Structured Packing Element with Optimized Grid Geometry
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Solution Overview
Problem
Structured packing elements in mass transfer columns face challenges in achieving high mass transfer efficiency and capacity while minimizing material costs and investment, as they often require expensive materials and have limited capacity due to high flow resistance and flooding issues.
Innovation Solution
A structured packing element design featuring at least two layers with a grid of openings and separating elements, where the average width of the separating elements is significantly larger than the layer material thickness and hydraulic diameter, allowing for improved mass transfer efficiency and capacity without using expensive materials, by optimizing the geometry and production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional corrugated sheets with small openings are used, then material cost is reduced, but wettability deteriorates and mass transfer efficiency decreases
Solution Approach 1:
The invention changes the geometric parameters of the grid structure, specifically setting the separating element width to 70-125% of the hydraulic diameter and at least 15 times the layer material thickness. This parameter optimization ensures adequate liquid distribution and wetting while using less material compared to traditional fine-perforated sheets.
Solution Approach 2:
The invention uses a grid structure with openings that creates a porous-like flow path system. The grid of openings allows liquid to distribute through the packing layer while the separating elements provide structural support and guide flow, achieving good wettability without requiring dense perforations.
2Reliability
If separating element width is increased, then mass transfer efficiency improves, but material usage increases
Solution Approach 1:
The invention optimizes the separating element width parameter to a specific range (70-125% of hydraulic diameter, and at least 15 times the layer material thickness). This optimized parameter range achieves the dual benefit of ensuring adequate liquid distribution for mass transfer while minimizing material consumption compared to traditional designs.
3Quantity of substance
If layer material thickness is reduced, then material cost decreases, but structural strength and flow distribution deteriorate
Solution Approach 1:
The invention establishes a critical relationship parameter: separating element width must be at least 15 times the layer material thickness. This ratio ensures that even with thin materials, the separating elements maintain sufficient structural strength and flow distribution capability, enabling cost reduction through thinner materials without sacrificing performance.
4Quantity of substance
If grid structure with openings is used instead of solid sheets, then material usage decreases, but flow resistance increases
Solution Approach 1:
The grid structure with openings creates a controlled porous flow path system. The openings allow light phase to ascend while the separating elements guide heavy phase flow, reducing flow resistance compared to solid sheets while maintaining adequate material usage for structural integrity and flow distribution.
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 enhances mass transfer efficiency and capacity while reducing material costs, as the larger separating element width and optimized geometry improve wetting and flow distribution, leading to better performance and reduced pressure drop, even with less physical area and material usage.
Implementation Method 1
The average width of at least 50% of the separating elements between adjacent openings is at least 15 times the layer material thickness
Implementation Method 2
improve wetting and flow distribution
Implementation Method 3
structured packing elements are typically operated in counter-current flow. While in distillation and absorption applications, the light phase is a gas or vapor and the heavy phase is a condensate or liquid
Implementation Method 4
adjacent corrugated sheets are oriented such that the corrugations of the adjacent corrugated sheets intersect in crisscross fashion with 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 element for a column for at least one of mass transfer and heat exchange between a heavy fluid phase and a light fluid phase. The structured packing element comprises at least two layers of a grid comprising openings that are surrounded and separated from each other by separating elements. At least two of the layers are arranged in a longitudinal direction parallel and in touching contact with each other such that an open space extending from one end to an opposite end of the layers is provided between the layers such that at least one of the heavy fluid phase and the light fluid phase may flow therethrough. An average width of at least 50% of the separating elements between adjacent openings is at least 15 times a layer material thickness and is between 70% and 125% of an average hydraulic diameter of the adjacent openings.