MXPA00006533A - Structured packing and element therefor - Google Patents

Abstract

A low pressure drop, highly efficient structured packing (2) comprises sheet material (4) formed into vertical preferably square channels (54, 56, 58) containing vortex generators (24) formed from the sheet material (4). The channels (54, 56, 58), while vertically linear, are periodically interrupted by the vortex generators (24) providing tortuous fluid paths along the channels (54, 56, 58). The thus formed vortex generators (24) form openings between adjacent channels (54, 56, 58) providing fluid communication between and uniform flow within the different channels (54, 56, 58). The packing (2) can be utilized in fluid mixing or those operations that require multiphase mass transfer, such as absorption or distillation. The addition of a catalyst makes the structure suitable for catalytic distillation. Turbulence is provided the fluids by the tortuous vertical path with low pressure drops transversely and vertically, with optimum liquid holdup.

Description

STRUCTURED PACKAGING AND ITS ELEMENT The present invention relates to a structured package which is used for systems for contacting fluids, such as a distillation tower or a single phase or multiple phase mixer and can be made catalytic for catalytic distillation. Commercially, distillation is usually practiced as a multi-stage counter-current operation of gas and liquid in a tower containing a packing device, to facilitate gas-liquid contact that is necessary for both mass transfer and heat transfer. Since there are multiple equilibrium stages in a tower, the compositions of the vapor and the liquid change through the tower. The desired products can be removed either as liquid or vapor at an optimal site in the tower. The more efficient the mass transfer device, the shorter the tower will be to achieve the same number of caps in equilibrium. Mass transfer devices are typically separate plates that allow the vapor to pass upward through a small height of liquid or continuous gaskets containing surfaces for gas-liquid contact. The ability to approximate the vapor-liquid balance is already designated by a fractional "plate efficiency" or "height equivalent to theoretical plate" (HETP = Height Equivalent to a Theorical Plate) for a continuous packing. The smaller the HETP, the more efficient the packaging. The advantage of structured packaging is high efficiency coupled with low pressure support drop. Low pressure drops are desired due to the increased cost in forcing gases upwards in the tower to overcome high pressure differentials, if present. Examples of catalytic distribution structures are described in U.S. Patents. Nos. 4,731,229 granted to Sperandio, 5,523,062 granted to Hearn, 5,189,001 granted to Johnson, and 5,431,890 granted to Crossland and collaborators. For example, the '229 patent discloses reactor packing elements comprising alternating grooved and non-grooved portions, with channels that are inclined relative to the vertical. Openings are provided in the parts to provide reagent communication that circulates through the package. The channels are inclined with respect to the vertical to ensure optimal fluid contact by providing liquid retention, the vertical channels allow minimal undesirable liquid retention, ie excessive liquid flow. The catalytic distillation combines the unitary operation of separation (distillation) with chemical reaction by placing a catalyst inside a distillation column. Since most reaction rates depend on the composition, it is possible to place the catalyst in an optimum position. Also, in chemical reaction limited by equilibrium, it is possible to remove the product (by distillation) and direct the reaction forward. More importantly, the use of catalytic distillation allows the use of smaller pieces of equipment. In this way, a two-vessel reactor distillation and reactor assembly can now be combined into a single structure. The U.S. Patent No. 5,321,163 discloses a catalytic distillation system. Improved prior art packaging structures have been developed comprising composite substrate structures, sometimes referred to as micro meshes, which are porous products constituted by a fibrous web of material. The Patents of the U.S.A. Nos.5, 304, 330; 5,080,962; 5,102,745 and 5,096,663, incorporated herein by reference, describe the production of porous composite substrates comprising fibrous webs of material. A mixture of substrates is typically constituted by metal fibers to form the porous compound and a structure-forming agent that functions as a binder, which are dispersed in an appropriate liquid. After preforming, the liquid is removed and the composite is heated to effect sintering of the fibers at bonding points to produce a porous substrate composite consisting of a three dimensional network of fibers. The structure forming agent is removed during or after sintering. Nevertheless, the substrate of porous material in a packing structure of the type described above, does not normally allow fluid communication through the pores for gases and liquids in the distillation process to provide the desired contact mixing required and the low pressure drop desired. This is possibly attributed to capillary action due to the relatively small pore size of the substrate material. This material can be for example sheets with a thickness of 100 microns (generally approximately .5 to .075 mm in thickness in one or more layers according to the desired strength) having the rigidity of conventional cardboard material and sometimes referred to as "paper" although they comprise metal fibers and is stronger than the paper of cellulose fibers. This material has a high surface to hollow volume ratio comprising approximately 90 to 95% gaps. The present inventors recognize a need to provide a structured packing of high efficiency resulting in improved distillation performance.

Advantageously, the present inventors recognize that this packaging material can be coated with a distillation catalyst for processing the reaction of the fluids of a distillation tower. A structured packing element for a fluid processing and mixing tower defines a vertical axis according to the present invention, comprises a sheet material element having a plurality of channels extending in an axial direction parallel to the vertical axis and a plurality of vortex generators in each of the channels, substantially forming a tortuous fluid path in each of the channels in the axial direction. In one aspect, the element has a plurality of through openings to allow fluid in each channel to flow transversely in the axial direction to and from adjacent channels. In a further aspect, the sheet material is porous and comprises sintered metal fibers. The vortex generators can be triangular or they can have a trapezoidal body segment with a tip segment or they can be rectangular where the channels are generally square when viewed in one direction over the axial direction.

Each of the channels may have opposite axially extending side walls, extending from an intermediate connecting wall, adjacent channels having a side wall with the connecting walls of adjacent channels as each in spaced planes to form a quasi-corrugation in a direction transverse to the channels, the vortex generators extend from a common side wall into adjacent adjacent channels. A packaging structure according to a further aspect of the present invention for a fluid processing and mixing tower defining a vertical axis, comprises a plurality of elements of sheet material, each element having a plurality of channels for extending in one direction axially parallel to the vertical axis, the elements are clamped in side-to-side confining relationship to form a set of annularly circumscribed inner channels and a plurality of vortex generators axially spaced in each of the channels, which form only one fluid path tortuous in 'each of the channels in the axial direction. In one aspect, the vortex generators each have a portion in superposed relation in the axial direction to substantially block the linear fluid flow in the axial direction. In a further aspect, the channels have normal planar sides to an intermediate wall, the vortex generators are integral in one piece with the sheet material and forming the openings. Whirlwind generators provide turbulence to maximize two-phase fluid contact or maximize fluid mixing on a simple basis. The vortex generators also provide the desired liquid retention in vertically oriented channels and provide liquid and gas communication to various portions of a channel and adjacent channels by openings in the channel walls to maximize interfluid contact. In a further aspect, a packaging structure for a fluid processing and mixing tower defining a vertical axis comprises a plurality of porous sheet material elements, each element having a plurality of channels extending in an axial direction parallel to the vertical axis, the material normally avoids fluid communication between adjacent channels irrespective of the presence of pores in the material, the elements are held in side-by-side confining relationship to form a set of annularly circumscribed inner channels, the elements have through openings for allow transverse fluid communication between the channels and a plurality of vortex generators axially spaced in each of the channels. In the drawing: Figure 1 is an isometric view of a packaging structure according to an embodiment of the present invention; Figure 2A is a top plan view of one of the packing elements of Figure 1; Figure 2 is a front elevational view of the packing element of Figure 2A taken on the line 2-2; Figure 3 is a top plan view of the structure of Figure 1; Figure 3A is a more detailed view of a portion of the structure of Figure 3; Figure 4 is a front elevational view of a preform that constitutes a packing element of the structure of Figure 1; Figure 5 is an isometric view of a packing element of a second embodiment of the present invention; Figure 6A is a top plan view of the element of Figure 5; Figure 6 is a front elevational view of the element of Figure 6A taken on lines 6-6; Figure 7 is a top plan view of a packaging structure employing a plurality of methods of Figures 5 and 6; Figure 8 is a more detailed plan view of a portion of the structure of Figure 7; Figure 9 is a front elevational view of the preform used to form the element of Figure 5; Figure 10 is a plan view of a portion of a packaging structure according to a further embodiment of the present invention; Figure 11 is a fragmentary side elevational view of the embodiment of Figure 10 taken on lines 11-11; and Figure 12 is an isometric view of the embodiment of Figure 11. In Figure 1, the structured package 2 comprises a set of identical packing elements 4, 6, 8 and 10 that are part of a larger set 3 (Figure 3).

While 9 elements are illustrated in Figure 3, this is by way of illustration, since in practice more or less elements may be employed according to a particular implementation. Also, the elements are illustrated in a square arrangement. This configuration is also by way of illustration. In practice, the arrangement may also be circular rectangular or any other desired shape in plan view, comparable to the view of Figure 3. If the arrangement is circular in cross section, the elements are not necessarily identical in total transverse width from left to right in Figure 3. The elements are housed in an outer tower housing 12 (shown in dotted lines) which in this case is square in transverse function. Other accommodations (not shown) may be rectangular or circular in cross section. The elements adapt to the interior shape of the housing 12 to fill the interior volume. Each element 4, 6, 8 and 10 is formed from an identical substrate preform 14, Figure 4, of porous metal fibers preferably composed, as described in the introductory part. The material of preference is formed from the material as described in U.S. Pat. annotated in the introduction portion and which are incorporated herein by reference. The material of the elements may also be a solid sheet metal or other materials as is known to those skilled in the art. The preform 14 is a fragment of and represents a portion of a larger complete preform formed by each of the elements of Figure 3. The complete preform (not shown) appears as illustrated for the partial preform 14, with an identical repetition of the illustrated pattern that extends to the right in the figure (and according to a certain implementation, can extend more vertically from the top to the bottom of the Figure). In Figure 4, the preform of the substrate 14 includes a plurality of through cuts represented by solid lines. Fold lines are illustrated by interrupted or dotted lines 16, 18, 20, 60 and so on. A first row 22 of identical tabs 24 and identical through holes 26 are formed with a tongue 24 and holes 26 placed between each of the alternating pairs of adjacent fold lines, such as lines 16 and 18, 20 and 21 and thus in ahead. The tongues 24 eventually form vortex generators as will be described below. The holes 26 are adjacent to the tip region of the tabs 24 and are located in a channel forming the fold line into which the sloping edge 30 emanates. Reference numerals with cousins and multiple cousins in the figures represent identical parts. Each tab 24 has a first coextensive edge 28 with a channel forming crease line, such as the line 18. The tongue 24 has a second edge 30, which emanates in a second channel fold line such as the fold lines 16 inclined with respect to the fold lines 16 and 18 ending at a segment tip of Distant end 32. The edges 28 and 30 terminate at one end in the tongue fold line 60 on the plane 33. The tip 32 has an edge that is coextensive with the edge 28 both of which are straight and meet each other. in a channel fold line such as the line 18. The edges 28 and 30 both emanate from a common transverse plane 33 like all the edges of the tabs 24 of the row 22. The tip 32, which is optional, is preferably square or rectangular for the purpose that will be described, but it may be in other ways as well in accordance with a particular implementation. Holes 26 are slightly larger than tip 32 to allow a tip 32 of a tab 24 to pass in a manner to be explained. All of the tabs 24 and holes of the row 22 are parallel aligned to the plane 33.

Additional rows 27 and 29 of the tabs 24 and holes 26 are aligned parallel to the row 22 and aligned in the same column such as the column 32 between a given set of fold lines such as lines 16 and 18. The tabs 24 and orifices 26 between the fold lines 16 and 18 are aligned in the column 34. The preform 14 as illustrated has alternating columns 36, 38 and so on corresponding to the column 34 of the tabs 24 and holes 26 which are aligned in respective rows 27 and 29. More or less of these rows and columns may be provided according to a particular implementation. The rows 22, 27 and 29 alternate with rows 40, 42 and 44 of tabs 24 and holes 26. The tabs 24 and holes 26 of the rows 40, 42 and 44 are on the alternating columns 46, 48 and 50 and so on. . Consequently, the preform 14 has a plurality of rows and columns of the tabs 24 and holes 26 with the tabs of a given set of alternating columns and rows in vertical and horizontal position with the tabs and holes of the remaining columns and rows as illustrated . In Figures 2 and 2A, the element 4, like all elements, is formed by folding the preform substrate material over fold lines 16, 18, 20, 21 and so on (Figure 4) in directions alternate opposites. This constitutes the preform 14 in a channeled quasi-corrugated structure. The structure has identical channels, preferably square in plan view, 54, 56 and 58 and so on. These channels face opposite alternating directions 59. In this way the channels 54, 58 and so on face towards the bottom of the figure, the directions 59 and the channels 56, 61, 63 and thus onwards face the opposite direction towards the top of the figure. In Figure 3a, the representative element 62 has channels 64, 66, 68, 70 each having a respective intermediate connecting wall 72, 74, 76 and 78 and so on placed in planes extending from left to right in the figure spaced in a normal direction. Channel 66 has side walls 80 and 82 and channel 68 has side walls 82 and 84, with wall 82 which is common for channels 66 and 68. Element 62 has additional ethical channels as seen in Figure 3. All the elements of the package 3 are similarly constructed with identical channels. Before forming the channels or at the same time, the tabs 24, FIG. 4, are bent to extend from the plane of the preform 14 to constitute vortex generators in co-linear fold lines 60 which are in the plane 33. tabs 24 in row 22 are bent out of the plane of the figure in opposite directions into alternate columns 34, 36, 38 and so on. In this way, the tabs of the columns 34, 38 and 45 are folded in the same direction, for example outward of the drawing plane in the direction of the observer. The tabs on columns 36 and 41 are folded away from the plane of the figure away from the observer. The same folding sequence is provided to the tabs of the rows 27 and 29 which are in the same columns as the tabs of the row 22, such that the tabs of a given column all bend in parallel directions. The tabs 24 'of the next row in the adjacent alternate columns 46, 48, 50 and so on all are all folded parallel in the same direction in corresponding co-linear fold lines 86 parallel to the plane 33 to the viewer or observer. All are also parallel to the tabs of columns 34, 36 and so on. The tabs 24"of the next row 27 are folded in their respective fold lines in the same direction as the tabs 24 'in the row 27, for example towards the observer outside the plane of the drawing .These tabs are parallel to the tabs of the row 40. The tabs 24 '"of the row 42 are folded into their fold lines 88 in a direction opposite to the fold of the tabs of the rows 27, 40, for example in a direction away from the plane of the drawing away from the observer. These tabs are 'parallel and bend in the same direction as the tabs on columns 36 and 41. The tabs of the row 29 are bent in the same direction as the row tabs 22 and 27 on the same columns by repeating these bends. The tabs of the row 44 are bent like the tabs of the rows 42 and 40 towards the observer. In Figures 1 and 2, the element 4 has a set of tongues 24x, 2 1 f, 24 ^ ', 2 1' '', 21 and 23 in the channel 54. The tongues 24l7 24 x "i 21, all they extend in the same direction, for example of the channel 54 connecting to the wall 90 in the channel 54. The tabs 24x'y 23 extend from the same side wall, for example the side wall 92. The tongue 24x '' ', however, it extends into channel 54 from opposite side wall 94. The tabs in plan view on the length of channel 54, from the top of the figure to the bottom, in Figures 1 and 2, interrupt the vertical channels and in this way they form a generally tortuous, only vertical path for fluid No continuous vertical fluid path is available over the channel lengths for any of the channels The tabs on the opposite opposite facing channel 56 are in image orientation in the mirror the tabs of channel 54 as m It is best seen in Figure 2. The interruption of the tortuous block of the vertical linear path by the tabs is best seen in Figure 3a. The channel 66 of the representative element 62 has a more upper tab 242, a following lower tab 242 'and then an additional following lower tab 242"and so on As illustrated, a portion of each of the tabs superimposes a portion. of the other tabs in the channel In the plan view, the channel 66 is completely blocked by the tabs, like all the channels, in the vertical direction norm to the plane of the figure, in this way, no trajectory is present of linear vertical fluid over the length of channel 66 (or channels 54, 56, 58 and so on in Figure 2) .Also, each tab in a given channel has an adjacent edge a and which either encloses the side wall or a The connecting holes 26 each receive a tip 32 and a corresponding tongue For example, in Figure 3A, a tip 322, of the tongue 242, extends through the hole 26 into the adjacent channel 96 of the tongue. an adjacent element 102. A tip 322 'of the tongue 242' extends into the adjacent channel 98 of the element 62. A tip 322"of the tongue 222" extends into the adjacent channel 100 of the element 62. The tongue tips of this way they extend through the corresponding holes 26 of their channel in a next adjacent channel for all the tabs. The tabs extend from an intermediate connecting wall such as the tongue 242, Figure 3a, connected to the wall 64 of the element 62, extend towards and pass through the hole 26 of the connecting wall of the adjacent packing element such as a wall 97 of the element 102. However, none of the tabs of the element 102 extend into or into the channels of the element 62. In this way, the tabs of each element are used to cooperate substantially with only the channels of this element for provide the desired tortuous fluid paths. The tabs of each element are substantially independent of the channels of the adjacent elements, however, the tips 32 of the connecting wall tabs cooperate as described with the connection walls and the channels of the adjacent elements.

The tabs 24 and the tips 32 do not bend away from the plane of the preform 14, Figure 4 for these walls of the following channels adjacent to the housing, these walls abutting the housing 12. In this manner, the tabs at the edges of the structured assembly 3, Figure 3, do not extend beyond the structure so as not to interfere with the inner walls of the housing 12. In the same way, the tabs on the edge surfaces of the structure 3 do not bend beyond the plane of this surface as illustrated in Figure 3. The holes 26 in these edge surfaces are also not necessary. The tips 32 and holes 26 are used to provide drip liquid flow on opposite sides of the respective channel walls, to improve fluid contact through the packing structure. The holes 26 also provide fluid communication between the channels in directions transverse to the vertical axis of the structured assembly 3. Of course, the openings in the sheet material of the structured elements formed by bending the tabs outside the plane of sheet material allow greater communication fluid between two channels in a transverse direction. These openings and openings 26 are formed in all four walls of each interior channel.

The structured assembly elements 3, Figure 3, such as the elements 4, 6, 8, 10 and so on, are preferably held together by spot welding the corners of the channels at the ends of the upper and lower assembly. bottom 3. Welding is optional since the elements can be dimensioned to fit clearly in the tower housing 12 (Figure 3) and hold the housing in place by friction or by other means (not shown) such as fasteners or the like. The elements may also be held together first by any suitable fastening devices or joining means. It will be understood that the number of tabs in a channel and their relative orientation is given by way of example. For example, only one tongue, such as the tongue 24x '' 'in the channel 54, extends from the side wall 94 to the channel 54. In practice, more than one tongue will extend from each side wall in each channel. Also, the sequence of the tongue orientation, for example that tabs extend from a given wall in a vertical sequence, is also exemplary, since other orientations may be employed according to a certain need. In addition, the vertical length of the elements and the channels of the package assembly of the assembly 3 in practice may vary from that shown. The channel lengths are determined by the factors involved for a given implementation as determined by the type of fluids, their volumes, flow rate, viscosities and other related parameters that are required to perform the desired process. In operation, the structured packing 2, Figure 1, can be employed in a distillation process, with or without a catalyst or in a single-stage or two-stage mixing process. In addition, the packaging can be used for liquid-vapor contact, providing high specific surface area (area per unit volume) a relatively uniform distribution of vapor and liquid through the column and uniform wetting of the involved surfaces. The preferred microporous substrate material that forms the structure provides improved wetting of the packing surface through its surface texture for catalytic applications. Alternately, the catalyst is connected to the solid sheet material forming the structure. The preferred micro-mesh material which is provided by the sintered fiber sheet material of the packing elements, provides high relative catalyst surface area with optimum access to the catalyst by the fluids. The fibers are already coated with the catalyst or support the catalyst particles trapped in the porous network of the sheet material. When relatively fast chemical reactions are desired, the use of the internal surface area of the porous material depends on the speed of transport of the reagents to this surface. Transport is also superior in the case of displaced forced flow (convection) than by simple concentration of gradients (diffusion). The structure therefore provides optimum cross-flow of fluids with low transverse pressure drop. To maximize capacity, the pressure drop remains relatively low. This is provided by a relatively high gap space per unit column volume, low friction (good aerodynamic characteristics) and prevention of undesirable stagnant liquid cavities. In a catalytic distillation process, a catalyst is secured to the sheet material forming the elements as discussed above. The catalyst can impregnate the voids of the sheet material of the element, or it can extend there. In a distillation process, it permeates liquid down through the packing while the gas rises to mix with the liquid.The rising gas exhibits turbulence due to the presence of tabs that act as whirlpool generators and due to the openings between the channels. The gas flows to the different channels through the holes 26 and through the openings formed by the bending of the tabs 24 from the plane of the sheet material substrate. As the gas rises, it can only travel a tortuous vertical path in each channel, since no direct vertical linear path is available due to superimposed portions of the whirling generating tabs. This improves gas and liquid contact (two phases) or multiple gases or liquids in a single phase. It can be shown that vertical channel orientation provides low pressure drop improvement with optimum liquid retention. The turbulence produced by the whirlpool generators contributes to the retention of liquid. Vertical channels have the advantage of low pressure drop, "but usually also exhibit poor gas-liquid mass transfer and mixing, however, the vortex generators and the openings between the elements of the structure of the present invention, allow the use of essentially straight vertical channels The structured packing resulting from the present invention exhibits the low pressure drop of the vertical linear channels, and at the same time also exhibits superior mixing and mass transfer characteristics due to tortuous fluid paths. whirlpool generating tabs 24 serve as drip points for the fluid to distribute fluid from one side of one channel to the other. The tips 32 serve to improve the dripping of liquid in adjacent channels and on opposite walls of a channel. Also, the tips couple the corresponding channel sides to resist vibrations and provide greater stability. The liquid circulates through the orifices 26 to the adjacent channels and the liquid contacts the opposite side walls of a channel and flows down these walls also as it flows through the inclined tabs. The holes 26 provide pressure compensation and communication from one channel to the next and create a tortuous path for fluids whether liquid or gas. The square or optionally rectangular preference shape of the vertically oriented channels provides more surface area compared to corrugated triangular channels inclined from the prior art. The channels can also have different geometries, such as round, triangular or other polygons in cross section. For example, the transverse section of the channels may be hexagonal or other regular or irregular shapes, according to a particular implementation. In a bubble regime, the liquid is transported from channel to channel with bubbles, providing improved liquid distribution. In this case, linked channels may be optional. Also, relatively smaller and more numerous vortex generators can be employed. The tips 32, Figures 1 to 4 can also act as whirlpool generators. Steam is distributed through the openings in the channel walls while liquid is distributed by circulating over the tabs in the adjacent channels. The tabs 24 also interrupt liquid as it circulates providing liquid film renewal relatively constant and therefore good mixing of the liquid phase. The tabs 24 prevent concentration of liquid at the corners of the channels by liquid deflection, i.e. minimizes landfill flow. In addition, reorientation of the packaging elements by 90 ° as is done with the angled channels is not necessary with the vertical channels. The number of whirlpool generators may differ from the top to the bottom of the structure. In this way, a larger number of vortex generators can be placed closer to the top of the structure for improved liquid distribution. Less vortex generators can be placed closer to the bottom of the structure to reduce total pressure drop. Sandwiched designs can also be used. These designs comprise axially segmented packing elements that perform different functions. For example, the mixing or distribution of liquid can be provided in a packing segment and chemical reaction can be provided in a different axially arranged packing segment. An important aspect is that very little material of the substrate is employed since the tabs that are employed in the structure also provide openings for transverse fluid communication in the channel sidewalls. The holes 26 that are optional, and non-essential, especially for a relatively large pore substrate material, represent a minor loss of material that is relatively expensive. In addition, a relatively large number of dropping points are provided to maximize the transfer of liquid-gas mass and mixing. Optimal side wall pressures can be provided by selecting the side wall positions of the tabs, i.e. by having an edge adjacent to a channel side wall or by placing the tabs in optimal relative vertical positions. The vortex generators can be of any shape, but preferably are triangular. For example they can be rectangular or round, for example semicircular, according to a certain implementation. They can also contain a trapezoidal segment as described. The whirlpool generators each contain a portion that substantially interrupts and redirects fluid flow in the axial vertical direction, providing the vertically desired tortuous path. The vortex generators provide turbulence to maximize the transfer of mass in two phases or mix fluids of a single phase. By directing liquid to the middle of a channel, the vortex generators also maximize the contact area in two phases in the vertical channels. The transverse openings between the channels made by the vortex generators also provide liquid and gas communication to various portions of each channel and adjacent channels. By way of example, the channels in one embodiment can be 12 mm in transverse dimension in a square channel. The channels and the vertical length of packaging can be 210 mm in that modality that employs eight vortex generators in one channel. Smaller or larger channels, their length and the number of generators are determined according to a given implementation. In Figures 5 to 9, an alternate embodiment of a packaging structure and element, is therefore illustrated. In Figures 5 and 6, the element 104 comprises a porous substrate material of the same porous metal fiber construction as the material of the elements of Figure 1, and as described in the introduction portion. It will be understood that the substrate porosity is not illustrated in the figures and that the drawings in relation to various dimensions are not to scale for purposes of illustration. The thickness of the sheet material and the fiber diameters are in the order of microns as discussed above. The element 104, which is a fragment of a larger element in the drawing, in practice extends both horizontally and vertically beyond what is illustrated, comprises a plurality of channels of transverse square section 106-110 and so on. . The element 104 in use is oriented with the vertical channels in a processing tower (not shown). A plurality of vortex-generating triangular tabs 114-126 and so on, are formed from the sheet material substrate and extend completely through the corresponding channel in which they are located. The tips of the tabs may be butted or spaced closely from the side wall of the opposite channel or wall with intermediate connection as applicable. In the case of the tabs extending from an intermediate connection wall, these tabs are confined to the top or are closely spaced to the wall intermediate connection of the next adjacent packing element as illustrated in Figures 7 and 8 to be described. This is such that the liquid drips on a tongue towards the side wall of the opposite channel and then on this wall. The tongue tips only need to be sufficiently close to the opposite wall in such a way that the liquid circulating in this tongue drips the liquid on that wall. The element 104 is formed of a substrate sheet material of a porous sintered metal fiber preform 126 preferably, Figure 9. The preform 126 comprises the same sintered fibrous porous material described above. The preform is a planar sheet where solid lines represent through cuts and dotted lines represent fold lines. The fold lines 128, 130 and 133 and so on form the channels 106-110 when the substrate 134 is bent at right angles in the fold lines. Fold lines 136 are aligned in linear rows normal to the fold lines of channel 128 and so on in parallel planes such as plane 138. Each of the tabs corresponds to and is bent into a fold line 136 outside the plane of the preform. Each tongue, for example tongue 114 has a first edge 131 inclined to and emanating from a vertical crease line, for example line 128, and a horizontal crease line, for example line 136 and has its tip ending in the next adjacent vertical crease line of that column, e.g. line 130. Each tab, e.g. tab 114 has a second edge that emanates from a horizontal crease line, e.g. line 136 and is vertically co-extensive with the next line of adjacent fold of this column, for example fold line 130. The tabs are aligned in vertical columns 142, 144 and 146 and so on and in horizontal rows 140, 141, 143, 145, 146 and 149 and so on onwards. The tabs in adjacent rows such as the rows 140 and 145 are in alternate columns. The tabs in the row 140 are in respective columns 142, 148 and the tabs in the rows 145 are in columns 144, 146 and so on. Alternate tabs in upper row 140 are bent in the same direction. For example, the tabs such as the tabs 114, 114 'and 114", in the row 140 are located in the columns 142, 150 and 154 are bent in the same direction towards the viewer outside the plane of the drawing. The columns 142, 150 and 154 of the respective connection walls 142 ', 150' and 154 ', Figure 5, and the columns 148, 145 form the respective connection walls 148', 145. In Figure 5, the tabs 114 , 114 'and 114", each extend parallel to the corresponding channel 106, 108 and 110 respectively from their corresponding channel connection walls The other alternate tabs, Figure 9 in the row 140, for example the tabs 120, 121' in respective columns 148 and 152 are bent in an opposite direction away from the viewer outside the plane of the drawing.These are connected with connecting walls 148 'and 152', Figure 5. These tabs are folded into corresponding channels 107 and 109 which give in opposite directions to the channels 106, 108 and 110 where the tabs 114, 114 'and 114"extend. The tabs in alternating rows in each column, for example rows 141 and 143 are folded in the same direction and parallel to the tabs of row 140. That is, tab 116 bends parallel to tab 114 and tab 122 in the next alternate column 148 is bent parallel to the tongue 121, the tabs on the columns 142, 150 and 154 are bent in opposite directions to the tabs on the columns 148, 145 and so on. This pattern of folds is repeated by the remaining columns for the tabs in the rows 140, 141 and 143. The tabs of the row 145, tabs 115, 127 and so on, and the row 147, tabs 118, 117, 124 and hereinafter, all are folded in parallel in the same direction from the plane of the substrate material, ie towards the viewer outside the plane of the drawing figure, Figure 9. The tabs of the row 147, for example the tabs 118 , 117, 124 and so on, are bent in the same direction as the tabs 121, 122 and 123 of the column 148 and the tabs of the column 152. These are bent in a direction away from the viewer outside the plane of the figure of the drawing. While only one row of tabs, the row 149 is bent in this opposite direction in the corresponding columns, more of these tabs are preferably provided, for example making the element 126 longer or rearranging the orientation of the tongue of the other tabs in each channel.

In Figure 5, tabs 114, 115, 116, 117 and 120 are all in channel 142 '. The tongue 118 is located in the channel 150 '. The tabs 115, 117 and 120 emanate from the same side wall of the channel 156. The tongue | 117 emanates from the opposite side wall 158. The remaining tabs of the channel 106 emanate from the connecting wall 60. The anterior pattern of tabs is repeated for each of the remaining channels, with the tab 121, 122 and 123 emanating from the connection walls 162 of the opposite facing channel 107. In Figures 7 and 8, the packaging structure 164 comprises a plurality of elements 166, 168, 170 and henceforth identical to element 104 arranged in a square distribution. The set or distribution may be other shapes such as rectangular or circular according to a specific need. In Figure 8, the connection walls 172 of the element 168 circumscribe the channels 174 to 175 and so on from the element 170 and walls 173 of the element 171 circumscribe the channels 176 and 177. In this way, all the inner channels are circumscribed by Connecting walls of the next adjacent element. The elements of structure 164 are connected to each other as described above for the embodiment of Figure 1.

In Figure 8, the uppermost tab 178 (corresponding to the tab 121, Figures 6 and 6a, for example) of the element 170 in the channel 174 depend on the connecting wall 180. The tongue edge 131 extends diagonally through the channel 174 from corner to corner. Tab edge 132 next is adjacent to side wall 183. Tip 182 of tab 178 next is adjacent to opposing connecting wall 172 'of element 168. The next lower tab 184 corresponding to tab 127, FIG. 6 (depends on the side wall 186. Its inclined edge 131 ', extends from the side wall 186 to the wall 183. Its other edge 132' next is adjacent to the connecting wall 180. The edges 132 and 132 'can confine butt or are closely spaced to the corresponding adjacent wall to allow liquid flow in the tabs to circulate on that wall The tip 187 of the tab 184 is at the corner joint of the walls 180 and 183. The circulating liquid at the tip in this way it circulates to that corner on the opposite side of the channel from the wall 186. The edges 131 and 171 'may overlap each other or slightly transpose the next adjacent tongue body. cente The next lower tab, the tongue 188 depends on the wall 183 and is below the tongue 184. The tongue 188 has an inclined edge 131"extending overlying the edge 131 '. The tongue 188 has the opposite edge 132 '' abutting or closely spaced with the connecting wall 172 'of the element 168. As a result, the tabs 178, 184 and 188 completely block the channel 174 in the vertical direction, providing a path of tortuous fluid in the vertical direction. A gas that flows vertically upwards in the channel 174 must flow past and with respect to the inclined edges 131, 131 ', 131"of the respective tabs. The remaining tabs in the channel provide a similar tortuous path for fluids attempting to circulate in a vertical direction. Linear vertical path for fluids is not provided. The tabs serve as vortex generators, maximizing the mixing and contact of circulating fluids. Liquids circulating down flow on the sides of the channel and on the tabs and are distributed to the various opposite channel side walls. The tabs when bent from a planar sheet substrate form large openings in the substrate.

These openings form transverse communication paths for flowing fluids to the channels of the adjacent elements. This minimizes the pressure drop transversely to the channels, and the tortuous vertical trajectory minimizes the pressure drop in the vertical directions. Turbulence is created by the tabs in each channel and in cooperation with the openings in the channel walls. The inclined tabs provide optimal fluid retention as the liquid flows downward. It will be appreciated that instead of triangular tabs, the tabs may be somewhat trapezoidal similar to the tabs of Figure 1, but without the extended tips 32. In this manner, the slanted edges are not vertically aligned but spaced transversely according to the amount that the tip of the tongue is truncated. This allows more overlap of the vertically spaced tabs in a channel to provide increased turbulence by increasing the tortuous nature of the vertical path beyond the edges of the tongue in a channel. In Figures 10 to 12, an additional embodiment is illustrated. In this embodiment, a packing structure 190 is fabricated from a sheet substrate of the same material as described above for the embodiments of Figures 1 and 5. The structure 190 comprises a plurality of identical packing elements 192. A representative element 192 comprises square alternating channels 194, 194 'in opposing opposite directions as in the previous embodiments. The whirl generator tabs 196, 198 and so on are in repetitive arrangements and are in each channel. The tabs 196 and 198 are preferably identical in peripheral dimensions and formed from a planar preform sheet of substrate material. The tabs are rectangular in plan view and inclined downwards from the wall from which they are formed and depend. The tongue 196 is formed from and extends from the side walls 195. The tongue 198 in the channel 194 is formed from and extends from the side wall 193. The tabs have a width w preferably greater than half the depth of the channel d. to have a portion 204 that overlaps each other in the vertical direction over the length of channel Figure 10. The tabs 196 have an edge 200 adjacent to the connecting wall 202. The tabs 198 have a distant edge 206. The tabs 198 have an edge 208 next adjacent the connecting wall 207 of the adjacent element 209. The tabs 198 have a distal edge 210. The edges 210 and 206 are spaced from each other when viewed vertically to form the portion 204. The tabs 196 and 198 they form openings in the side walls from which they are formed. The openings 210 are formed in the channel connection walls 210 to provide fluid communication to the channels of adjacent elements such as the elements 192 and 209. It should be understood that the elements may include a greater number of channels and tabs than those shown they are a relatively smaller portion of the package assemblies of the elements. The pattern of the tabs may be repeated in the manner shown or any other arrangement or arrangement according to a particular implementation. Like other modalities, linear vertical fluid trajectory in any of the channels is not presented. The overlapping tabs provide a tortuous vertical path for fluids. While particular modalities have been described, it is intended that the modalities described be given by way of illustration rather than limitation. Modifications can be made by a person with ordinary skill. The scope of the invention is defined in the appended claims.

Claims (21)

1. CLAIMS 1. - Structured packaging element for a mixing and fluid processing tower defining a vertical axis, comprising: a sheet material element having a plurality of channels for extending in an axial direction parallel to the vertical axis; and a plurality of vortex generators in each of the channels that substantially form a tortuous path of fluid in each of the channels in the axial direction.
2. 2. - The packaging element according to claim 1, characterized in that the element has a plurality of through openings to allow the fluid in each channel to flow transversely to the axial direction and adjacent channels.
3. 3. - The packaging element according to claim 1, characterized in that the sheet material is porous and comprises sintered metal fibers.
4. 4. - The packaging element according to claim 1, characterized in that the vortex generators are triangular.
5. 5. - The packaging element according to claim 1, characterized in that the vortex generators include a trapezoidal body segment and a tip segment.
6. 6. - The packaging element according to claim 1, characterized in that the vortex generators are rectangular and the channels in general are square when viewed in a direction over the axial direction.
7. 7. - The packaging element according to claim 1, characterized in that each of the channels has opposite axially extending side walls, extending from an intermediate connection wall, adjacent channels have a common side wall with connecting walls of adjacent channels arranged in spaced planes to form a quasi-corrugation transverse to the channels, the vortex generators extend from a common side wall into adjacent adjacent channels.
8. 8. - The packaging element according to claim 7, characterized in that it includes a vortex generator that extends from a connection wall in the corresponding channel where the vortex channels in a channel are arranged to form a flow path of non-linear continuous fluid over the channel length.
9. 9. - The packaging element according to claim 7, characterized in that the side walls are normal to the connecting wall, a first of the vortex generators in each channel extends from a first side wall and has a first parallel edge a and adjacent to the connecting wall of that channel to prevent fluid flow between them at the first edge and a second edge inclined relative to the first edge and the connecting wall and a second vortex generator axially spaced in that direction from the first generator of vortex and extending from a second side wall with a first edge parallel to and coextensive with a second connecting wall of a next adjacent channel and a second edge inclined with respect to the first edge and the connecting wall.
10. 10. The packaging element according to claim 8, characterized in that the vortex generators are generally triangular with a tip adjacent to the side wall opposite the common wall, to effect transfer of liquid from a region at the tip to the end. opposite side wall.
11. 11. The packaging element according to claim 1, characterized in that it includes a plurality of the elements held together to form a structure of parallel channels that extend axially similar, the assembly extends transversely in the axial direction.
12. 12. - The packaging element according to claim 1, characterized in that the vortex generators in each channel each have a portion that overlap each other in the axial direction and substantially enclose each channel when viewed in the axial direction.
13. 13. - The packaging element according to claim 2, characterized in that it includes a plurality of elements subject to form a two-dimensional assembly or structure of parallel channels extending axially similar, the assembly extends transversely in the axial direction, the vortex generators have superimposed portions, the generators each have a portion of body and a tip portion, the tip portion corresponds to and to pass through an opening.
14. 14. - The packaging element according to claim 3, characterized in that it includes a catalytic material connected to the element.
15. 15. A packaging structure for a mixing tower and fluid processing that defines a vertical axis, characterized in that it comprises: a plurality of elements of sheet material, each element has a plurality of channels to extend in an axial direction parallel to the axis vertical, the elements are held in a confining relationship with each side, to form a set of inner channels circumscribed annularly; and a plurality of vortex generators axially spaced in each of the channels forming only a tortuous fluid path in each of the channels in the axial direction.
16. 16. - The structure according to claim 15, characterized in that the vortex generators each have a portion in superposed relation in the axial direction to substantially block the linear fluid flow in the axial direction. The structure according to claim 15, characterized in that it includes a plurality of openings in each of the elements to provide fluid coupling between adjacent channels. 18. The structure according to claim 17, characterized in that the channels have planar sides and have normal sides to an intermediate wall, the vortex generators are integral in one piece with the sheet material and form the openings. 19. The structure according to claim 15, characterized in that it includes a catalytic material connected to the element, the element comprises porous metallic fibrous material. 20. A packaging structure for a tower for mixing and processing fluid, which defines a vertical axis, characterized in that it comprises: a plurality of elements of porous sheet material, each element has a plurality of channels extending in parallel axial direction to the vertical axis, the material normally avoids fluid communication between adjacent channels regardless of the presence of pores in the material, the elements are held in side relation confinante to stop side by side, to form a set of inner channels circumscribed annularly, the elements have through openings to provide smooth transverse communication between the channels; and a plurality of vortex generators axially spaced in each of the channels. The structure according to claim 20, characterized in that the vortex generators are arranged in each channel to substantially form a tortuous fluid path in each of the channels in the axial direction.