Liquid Flow on Structured Packing: CFD Simulation and Experimental Study

A CFD model of the two‐phase countercurrent flow in the geometry of the plate‐type structured packing Mellapak 250.Y was built, tested and verified. The model was applied to determine the effect of liquid and gas flow rates and physicochemical properties of the flowing liquids on the interfacial area formed on structured packing. The CFD model allowed us to determine the minimum liquid flow rate at which an unbroken liquid film was observed on the packing surface. The simulations confirmed that with an increase of the wetting rate the surface of the packing covered with a liquid film increased until the surface was totally covered up, while further slight changes of an interfacial area were the result of wave formation. The effect of gas load (F factor) on the film surface was in the range of a calculation error. Results of the CFD simulation allow us to predict the stages of film formation during liquid flow, to follow local velocity oscillations, film thickness and velocity profiles of phases.     

Hydraulic Calculations for Cross‐channeled Packings in Distillation Unit Based on a Physical Model

A physically based calculation model has been developed in order to describe the liquid and the gas flow in column packings with any arbitrary cross‐channel structure. An equation system is presented which characterizes the film flow on the surface as influenced by the countercurrent flowing gas stream and the respective geometric parameters of the packing. The considered hydraulic operating parameters are the pressure drop, the film thickness, and the radial liquid distribution as a function of the column load up to the flooding point. Care was taken to introduce only constants that can be interpreted physically. Their number was reduced to a minimum of three in order to provide the possibility of easy extrapolation to other packing dimensions. Numerical simulations have been carried out for different liquids assuming a fully wetted packing surface. A distribution width is introduced as the parameter characterizing the radial liquid distribution. Its value together with the respective gas split factors are important variables for the inclusion of maldistribution in the calculation of a distillation column. The numerical simulations up to the flooding point correspond well to the experimental data obtained from a test column.     

A new approach to fluid separation modelling in the columns equipped with structured packings

An analogy between the flow patterns in real separation columns equipped with structured packing and film flow is used to develop a new modelling approach. The packing is represented as a bundle of channels with identical triangular cross section. The dimensions of the channels as well as their number are derived from the packing geometry. The channel inner surface is wetted by a liquid flowing downwards, whereas the rest of the volume is occupied by a countercurrent vapour flow. Both phases are assumed to be totally mixed at regular intervals, determined by the corrugation geometry of the packing. The mathematical model is based on a set of partial differential equations describing hydrodynamics and mass and heat transport phenomena. These equations are complemented by the conjugate boundary conditions at the phase interface. A numerical solution of the model yields velocity profiles as well as concentration and temperature fields throughout the column. The model is verified using experimental data for a binary distillation in a column equipped with Montz-Pak A3-500.     

激光诱导荧光技术观测填料表面非等温降膜流动形态变化

非等温降膜流动在精馏过程中较为常见,其流动特性较为特殊,对填料表面的质量和热量传递有重要影响。本文搭建了可视化的实验装置,在保证液相室温进料的前提下升高填料温度,在规整填料表面构造液相被加热的非等温降膜流动,运用激光诱导荧光技术对液膜形态变化进行观测分析,对液体润湿面积、液膜厚度等参数进行比较。结果表明,随着填料温度的升高,液体润湿面积显著减小,波谷处液膜厚度显著增加,液膜逐渐收缩为沟流,填料表面的不规则液滴数目增多,干板现象越发严重。液体的聚并和分散轨迹消失,液相再分布及表面更新能力降低。因此,填料表面的非等温降膜流动液膜收缩现象十分明显,降低传热传质能力,需在工业生产中引起足够重视。     

Separation of mixtures and distribution of a liquid on a structured packing in a large-scale model of a distillation column

A large-scale experimental setup is designed to study the hydrodynamic parameters and the mass-transfer efficiency in a countercurrent flow of mixtures of Freon R21 and Freon R114 on structured packings in a column 0.9 m in diameter. The study deals with the local and integral parameters of separation of the mixture, the degrees of nonuniformity of the flow rates and concentration distributions of the liquid and vapor phases over a cross section and on the column wall, and the pressure difference while varying the number of packing layers and their rotation angle. The mass-transfer processes while independently varying the liquid and vapor flow rates over wide ranges are also investigated. Experimental data are presented to illustrate the effect of the operating parameters on the height of an equivalent theoretical plate, the relative pressure difference, and the distributions of the local parameters of the flows.     

Coating flows with interfacial air drag. A nonlinear theory

The problem of the coating flow of a Newtonian liquid under the influence of a contiguous air flow is considered. The effect of the air flow is simulated by a constant tangential viscous shearing, calculated as the average skin friction per unit area of a boundary layer air flow over a smooth flat plate. Predictions are obtained for the liquid flow characteristics in cases of cocurrent and countercurrent forced air flows. Significant changes in the liquid film thickness start to occur when the absolute value of a dimensionless shearing number, Tn, exceeds 0.01. This value is not sensitive to the other flow parameters. The study is limited to low and moderate liquid Reynolds numbers, when the surface tension forces have considerable to noticeable effect.     

规整填料表面液膜流动特性的数值模拟

精馏过程气液两相流运动分布特征对分离效率具有重要影响。为研究规整填料表面液膜流体动力学特性建立了基于VOF方法的CFD分析模型,并基于文献试验结果进行了验证。对液膜随时间和空间的演化分布特征、速度场分布和液相流量影响进行了模拟分析。液膜在波纹顶部下沿聚集形成凸起状波峰,在波纹底部波峰消失,而到达下节波纹上沿时,波峰重新形成;瞬态液膜厚度随时间波动,且沿填料表面液膜平均厚度先减小后保持稳定;发现液相聚集及形成液滴坠落容易导致出现干板区。不同位置液膜速度分布存在明显差异,沿填料表面液膜平均速度先增后减或保持稳定;液膜绕过波纹顶部时会加速,在波纹底部和上沿处会减速。液相流量增大,液膜平均厚度和速度均有所增大。     

Mass transfer characteristics of liquid films flowing down a vertical wire in a counter current gas flow

The wetted-wire packing, mainly consisting of a bundle of vertical parallel wires, is a promising concept for the use in separation columns. To investigate the multiphase flow inside the packing in detail and to estimate the performance of the packing, experiments on liquid films on a single vertical wire in a counter current gas flow were carried out. To get information about the interfacial area, an optical measurement of the film thickness was carried out with a digital high speed camera and image recognition tools. By measuring the evaporation of water and aqueous polyvinylpyrrolidone solutions into air, the gas-side mass transfer was determined. The liquid-side mass transfer was examined by measuring the desorption of CO₂ from water into air. The results show that the mass transfer coefficients are comparable to those appearing in common structured packings. When assuming a sufficiently high wire packing density, a specific interfacial area similar to corrugated sheet structured packings can be reached. Previous studies predicted a low pressure drop per packing height and extended capacity limits compared to common packings. In consideration of these results, the wetted wire packing therefore is shown to be suitable especially for absorption processes where a low pressure drop is favourable.     

Prediction of effective area and liquid hold-up in structured packings by CFD

Interfacial effective area and liquid hold-up in structured packing geometries are investigated using the volume of fluid method. Three-dimensional numerical simulations of gas–liquid flow on inclined plane plate and in a structured packing are performed. The VOF method is used to capture the gas–liquid interface motion. After a first validation case on the wetting phenomena prediction on an inclined plane plate, the effective interfacial area, the liquid hold-up and the degree of wetting of packing are studied as function of liquid flow rate and wall surface characteristic (adherence contact angle). Results show that the liquid flow-rate and the contact angle play a significant role. It is found that the interfacial effective area and the degree of wetting of packing increase as the liquid flow rate increases and as the contact angle decreases. Moreover, under the influence of the contact angle, different liquid film shapes are observed. The simulations results are compared to experimental data available in literature. This work shows that the CFD is a powerful tool to investigate performance characteristics of structured packings. Moreover, this work shows how CFD can be used as an effective tool to provide information on fluid flow behavior and determination of interfacial area, liquid hold-up and minimum flow-rate to ensure complete wetting. These parameters could be further used in process simulation at larger scale for the development and the design of efficient packings.     

TUM–WelChem cell model for the prediction of liquid distribution in random packed columns

Liquid maldistribution is one of the main deficiencies in random packed column design. Therefore, the knowledge of liquid distribution and its model-based prediction is of great interest. This work aims to further develop and validate the TUM–WelChem Cell Model for random packed columns. First, cell dimension calculations and the determination of random packing element orientations are standardized. The original WelChem Cell Model applies a liquid distribution mechanism based on liquid spread factors derived by virtual 3D irrigation experiments. An extension of the model involves the implementation of liquid and gas load related distribution mechanisms, considering dispersion effects caused by liquid loading and the countercurrent gas flow. The wall flow is refined by an increase of packing porosity at the column wall. Liquid distribution profiles provided by the TUM–WelChem Cell Model are validated against experimental data and show good agreement for both uniform and point source initial liquid distribution.     

Liquid holdup in columns packed with structured packings: Countercurrent vs. cocurrent operation

An experimental study of the liquid holdup and the liquid holdup axial profile in a square section column with structured packing is carried out. Both cocurrent and countercurrent operations are examined. A conductivity technique to estimate liquid holdups is proposed and calibrated against values measured by the drainage method. Liquid holdups estimated by this technique follow the same trends as those previously found by other methods. Axial profiles of liquid holdup in the cocurrent and countercurrent operation are illustrated for liquid velocities below the loading point, and for solutions of different viscosity and foaming character. Variations between operation modes are larger for the foaming liquid than for the other liquid solutions employed.     

波纹板规整填料塔液体分布

将填料单元处理成立体节点网,根据节点网内网线液流和节点液流各自的运动方式建立了填料单元的液体分布模型.通过将填料与塔壁间的液体交换规范成填料节点网与塔壁节点网间的液量传递建立了填料单元对应塔壁区的流体分布模型.提出了规整填料塔液体分布问题的边界条件.2个描述填料单元及其对应塔壁区液体分布的数学模型与2类边界条件共同构成了波纹板规整填料塔的液体分布模型.采用单纯形法对3个模型参数进行了估计.模型计算结果与实验数据一致,表明模型能合理地描述波纹板规整填料塔的液体分布性能.     

Pressure drops in gas—liquid flow in a 15 cm reciprocating platecolumn

Time-averaged pressure drops have been measured in a 15 cm internal diameter reciprocating plate column, using the water/air system under conditions of cocurrent, countercurrent and single phase (water) flow. The reciprocation frequency was varied from 1 to 4 Hz, while the stroke (peak to trough amplitude) was set at 2.54 cm. Two types of perforated plate were used, having perforation diameters 14.3 and 6.35 mm. Under single phase flow conditions, the pressure drops were in agreement with an earlier model due to Noh and Baird (1984). Under cocurrent conditions the gas flow had the effect of increasing the pressure drop, particularly at low reciprocation rates; this was interpreted in terms of enhanced circulation velocities in the liquid phase. In countercurrent flow the pressure drop was also affected by bubbles clustering at the plates.     

亲水无纺布PVC复合规整填料除湿性能实验

将亲水无纺布PVC复合规整填料作为溶液除湿塔芯体,开展亲水无纺布PVC复合规整填料除湿性能实验,分析在不同空气流量、溶液流量、溶液温度下,亲水无纺布PVC复合规整填料除湿率、除湿效率、传质系数和传热系数的变化。在实验条件下,除湿率、除湿效率、传质系数、传热系数最大值分别为11.05 g·kg^-1、86.7%、12.95 g·(m²·s)^-1、10.33 W·(m²·℃)^-1;与CELdek规整填料和塑料波纹孔板填料相比,亲水无纺布PVC复合规整填料除湿性能最优。对实验数据回归分析,得到亲水无纺布PVC复合规整填料除湿效率实验关联式。     

Experimental Investigation and Simulation of a Gas‐agitated Sieve Plate Column

The extraction of hydrogen peroxide by means of deionized water from anthraquinone working solution via anthraquinone process was carried out in a gas‐agitated sieve plate extraction column. The effects of the superficial velocity of air, dispersed phase and continuous phase on the overall plate extraction efficiency have been investigated. The corrections for the prediction of the overall plate extraction efficiency were presented. The correction proposed to predict the overall plate extraction efficiency in the air, water, anthraquinone working solution three‐phase system agreed satisfactory with experimental data with a maximum absolute deviation of 5.6 %. A new design method for gas‐liquid‐liquid three‐phase extractors is developed based on the multistage countercurrent extraction model. The calculated data by the model agreed well with experimental data and the average relative deviation was less than 10 %. Moreover, the model was used to predict a gas‐agitated sieve plate extraction column for industrial production of hydrogen peroxide. The results show that the plate numbers of gas‐agitated sieve plate extraction column are 30–40 % less than that of liquid‐liquid sieve plate column.     

竖直多孔平板上液膜流动特性的研究

孔结构被广泛应用于传质塔填料中,对填料上的液膜流动和传质行为影响较大。对竖直光板和多孔板上的液膜流动进行了三维模拟,并通过实验验证了模拟的准确性。通过模拟研究了孔结构对液膜流动特性的影响。结果表明,干燥孔会阻碍液膜的铺展,而润湿孔促进液膜的铺展。与光板相比,多孔板上的液膜具有起伏波,这将影响液膜的厚度分布和速度分布。液膜厚度波动和水平方向的速度波动随着孔径的增加而增加,而竖直流动方向的速度随着孔径的增加而降低。当孔径增加到一定值时,毛细波将出现在孔中的液膜中,这大大增加液膜水平方向上的波动速度,而降低流动方向上的速度。当孔径继续增加到临界值时,液膜将破裂。多孔板上孔内和气侧区域存在涡旋,能够促进内部液体交换和增大气侧扰动,从而增强传质能力。     

Performance characteristics of a new structured packing

A new structured packing using carbon fibres, called Sepcarb^® 4D, is presented. This packing has several attractive properties, such as high voidage (ε=94%) and high effective area (a=420 m² m^?3). These properties are advantageous for packing used as a gas–liquid contactor for separation units. To determine the internal characteristics of this packing, we performed several experiments using a 150-mm-internal-diameter column. Firstly, hydrodynamics experiments were conducted using an air–water counter current flow to determine the pressure drop (for both dry and wet packing) and flooding point. Secondly, the mass transfer efficiency was determined in terms of HETP (height equivalent to theoretical plate) by total reflux experiments with an n-heptane/cyclohexane mixture at atmospheric pressure. Hydrodynamic performance and mass transfer efficiency were compared with those of packings generally used in distillation and absorption.     

A new design concept of structured packing column auxiliaries

This paper discusses the criteria for obtaining an improved performance of structured packing columns in gas-liquid contacting, by improving the liquid and gas distributors. A new liquid distributor design, specific for structured packing columns is presented. Experimental measurements which quantify the improvements attained by the new distributor are also presented. Furthermore, gas flow distribution requirements for structured packing columns are discussed. Three “case studies” indicative of the implementation of the proposed distributor concept in industrial columns are included. Case (a) CO₂/MEA removal column, case (b) ammonia splitter and case (c) acid gas neutralization column.     

泡沫碳化硅波纹规整填料内的液体流动特性

通过采用配备微距镜头的高速摄像仪记录单波纹片上的液体流动行为,发现了泡沫碳化硅波纹规整填料内同时存在液膜流动和准壁流两种液体流动模式。同时测定了组合波纹片之间的液体传递量,并将泡沫碳化硅波纹规整填料与金属丝网波纹填料和金属板波纹规整填料的测试结果进行比较,结果表明泡沫碳化硅波纹规整填料的单波纹片上的液体扩散程度较大,组合波纹片之间的液体传递量高于金属丝网波纹填料和金属板波纹规整填料。研究结果揭示了泡沫碳化硅波纹规整填料具有高效传质特性的根本原因在于其独特的三维空间网孔结构增强了液体在单波纹片上的横向扩散能力和在组合波纹片之间的径向传递能力,为新型高效规整填料的机理研究和进一步开发开拓了思路。