Structured Packing With Variable Corrugation Angles
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Solution Overview
Problem
Vapor-liquid contact towers with structured packing face challenges in self-regulation of internal pressure differentials and prevention of non-homogeneous vapor-liquid flow, leading to inefficient fluid interaction and increased pressure drops due to random flow patterns and sharp corrugation angles.
Innovation Solution
The structured packing system features corrugated sheets with linear fluid flow interface regions angled between 15 degrees and 7 degrees from vertical, facilitating laminar flow and enhanced interaction by reducing pressure drops and promoting homogeneous flow patterns across the packing layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If corrugated sheets with sharp corrugation angles are used, then vapor-liquid contact efficiency is improved, but pressure drop increases and flow patterns become non-homogeneous
Solution Approach 1:
The patent applies different corrugation angles to different regions of the packing sheet. The intermediate corrugated body portions have a first angle (more acute) for enhanced vapor-liquid contact, while the linear corrugated fluid flow interface regions have a second angle (less acute, 15-7 degrees from vertical) for reduced pressure drop and laminar flow. This local differentiation resolves the contradiction between contact efficiency and pressure drop.
Solution Approach 2:
The packing sheet is segmented into distinct functional regions: intermediate corrugated body portions for vapor-liquid contact and linear corrugated fluid flow interface regions for flow regulation. This segmentation allows each region to optimize its local function, with the interface regions preventing non-homogeneous flow patterns while the body portions maximize contact efficiency.
2Quantity of substance
If corrugated sheets with acute corrugation angles are used, then mass transfer surface area is increased, but flow homogeneity deteriorates
Solution Approach 1:
Different regions of the packing sheet are assigned different corrugation angles to fulfill different functions. The intermediate body portions use acute angles to maximize surface area for mass transfer, while the linear interface regions use gentler angles (15-7 degrees from vertical) to ensure homogeneous flow distribution, preventing random flow patterns.
Solution Approach 2:
The packing structure is divided into functional segments where intermediate corrugated body portions provide mass transfer surface area and linear corrugated fluid flow interface regions ensure flow homogeneity. This segmentation allows simultaneous achievement of high surface area and uniform flow patterns.
3Productivity
If vertically aligned packing sections are stacked, then tower capacity is increased, but fluid flow regulation at interfaces deteriorates
Solution Approach 1:
The linear corrugated fluid flow interface regions are designed in advance with specific angles (15-7 degrees from vertical) to preemptively regulate flow at the interfaces between vertically aligned packing sections. This preliminary design prevents non-homogeneous flow patterns and pressure differential issues before they occur, enabling stable stacking of multiple sections to increase tower capacity.
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 enhances fluid interaction and efficiency by maintaining laminar flow and reducing pressure drops, thereby improving the vapor-liquid contact process and product purity in vapor-liquid contact towers.
Implementation Method 1
facilitating laminar flow and enhanced interaction by reducing pressure drops and promoting homogeneous flow patterns
Implementation Method 2
efficient heat transfer, fluid vaporization, or vapor condensation whereby cooling of one of the fluids can be accomplished
Implementation Method 3
the quality as well as the quantity of the mass heat transfer occurring in process towers
Implementation Method 4
fluid vaporization, or vapor condensation whereby cooling of one of the fluids can be accomplished
Implementation Method 5
Quick cooling of the ascending vapor is generally a prerequisite for efficient operation to effect efficient heat transfer for vapor condensation
Data Source
AI summary
A structured packing sheet includes a top interface region, a first turning region, a central region, a second turning region, and a bottom interface region. The central region includes a plurality of corrugations extending thereacross in a linear fashion and arranged generally parallel to each other. The plurality of corrugations are arranged at a first angle with respect to a vertical axis. The top interface region and the bottom interface region include the plurality of corrugations extending thereacross in a linear fashion. The plurality of corrugations are arranged at a second angle with respect to the vertical axis. The second angle is smaller than the first angle. The first turning region and the second turning region include the plurality of corrugations extending thereacross. The plurality of corrugations have a plurality of breaks in the first turning region and the second turning region.