Gas–liquid flow modeling in columns equipped with structured packing

The modeling of gas–liquid flow in distillation columns equipped with structured packing has been dealt. The devices are seen as bistructured porous media, and a macroscale model is proposed taking into account this specific geometry. In this model, the two liquid films, one‐per‐sheet, are treated separately and are allowed to exchange matter at the vicinity of the contact points between corrugated sheets. The model emphasizes mechanisms that lead to the liquid radial dispersion effects: a main part comes from the geometry itself, another part is due to the capillary effects. A particular attention is paid to model these phenomena from a macroscale point of view. Finally, the simulation results are confronted to tomography imaging within a lab‐scale column and show a qualitative good agreement of the liquid distribution. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3665–3674, 2014     

Modeling of dry pressure drop for fully developed gas flow in structured packing using CFD simulations

Dry pressure drop in columns equipped with structured packings is considered to involve two components: drag force due to the direction changes near the column walls and in the transition region between two packing layers rotated to each other by 90°, and friction force between the different gas flows inside the crossing triangular channels and with the packing solid walls. It is believed that in a packed bed with compact sheet density and large packing surface area (above 250 m²/m³), the major contribution of the pressure drop is generated by the friction component.In this paper, a model is proposed to determine the dry pressure drop friction component. The gas is assumed to establish a fully developed turbulent flow inside the structured packing channels. The structured packing geometry consists of a combination of periodic elements. It is shown that the reproduction of one periodic element aerodynamics leads to determine the gas distribution and pressure drop inside the packed bed. Therefore, modeling the dry pressure drop through one periodic element is a meaningful representation of the dry pressure drop over the packing.CFD simulations are carried out on periodic elements using different turbulence models: RNG k−ε, realizable k−ε, and SST k−ω. The best results that agree with the experimental data in the literature are obtained with the SST k−ω model. The CFD model proposed is used to study the impact of packing geometry variations on the dry pressure drop and to bring up a correlation for the pressure drop with respect to changes of packing geometry: channel height dimension, channel opening angle, and corrugation angle.     

A multi-scale approach for CFD calculations of gas-liquid flow within large size column equipped with structured packing

This work has been carried out in the framework of post-combustion CO₂ capture process development. Considering the huge amount of gases to be treated and the constraints in terms of pressure drop, it appears that the absorption column will be equipped with high efficiency high capacity packings such as structured packings. The present paper focuses on the CFD modellisation of the two-phase flow within this complex geometry. For limited computational resources reasons, it is presently impossible to run computations at large scales taking into account the gas-liquid interaction and the real geometry of the packing and original approaches must be developed. In the present work, a multi-scale approach is proposed. It first considers liquid-wall and liquid-gas interaction at small scale via two-phase flow calculations using the VOF method. Second, the latter results are used in three-dimensional calculations run at a meso-scale corresponding to a periodic element representative of the real packing geometry. Last, those results are further used at large scale in three-dimensional calculations with a geometry corresponding to a complete column. Results are compared with experimental data and with other CFD simulations in terms of liquid hold-up, pressure drop and unit operation. Some suggestions are made for further development.     

Modelling and measurement of gas flow distribution in corrugated sheet structured packings

A mathematical model and calculation procedure are developed for the gas flow distribution in channels formed between tightly packed, corrugated, unperforated metal sheets. The model is a discrete cell model based on averaged mass, momentum and energy balance equations for each of numerous crossings of gas flow channels, with characteristic friction factors for gas inlet, bulk zone and wall zone as model parameters, which can be easily obtained from pressure drop measurements for each type and size of structured packing. The model enables prediction of velocity profiles leaving an element or packing layer consisting of segments of unperforated, structured packing. It is also suited for perforated packings which under operating (wetted) conditions function as a closed surface packing.     

Hydrodynamic analogy approach for modelling of reactive stripping with structured catalyst supports

Modelling of gas/vapour–liquid separation processes usually requires experimentally determined parameters, e.g., mass transfer coefficients. This results in expensive experimental work, especially for new types of column internals. A novel modelling approach based on hydrodynamic analogies (HA) has recently been developed for distillation units equipped with structured corrugated sheet packings. The HA model takes the packing geometry directly into account whereas the experimental determination of mass transfer coefficients is not required.In this work, the HA approach is extended to cover heterogeneously catalysed reactive stripping processes. Experimental investigations are performed with a test system, esterification of hexanoic acid and 1-octanol, using different types of catalytically coated supports as column internals (one corrugated sheet packing and three film-flow monoliths with different channel geometries). Simulation results obtained with the extended HA model are in a good agreement with experimental values.     

Models describing the behavior of new carbon fiber packings inn rectification processes

Many rectification processes are used to separate corrosive substances with high boiling points. This reports deals with a new type of structured column pacing mode of corrosion-resistant carbon fiber material. These column internals allows for low pressure drop at high throughput rated with reasonable column efficiency. Experiments in columns of 50 and 100 mm diameter have been carried out to investigated separation efficiency, pressure drop and liquid holdup of the packing even at low operation pressures. In the respective columns twp geometrical different types of packing have been tested using binary mixtures of chlorobenzene/ethylbenzene with a packing geometry similar to the Sulzer EX packing, the 100 mm diameter column was filled with elements of rougher structure and smaller specific surface. Basing on the experimental results, model equations are presented, which allow the calculation of the investigated performance characteristics.     

INFLUENCE OF INITIAL LIQUID DISTRIBUTION ON MASS TRANSFER IN PACKED BEDS

1 INTRODUCTIONA major problem in the design of packed columns is dimensioning the liquid distributor.Thenumber of outlets is an important factor,because it governs the quality of the liquiddistribution at the inlet cross-section and thus the extent to which the packing is Wetted.Thehigher the degree of wetting and thus the greater the area of phase contact,the more efficientthe mass and heat transfer within the bed of packing.     

新型多管塔流体力学特性

1 INTRODUCTION The column packed with Dixon gauze ring or heli-pak has been widely used for separating isotopes and isomerides for its remarkably low HETP when operated under optimum conditions. However a fatal weakness of such columns is that it works well only for small diameter columns. No matter whatever type of packing is used in the column, normally the HETP increases with the increase of the diameter of the column, and it appears that the more efficient the packing is, the more …     

规整填料塔液相流动的计算流体力学模拟

规整填料因具有诸多优异性能,已在工业上广泛应用,但是至今人们对规整填料内流体流动机理的研究还不是十分透彻,从而限制了其进一步的发展和更新．与散堆填料不同,规整填料在结构上既有规整性又有复杂性,属各向异性,因此对其内流体流动的研究具有一定的难度．而现代计算流体力     

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.     

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.     

规整填料塔中精馏过程的三维模拟(Ⅰ)物理模型和模型方程

建立了能描述规整填料塔中液体三维流动和混合的精馏过程混合池模型。对模型方程组的封闭性作了分析,并给出模型中液体流动分布和混合参数的计算方法。针对完整的三维混合池模型在求解计算上的费时,提出了适用于规整填料塔精馏过程的简化三维混合池模型和求解该方程的两步法。     

The hydrodynamics or gas-liquid contacting in towers with fluidised packings

A model is developed of gas liquid contactors in which packing pieces are maintained in the fluidized state. The model proposes that the column can exist in either of two modes, namely fluidisation without flooding and fluidisation due to incipient flooding. The mode of operation established depends primarily on the packing density and to a lesser extent on the packing size, liquid flow and liquid properties. Equations predicting the transition from one mode to the next are developed. The inherent advantages of operating in the “incipient flooding” mode are stressed. It is argued that the pressure build up associated with flooding will be sufficient to support the weight of packing pieces and the liquid in the column. At this stage, rather than reject counter current flow (true flooding) the bed expands to maintain a state of incipient flooding. In this way counter current flow can be maintained in a situation well above the normal flooding point. This explains the high performance of such units.     

Pressure drop in pulsed extraction columns with internals of discs and doughnuts

A study on the pressure drop in pulsed extraction columns with internals of immobile discs and rings, usually called Discs and Doughnuts Columns (DDC) is carried out. The local pressure at a desired level of the column is obtained by resolving of turbulent flow model based on Reynolds equations coupled with k–? model of turbulence. Consequently, the pressure drop for a column stage or for a unit of column length is determined. The results are used for development of correlations for determination of pressure drop as a function of plate free area, interplate distance and pulsation parameters – amplitude and frequency. Good correspondence to experimental data is observed. The developed quantitative relations are useful for non-experimental numerical optimization of stage geometry in view of lesser energy consumption.     

CFD Study on the Local Mass Transfer Efficiency in the Gas Phase of Structured Packing

Visualization of local mass transfer coefficients over the dry surface of corrugated‐sheet structured packing is essential for optimizing the existing geometry of structured packing and for improving mass transfer efficiency to develop new structured packing. The local flow patterns between packing sheets and the gas‐phase mass transfer coefficient at each point over the surface are illustrated by employing a wall‐surface reaction model. Different turbulence models are utilized, i.e., a standard κ‐? model and three different low‐Re‐κ‐? models. The numerical calculation results with the Lam‐Bremhorst low‐Re‐κ‐? turbulence model is found to agree well with experimental data. There are three similar regions with enhanced mass transfer efficiency in each mass transfer unit cell of structured packing.     

Performance Prediction of Structured Packing Column for Cryogenic Air Separation with Hybrid Model

A detailed investigation of a thermodynamic process in a structured packing distil ation column is of great impor-tance in prediction of process efficiency. In order to keep the simplicity of an equili...     

Mass transfer performance of structured packings in a CO2 absorption tower

This paper studies the mass transfer performance of structured packings in the absorption of CO2 from air with aqueous NaOH solution. The Eight structured packings tested are sheet metal ones with corrugations of different geometry parameters. Effective mass transfer area and overall gas phase mass transfer coefficient have been measured in an absorption column of 200 mm diameter under the conditions of gas F-factor in 0.38–1.52 Pa0.5 and aqueous NaOH solution concentration of 0.10–0.15 kmol·m?3. The effects of gas/liquid phase flow rates and packing geometry parameters are also investigated. The results show that the effective mass transfer area changes not only with packing geometry parameters and liquid load, but also with gas F-factor. A new effective mass transfer area correlation on the gas F-factor and the liquid load was proposed, which is found to fit experiment data very well.     

Local mass-transfer distribution in the channels of a serpentine flow baffled parallel plate cell

Mass-transfer measurements were made in a parallel plate cell equipped with baffles which produced a three-channel serpentine flow pattern and three-dimensional mass-transfer distribution effects. The entry and exit configurations were in the form of slots of rectangular cross-section. Local mass-transfer coefficient values obtained in the different channels, using surface-flush microelectrodes, reflected the complex hydrodynamics associated with phenomena such as the cell inlet and exit effects, the flow reversal effects at the baffles and preferential flow phenomena in the channels. Mass-transfer measurements obtained by averaging point measurements over various zones of the cell compared favourably with those of other workers. A hydrodynamic model of flow in the cell corresponded well to the measured mass-transfer distribution.     

Computational Fluid Dynamics Simulation of 13CO Distillation in Structured Packing

Physical 3D models were established for corrugated packing used in the enrichment of the isotope ¹³C. Computational fluid dynamics (CFD) simulation results indicated that common corrugated packing was not well wetted when used for isotope distillation. It is concluded that liquid misdistribution in the packed tower results from the structure of the packing rather than from the height of the packing beds. The existence of entrainment was also demonstrated by CFD simulation. It is proved that mass transfer equations based on the Nusselt theory are not suitable for distillation calculation in such a corrugated packing system. By comparison, the recently developed structured packing model with a corrugation geometry based on the right‐angled triangle, known as Zigzag‐pak, describes vapor‐liquid distribution properties well and has significant advantages over common corrugated packing due to its better liquid distribution character.     

从浓度分布评价填料塔性能

精馏塔性能的优劣通常可以用在塔顶和塔底取样,然后计算其分离效率的方法来判断,但这种方法只可以判断出精馏设备效率的高低,却几乎无法找出造成设备效率不够理想或低效的原因．不良初始分布、壁流、沟流和溪流、端效应以及气相或液相返混等现象都可以造成填料塔效率的下降,而