Segmented Cross-Flow Packed Column Contact Device
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Solution Overview
Problem
Existing cross-flow packed columns face issues such as narrow working ranges, inefficient heat/mass exchange, and complications in design and operation due to limitations in liquid and vapor phase organization, leading to reduced separation efficiency and increased costs.
Innovation Solution
A sectional cross-flow packed column design featuring identical contact elements assembled in blocks with horizontal segmental baffles and a liquid distributor plate, allowing for uniform liquid distribution and phase separation, and enabling efficient heat/mass exchange in gas/liquid and liquid/liquid systems while simplifying mounting and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If liquid phase flow rate is reduced, then energy consumption decreases, but heat/mass exchange efficiency deteriorates due to jet interruptions and gaseous phase breakthrough
Solution Approach 1:
The contact device is divided into multiple identical contact elements assembled in blocks, with each element containing corrugated sheets that create segmented flow paths. This segmentation maintains stable liquid film flow at reduced flow rates by preventing jet interruptions and ensuring continuous contact between phases, thereby maintaining heat/mass exchange efficiency while reducing energy consumption
Solution Approach 2:
The corrugated sheets are designed with specific geometric parameters (corrugation pitch, amplitude, and angle) that dynamically adapt to varying liquid flow rates. The dynamic structure maintains optimal liquid film distribution and prevents gaseous phase breakthrough across the working range, ensuring stable heat/mass exchange efficiency at reduced energy consumption
2Productivity
If liquid phase flow rate is increased, then heat/mass exchange efficiency improves, but liquid film breakaway occurs leading to deterioration of separation
Solution Approach 1:
Different regions of the contact device have optimized local characteristics through the corrugated sheet geometry and block arrangement. The local structure maintains liquid film stability at high flow rates by distributing the liquid uniformly across the contact surface, preventing breakaway and maintaining separation efficiency while allowing high heat/mass exchange efficiency
Solution Approach 2:
The contact device structure dynamically responds to increased liquid flow rates by maintaining stable liquid film flow through the corrugated geometry. The dynamic design prevents film breakaway and liquid product throwing onto upper contact devices, ensuring separation efficiency is maintained even at high heat/mass exchange efficiency operating conditions
3Loss of substance
If corrugated sheets are made from mesh, then material usage is reduced, but shaping and structural strength become complicated
Solution Approach 1:
The contact device uses composite construction with corrugated sheets made from solid or perforated sheet metal combined with a support structure of vertical posts and horizontal baffles. This composite approach provides the necessary structural strength and ease of shaping while maintaining reasonable material usage, overcoming the limitations of using mesh alone
4Ease of manufacture
If block configuration is standardized, then manufacturing cost decreases, but design flexibility may be limited
Solution Approach 1:
The contact device is segmented into identical modular blocks that can be standardized for manufacturing. Each block contains corrugated sheets and support elements that can be independently manufactured and then assembled in various configurations to suit different column diameters and application requirements, achieving both cost efficiency and design flexibility
Solution Approach 2:
The standardized blocks are designed to be universal components that can be used in different column sizes and applications. The same basic block design can be adapted to various configurations by changing the number of blocks, their arrangement, or the specific corrugation parameters, providing both manufacturing economy and design versatility
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 design enhances heat/mass transfer efficiency, stabilizes reflux flow, and optimizes phase separation, achieving over 80% free cross-section utilization and reducing costs by allowing flexible block configurations and standardization, thus improving overall mass exchange apparatus efficiency.
Implementation Method 1
contact device for carrying out heat/mass exchange and separation of phases
Implementation Method 2
processes of rectification, distillation, absorption, and extraction
Implementation Method 3
mass exchange cross-flow packed column
Implementation Method 4
horizontal segmental baffles and a liquid distributor plate, allowing for uniform liquid distribution and phase separation
Implementation Method 5
separation of phases in sectional cross-flow packed columns in gas/liquid and liquid/liquid systems
Data Source
AI summary
The invention relates to packed contact devices used in heat/mass exchange column apparatuses in which the processes of rectification, distillation, absorption, and extraction are run, and can be applied in the oil refining, petrochemical, chemical, gas-processing, and food-manufacturing industries. A contact device for carrying out heat/mass exchange and separation of phases in sectional cross-flow packed columns in gas/liquid and liquid/liquid systems comprises a plurality of identical contact elements assembled one upon another in one or more rows in blocks held together by spokes and vertical posts, with formation of walls in the column body that are restricted on horizontal end faces by horizontal segmental baffles conjugated in an arc with the column body; thereat, arranged between the walls are liquid distributors having a perforated part, an additional baffle, deflector plates, and vertical support plates. The space between the lower and upper walls is sealed by means of battens.