Valve Tray Circumferential Vane for Vapor-Liquid Mixing
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Solution Overview
Problem
Commercially available valve trays in chemical-process columns suffer from inefficient mixing of gas or vapor with liquid, leading to reduced contact efficiency and potential flooding issues due to backflow and pressure-related problems.
Innovation Solution
A valve tray design featuring a tray surface with apertures and fixed valves having a circumferential vane angled between 11° to 79° from horizontal, which directs ascending vapor downward for intimate mixing with liquid, along with retainer legs securing the valve to the tray deck, promoting perpendicular flow and enhanced mass transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional valve trays are used, then the structure is simple and easy to manufacture, but the mixing efficiency between vapor and liquid is poor and contact efficiency is reduced
Solution Approach 1:
The valve body is segmented into multiple functional zones: an upper valve body for vapor distribution, a lower valve body for liquid contact, and a circumferential vane system for flow direction control. This segmentation allows each zone to perform its specific function optimally, improving mixing efficiency while maintaining manufacturing simplicity through modular construction
Solution Approach 2:
The circumferential vane acts as an intermediary element between the ascending vapor and the liquid flowing across the tray. It mediates the interaction by directing vapor downward and perpendicular to the liquid flow, creating intimate mixing without requiring complex mechanical agitators or high-energy inputs
2Productivity
If fixed valves with circumferential vane are used, then contact efficiency is improved, but device complexity increases
Solution Approach 1:
The circumferential vane is positioned specifically at the lower valve body where vapor-liquid contact occurs most intensively. This localized feature concentrates its flow-directing function exactly where needed, maximizing contact efficiency without adding complexity to other parts of the tray system
Solution Approach 2:
Instead of allowing vapor to rise directly upward through the tray, the circumferential vane inverts the flow direction, directing vapor downward and perpendicular to the liquid flow. This inverted approach creates more effective counter-current contact and improves mass transfer efficiency
3Productivity
If vapor flow rate is increased to improve mass transfer, then contact efficiency increases, but backflow and flooding issues occur
Solution Approach 1:
The circumferential vane performs preliminary flow direction control before vapor enters the main liquid contact zone. By pre-directing vapor downward and perpendicular to liquid flow, it prevents the formation of backflow patterns and reduces the likelihood of flooding, allowing higher vapor rates to be operated stably
Solution Approach 2:
The circumferential vane introduces a perpendicular flow dimension, directing vapor not just upward or downward but at right angles to the liquid flow direction. This dimensional change in flow pattern disrupts backflow circulation and prevents flooding while maintaining high mass transfer efficiency
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 design improves mixing efficiency and contact between vapor and liquid, reducing backflow and pressure-related issues, thereby increasing the tray's capacity and operational stability.
Implementation Method 1
a circumferential vane angled between 11° to 79° from horizontal, which directs ascending vapor downward for intimate mixing with liquid
Implementation Method 2
orifice control of valve pressure drop
Implementation Method 3
enhanced mass transfer
Data Source
AI summary
The present disclosure relates to a valve tray for use in a chemical process column. The valve tray includes a plurality of apertures formed therein. A plurality of valves are maintained in a spaced relationship relative to individual apertures of the plurality of apertures. An area of the individual apertures is less than an area of individual valves of the plurality of valves.