Segmented Star-Shaped Packing Element for Dirty Media
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Solution Overview
Problem
Current packings in thermal process engineering, such as McPac®, while improving separation efficiency and reducing pressure loss, still face limitations in load-bearing capacity and gas distribution, particularly in dirty media applications like reactive absorption and process gas purification.
Innovation Solution
The packing is enhanced by subdividing the star-shaped lateral surface of the outer sections into more drainage points, creating a larger mass transfer surface with improved gas distribution and contact points, and a refined lattice structure that reduces drag and allows for a higher flood limit, enabling more efficient separation and gas throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the star-shaped surface of outer sections is subdivided into more drainage points, then separation efficiency and mass transfer area are improved, but device complexity increases
Solution Approach 1:
The star-shaped lateral surface of each outer section is segmented into multiple drainage points by subdividing the indentations. Each indentation is divided into at least two subsections, one directed further inwards than the other, creating additional drainage pathways. This segmentation increases the mass transfer surface area and separation efficiency while maintaining a systematic structure that can be manufactured from a sheet metal strip through controlled bending and punching operations.
2Loss of energy
If the lattice structure is refined to reduce drag, then pressure loss is reduced, but load-bearing capacity may be compromised
Solution Approach 1:
The packing element employs local quality variations in the lattice structure. The outer sections feature star-shaped indentations with subsections that create localized drainage points and flow pathways, while the central section maintains a closed ring wall structure for structural integrity. The web thickness is optimized locally - narrower in regions requiring flow resistance reduction and sufficient thickness in load-bearing areas. This local differentiation allows reduced pressure loss while maintaining adequate load-bearing capacity.
3Volume of moving object
If column dimensions are reduced using the refined packing structure, then space efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The complex star-shaped indentations with multiple subsections are pre-formed during the manufacturing process by punching and bending the sheet metal strip before assembly. The radial indentations are created in a controlled manner during fabrication, ensuring consistent geometry and dimensions. This preliminary formation of the complex structure during manufacturing, rather than requiring post-assembly adjustments, enables precise reproduction of the design geometry while facilitating efficient production through standardized processes.
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
This design results in improved separation efficiency, reduced pressure loss, and increased load-bearing capacity, allowing for smaller column dimensions and higher gas throughput, particularly beneficial in dirty media applications, with optimized energy consumption and material usage.
Implementation Method 1
to achieve intensive mass transfer between the liquid and gaseous phases within the column
Implementation Method 2
which contributes to lower flow resistance and thus a higher flooding limit
Data Source
Figure 1~3
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Figure 9~13
AI summary
The invention relates to a packing material (1), particularly for use in packed columns in thermal process engineering. The packing material (1) has an annular wall (2) and inwardly directed indentations (3) made of the material of the annular wall (2), wherein the overall height of the packing material (1) is divided into at least three sections (5, 6, 7), of which the central section (6) is formed by a cylindrical surface (10) of the annular wall (2) and the outer sections (5, 7) adjoining the central section (6) each have several interconnected indentations (3) in the form of a star. According to the invention, each indentation (3) has at least two subsections (11, 12), one of which (12) is directed further inward than the other (11).