MXPA00011458A - Structured packing and element therefor - Google Patents

Abstract

A structured packing (2) (which may or may not include a catalyst) formed from a mesh material having pore openings of less than 50 microns wherein the packing (2) is provided with turbulence generators (24) to promote flow of fluid through the pore openings and may be further provided with additional openings larger than the pores to improve bulk mixing.

Description

STRUCTURED PACKAGING AND ITS ELEMENTS The present invention relates to a structured packing, used for contact systems of fluid contact systems such as distillation towers or single phase or multiple phase mixers and can be made catalytic for catalytic distillation. Commercially, distillation is practiced in a normal manner as a counter-current operation of gas and liquid multi-stage operation in a tower containing packing devices to facilitate the gas-liquid contact that is necessary for both mass and heat transfer . Since multiple equilibrium stages exist in a tower, the vapor and liquid compositions change through the length of the tower. The desired products can be disposed of 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 stages in equilibrium. Mass transfer devices are typically separate trays or trays, which allow the vapor to pass upwardly through a small height of the liquid or continuous gaskets containing surfaces for gas-liquid contact. The ability to approach the vapor-liquid equilibrium is already designated by a fractional "tray efficiency" or a "Height Equivalent to a Theoretical Plate" (HETP = Height Equivalent to a Theoretical Plate) for continuous packaging. The smaller the HETP, the more efficient the package will be. The advantage of structured packaging is high efficiency coupled with low vapor pressure drop. Low pressure drops are convenient due to the increased cost of forcing gases upwards in the tower, to overcome high pressure differentials, if present. Examples of catalytic distribution structures are described in US Patents. Us. 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 fluted parts with channels that are inclined relative to the vertical. Openings are provided in the parts to provide reagent communication flow through the package. The channels are inclined with respect to the vertical to ensure optimal fluid contact and provide liquid retention, the vertical channels allow minimal undesirable liquid retention, ie excessive liquid flow.

The catalytic distillation combines the operation of the separation unit (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 a limited chemical reaction in 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 fewer pieces of equipment. In this way, a previous structure of a distillation tower and a two-vessel reactor can now be combined in a single structure. The patent of the U.S.A. No. 5,321,163 discloses a catalytic distillation system. The present invention is directed to an improved package for promoting contact between fluids; for example, liquid-liquid or gas-liquid contact can be used for a variety of purposes including conventional distillation and catalytic distillation. In accordance with one aspect of the present invention, there is provided a structured porous package for promoting liquid-liquid contact and / or gas-liquid contact, wherein the average pore openings of porous material are formed in packages not exceeding approximately fifty microns and where the packaging is provided with turbulence generators, such as baffles or tabs, which are spaced on the structured package so that essentially over the entire packing surface there is liquid flow through the pore openings in the package. The porous packing is preferably formed from a wire mesh or screen. In a preferred embodiment, the package is also provided with additional openings to promote bulk mixing. In a particularly preferred embodiment, a wire screen or mesh which is a micro-mesh, is used as the porous packing. A three-dimensional network or mesh is formed of metal fibers or wires, with these fibers or wires generally having a diameter of at least 1 mire, with the fibers having a diameter that generally does not exceed 25 microns, although they can be used smaller or larger diameters. The network can be of the type described in US Patents. Nos. 5,304,330; 5,080,962; 5,102,745; or 5,096,663. The three-dimensional network of materials can be one that is made of fibers and can be a metal felt or the like, a metal or paper fiber filter or can be a porous metal composite. The compacted fibers or wires define a three-dimensional network of material having a thickness.

In general, the thickness of the three-dimensional network of material is at least 5 microns and generally does not exceed 10 mm. In general, the thickness of the network is at least 50 microns and does not exceed 2 mm. The three-dimensional network may be coated or uncoated and this three-dimensional network may have particles trapped or contained therein. The network may have different pore sizes over its thickness and may be laminated and / or constituted from the same materials or may have multiple layers. It will be understood that the mesh may be comprised of one type of fibers or may be comprised of two or more different fibers or the mesh may have a single diameter or may have different diameters. The mesh is preferably formed of a metal, however other materials such as ceramic may be used. As representative examples of these metals, Nickel, various stainless steels may be mentioned; for example 304, 310, and 316, Hastelloy, Fe-Cr alloys, etc. The mesh may retain particles or fibers in its interstices and the particles or fibers may contain a catalytic function. The structured packing may or may not include a catalyst. The catalyst, if employed, can be coated on the fibers to form the package and / or the supported or unsupported catalyst can be trapped in the mesh openings. Although it has been proposed to manufacture gaskets from porous materials, such as micro-mesh structures, applicants have found efficient use of these porous materials as gaskets, it is necessary to provide turbulence generators that are spaced on the gas packaging structure. In order to provide an efficient flow of liquid through the pores in the package. In a preferred embodiment, in addition to the turbulence generators, the package is provided with additional openings. In general, the size of the additional openings is 0.5 mm, preferably at least 1.0 mm in diameter (based on a circular opening). If the holes or openings are not circular, then these holes are sized such that at least the area of these openings is essentially the same as the minimum area of a circular opening having this diameter. In each of the embodiments described with reference to the drawings, the holes formed in the packing structure (in addition to the holes or pores inherently present in the mesh material from which the packing is formed) in combination with turbulence generators ( for example, in the form of tongue or baffles) function to provide improved flow of fluid through the pores of the package and improved mixing in bulk or in volume for essentially the entire surface area of the package. The applicant has found, in the absence of turbulence generators, the packing operates in a less efficient manner since the fluid does not effectively circulate through the pores of the package. In accordance with the invention, the turbulence generators and the holes formed in the packing structure (in addition to the holes or pores inherently present in the mesh material from which the package is formed) function to provide flow optimization through the pores and mixing in improved volume over the length of the package, while still allowing sufficient surface area for gas / liquid mass transfer and / or catalytic reaction. These holes and additional turbulence generators are spaced on the package to achieve this optimization. This can be done either by experimentation or more preferably by a process model that describes the structure (including geometry, thickness, porosity and fiber diameter) and gas and liquid flow patterns through the structure, including any thermal effects. created by included reactions. An example of this model would be to use the procedure known as computational fluid dynamics. The holes or openings that are added to the porous packaging generally comprise at least about 3% and preferably at least 10% of the packing surface. In most cases, the additional openings do not comprise more than 20% of the surface and preferably not more than 25% of the surface. The tabs or deflectors work to break bubbles and also create bubbles for the tongue or baffle. In addition, the tabs or deflectors work to increase the mass transfer of liquid by inducing turbulence and creating bubbles. The invention will be further described with respect to representative embodiments of packing structures formed from a mesh material; however, these structures are by way of illustration since the present invention is applicable to other structures and designs. Thus, the present invention is partly based on the discovery of the inventors that highly porous mesh material, as used as a package, even when this material has a high void volume: for example, greater than 70% and in many cases greater than 90% fluid and does not effectively flow through the pores of the package and that fluid flow through these pores can be improved by providing turbulence generators. Thus, in accordance with the present invention, the turbulence generators are provided with the selected number, size and spacing to improve the flow of liquid through the pores of the mesh structure on the surface of the mesh structure. . In a preferred embodiment, the package is also provided with additional openings. The size and spacing of the additional holes or openings preferably in combination with turbulence generators are chosen to obtain a desired volume or bulk mixing and pressure drop through the structured packing mesh. In the following illustrative embodiments, the additional openings are formed by creating tabs that function as turbulence generators, these tabs B prefer as they allow the generation of turbulence and also have additional advantages as described below. However, the openings can be created according to the invention without creating tabs. In addition, turbulence generators may be provided spaced apart from the openings. These turbulence generators can be in the form of baffles or tabs independent of additional openings or for example by providing embossments or depressions or corrugations in the package. In the following embodiments, the mesh structure of the structured package includes openings in addition to those created by forming the tabs. These additional openings can or. not required depending on the form 0 of the package and the conditions contemplated for the structure ~ 3e packaging. ~ IN THE DRAWINGS: - "" - "FIGURE 1 is an isometric view of a - packing structure according to a modality of the present invention: - _ "_... * _ Da FIGÜR &2a is a top view of one of the elements of" packaging of the figure 1; - r XX ~ XX ^ X? X > 3- FTGÜRA ~ 2 is a view of the front elevation of the packing element of Figure 2a that is taken by the 0 lines 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 elevation view of a preform constituting 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 packing structure employing a plurality of elements 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 constitute 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 an 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 assembly. Figure 3. While nine elements are illustrated in Figure 3, this is in the form of illustration, since in practice more or less elements can be used in accordance with a determined implementation. This arrangement is also by way of illustration In practice, the arrangement or assembly may also be rectangular, circular or any desired shape in plan view, as compared with the view of Figure 3. If the assembly is circular in transverse section, the elements are not necessarily identical in the total left or right transverse width in Figure 3. The elements are located in an outer tower housing 12 (m ostrado on the dotted line) which in this case is square in cross section. 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, or preferably composite porous metal fibers as described in the introductory portion. The material of preference is formed from the material as described in the patents noted in the introductory portion and which is incorporated by reference herein. The material of the elements may also be 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 that constitutes each of the elements of Figure 3. The entire preform (not shown) appears as illustrated for the partial preform 14 with an identical pattern repeat illustrated 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 substrate preform 14 includes a plurality of through cuts represented by solid lines. Fold lines are illustrated by interrupted 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 hole 26 placed between each of the alternating pairs of adjacent fold lines., such as lines 16 and 18, 20 and 21 and so on. The tabs 24 eventually form vortex generators as described below. The holes 26 are adjacent to the tip region of the tabs 24 and are located in a channel forming crease line in which the sloping edge 30 emanates. Reference numbers with premium and multiple premiums in the figures represent identical parts. Each tab 24 has a first edge 28 coextensive with a channel forming fold line, such as line 18. The tab 24 has a second edge 30 that emanates in a second second channel fold line such as the fold line 16. inclined to the fold lines 16 and 18 terminating at a distant end segment tip 32. The edges 28 and 30 terminate at one end at the tongue fold line 60 on the plane 33. The tip 32 has an edge that is coextensive with the edge 28, both of whose edges are straight and are in a channel fold line such as the line 18. The edges 28 and 30 both emanate from a common transverse plane 33 as do all the edges of the tabs 24 of row 22. Tip 32, which is optional, is preferably square or rectangular for the purpose to be described, but may be otherwise equally, according to a particular implementation. The holes 26, are slightly larger than the tip 32 to allow a tip 32 of a tab 24 to pass in a manner to be described. All of the tabs 24 and the holes of the row 22 are aligned parallel to the plane 33. Additional rows 27 and 29 of the tabs 24 and the holes 26, are aligned parallel to the rows 22 and are aligned on the same column such as the column 34 between a certain set of fold lines such as lines 16 and 18. The tabs 24 and the holes 26 between the 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 the holes 26 which are aligned in respective rows 27 and 29. More or less of these rows and columns can be provided according to a particular implementation. The rows 22, 27 and 29 alternate with rows 40, 42 and 44 of the tabs 24 and holes 26. the tabs 24 and the holes 26 of the rows 40, 42 and 44 are in the alternating columns 46, 48, 50 and thus onwards. 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 columns and rows alternating in vertical and horizontal position with the tabs and holes of the remaining columns and rows as shown. illustrate or _-...- In Figures 2 and 2a, the element 4, like all elements, is formed by folding the substrate material in the preform over the fold lines 16, 18, 20, 21 view in square plan, preferably identical, 54, 56, 58 and so on. These channels face opposite alternating directions 59. In this way, channels 54, 58 and so on face towards the bottom of the figure, directions 59 and channels 56, 61, 63 and thus onwards face 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 connection 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 identical channels as seen in Figure 3. Bdos " ?. - Packing elements 2 are similarly constructed with identical channels. Before forming the channels or at the same time, the tabs 24, Figure 4, are bent to extend from the plane of the preform 14 to constitute whirlwind generators in colinear fold lines 60 placed in plane 33. The tabs 24 in the row 22 fold 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 out of the plane of the "drawing towards the viewer." The tabs on the columns 36 and 41 are bent in the opposite direction away from the plane of the figure away from the viewer The same sequence of bending is provided in the tabs of the rows 27 and 29 which are in the same columns in the tabs of the row 22 in such a way that the tabs of a given column all bend in parallel directions The tabs 24 'of the next row 40 on the adjacent alternate columns 46, 48, 50 and so on all are folded parallel in the same direction in corresponding collinear fold lines 86 parallel to the plane 33 towards the viewer They are also parallel to the tabs of the columns 34, 38 and so on.The tabs 24"of the next row 27 are folded into their respective fold lines in the same direction as the lines. the tabs 24 'in the row 27, for example towards the viewer outside the drawing plane. 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 and 40, for example in one direction outside the drawing plane away from the viewer.These tabs are parallel and bend in the same direction as the tabs on the columns 36 and 41. The tabs of the rows 29 are bent in the same direction as the tabs of the rows 22 and 27 in the same columns, repeating these bends or elbows The tabs of the row 44 are bent like the tabs of the rows 42 and 40 towards the viewer In Figures 1 and 2, the element 4 has a set of tabs 241 # 24 ^, 24x ", 24 ^", 21 and 23 on the channel 54. The tabs 24x, 24 ± ", and 21 all extend in the same direction, for example, of the channel 54 that connects to the wall 90 in channel 54. Tabs 24 ^, and 23 extend from the same pa lateral network, for example the side wall 92. The tabs 24 ^ ", however extend into the channel 54 from the opposite side wall 94. The tabs in plan view on the length of channel 54, from the top of the figure at the bottom, in Figures 1 and 2, interrupt the vertical channels and in this way form a generally tortuous vertical route, only for fluids. There is no available route for continuous vertical linear fluid open over the channel lengths for any of the channels. The tabs on the opposite opposite facing channel 56 are in an image orientation in the mirror relative to the channel tabs 54 as best seen in Figure 2. The tortuous locking interruption of the vertical linear path by the tabs, it is best seen in Figure 3a. The representative element 62, channel 66, has a more upper tab 242, a following lower tab 242 'and then still a subsequent 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, channel 66 is completely blocked by the tabs, like all the channels, in the normal vertical direction to the plane of the figure, in this way, there is no present route 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 edge adjacent to and abutting to either side wall or a connecting wall, the holes 26 each receiving a tip 32 of a corresponding tongue, For example, in Figure 3a, a tip 322 of the tongue 242 extends through a hole 26 in an adjacent channel. 6 of an adjacent element 102. A tip 322 'of the tongue 242' extends in μn adjacent channel 98 of the element 62. A tip 322"of the tongue 242" extends into the adjacent channel 100 of the element 62. The tips of tongue in this manner extend through corresponding holes 26 of its channel in a next adjacent channel for all the tabs. The tongues extend from a wall with intermediate connection such as the tongue 242, Figure 3a, connected to a wall 74 of the element 62, extends towards and passes through the hole 26 of the connecting wall of the adjacent packing element, such as the 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 the element. this element, to provide the desired tortuous fluid paths. The tabs of each element are substantially independent of the channels of the adjacent elements, although the tips 32 of the connecting wall tabs cooperate as described with the walls and connecting channels of the adjacent elements. The tongues 24 and the tips 32 do not bend away from the plane of the preform 14, Figure 4 for those walls of channels adjacent to the housing, these walls abut the housing 12. In this way, the tabs on the edges of the assembly of its structure 3, Figure 3, does 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 these surfaces, as illustrated in Figure 3. The holes 26 in these edge surfaces are also not necessary. The tips 32 and the holes 26 are used to provide flow by liquid flow to 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 set of structures 3. Of course, openings in the sheet material of the structured elements formed by bending the tabs outside the plane of the sheet material, provide greater fluid communication between the channels in a transverse direction. These openings and openings 26 are formed in all four walls of each interior channel. The elements of the set of structures 3, Figure 3, such as the elements 4, 6, 8, 10 and so on, are preferably held together by spot welding at the corners of the channels at the ends of the lower upper assembly 3. Welding is optional since the elements can be sized to fit closely in the tower housing 12 (Figure 3) and held in place in the housing by friction or 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, just one tab, such as tab 24? In the channel 54, it extends from the side wall 94 in the channel 54. In practice, more than one tongue will extend from each side wall of each channel, also, the tongue orientation sequence, for example tabs. they extend from a determined wall in a vertical sequence, it is also by way of example, as other orientations can be used according to a certain need, In addition, the vertical length of the elements and the channels of the assembly of packages of assembly 3, in practice it can be varied from the one shown.The channel length is determined by the factors involved by a given implementation, as determined by the types of fluids, their volumes, flow data, viscosities and other related parameters that are required to perform The desired process In operation, structured packing 2, Figure 1, can be used in a distillation process, with or without a catalyst or mixing process. single stage or two stages. In addition, the packaging can be used for liquid-vapor contact, providing a high specific surface area (area per unit volume), a relatively uniform distribution of vapor and liquid through the column and a uniform mixing 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 that forms the structure. The preferred micro-mesh material that is provided by the sheet material with sintered fibers of the packing elements, provides a relatively high surface area of catalyst with optimal 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 rapid chemical reactions are desired, the use of the internal surface area of the porous material depends on the rate of transport of the reagents to these surfaces. The transport of mass is higher in the case of forced flow (convection) that by itself has 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 subjected to the sheet material that forms the elements as discussed above. The catalyst can impregnate the voids of the laminar material of the element or it can be external. In a distillation process, the liquid permeates downward through the package while the gas to be mixed with the liquid rises. 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 into 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 a direct vertical path or path is not available due to the superimposed portions of the whirling generating tabs. This improves the contact of gas and liquid (two phases) or multiple gases or liquids in a single phase. It can be shown that the vertical channel orientation provides improved low pressure drop with optimum liquid retention. The resulting turbulence produced by the vortex generators contributes to liquid retention. Vertical channels have the advantage of low pressure drop, but normally they also exhibit poor mixing and gas-liquid mass transfer. 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 the tortuous fluid paths. Also, the vortex generating tabs 24 serve as drip points so that the liquid distributes fluid from one side of the channel to the other. The tips 32 serve to improve the runoff of liquid in adjacent channels and on opposite walls of a channel. Also, the tips engage the corresponding channel sides to resist vibrations and provide additional stability. The liquid flows 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 down the inclined tabs. The holes 26 provide pressure compensation and communication from one channel to the next and create a tortuous path for the fluids either gas or liquid. 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 various geometries such as round, triangular, or other polygons in cross section. For example, the cross 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, articulated or linked channels may be optional. As well, when circulating over the tabs in the adjacent channels. The tabs 24 also interrupt the liquid as it circulates, providing a relatively constant liquid film turnover and therefore good mixing in the liquid phase. The tabs 24 prevent liquid concentration at the corners of the channels by liquid deflection, i.e. minimizing discharge flow. In addition, the reorientation of the packing elements by 90 °, as is done with angled channels, is not necessary with 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 experienced packing elements and perform different functions. For example, the mixing or distribution of liquid can be provided in a packing segment and the chemical reaction can be provided in a different axially arranged packing segment. An important aspect is that very little material from the substrate is lost since the tabs that are used in the structure also provide openings for cross-fluid communication in the channel sidewalls. The holes 26, which are optional, and are not essential, especially for substrate material with relatively large pores, represent a minor loss of material that is relatively expensive. In addition, a relatively large number of pour 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 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. They can, for example, be rectangular or round, for example semicircular, according to a particular implementation. They can also contain a trapezoidal segment as described. The vortex generators each contain a portion that substantially interrupts and redirects the flow of fluid in the axial vertical direction, providing the tortuous path that extends vertically as desired. The vortex generators provide turbulence to maximize the transfer of mass in two phases or mixing of single phase fluids. By directing the liquid to the middle of a channel, the vortex generators also maximize a two-phase contact area in the vertical channels. The cross-channel openings 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 employs eight vortex generators in one channel. Smaller or larger channels, their length and the number of generators are determined according to a particular implementation. In Figures 5-9, an alternate embodiment of a packaging structure and its element are 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 introductory portion. It will be understood that the porosity of the substrate 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 of the drawing, in practice extends both horizontally and vertically beyond what is illustrated, comprises a plurality of channels with square cross 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, is formed of the sheet material substrate and extends completely through the corresponding channel where they are located. The tips of the tabs may be butted or closely spaced from the side wall of the opposite channel or intermediate in the connecting wall as applied. In the case of the tabs extending from an intermediate connecting wall, these tabs are butted or closely spaced with the intermediate connecting wall of the next adjacent packing element as illustrated in Figures 7 and 8 to be described. This is such that the liquid drips or drips on a tongue on that side wall of the opposite channel and then on this wall. The tips of the tongue only need to be sufficiently close to the opposite wall, so that the liquid that circulates in that tongue drips the liquid on that wall.

The element 104 is formed from a substrate laminate preferably of a preferably porous sintered fiber-metal preform 126, Figure 9. The preform 126 preferably 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, 132 and so on form the channels 106-110 where the substrate 134 is bent at right angles in the fold lines. The 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. The tabs each correspond to and bend in the 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 to line 128, and a horizontal crease line, for example line 136, and has its tip that terminates in the next adjacent vertical fold line of that column, for example line 130. Each tab, for example tab 114, has a second edge that emanates from a horizontal fold line, for example line 136, and is vertically coextensive with the next adjacent fold line of this column, for example in fold line 130. The tabs are aligned in vertical columns 142, 144, 146, 147, 148, 150, 152 and 154 and so on and in horizontal rows 140, 141, 143, 145, 146 and 149 and so on. The tabs in adjacent rows such as rows 140 and 145 are in alternate columns. The tabs in the row 140 are in respective columns 142, 148 and the tabs in rows 145 are in columns 144, 146 and so on. Alternate tabs in upper row 140 are bent in the same direction. For example, tabs such as the tabs 114, 114 'and 114", in the row 140 and located in the columns 142, 150, and 154 are folded in the same direction toward the viewer outside the plane of the drawing. 150 and 154 form 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 extends parallel to the corresponding channels 106, 108 and 110 respectively from their corresponding channel connection walls. The other alternate tabs, Figure 9, in row 140, for example tabs 121, 121 'in respective rows of columns 148 and 152, are folded in the opposite direction away from the viewer outside the plane of the drawing. These are connected with connection walls 148 'and 152', Figure 5. These tabs are folded into the corresponding channels 107 and 109 facing opposite directions to the channels 106, 108 and 110, where the tabs 114, 114 'and 114 The tabs in alternating rows in each column, for example in 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 the tongue. 114 and the tab 122 in the next alternate column 148 is folded parallel to the tab 121, the tabs in the columns 142, 150 and 154 are bent in opposite directions than the tabs in the columns 148, 145 and so on. of bends is repeated for 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 in the foregoing and the row 147, tabs 118_, 117 and 124 and so on, all are doubled parallel in the same direction from the plane of the material of the substrate, ie to the viewer outside the plane of the figure d jdibuj-O, Figure 9. - - The tabs of the row 147, for example tabs 118, 117, 124 and henceforth they 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 out of the plane ~ 3e 'the figure is blurred . "While only one row of tabs, the row 149 bends in this opposite direction in the corresponding columns, more of these tabs are preferably provided, for example by making the element 126 longer or rearranging the orientation of the tongue of the legs. other tabs on each channel _ ... __ 7. J'rTl Figure 5 ', the tabs 114, 115, 116, 117 _y 120, "they are all on" 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 tab 117 emanates from the opposite side wall 158. The remaining tabs of the channel 106 emanate from the connecting wall 160. The anterior pattern of tabs is Repeat for each of the remaining channels, with the tabs 121, 122 and 123 emanating from the connecting wall 162 of the opposite opposite 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 structure. The structure can be another shape such as rectangular or circular according to a certain need. In Figure 8, the connecting walls 172 of the element 168 circumscribe the channels 174-175 and so on of the element 170 and the 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 the 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 they depend on the connection wall 180. The tongue edge 131 extends diagonally through the corner corner channel 174. The tab edge 132 next is adjacent to the side wall 183. The tip 182 of the tab 178 below is adjacent to the opposite connecting wall 172 'of the element 168. The next outer tab 184 (corresponding to the tab 127, Figure 6) depend 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 be closely spaced to the corresponding adjacent wall, to allow liquid flow in the tabs to circulate on this wall. The tip 187 of the tongue 184 is at the corner joint of the walls 180 and 183. The liquid circulating at the tip in this manner flows to this corner on the opposite side of the channel from the wall 186. The edges 131 and 131 'may overlap each other or slightly overlap to the next adjacent tongue body. The next lower tab, the tab 188, depends on the wall 183 and is below the tongue 184. The tongue 188 has an inclined edge 131"extending to the overlapping edge 131 'The tongue 188 has the opposite edge 132" confining buttressed 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 tortuous fluid path in the vertical direction. A gas that flows vertically upwards in channel 174 must flow past and with respect to the inclined edges 131, 131 'and 131"of the respective tabs.The remaining tabs in that channel provide a similar tortuous path for fluids attempting to circulate in a vertical direction A linear vertical route for fluids is not provided The tabs serve as vortex generators to maximize the mixing and contact of circulating fluids.

Liquids that circulate in descending form, circulate on the channel sides and on the tabs and are distributed to the different side walls of the opposite channel. The tabs when bent from a flat sheet substrate form large openings in the substrate. These openings form transversal communication routes for the fluids to circulate to the channels of the adjacent elements. This minimizes the pressure drop transversely to the channels, and the vertical tortuous path 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 and the liquid circulates in a descending manner. It will be appreciated that instead of triangular tabs, the tabs may be trapezoidal somewhat similar to the tabs of Figure 1, but without the extended tips 32. In this manner, the inclined edges do not align vertically, but are spaced transversely according to the amount the tip is truncated of the tongue. This provides additional overlap of the vertically spaced tabs in a channel to provide increased turbulence by increasing the tortuous nature of the vertical path beyond the tab edges in a channel.

In Figures 10-12, an additional embodiment is illustrated. In this embodiment, the packaging structure 190 is fabricated from a sheet substrate of the same material as described above by the embodiments of Figures 1 and 5. The structure 190 comprises a plurality of identical packing elements 192. An element representative 192 comprises square alteing channels 194, 194 'in opposing opposite directions as in the previous embodiments. The vortex generating tabs 196, 198 and so on are in repetitive sets and in each channel. The tabs 196 and 198 are preferably identical in peripheral dimensions and formed from a planar preform sheet of the 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 wall 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 overlap each other in the vertical direction over the channel length Figure 10. The tabs 196 have an edge 200 adjacent the connection wall 202. The tabs 196 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 apart when viewed vertically to form the portion 204. The tabs 196 and 198 they form openings in the side walls of which they are constituted. The openings 211 are formed in the channel connection walls 210 to provide fluid communication with 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 shown. , which are a relatively small portion of the package of elements. The pattern of the tabs may be repeated in the manner shown or any other arrangement according to a particular implementation. Like other modalities, there is no present linear vertical fluid path in any of the channels. The overlapping tabs provide a tortuous vertical route for fluids. Although the invention has been described with respect to a specific structure, it will be understood that the present invention is not limited to these structures.

The present invention has broad applicability to the use of mesh structures as a package, with or without a catalyst, preferably with a catalyst, wherein the operation of this package is improved by providing the package with turbulence generators. This improvement is obtained in part by increasing liquid flow through the pores (openings) of the porous package and in a preferred embodiment, the package is provided with openings in addition to the pores in the package, these openings are larger than the pores . The packaging formed in this way can be assembled in a wide variety of configurations. The present invention has particular applicability in a structured package which is employed in catalytic distillation reactors, wherein the structured package includes a catalyst coating, for example, the fibers forming the mesh structure include a catalyst coating. While particular modalities have been described, it is intended that the embodiments described are 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 by the appended claims.

Claims (5)

1. CLAIMS 1. A product, characterized in that it comprises: a structured package to promote contact between fluids, the structured package comprises a porous material, where the average pore size is not greater than 50 microns, the porous material includes turbulence generators to promote flow of liquid through the packaging essentially over the entire surface of the package.
2. 2. The product according to claim 1, characterized in that it includes additional openings through the package that are larger than the pores.
3. 3. The product according to claim 2, characterized in that the structured packing is formed of a plurality of metal fibers having a diameter of 1 to 25 microns. 4. The product according to claim 1, characterized in that the structured package includes a catalyst coating. 5. The product according to claim 4, characterized in that the structured packing is formed of a plurality of metal fibers having a diameter of 1 to 25 microns. 6. The product according to claim 5, characterized in that the structured package includes additional openings that are larger than the pores. The product according to claim 6, characterized in that the structured package provides a plurality of flow channels. 8. An apparatus, characterized in that it comprises: a catalytic distillation reactor and structured packing in the reactor, the structured packing comprises the product according to claim
4. 4. 9. An apparatus characterized in that it comprises: a catalytic distillation reactor and structured packing in the reactor, the structured package comprises the product of claim
5. 5.