Rotated Cross-Channel Packing Bed for High-Pressure Mass Transfer
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Solution Overview
Problem
Structured packing elements used in high-pressure mass transfer and heat exchange columns experience decreased efficiency due to axial liquid backmixing and high pressure drop, particularly at pressures above 10 bar, which is not effectively addressed by existing technologies.
Innovation Solution
A structured packing bed design comprising layers of cross-channel packing elements with specific surface area and height, rotated at 70 to 110°, reducing axial backmixing and pressure drop by shortening flow paths and optimizing gas distribution, using elements with 60 to 500 m²/m³ surface area and 50 to 150 mm height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional structured packing elements are used in high-pressure columns, then mass transfer efficiency decreases due to axial liquid backmixing, but pressure drop increases
Solution Approach 1:
The packing element is segmented into multiple horizontal channels separated by partition walls, creating distinct flow paths for gas and liquid phases. This segmentation prevents axial backmixing by confining liquid flow to specific channels while allowing gas to flow through open spaces, thereby maintaining mass transfer efficiency at high pressures.
Solution Approach 2:
The packing element features a nested structure where vertical through-flow channels are integrated within the horizontal channel system. The partition walls create nested compartments that guide liquid flow while gas flows through the central open space, optimizing both mass transfer and pressure drop characteristics.
2Reliability
If packing element height is increased to improve mass transfer, then mass transfer efficiency improves, but pressure drop and axial backmixing increase
Solution Approach 1:
The packing element is divided into multiple horizontal channels of controlled height (10-50 mm each) separated by partition walls. This segmentation allows the total packing height to be increased for improved mass transfer while each individual channel maintains low backmixing through its confined geometry and structured flow paths.
Solution Approach 2:
The invention transitions from conventional vertical channel structures to a multi-level horizontal channel system with partition walls. This dimensional reorganization creates separate flow zones that prevent axial mixing while allowing vertical stacking of multiple channels to achieve the required total height for mass transfer.
3Productivity
If column diameter is increased for large-scale applications, then processing capacity increases, but gas distribution uniformity decreases
Solution Approach 1:
The packing element design with central through-flow channels and radial partition walls creates a universal flow distribution pattern that scales effectively with column diameter. The geometric structure ensures uniform gas distribution across the entire cross-section regardless of column size, maintaining processing efficiency in large-scale applications.
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 solution maintains high mass transfer efficiency and low pressure drop even at pressures above 10 bar, combining the advantages of random and structured packing elements, suitable for large-scale applications.
Implementation Method 1
heat exchange between a first fluid phase and a second fluid phase
Implementation Method 2
mass transfer between the phases is thus facilitated
Implementation Method 3
the light phase to ascend, while it is driven by a pressure gradient. The pressure gradient is required to overcome the flow resistance
Implementation Method 4
the corrugations of the corrugated sheets extending obliquely relative to the vertical or longitudinal direction, thus forming inclined channels which continuously cross one another
Data Source
AI summary
A structured packing bed for a column is provided. The structured packing bed comprises at least two layers stacked vertically above each other, and at least two of the layers each comprise at least one structured cross-channel packing element having a specific surface area of 60 to 500 m2/m3 and a height of 50 to less than 150 mm. At least 50% of the structured cross-channel packing elements are a block comprising a plurality of sheets with periodic deformations. The sheets are arranged in a longitudinal direction parallel and in touching contact with each other such that an open space is provided between them. Adjacent sheets are oriented such that their deformations intersect in crisscross fashion with each other, and a structured cross-channel packing element of a layer is rotated with regard to a structured cross-channel packing element of an adjacent layer by 70 to 110°.