Structured Packing Windows for High-Viscosity Mass Transfer
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Solution Overview
Problem
Current structured packings are inefficient for high viscosity fluids, leading to a decline in mass transfer efficiency and increased energy consumption due to the negative correlation between interfacial mass transfer coefficient and fluid viscosity.
Innovation Solution
A packing element comprising a collection-predistribution unit, fluid uniform distribution unit, and opening window unit, with specific geometric arrangements and dimensions to enhance liquid film uniformity and thinning, improving interfacial mass transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional structured packing (corrugated plate or wire gauze) is used, then the structure is simple and easy to manufacture, but the mass transfer efficiency sharply declines when fluid viscosity increases
Solution Approach 1:
The packing surface is segmented into multiple functional zones: distribution channels for liquid allocation, flow acceleration zones to increase fluid velocity, and thin film regions to reduce film thickness. This segmentation allows each zone to perform its specific function optimally, maintaining mass transfer efficiency even for high viscosity fluids while keeping the overall structure manufacturable
Solution Approach 2:
Different regions of the packing are designed with different local structures: some areas have dense corrugations for liquid distribution, while other areas have open spaces for flow acceleration. This local quality variation enables the packing to simultaneously achieve good liquid distribution and high flow velocity, resolving the contradiction between structural simplicity and mass transfer efficiency
2Quantity of substance
If the liquid film thickness is increased to handle high viscosity fluids, then the fluid flow is improved, but the mass transfer resistance increases
Solution Approach 1:
The packing design creates dynamic flow conditions through inclined channels and acceleration zones that increase liquid velocity along the flow path. This dynamic approach allows the liquid film to maintain adequate thickness for high viscosity fluids while achieving higher flow rates that reduce residence time and mass transfer resistance through enhanced convection
3Productivity
If the packing structure is optimized to improve liquid film hydrodynamics, then the mass transfer performance is enhanced, but the device complexity increases
Solution Approach 1:
The invention extracts and emphasizes only the essential structural elements needed for high viscosity fluid handling: inclined channels at specific angles, flow acceleration zones, and thin film regions. By removing unnecessary complex features and focusing on these key elements, the design achieves superior mass transfer performance while maintaining relative structural simplicity and manufacturability
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 structured packing effectively enhances interfacial mass transfer between gas and high viscous fluids by accelerating and thinning the liquid film, resulting in improved surface renewal frequency and reduced mass transfer resistance.
Implementation Method 1
The fluid uniform distribution unit (2) includes a first substrate and a plurality of orifices 2-1 arranged on the first substrate
Implementation Method 2
The opening window unit (3) includes a second substrate and a plurality of windows 3-1 arranged on the second substrate. The length of the windows 3-1 is proportional to 0.5 power of the fluid viscosity
Data Source
AI summary
The present disclosure belongs to the technical field of packings, and in particular, to a packing element, a structured packing and an application of the structured packing. The packing element includes a collection-predistribution unit, a fluid uniform distribution unit, and an opening window unit that are sequentially arranged. The fluid uniform distribution unit includes a first substrate and a plurality of orifices arranged on the first substrate. Each orifice is circular and/or semicircular. Each orifice has an equivalent diameter of 1-5 mm. The opening window unit is provided with a plurality of windows, and each window has a length proportional to 0.5 power of the fluid viscosity. Fluid forms a confined free film in the window region of the opening window unit and wall-bounded film on the wall surface region.