Packed columns are widely used in the chemical, petrochemical, and environmental industries, playing a crucial role in separation processes such as distillation, absorption, and degassing. Among these, liquid distributors are the core components that determine the mass (and heat) transfer efficiency of packed columns. Since the inception of packed columns, liquid distributors have evolved through various stages, including spray heads, ring and pipe distributors, and enhanced distribution types, continuously improving their performance.
Limitations of Traditional Liquid Distributors
In packed columns, gas-liquid contact is achieved through the continuous formation of thin liquid films on the packing surface. Therefore, the ability of the distributor to spread the liquid into a thin, uniform film layer is crucial for mass transfer efficiency. However, traditional distributors, based on the principle of point distribution or multi-point distribution, often result in significant fluctuations in the liquid film formed inside the tower, thereby affecting the driving force for mass transfer.
One fundamental flaw inherent in traditional liquid distributors is their reliance on "point distribution" or "multi-point distribution." Even the most advanced enhanced distribution distributors have a limited number of liquid distribution points. This inherently limits the achievable uniformity of distribution, making it difficult to attain an ideal uniform state.
Infinite Point Distribution: A Groundbreaking Concept
To overcome this bottleneck, our company has introduced the innovative concept of "infinite point distribution." This concept breaks free from the mindset of having a limited number of liquid distribution points, allowing the liquid to be truly uniformly distributed across every unit area of the packing bed layer, achieving "line distribution" and "surface distribution." This represents a qualitative leap in liquid distributor design.
The key to this concept lies in utilizing multi-level flow splitting and distribution devices within the distributor, causing the single-point injected liquid to continuously subdivide into finer streams on the packing surface, ultimately forming countless tiny droplets/streams uniformly distributed across the entire packing layer surface. Theoretically, by increasing the number of splitting levels sufficiently, the liquid distribution on the packing surface can approach the ideal state of surface distribution.
Clog-Resistant Trough-Box Liquid Surface Distributor: Embodiment of Innovation
Our clog-resistant trough-box liquid surface distributor is a practical embodiment of this innovative concept. Depending on the tower diameter, there may be one or more main troughs. Multiple parallel side troughs are connected to the main trough(s), and the liquid from the main trough is initially distributed at multiple points through small holes on the side troughs. Each liquid stream from these holes is then guided to a secondary distribution plate for re-distribution, where each initial stream is sliced into 3-6 strands.
These sliced strands of liquid flow are directionally guided to the secondary distribution plate for further distribution. Here, the liquid flow (droplets) is pulled into films and undergoes breakup, transforming into a liquid film and countless small droplets spread across the packed bed surface. This forms a distribution mechanism transitioning from point to line and then to surface.
Proven Performance and Advantages
Experimental data has validated the outstanding performance of this distributor. Under various liquid loads from 8m3/h to 32m3/h, and packing bed heights ranging from 100mm to 500mm using SINOPAK structured packing, its non-uniformity can be consistently controlled within 20% for a 100mm bed height and approaches 10% for a 500mm bed height. This is far lower than traditional multi-point distributors, which typically have non-uniformities three times higher.
Furthermore, the pressure drop is remarkably low, at only 3-5 mmH2O under a gas velocity of 1.2m/s. More importantly, it features a patented anti-clogging design, ensuring consistent distribution uniformity even in fouling services.
The introduction of the infinite point distribution concept and the development of the clog-resistant trough-box distributor mark a new era in liquid distribution technology. Compared to traditional multi-point distribution, this near-ideal surface distribution approach will significantly improve the separation efficiency of packed columns, contributing a pivotal force to the advancement of separation processes.
The clog-resistant trough-box liquid surface distributor has proven its versatility across a wide range of applications and operating conditions within the chemical process industries.
Industrial Applications
Separation of Petrochemical Products (Medium Liquid Load 3-20 m3/m2·h)
The clog-resistant trough-box distributor has seen extensive use in the separation of petrochemical products such as acetic acid-water, propylene oxide-water, light hydrocarbons, methyl chlorides (mono, di, tri, and tetrachlorides), benzene-toluene-xylene systems, and more (column diameters ranging from 300 - 8400 mm).
Fine Chemical Product Separation (Low or Ultra-Low Liquid Load 0.5-3 m3/m2·h)
In the flavor and fragrance industry, this distributor has demonstrated outstanding distribution performance for the separation of products like pine oil, dihydromyrcene, dihydromyrcenol, linalool, borneol, and more, even under low or ultra-low liquid loads. It has also shown excellent results in the separation of agrochemical intermediates, pharmaceutical intermediates, waste gas recovery, and solvent recovery applications (column diameters 300 - 3800 mm).
Absorption-Desorption in Fertilizer Industry (High Liquid Load 20-180 m3/m2·h)
Over 20 fertilizer plants across the country have successfully implemented the clog-resistant trough-box distributor in their decarbonisation absorption-desorption and other absorption-desorption processes, with column diameters ranging from 600 mm to 5000 mm.
Conclusion
The clog-resistant trough-box liquid surface distributor represents a fourth-generation concept in liquid distribution technology, offering liquid distribution performance closer to the ideal state.
Its design breaks free from the traditional multi-point distribution mindset, enabling true infinite point distribution, a departure from conventional liquid distribution theories.
With its innovative design, outstanding distribution uniformity, low-pressure drop, and robust anti-clogging capabilities, the clog-resistant trough-box distributor is poised to drive significant advancements in separation process efficiency across various industries.
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