces solid particle accumulation, simplifies the cleaning process, and minimizes safety risks associated with manual cleaning in confined spaces, thereby enhancing separation efficiency and operational safety.

Implementation Method 1

When the valve is not acted on by the ascending gas flow, it can be open due to an effect of its own gravity

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS20250186902A1Mass transfer tray, use thereof, column having the same, and thermal separation process

Publication Date: 2025.06.12 BASF SE

AI summary

The present invention relates to a mass transfer tray comprising a bottom plate, at least one gas transmission part and a liquid transmission part, wherein the mass transfer tray has at least one valve located in the liquid transmission part, relates to use of a mass transfer tray of the present invention in liquid separation process, relates to a column comprising the trays of the present invention, and relates to a thermal separation process, comprising performing thermal separation within the column of the present invention.