Structured Packing Module for Fouling-Resistant Mass Transfer
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Solution Overview
Problem
Conventional packing elements in mass transfer or heat exchange columns face challenges in severe service applications due to fouling, coking, and erosion, as they either lack structural strength or resistance to deposition, or provide insufficient separation efficiency.
Innovation Solution
Structured packing modules comprising upright, parallel-extending, corrugated plates with criss-crossing corrugations and spacer elements to maintain separation, ensuring unimpeded fluid flow and resistance to fouling and coking, while providing structural strength and separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional packing elements are used to provide structural strength and separation efficiency, then separation efficiency is improved, but fouling and coking resistance deteriorates
Solution Approach 1:
The packing element is divided into multiple corrugated plates with criss-crossing corrugations, creating a segmented structure that provides both separation efficiency through multiple contact surfaces and fouling resistance by preventing solid particle deposition in the open spaces between corrugations
Solution Approach 2:
The packing element transitions from conventional two-dimensional random packing to a three-dimensional structured arrangement of corrugated plates with criss-crossing patterns, creating open flow paths in multiple dimensions that prevent fouling while maintaining separation efficiency
2Object-affected harmful factors
If conventional packing elements are used to resist fouling and coking, then fouling resistance is improved, but structural strength and separation efficiency deteriorates
Solution Approach 1:
The packing element combines multiple corrugated plates with spacer elements to form a composite structured assembly that provides both structural strength through the plate framework and fouling resistance through the open criss-crossing corrugation pattern
Solution Approach 2:
The segmented corrugated plate structure with spacer elements creates a rigid framework that maintains structural strength while the open spaces between corrugations prevent solid particle deposition, achieving both structural integrity and fouling resistance
3Strength
If corrugations of adjacent plates are in contact to provide structural support, then structural strength is improved, but flow uniformity deteriorates due to low flow zones
Solution Approach 1:
Spacer elements are introduced as intermediary components between adjacent corrugated plates to maintain appropriate spacing, preventing direct contact that would create low flow zones while still providing structural support through the overall plate framework
Solution Approach 2:
The segmentation of corrugated plates with spacer elements maintaining separation creates multiple open flow paths throughout the structure, ensuring uniform fluid distribution across all plates while the segmented framework maintains structural integrity
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 enables uniform fluid flow and resistance to fouling and coking, maintaining structural integrity and separation efficiency in severe service conditions, thereby enhancing the performance of mass transfer and heat exchange processes.
Implementation Method 1
The packing elements generally improve the mass transfer or heat exchange by providing surfaces onto which the fluid streams are able to spread to increase the area of contact between the ascending and descending fluid streams
Implementation Method 2
an apparatus and a method for facilitating vapor-liquid or liquid-liquid contact in columns in which mass transfer and/or heat exchange processes occur
Implementation Method 3
an apparatus and a method for facilitating vapor-liquid or liquid-liquid contact in columns in which mass transfer and/or heat exchange processes occur
Data Source
Figure 1
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AI summary
A cross-corrugated structure packing module is provided for use in mass transfer or heat exchange columns and has particular applicability in severe service applications in which fouling, coking, and erosion are of concern. The structured packing module has a plurality of upright, parallel-extending, corrugated plates. Spacer elements are used to maintain the corrugations of adjacent plates in spaced apart relationship to reduce the opportunity for solids to accumulate on the surfaces of the plates. The plates are also free of apertures or surface treatments that would increase the opportunity for solids to accumulate on the plates.