Structured Packing Corrugation Layout for Lower Pressure Drop
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Solution Overview
Problem
Conventional structured packings face limitations in hydraulic capacity due to abrupt changes in flow direction, leading to increased pressure drop and reduced efficiency, which restricts the flow rate and increases distillation column height and costs.
Innovation Solution
The structured packing features rectangular sheets with end regions at right angles, main regions at an acute angle, and transition regions with arcuate corrugations, reducing internal pressure drop and enhancing hydraulic capacity by smoothing the flow direction and reducing turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional structured packing uses constant acute angle corrugations, then mass transfer surface area is provided, but pressure drop increases and hydraulic capacity is limited due to abrupt flow direction changes
Solution Approach 1:
The patent applies curvature to the corrugation pattern by introducing transition regions with arcuate sections that connect end regions (at right angles to sheet edges) to main regions (at acute angles). This curved transition smooths the flow direction change for both vapor and liquid phases, reducing turbulence and pressure drop while maintaining effective mass transfer surface area. The arcuate corrugations in transition regions gradually redirect flow rather than creating abrupt directional changes.
2Length of stationary object
If packing density is increased to maintain mass transfer efficiency, then column height can be reduced, but hydraulic flooding capacity decreases
Solution Approach 1:
The patent applies local quality by creating different regional characteristics within the packing sheet: end regions with corrugations at right angles to edges for reduced pressure drop at sheet boundaries, main regions with acute angle corrugations for effective mass transfer, and transition regions with arcuate corrugations for smooth flow transition. This localized differentiation allows the packing to simultaneously achieve high hydraulic capacity and maintain mass transfer efficiency at higher densities.
3Productivity
If column diameter is reduced to lower fabrication costs, then productivity decreases, but if column diameter is increased to maintain productivity, then fabrication costs increase
Solution Approach 1:
The patent changes the geometric parameters of the corrugations - specifically the angle variations from constant acute angle to variable angles (right angle at ends, acute angle in main regions, with arcuate transitions). This parameter modification increases hydraulic capacity and allows the column to operate at higher flow rates without flooding, enabling reduced column diameter for the same productivity level, thereby lowering fabrication costs.
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 increases hydraulic capacity and allows operation closer to flooding limits without significant efficiency loss, enabling higher production rates and potentially reducing column diameters and fabrication costs.
Implementation Method 1
transition regions, connecting corrugations within the end and main regions and having corrugations of arcuate configuration
Implementation Method 2
The vapor flows upwardly through the corrugations and also tends to spread out through the packing and contact the descending liquid. The intimate contact of the vapor and the liquid produces a variation of the liquid and vapor mixtures that tends towards equilibrium.
Implementation Method 3
Every structured packing has a hydraulic flooding capacity in which the pressure drop starts to rise rapidly. As the liquid flow in a downward direction through the packing is impeded as a result of excessive upflowing vapor, the liquid begins to build up at the interface between packing layers resulting in the rapid rise in pressure drop leading to flooding.
Data Source
AI summary
A structured packing formed of a plurality of corrugated, rectangular sheets and a method relating to the use thereof. End regions of the corrugations are provided with straight, parallel corrugations extending inwardly from opposed edges of the sheets and a right angles thereto to reduce pressure drop at the interfaces between packing layers and thereby increase hydraulic capacity. Contact is promoted between descending liquid and ascending vapor phases within a main region of the corrugations that have straight, parallel sections of the corrugations oriented at an acute angle to the opposed edges. Transition regions having arcuate sections of the corrugations connect corrugations within the main and end regions to reduce internal pressure drop within the structured packing and thereby further reduce pressure drop at the interfaces and further increase the hydraulic capacity.