WO*'

Lx

GAS AND LIQUID MALDISTRIBUTIONS IN PACKED COLUMNS

PROEFSCHRIFT ter verkrijging van de graad van doctor aan de Technische Universiteit Delft, op gezag van de Rector Magnificus, prof.drs. P.A. Schenck, in het openbaar te verdedigen ten overstaan van een commissie aangewezen door het College van Dekanen op 27 april 1989 te 14.00 uur door Robertus Martinus Stikkelman geboren te 's-Gravenhage scheikundig ingenieur

TRdiss 1716

Dit proefschrift is goedgekeurd door de promotoren

prof.ir. J.A. Uesselingh prof.dr.ir. J. de Graauw

STELLINGEN

0. Een stelling is slechts te verdedigen binnen een geaccepteerd axiomastelsel. 1. De uitkomst van maldistributiefactormetingen in gepakte scheidingskolommen is afhankelijk van het meetsysteem. 2. Het bepalen van spreidingscofficinten voor de vloeistoffase bij een lage pakkingshoogte is onnauwkeurig. 3Voorde-interpretatie-van-stofoverdrachtgegevens-voorgepakte kolommen is een nauwkeurige beschrijving van de kolom en de randapparatuur onmisbaar. 4. Het stijgen van de HETP van gestructureerde pakkkingen bij hoge gasbelasting is niet een gevolg van "flooding" maar van * het optreden van grootschalige maldistributie. 5. De inschatting van Baerends dat de tijd voor het berekenen van atomen/molekulen volgens de "discrete variational HartreeFock-Slater" methode in de orde ligt van het aantal electronen In het kwadraat is te optimistisch. E.J.Baerends, D.E.Ellis and P.Ros, Chem. Phys. 2 (1973) 41 6. Alles is een perpetuum mobile. 7. Filevorming en milieuvervuiling kunnen verminderd worden door het afschaffen van: - de reiskostenvergoedingen en - de overdrachtsbelasting bij de huizenverkoop 8. Het belang van presentatie- en communicatievaardigheden wordt in het huidige studieprogramma voor scheikundig ingenieur onderschat. 9. Fusie leidt tot confusie. 10. De verklaring van het woord stripverhaal heeft tegenwoordig meer met de inhoud dan met de vorm te maken. R.M.Stikkelman Delft, 27 april 1989

SUMMARY

Packed

columns

are

increasingly For of the

used the

in

distillation of

and

absorption/stripping colums a good This

processes.

application in

these.

understanding

flows

the packing is

desirable. in has

study describes the gas and liquid distributions

random as well as structured packings. The experimental column a diameter in the of 0.5 top m. It is equipped with a total of 1289

detectors yield a

and bottom cross section. These detectors

detailed picture of air and water flows through elements

of only 25x25 mm 2 .

Random packings

The observed maldistribution in the gas bulk flow is negligible compared with that of liquid bulk flow. The gas flow rate near the wall 25 mm equals 1.1-1.3 No times the superficial velocity for common of the liquid flow rate has been

palEkings. The

influence

observed.

radial

spreading cofficint of the gas is in the

order of A mm. The liquid flow in the bulk becomes less uniform when the

superficial is almost a

liquid

velocity is diminished. The flow distribution of the gas flow. The spreading of liquid

independent srnall increase

shows

up to the loading point, above which it

increases more rapidly. Values of the radial spreading cofficint of the liquid wall are approximately 3 mm. In the loading region the

liquid

flow at a fixed packing height tends to lower values

at higher gas flow rates. The measurements with a of the gas and liquid flow profiles can be

simulated prediction wall

simple Monte Carlo cell model. It gives a good

of the liquid and gas spreading, of the development of of the small scale maldistribution and of the effects

flow,

of the superficial gas velocity. Two types of and a tower internals have been simulated: an initial wall wiper. Drip point densities of more than

distributor 200/m mm
2

hardly improve the liquid distribution in a column with 25

packing. In a column with a diameter of 0.5 m the wall flow is

only reduced over a small packing height by a wall wiper.

The

effect

of

severe

initial liquid maldistribution in a column has been investigated. This

methanol/ethanol

distillation

was done in a 0.45 m diameter column with a packing height of 2.65 m. Sealing half of the distributor resulted in a sharp increase of the height of a transfer unit based on over-all gas-phase

resistance. The fer Monte Carlo cell model, extended with a simple mass trans gives a realistic simulation of the distillation

model,

results. The separation properties of the first meter of a typical 25 mm packing 30 drip lost. with points different per m2 distributors have been simulated. With

a packing height of 0.4 m is effectively

Structured packings

The the

maldistribution

in

the gas bulk flow is negligible. Only

observed

wall flow can contribute to malperformance. The gas

flows parallel to the sheet orientation, thus introducing a radial transport. Together with the change in the orientation of

subsequent packing elements, this results in good gas mixing. It gas was observed that the liquid wall flow decreases when the

velocity

is higher than 1.7 m/s. Up to the loading point the of the liquid is constant. Above this point the deteriorates rapidly, due to the

maldistribution quality of the

distribution

appearance of large scale liquid segregation.

Appendix A provides a method of characterizing a flow distribution with a relatively small number of parameters. A channel mal

distribution contribute overall

factor is defined that indicates which channel sizes most to an overall maldistribution. A newly defined

maldistribution factor is shown to give a good ranking of

different distributions.

SAMENVATTING

Gepakte

kolommen Het

worden is voor

steeds

vaker

toegepast

in

de

procesindustrie. selijk Dit kan

het ontwerpen van zo'n kolom wen

dat de stroming in de pakking nauwkeurig beschreven wordt. helpen om tegenvallende prestaties te voorkomen. In dit

proefschrift losse 1289 als

is het stromingsgedrag van water en lucht voor zowel gestructureerde pakkingen bestudeerd. In een kolom met zijn aan de top en bodem van de pakking

stromingsdetectoren

gedetailleerde 0.5 m.

profielen gemeten. De kolom heeft een diameter van

Losse pakkingen

De gering

maldistributie

van

het

gas

in de bulk van de pakking is

ten opzichte van die van de vloeistof. Voor gangbare 25 mm is de gemiddelde gassnelheid langs de wand een factor

pakkingen 1.1-1.3 heeft

groter dan de_sup_erficile_snelheid.De-vloeistofstroming

nauwelijks invloed op het-gas. De radiale spreidingscoffi

cint voor het gas is ongeveer 4mm. Bij lage vloeistofsnelheden in de bulk van neemt de kwaliteit van de vloei de pakking van de af. Deze kwaliteit De

stofverdeling gedraagt spreiding toe; van het zich van

vrijwel de

onafhankelijk

gasbelasting.

vloeistof

neemt tot het stuwingspunt enigzins

daarboven de radiale

is er een sterkere toename waargenomen. De waarde spreidingscofficint bedraagt ongeveer 3 mm; In neemt de wandstroming bij een gelijkblijvende

stuwingsgebied

pakkingshoogte af. De meetresultaten van de gasen vloeistofprofielen zijn

gesimuleerd de

met een Monte Carlo cellenmodel. Dit model beschrijft en gasspreiding, de ontwikkeling van wandstroming,

vloeistof-

gemiddelde onregelmatigheden op kleine schaal en het effect van de superficile gassnelheid. Voor een beginverdeler van meer dan is berekend
2

dat

voor

een

aantal

sproeipunten nauwelijks dat de

200/m

de kwaliteit van de verdeling

verbetert. De simulatie van een wandschraper laat zien van de vloeistof slechts over een klein

wandstroming

gedeelte van de pakking wordt verminderd.

In het heeft hoogte

een effect

destillatiekolom van een

voor een methanol/ethanol mengsel is beginverdeler onderzocht. De kolom

slechte

een diarater van 0.45 ra en een pakkingshoogte van 2.65 m. De van een neemt stofoverdrachtseenheid sterk gebaseerd op de gasfase

weerstand

toe als de helft van de beginverdeler af-

geblind wordt. Het Monte Carlo cellenraodel, geeft een uitgebreid rele met een eenvoudig van de

stofoverdrachtsmodel, destillatieresultaten. Met het

beschrijving

model is het effect van het aantal sproeipunten op de werking van 25 mm pakkingselementen voor een kolom van gesimuleerd. Bij 30 sproeipunten per vierkante meter

scheidende 1 m

hoogte

gaat effectief een pakkingshoogte van ongeveer 0.4 m verloren .

Gestructureerd pakkingen

De maldistributie voor de gasstroming in de bulk van de pakking is verwaarloosbaar. Alleen aan de wand treden er onregelmatigheden op. Het gas stroomt parallel aan de kanalen in de pakking. Doordat de pakkingselementen onderling verdraaid zijn treedt er een goede

gasmenging op. Bij de de gassnelheden groter dan 1.7 ra/s neemt de wandstroming van

vloeistof

af. Onder het stuwingspunt is de maldistributie van

vloeistof constant. Daarboven neemt de kwaliteit van de verde

ling sterk af, doordat er grootschalige segregatie ontstaat.

In

appendix A is een methode ontwikkeld, waarmee een verdeling kan worden met een gering aantal parameters. Met een maldistributiefactor voor verschillende

gekarakteriseerd behulp van

kanaalgroottes aan

kan bepaald worden welk kanaal het meest bijdraagt Een algemene maldistributiefactor geeft een

maldistributie.

goede indicatie voor de kwaliteit van verschillende verdelingen.

Aan mijn ouders

DANKWOORD

I their

would

like

to thank the Koninklijke/Shell-Laboratorium for support and Norton Ltd., Raschig GmbH, Julius

financial

Montz GmbH and Gebrder Sulzer AG for supplying us with packing.

Verder

wil

ik

alle collega's bedanken met wie ik prettig heb gevoelens gaan uit voor diegene die zich

samengewerkt.

Speciale

het getal driehonderdtwee-endertig herinnneren: Piet en Peter voor het voor 0.1 de mm werk. Frits en Piet voor de electronica. Arie en Wim Bram en kornuiten voor de constructie. De

ontwerpen.

uitvoerders van de Centrale Werkplaats.

De tijdens

beide promotoren Hans Wesselingh en Jan de Graauw hebben me het voor onderzoek zowel veel het vrijheid gegeven. Dit vind ik

belangrijk

onderzoek

als mezelf. Het zijn vier

leerzame jaren geweest.

Gedurende gemakkelijk.

de Veel

promotieperiode ondersteuning Vooral

was heb

het ik

niet toen

altijd gehad van

even de

afstudeerders/stagiaires. man (M/V) en

het laatste jaar hebben zij met

macht gewerkt om het project tot een goed einde te Aike, Connie, Jos, Krijn, Rens, Maxim, Antonio,

brengen. Manuela,

Kees,

Aad, Ton, Floris, Ruud, Abdel, Hessel, Jan-Jelle. Zonder

jullie was het niet gelukt.

CONTENTS

Summary Samenvatting Dankwoord

A C F

CHAPTER I

General introduction Scope Earlier investigations Objective of the thesis Structure of the thesis References

1 3 4 5 5

CHAPTER II

The experimental setup Introduction Description of the equipment The raeasuring techniques used Data acquisition Characteristics of the equipment References

9 9 12 15 15 17

CHAPTER III Measurements of the gas and liquid maldistribution in columns with a random packing Introduction _._ ~ Literature Velocity profiles Gas profiles Liquid profiles Radial spreading Gas spreading Liquid spreading Interpretation Conclusions Symbols References

-19 19 21 23 25 27 28 28 30 32 33 34

CHAPTER IV

Simulation of the gas and liquid distribution Introduction Literature The simulation model Liquid bulk flow Gas bulk flow Wali flow Results Liquid spreading Liquid profiles Gas flow effect on liquid wall flow Drip point density Wall wiper Other cell dimensions Conclusions Symbols References

37 38 39 40 43 44 45 46 48 48 50 51 52 53 54 55

CHAPTER V

Measurement and simulation of the influence of maldistribution on distillation in a column with a random packing Introduction 57 The distillation unit 59 60 Determination of the HTU value OG Distillation results 61 63 Simulation of mass transfer 67 Simulation results 69 Influence of the drip point density 71 Discussion 71 Conclusions 72 Symbols References 73

CHAPTER VI

A study of gas and liquid distributions in structured packings Introduction Literature survey Gas profiles Gas spreading Liquid profiles Liquid spreading Discussion Conclusions References

75 76 78 80 80 84 85 86 87

APPENDIX A

Characterlzation of the flow distributions in a cross section of a packed column Introduction Channel and overall maldistribution Sample distributions and discussion A checkerboard distribution A column with an irrigated outer ring A point source A series of checkerboard distributions Conclusions Symbols References

89 91 93 93 94 95 96 96 97 97

APPENDIX B

Description of the computer programs used General information The flow simulation program The mass transfer simulation program The evaluation program

99 99 101 101

CHAPTER I

General introduction

Scope

For chemical

long

time gas liquid contact devices have been used in to separate mixtures. Destillation, absorp-

engineering

tion and stripping are carried out in tray, wetted wall, spray and packed oil columns. Some typical applications are gas drying, crude purification, alcohol separation and gas

refinery,

monomer

cleaning. One of the problems from for a process designer is to choose the the various devices. Although the

economical knowledge

optimum

on gas liquid contacting has reached a high technologi-

cal maturity, innovations in equipment and widening of theoretical backgrounds still happen. Minor improvements can result in large

profits becaus_e_ofthe-enormous-quant-it-lesinvolvedAn by 1973 to example to emphasize the importance of innovations is given

the petrochemical industry. During the perlod between 1950 and the world refinery capacity was rapidly extended from 13xl06 6Axl06 barrels feil rising a day. After the first oil shock in 1973, oil rather sharply, but primary distillation

product capacity under

demand kept

because of the completion of plant already Refiners have reacted by closing the least

construction.

efficint 1979 and

and simplest refineries. Due to the second oil shock in shift in the oil product demand to light components the

utilization rate in 1987 equaled about 75 per cent with low simple refining became margins . to load like light have the The most their important requirement for refiners complex conversion and upgrading

fully

capacity, produce refiners Especially

visbreaking, oil to products. optimize

flexicoking and the hyconproces, to Still the margins are small, so

both supply and refinery operations. use of energy is important, because

efficint

refinery fuel and electricity costs increased their share of total manufacturing The worldwide costs from around 20 per cent to over 40 per cent.

amount of crude oil processed in refineries during 2 the past ten years approximates 60xl0 6 barrels a day . One of the possibilities to minimize manufacturing costs is to plate columns with packings. The gain of flexibility and 1

revamp

capacity

obtained in this marmer is important for the atmospheric of crude oil. A second advantage is the decrease of per mass tranfer stage. Especially for vacum results in lower bottom temperatures and lower

distillation the pressure

drop this

distillation

energy consumption. Also in the chemical industry packed columns can improve the

column performance. Due to the low pressure drop per mass transfer stage the decomposition In that general of a the tray of thermolabile products can be

suppressed. lower packing than

height of of mass transfer stage is tower. Revamping those towers with

mostly of

results in better product specifications. For the agressive chemical compounds the ceramic types of

separation

structured as well as dumped packings are very suitable. Many applications of structured as well as dumped packings have , _ . in , 3-17 been described literature More than fifty varieties of random and structured packings are commercially divided rings, available on an active market. Roughly they can be

into three types : conventional dumped packings ( Raschig Pall rings, Berl saddles, Intalox saddles, etc. ) , high

performance dumped packings ( Intalox Metall Tower Packing, Nutter rings, etc. ) and structured packings ( Mellapak, Gempack, Montz's BI, Ralu-pak, Rombopak, Intalox 2T(C0M), etc. ). Table I outlines

typical design data of trays and packings.

Table I

Typical

design data of trays, dumped packings and struc18 tured packings according to Chen

Trays Dumped F-factor [(kg/m/s2)0*] HETP [m] AP/HETP [Pa] x 102 0.3- 2.4 0.6- 1.22 4 -11

Packings Structured 0.12 -4.4 0.1 -0.76 0.013-1.0

0.3 -2.9 0.46-1.52 1.2 -2.4

In small

the past, the use of packings was limited to columns with a diameter/packing height ratio, because the performance was

considered to be rather unpredlctable. Today this picture has been changed, deslgned mainly for two reasons: the availability of carefully

and installed packings and the improved understanding of

the flow mechanisms inside the packing.

However, there still are a number of disappointing performances of the tion large columns. A nonuniform liquid and gas distribution within packing is thought to have an negative effect on the separaA so considerable called amount of literature has been problem. A general

efficiency. on the

produced overview

maldistribution

is given in the next paragraph. A detailed survey of the

studies is presented in the concerning chapters.

Earlier investipations

Many have

factors that can cause irregular flows in a packed column investigated in the literature. The most important

been

factors are summarized below.

A principal cause of maldistribution is the packing itself. The liquid Sometimes ing rivulets follow specific paths through the packing.

they split, sometimes they flow together thus introducon a small scale. The equillibriumf-low-

irregularities in the

distribution

according to 20 Hoek . The continuous gas flow is forced through the openings of the packing. The different orientations and dimensions of these

bulk of the packing is called natural flow 19 Albright . This natural flow has been measured by

result in a natural flow distribution for the gas, which 21 22 has been determined by Ali and Stikkelman A from tions etc. the wall A change a in the isotropy of the packing can give a departure distribution. Practical examples are void variainproperly installed packing, corrosion, fouling,

openings

uniform due to

serious

change in the isotropy is the transition between

packing

and the column wall. Liquid moves more easily to the

than vice versa causing wall flow. Liquid wall flow has been 20 23-30 by many authors. ' Gas wall flow received less 31,32 attention. studied

The

quality to

of

the

initial

distribution of both phases can

contribute

a column malperformance. Especially for the liquid

an initial maldistribution results in a decrease of the separation 33-35 efficiency . Large scale flow irregularities are diminished by radial spreading. Many spreading data are known for the liquid

without loading effects

20 30 36-39 ' ' . Rough data of the gas are only 40 available for 250Y Sulzer Mellapak

The

interaction

between

gas and liquid intensifies above the

loading point. Many correlations have been proposed for the liquid hold up and the pressure drop, but only few authors studied the 32 41 '

effect of loading on the flow distribution

The the

surface

tension and viscosity of the liquid can influence area between tension both phases. Even over the column can vary due to a change in 37 42-48 ' are

interfacial the

length

surface

composition. mostly not

Although the studies of these phenomenae integrated with

maldistribution, the effects on the

separation efficiency can be considerably.

Obiective of the thesis

In its

literature effect

little

attention is given to the gas phase and

on the liquid phase. Therefore the two main objec-

tives of this thesis are the study of:

Gas flow characteristics

The influence of gas flow on the liquid flow behaviour

Experimental data on spreading and flow profiles of both phases will be measured column. for structured as well as random packing in an This information will contribute to a better

air/water

understanding of the complex flow mechanism inside the packing.

flow

model

will

be developed to simulate the experimental

results.

This

model can also be applied to evaluate hypothetical

cases. In this way some design failures can be anticipated. The model, extended with simple mass transfer equations, will

be tested to practical distillations with severe maldistribution.

Structure of the thesis

In chapter 2 the measuring equipment will be decribed. The next three chapters deal with random packing. They form an

integrated unit starting with basic experimental flow characteristics and ending with a will complex be distillation simulation. The

experiraental simulation distillation

results model on

presented

in chapter 3, The flow

will be explained and evaluated in chapter 4. A a pilot plant scale with severe initial liquid

maldistribution is studied in chapter 5. In chapter 6 the gas and liquid distribution results are given

for structured packings. The of first appendix at the end of the thesis concerns a method a flow distribution with a relatively small

characterizing

number of parameters. In the second appendix the computer programs used are outlined.

The

greater In

part this

of

the

chapters

have

been submitted for

publication.

thesis

theirlay-outhasbeen-slrghtly -

modified to give a consistent and readable form.

References 1 De olieprijzen Shell Brochure Series, december 1987 ISBN 90-6644-083-x 2 Energie in kort bestek Shell Brochure Series, august 1987 ISBN 90-6644-079-1. 3 W.Meier, R.Hunkelar, W.D.Stocker I. Chem. E. Symposium Series No.56 (1979) 3.3/1-17 4 R.F.Strigle, K.E.Porter I. Chem. E. Symposium Series No.56 (1979) 3.3/19-33 5 R.F.Strigle, F.Rukovena Chem. Eng. Progr., 75 (1979) 86-91 6 G.K.Chen, L.Kitterman, J.Shieh Chem. Eng. Progr., 79 (1983) 46-49 7 N.P.Lieberman Hydrocarbon Processing, 66 (1984) 143-145 8 R.Billet, J.Mackowiak Chem. Ing. Tech., 57 (1985) 1-3 9 R.F.Strigle Chem. Eng. Progr., 81 (1985) 67-71 10 R.F.Strigle 3rd World Congress of Chemical Engineering, Tokio, 1986 Paper No. 6F-354, 770-773 11 J.R.Sauter, W.E.Younts Oil 6 . Gas Journal, 84 (1986) Sept 12 P.Roy, A.C.Mercer I. Chem. E. Symposium Series No.104 (1987) A103-114

13 U.Bulhmann I. Chem. E. Symposium Series No.104 (1987) A115-127 14 D.E.Nutter I. Chem. E. Symposium Series No.104 (1987) A129-142 15 H.A.Gangriwala I. Chem. E. Symposiun Series No.104 (1987) B89-99 16 M.Roza, R.Hunkelar, O.J.Berven, S.Ide I. Chem. E. Symposium Series No.104 (1987) B165-178 17 L . S p i e g e l , P.Bomio Chem. Ing. Tech., 59 (1987) 130-132 18 G.K.Chen Chem. Eng., 91 (1984) 40-51 19 M.A.Albright Hydrocarbon Processing, 9 (1984) 173 20 P.J.Hoek Ph.D. Thesis, Technische Hogeschool Delft, 1983 21 Q.H.Ali Ph.D. Thesis, University of Aston, 1984 22 R.M.Stikkelman and J.A.Wesselingh I. Chem. E. Symposium Series No.104 (1987) B155-164 23 K.E.Porter, J.J.Templeman Chem. Eng. Sci., 20 (1965) 1139-1140 24 K.E.Porter, J.J.Templeman Trans. Instn. Chem. Engrs., 46 (1968) t68 25 E.Dutkai, E.Ruckenstein Chem. Eng. Sci., 23 (1968) 1365-1373 26 V.Stanek, V.Kolar Czech. Chem. Commun., 33 (1968) 1062-1077 27 E.A.Brignole, G.Zacharonek, J.Mangosio Chem. Eng. Sci., 28 (1973) 1225-1229 28 H.C.Groenhof, S.Stemerding Chemie-ing. Techn., 49 (1977) 835 29 M.M.Farid, D.J.Gunn Chem. Eng. Sci., 33 (1978) 1221-1231 30 P.J.Hoek, J.A.Wesselingh and F.J.Zuiderweg Chem. Eng. Res. Des., 64 (1986) 431-449 31 G.Speek Ph.D. Thesis, Technische Hochschule Dresden, 1955 32 R.J.Kouri and J.J.Sohlo I. Chem E. Symposium Series No.104 (1987) B193-211 33 M.Huber, R.Hiltbrunner Chem. Eng. Sci., 21 (1966) 819-832 34 K.J.R.ter Veer, H.W.van der Klooster, A.A.H.Drinkenburg Chem. Engrs. Sci., 35 (1980) 759-761 35 J.G.Kunesh, L.L.Lahm, T.Yanigi I. Chem. E. Symposium Series No.104 (1987) A233-244 36 K.E.Porter, V.D.Barnett and J.J.Templeman Trans. Instn. Chem. Engrs., 46 (1968) t74-85 37 K.Onda, H.Takeuchi, Y.Maeda, N. Takeuchi Chem. Eng. Sci., 28 (1973) 1677-1683 38 V.Stanek, M.Kolev Chem. Eng. Sci., 33 (1978) 1049-1053 39 G.G.Bemer, F.J.Zuiderweg Chem. Eng. Sci., 33 (1978) 1637-1643 40 W.Meier, R.Hunkler and D.Stcker I. Chem. E. Symposiun Series No.56 (1979) 3.3/1-17 41 E.Dutkai, E.Ruckenstein Chem. Eng. Sci., 25 (1970) 483-488

42 F.J.Zuiderweg, A.Harmens Chem. Eng. Sci., Genie Chemiqie, 9 (1958) 89-103 43 R.C.Francis, J.C.Berg Chem. Eng. Sci., 22 (1967) 685-692 44 S.S.Paranik, A.Vogelpohl Chem. Eng. Sci., 29 (1974) 501-507 45 A.B.Ponter, P.Trauffler, S.Vijayan Ind. Eng. Chem. Process. Des. Dev., 15 (1976) 196-199 46 H.W.van der Klooster, A.A.H.Drinkenburg I. Chem. E. Symposium Series no.56 (1979) 2.5/21-37 47 H.Sipma, B.J.Schram, A.A.H.Drinkenburg I2-procestechnologie, 2 (1985) 30-33 48 T.D.Koshy, F.Rukovena Hydrocarbon Processing, (1986) 64-66

CHAPTER II

The experimental setup

Introduction

The the gas

equipment flow

used in this study has to supply information on

profile and the liquid flow profile in the top and

the bottom cross sections of a packed column. Both the gas and the liquid grid profiles have to be measured simultaneously. The measuring should be sized These able to detect maldistribution on the scale of a column as well as on the scale of the packing

reasonable element.

requirrements have lead to the design of a column

with a diameter of 0.5 m and with a maximum packing height of 3 m. The column is placed on top of an apparatus containing 332 measur ing modules. The column is operated at atmospheric pressure, with

water flowing downwards and air upwards. ___The_measjjring_par-t_of_the-equipmenfr;asfuHy^described-irT~the following of 25 mm. paragraphs, consists of modules with a nominal diameter This matches with the dimensions of 1 inch dumped

packings. The data flows through the modules are collected by an automatic Data reduction and interpretation are

acquisition

system.

carried out on a personal computer. Mass tillation transfer column experiments are performed on a pilot plant diswith a diameter of 0.45 m and packing height of

2.65 m. This column is described in chapter 5.

Description of the equipment

Five

different

parts can be distinguished in the general flow

scheme of the equipment as shown in Figure 1:

- the water circulation unit

A centrifugal water pump feeds a constant head tank. A fraction of the liquid The is directed via a flow controller into the liquid superficial velocity of the water in the column 0 and 15 mm/s. After passing the packed 9

distributor. can be

varied

between

column and the bottom section the water runs into a buffer vessel. The overflow of the constant head tank is lead directly into the buffer vessel.

constant head tank air out

Inltlal distrlbutor

coollng water

air cooler

t4

air pump

draln'

Figure 1 The general flow scheme of the equipment

the air supply unit Hot fixed filled cial a air, supplied by a centrifugal blower, is conditioned to a temperature with and humidity by tap water in an air cooler dumped packings. It enters the column via the bottom

section,

where the gas velocity profile is measured. The superfi-

air velocity is adjustable between 0 and 3.4 m/s by means of

valve. From the top of the packed column the air is vented into

the surroundings.

10

Support

gr

L/G sepo.ro.tl

flow detector G detectlon 8 < Input y f f l E L O ( level detector

level detector

Figure 2 The bottom section with an enlargement of one flow detection module

- the bottom section

The bottom section ( Figure 2 ) combines a number of functions: The upper the of part ( L/G separation section ) serves as a support packing in the column. This grid divides the cross

grid. for section of the

the packed column into 332 modules of 25x25 mm 2 . Some modules are partly covered by the column wall.

outer

Furthermore, tubes

the downcoming water flows around the gas pipes into

in the middle part of the bottom section and is in this way

separated from the upflowing air. In the middle part ( G detection & input section ) the gas flow from tive the cooler is forced through a perforated plate with a relahigh pressure The air drop to obtain a uniform initial gas

distribution.

enters the L/G separation section via 332

small pipes, each of them provided with a flow detector.

11

Water ference section tion ).

from by into Each air

the

L/G

separation

section falls without inter-

via 332 pipes located in the G detection & input

square U-tubes in the lower part ( L detection sec of these tubes contains two level sensors and a

pneumatic levels

actuated

valve. After the filling time between the two

is registered, the valve can be opened to drain the U-tube

and to prepare a new measurement.

- the packed column

The column is built from perspex units with a height of 1 m and a diameter of 0.5 m. Many types of structured as well as random

packings, provided by manufacturers, are available.

- the liquid distributor

The distributor, situated above the packing, hollow

consists plate,

of

perforated

with vertical gas tubes and provided The with drip points. distribution from 149

initial be

Liquid Gas

can

adjusted

drip down with

points to all one

( 760 dp/m2 ) point source

possibilities in A grid of 293 gas

between.

T T T

tubes, taining

each a

of

them conflow the gas

gas

detector, to with

enables

flow out of the packing a low resistance. A section of

vertical

cross

the distributor is shown in Figure 3. Figure 3 The liquid distributor

The measuring techniques used

Gas

flows

are

measured

by means of miniature NTC ( Negative resistors. The resistance of these

Temperature Cofficint )

12

devices decreases

is

dependent on their temperature in such a way, that it the temperature increases. The resistors are

when

heated by an electrical current so that their temperature is about 180 flow, C in the absence of gas flow. However, if there is a gas

the resistor is cooled by the gas, resulting in a change of and a corresponding change of resistance. The NTC

temperature

resistor is part of a Wheatstone bridge ( Figure 4 ) . The relation between by: the measured bridge voltage and the gas velocity is given

A + B x exp(AV)

(21)

For

each

resistor measuments

the with

constants A and B are calculated from known gas velocities. A typical

calibration

calibration curve is given in Figure 4.

150 ,15 V 680 n

I
,,

27 k A . AV
.__!
2.7 k / \

TT
_i i i
ii

i_

4.5

5.5

6.5

Voltage
Figure 4 Response

(V)

of an NTC resistor in a Wheatstone circuit as a

function of the gas flow through one sensor

The 2 X.

relative The

error with a reliability of 95 % is smaller than system responds within a few seconds, thus

measuring

measurements of must the gas

can be done almost instantaneously. As the detection flow depends on the cooling of the resistor, the gas exactly the same temperature as during calibration. A 13

have

convenient at than ture under

temperature

is 25.0 C. The consequences of raeasuring

a different temperature are negligible for differences smaller 0.2 C. of It turned out to be easy to maintain a gas tempera

25.0 C. No deviations were found in the resistor signal conditions for a period lasting more than six weeks.

fixed

However, mechanical and electrical shocks should be avoided.

9.6 V

-10 V

1 k.TL

1l

4. Y -"*+
/A -f- *^^^\

7T g

i
f

10

kA

AV

emltter

recelver

Figure 5 The Wheatstone circuit for a liquid level detector

Liquid flows are measured by means of U-formed tubes. Each tube contains bottom. A a level sensor sensor at the top and a level sensor at the

consists of a pair of diodes: one LED emitting

infrared light and one photodiode whose resistance varies with the amount a of infrared light received. This photodiode is included in bridge ( Figure 6 ) of in the same way as the NTC

Wheatstone The

resistor. from

absorbance

infrared light in air is different

that in water. When water passes the sensor, a change in the

bridge voltage is detected, and the time is registered by means of a computer. is At the end of a measurement the liquid flow for each computed by dividing the tube volume by the time dif-

element

ference between top and bottom sensor. For jected leaving light the in determination the bottom of of gas spreading C0 2 tracer gas is Inthe packing. The C0 2 concentrations

the packing are measured by an analyzer based on infrared absorbtion. This analyzer works in a range from 0 to

0.3 vol-%, so the amount of tracer gas required is acceptable.

14

Data acouisition

There are 1289 sensors in the equipment, so an automatic system is indispensable for collecting and processing data. All signals

from the sensors are directed to an analogue multiplexer, made out of ordinary CMOS-switches and some address decoding logic. An

address, one of

generated the

by an Olivetti M24 personal computer, selects and connects it to an analogue-to-digital

signals

converter, which is placed on a LabMaster I/O expansion board. The resulting digitized number is, after some checking and converting, stored into memory and another sensor can be selected. In this way all sensors are measured in sequence. The can entire initial gas distribution, or final gas distribution

be detected ( each NTC is scanned five times ) , processed and

saved on a floppy disk in about 5 seconds. The time needed to find the distribution of the liquid dependents on the superficial

liquid velocity. Typical spans range from 10 to 60 minutes. During the measurement each photodiode is scanned 10 times per second,

whichmeansthattheaceuracyoff illtime-determination_is-_quite adequate.

Characteristics of the equipment

For a the

a better understanding of the influence of the gas flow in column gas an even initial distribution is desirable. From distribution measurements without packing it is

packed

initial

concluded that for the range of gas flows used the maldistribution is negligible. The Mf-factor as defined by Groenhof equals 0.005.

The variance of the initial liquid distribution, based upon 149 drip The points does not depend on the liquid flow rate ( Figure 6 ) . maldistribution of the distributor is so low, that it has no

negative

influence on Mf-measurements of packings. An inclination

of 3 has no effect on the quality of the distribution, except for very low liquid flows. However, the results are still acceptable. A bottom caused For low pressure is drop over the L/G separation section of the

section by

important, otherwise the gas velocity profile

this part dominates the profile caused by the packing. same reason a low pressure drop over the liquid dis

the

tributor is desired. The pressure drops of interest are shown with those of Sulzer 250Y and 25 mm metal Pall rings in Figure 7. 15

-I

1 -

-i

r-

O, 0.06 O t
fI

* : horizontal O : inclined

cd 0.04 > >

ii

cd 0.02
II

*
_i i >

*
i

*
i i

*
i i i i 1 1

*
1

0.00

10

15

Liquid Velocity
Figure 6 The variance of function

(mm/s)

the flows through 149 drip points as a

of superficial liquid velocity for a horizontal

and a 3 tilted liquid distributor

1000
(

'

'

' -

Pu
OH

O
Q

500

Pall

/
^

u
Vi

250Y

m
<D i-, s^
-~~~**t^

y
^*"~"""~^ 1
i ~~

Init
^ ^ . :

CU 0

"

" , 3

Bot 4

Gas Velocity
Figure 7 Pressure drop of the

(m/s)

equipment and over 1 m of Sulzer

Mellapak 250Y and 25rarametal Pall rings as a function of superficial gas velocity. ( Init-liquid distributor,

Bot=L/G separation section ) .

16

These

are

typical

examples of the structured and dumped pac

kings used in this study.For 25 mm dumped packings the differences between measured gas flow profiles and ideal profiles can be

atttributed

to the packings. For structured packings the measured

profiles will be slightly smoothed by the measuring section. Flooding in the upper part of the bottom section does not occur for the range of gas and liquid velocities used in this study.

References

1 H.G.Groenhof Chem. Eng. J., 14 (1977) 193

17

CHAPTER III

Measurements of the gas and liquid maldistribution in columns with a random packing

Introduction

Research almost only

on

maldistribution concerned

in

packed columns has up to now the liquid distributlon. The

been

with

characteristics

of the gas as well as its influence on the liquid

has received little attention. However, many authors emphasize the 1 2 need of research in this field ' 3 The experience at our laboratory with the liquid has therefore been extended with gas flow measurements. The equipment has been

designed to study the flow of gas and liquid simultaneously on the scale of a packing element. A wide range of loadings can be ap-

plied in a column with a diameter of 0.5 m and a packing height up to into 3 m. The cross section at the bottom of~the packing is-divdd 332 measuring modules of 25x25 mm 2 . Each of these modules is with liquid and gas flow detectors. The liquid dis-

provided tributor equipment thesis.

contains 149 drip points and 293 gas flow detectors. The is described in detail in chapter II of this Ph.D.

The aim of the present work is to determine the maldistribution of the gas and and above the the liquid and their influence upon each other loading point for the packings as shown in

below

Table I. the

The shape of the velocity profiles of a cross section of and the mixing of both phases will be discussed in

column

terms of wall flow, maldistribution and radial spreading.

Literature

Flow

irregularities

in

the

gas distribution can result in a

disappointing performance of a packed column. 4 Moore and Rukovena found that the initial gas maldistribution is a function of the kinetic energy of the inlet gas, the pressure drop in the packed section, and to a lesser extent, the distance the gas inlet and the bottom of the packed bed. According

between

to Ali , a severe maldistribution at the gas inlet is converted to 19

almost uniform bulk flow within one-half a column diameter. A high pressure drop packing is better with respect to gas redistribution than a low pressure drop packing. Measurements on a small scale

showed that flow deviations at the top of a deep bed provided with an elaborate gas distribution system under the bed, are negligible compared with those of the liquid. This observation was also made

by Stikkelman and Wesselingh . An

Q

excess

of

gas

flow near the wall was observed by Speek .

Krebs Raschig

modelled the wall flow in columns filled with 15 mm ceramic rings by taking a bundie of channels with unequal widths,

allowing complete mixing between each layer of packing. In a tower 9 of 10.2 cm diameter with 1 cm glass Raschig rings Spedding et al. absorbed liquid at the ammonia into water. The gas wall flow, combined with the wall top flow, resulted in a radial gas concentration profile of the packing. Gas wall flow is also found in beds used two sizes

packed with catalytic particles. Chourhary et al. of high particles ( 1/16 core

and 1/8 inch ) to build packed beds with a or annulus. Measured distributions were

resistance

simulated with a vectorial form of the Ergun equation. Kouri special flow and Sohlo used an 500 mm diameter column fitted with

top and bottom sections for measurement of gas and liquid five or six rings. The results of the gas flow dis

through

tribution measurements showed that with good initial distributions of the liquid may be and gas, to the gas bulk flow through plastic Pall be quite uniform and independent of

rings

expected

packing height and flow rates. The quality of the liquid distribu tion for 25 mm Pall rings was said to tend to deteriorate at high al. 12 observed, that the gas flow hardly effects the

gas loads. Baker et liquid

distribution, even near the loading point. Above the load-

ing point, it assists in obtaining a uniform liquid distribution. 13 Dutkai and Ruckenstein came to the same conclusion for Raschig rings and Intalox saddles. Their diffusion model was valid up for dings to the the 703! of flooding without adjusting the radial spread factor liquid radial and the wall flow parameters. At higher gas loaspread factor increases while the wall flow

decreases.

Just the opposite occurs when using cocurrent gas flow .

for 6 mm Raschig rings and Berl saddles Stichlmair profiles. and Stemmer with

did not measure flow but temperature a good initial distribution, they found

Starting

20

that the largest deviations in temperature are located half-way up the packing. From the literature on the liquid phase (discussed by Hoek recently by Porter ) a nuraber of conclusions can be drawn:
o 1fi_ 1 ft

and

The may be

maldistribution

on

the scale of a packing element '

considered as an inherent and stabile property of the 19 packing. Albright denoted this by the terra natural distribution and concluded that an initial distribution that is better than the 20 natural one will degrade to it quickly. Zuiderweg calculated that on the the natural distribution appears to have only minor effects separation efficiency of the packing, due to the

basic

influence of radial mixing. spreading of liquid in the absence of gas has been studied 21 by many authors, dating back as far as 1893 . Their results can 22-27 be decribed as a random movement of the liquid or as rivulets 3 20 28-31 following specific paths in the packing ' ' . I n either description, a parameter, D , having the unit of length is used in combination ~symmtry: g ^ - D x dz r The ing ( 2 f( Z .r) + df(z,r) dr 2 rdr with a diffusion like equation assuming axial The

wall flow, caused by a change in the isotropy of the pack the wall, is said to find its origin in a difference

near

between the

the liquid flow towards the wall and the liquid flow from 9 f i 97 wall ' . Solving equation (1), using different boundary for the wall and centre of the column ' ' results

conditions in

relations

between wall flow, initial distribution and packing

height. In summary: of and few there are very few studies in which the mutual

influence of only Kouri a

gas and liquid have received attention. The studies 11 13 Sohlo sampling and Dutkai and Ruckenstein areas. were based on

Furthermore gas spreading data are

missing. Velocitv profiles

The

velocity

profiles

of

the

gas and liquid, using various

packing heights and superficial velocities, have been measured for the packings presented in Table I. Two typical phenomena can be

21

recognized

in

such

a profile as shown in Figure 1: an irregular

bulk flow and wall flow.

Table I

The types of dumped packings used.

Type

Size [mm]

Material

Code

Pall Ring Ralu Ring Ralu Ring Ralu Ring Ralu Ring Torus Saddle Torus Saddle IMTP

25 25 25 38 38 25 25 25

Stainless Steel Plastic Hydrofilated Plastic Plastic Hydrofilated Plastic Plastic Hydrofilated Plastic Stainless Steel

PR25S R25P R25HP R38P R38HP T25P T25HP IMTP

Figure 1 A

three

dimensional

presentation

of

a liquid profile

showing an irregular bulk flow and pronounced wall flow.

22

The bulk

maldistribution flow. According

factor, to

Groenhof

Mf, is used to characterize the 32 this relative factor can be

expressed as: 1 i?n ( u(i)-<u> )

2 2

M f - n ^ i=l X^fe <u> r^The Mf-value depends on the scale of

(2)
detection of the local

velocities. In this work the scale is based upon the dimensions of the measuring used. module, which matches the nominal size of most

packings local An

Furthermore the Mf takes only the variance of the and not their spatial orientation into account. 33 method can be applied that overcomes the disad-

velocities

alternative

vantages mentioned above. The wall flow factor, Wf, is calculated from the average

velocity, <u > in a ring adjacent to the wall for both the gas and w the the liquid. The ring is chosen to have a thickness of one half of nominal packing diameter ( ? d ) . This wall flow velocity is

compared with the superficial velocity: <u > - ^ -

Wf-

(3)

In

the

ideal

case of plug flow the Mf-value equals 0 and the

Wf-value is 1.

Gas profiles

A typical gas velocity profile ( Figure 2 ) shows a smooth bulk flow, Wf with Mf -values between smaller 1.1 than 0.03, and a wall flow, with

-values t, G

and 1.3. Only for the torus saddles is

this value higher. The experimental results for the bottom and the top of the packing are summarized in Table II. The bottom liquid influence of the of the gas velocity on the gas wall flow at the packing has been investigated with a superficial

velocity

of 3.4 mm/s. The column contained 1.72 m of IMTP -

packing. values

Over a gas velocity range from 1.5 to 3.9 m/s the Wf, randomly value between of the 1.35 and 1.41. These

varied the

values

approximate

initial gas distribution without

packing. It is assumed that the wall profile caused by the measur ing equipment determines the Wf,
D ,

-value.
CF

23

r 4

-0.25

0.00

0.25

Radius
re 2 A typical gas velocity profile.

(m)

e II Wall

flow

factors the gas

values at the top, Wf and raaldistribution t, G at the bottom, Mf, , and at the top, Mf , for b,G t,u phase and at the bottora, Mf, , for the liquid

phase.

Code

Mf b,G

Mf t,G

Wf t,G

Mf b,L

PR25S R25P R25HP R38P R38HP T25P T25HP IMTP INITIAL GAS

0.022 0.007 0.030 0.023 0.019 0.018 0.025 0.003 0.011

0.030 0.026 0.027 0.023 0.014 0.021 0.031 0.004

1.2 1.3 1.3 1.2 1.2 1.7 1.5 1.1 ...

0.81 0.55 0.63 0.69 0.81 1.05 1.13 0.57

24

At of up to

the

top of the packing the Wf

-values depend on the type

packing.

No significant effects of the liquid load were found

to a superficial gas velocity of 2.5 m/s. Care should be taken prevent irregularities in packing height, otherwise gas flow

channels may occur in which packing particles are lifted.

Liquid profiles

Liquid Small

velocity

profiles

are less uniform than gas profiles.

scale

maldistribution of the bulk flow is characterized by

Mf, -values between 0.5 and 0.8. Again the torus saddles give b,L higher values of about 1.1. It was found that the gas velocity hardly influences the small scale maldistribution, except for

situations close to flooding. At low liquid velocities the quality of the distribution slightly deteriorates ( Figure 3 ) . Average

Mf, -values for different packings are given in Table II. b, L

tJ.U

1.5

Mf
1.0

A A

A
A A

s
o

<w

0.5

8
*

o
o

n n

10

Liquid Velocity
Figure 2 The tion T25P maldistribution of the superficial T25HP

(mm/s)

factor, Mf, of the liquid as afuncliquid velocity for 1.72 m of IMTP (o ), PR25S (<? ) and

(, ; , ) ,

(*) ,

R25P ( o ) packings without gas loading.

25

The

wall as

flow

tendency at the bottom of the packing is quite for R25HP packing in Figure 4. For a gas

remarkable

shown

velocity of 0 m/s in the

the wall flow increases rapidly going downwards

column as a function of the packing height. Starting with developes

an Wf -value of 0.53 at the liquid distributor the Wf to 2 for a packing height of 1.72.

'1-

(5

O
o

Wf

o
o
<i

0
0
0

Initial distributor
i , i

Gas Velocity
Figure 4 The tion development of the gas velocity

(m/s)
for a packing height of

of the liquid wall flow, Wf ,as a func

0.21 ( e ) , 0.43 ( (?) , 0.86 (of) and 1.72 ( ) m of R25HP rings. The superficial liquid velocity is 3.4 mm/s.

The gas velocity stimulates or reduces the wall flow, depending on the height of packing used. At a height of 0.21 m the wall flow increases to wall at higher gas flow rates where as at a height of 1.72 m flow The diminishes. Wf, -values G Almost of all packings show the same

behaviur.

these packings are presented in

Figure 5 as a function of u

for a packing height of 1.72 m.

26

-i

3^r

Wf
2H
#
* O O <*

1 -

$_

Gas Velocity
of the gas velocity

(m/s)

Figure5-The^development ofthel-i-qu-id-wall-flow.,_Wf.as __a_func_t.ion. for a packing height of 1.72 m of PR25S (*), R25P ( O ) , R25HP (), R38P ( ) , R38HP ( ) , T25P ( A ) , T25HP ( O AND IMTP ($) packings. The superficial liquid velocity is 3.4 mm/s.

Radial spreading Radial spreading coefficients have been determined as well Solving as for the liquid equation for the gas

under various loading conditions.

(1) for a point source with an infinite column

radius results in: exp(-

f (z,r)

4TTD Z

4D z r

where Q is defined as the total flow rate of the point source. The flow rate passing through a circular area, Q x' is obtained by integration of (4): , with radius r x

r ,z x

-n

r 2 ? r x f(z,r)rdrdfl - Qx(l-exp(27 4D z r -)) (5)

o o

The

value

of are

can

be to

determined from experiments. Measured the following expression using Standard

profiles

fitted

statistical methods: - r2
D

4zxln(l-Q

~^/W x'

(6)

Gas spreading A point gas source will with a as high with gas flow cannot be applied to

measure gradint

spreading

a liquid. A horizontal pressure

cause an rapid redistribution effect within a few This effect can be overcome by using a homogeneous

decimeters the

of packing. This is not representative for the rest of

packing.

initial distribution of gas, and a point source of tracer gas. The concentration profile which leaves the top of the packing provides information for the calculation of D .-values. The flow rate in r,G

equation (6) should then be substituted by the flow rate of tracer gas. Carbon dioxide is introduced at the center of the bottom of the packing profile packing, via a vertical pipe of 10 mm diameter. The concentration the whole cross section. A packing height of -values is less than 10 %. r ,G is measured at 49 points, located at 4 axes on top of the covering

0.9 m was used; with this height the tracer gas does not reach the wall. The relative error for the D

The results of experiments with various gas velocities indicate that the radial spreading cofficint is almost independent of the superficial effect on D gas velocity. Liquid loading a s shown in Tabel III. r ,G Liquid spreading has a small positive

A nozzle

water A of The

flow smooth the

rate

of

6.5

l/min is carefully fed via a jet gas flow is introduced at the

with a diameter of 10 mm into the center of the top of the countercurrent of packing with various superficial velocities up to packing is chosen to be 0.86 m to avoid

packing. bottom 3.2 m/s.

height

wall effects.

28

Table III

, for several dumped pacr, o kings with and without liquid loading

Gas

spreading

factors, D

u . = 0 mm/s

u = 3 . 4 mm/s

Type of

packing

r,G

r,G
[ m]

[ * ]

PR25S R25P R25HP R38P R38HP T25P T25HP IMTP

0.0038 0.0038 0.0037 0.0036 0.0034 0.0040 0.0035 0.0018

0.0041 0.0039 0.0040 0.0037 0.0034 0.0045 0.0042 0.0027

0 0 0 0 0 0 0

0 o o o o o o o o 0 0 0 0 0 0 0 5 0 0 0 115 0 0 0 0 0 0 0 o o o o o o o o 0 0 0 0 0 0 0 0 0 8 5 0 10 0 12 5 7 0 0 0 0 0

0 0 0 0 0 0 22 19 11 0 0 14 0 0 0 0 0 0 0 0 0 0 s 0 0 0 0 14 17 6 7 14 5 0 0 0 0 0 0 0 0 0 10 0 0 10 11 34 11 9 9 15 0 0 0 0 0 0 0 0 6 0 0 19 52 14 28 20 1 6 27 6 23 7 5 0 0 0 0 0 0 6 0 0 15 91 0 15 45 41 5 0 5 0 0 0 0 0 0 0 0 5 7 0 13 23 49 11 36 48 6 22 0 11 6 E 0 0 0 0 0 0 0 10 15 0 19 14 13 0 7 5 25 10 0 0 0 0 0 0 0 0 0 0 0 24 29 15 28 22 0 0 0 0 6 14 0 0 0 0 0 0 0 0 13 0 0 11 11 0 11 12 8 0 0 0 0 0 0 27 18 0 15 9 0 12 0 0 0 0 0 0 0 0 0 0 0 0 0 1512 0 6 0 0 0 0 0 0 0 0 0 6 0 7 0 0 15 0 7 0 0 0 0 0 0 0 0 15 0 0 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 0 0 0 0 34 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Figure 6 An

example

of from

a liquid velocity distribution (m/sxl04) a point source after 0.86 m of IMTP

resulting packing.

29

An

example the are

of

liquid

flow on a

distribution small

( Figure 6 )

demonstrates spreadings

irregularity quite

scale. However, the

reproducible.

Even after redumping of the

packing the values seldom change by more than ten percent. The dependency of the liquid spreading factor, D , of all

r, L
types of packing upon the superficial gas velocity is presented in Figure 7. All the relations show approximately the same behaviour: The D -value shows a small increase up to a certain gas

velocity, above which the spreading increases more rapidly.

0.010

0.005 Q

0.000

Gas Velocity
Figure 7 The the liquid gas spreading

(m/s)

cofficint, Dr, as a function of

velocity for PR25S ( O ) , R25P ( O ) , R25HP ( ) , R38HP ( ) , packing. T25P ( A ) , . T25HP (*) AND

R38P ( o ) , IMTP ( )

Interpretation

The

results

for

the

gas

bulk

flow

confirm

earlier

findings ' ' The

, that small scale maldistribution is not important.

wall flow, however, can be serious especially for the liquid.

When it is assumed that a flow equilibrium is established within a few decimeters of packing , the differences in the packing size

and form are the most important factors that fix the Wf -value. As an example the IMTP packing and Torus saddles differ in size, 30

although

they are denoted with the same nominal diameter. An IMTP

element fits in a box with the dimensions of 28x23x14 mm 3 , whereas a Torus saddle an is enclosed by the dimensions 53x28x23 mm 3 .

Therefore

IMTP element is better in filling the non-isotropic

zone between bulk and wall and thus yields in a lower Wf -value. The tested fers, value is which for the gas spreading cofficint of the packings

around can

4 mm. Only the value for the IMTP packing difbe explained as mentioned above in combination

with the high porosity of the IMTP packing. measured maldistribution of the liquid without gas loading 3 with the results of Hoek . The increase in mal29 distribution for low liquid loadings as found by Bemer has also is consistent been observed for the packings used in this work. The bulk dis The

tribution quality is almost independant of gas loading. In the loading zone the flow near the wall is influenced by the gas. for more The equilibrium value Wf 25 mm metal is higher from becomes lower. This is illustrated

Pall rings in Figure 8. At high gas velocities transported gas to flow in in a radial direction. the wall zone, Due to the

liquid

relatively mechanism

the returning

wall

bulk is also stimulated. The higher ex-

change rate between wall and bulk leads to different Wf -values. A striking This exception saddle is given by the 25 mm plastic Torus

saddle.

has a form which gives only a small contact

length with the wall and its material is hydrofobic. Water piek up from the wall is therefore reduced . The hydrofilated version,

T25HP, has better wetting capabilities, and thus enables more back flow to the bulk. The decline of the wall flow in the loading region might be an the minimum in the HETP-curves for several pack34 in columns with a relatively small diameter . In literature is said to be caused by a higher interaction between for

explanation ings the the

minimum

gas and the liquid, but no proof is given. The absence of the 35 minimum in columns with a relatively large diameter is another support for the wall effect, because the larger the diameter the

less it effects the overall performance.

31

2 -

Wf
1

.
" $

o I

0.0

0.5

1.0

1.5

2.0

Packirig Depth
Figure 8 The liquid wall

(m)

flow, Wf, as a function of the packing

depth of PR25S. The superficial gas velocity is 0 ( + ) or 2.54 mm/s. ( x ) m/s and the superficial liquid velocity is 3.4

Conclusions.

A packed bed can be divided in a bulk and a wall zone. In the bulk zone a poor initial distribution of the liquid has

to be considered as the main cause of a possible malperformance of a column. The is gas profile plays a secondary role. The gas flow and much better than that of the liquid. at the inlet is converted to almost

distribution Moreover,

smooth

maldistribution

uniform bulk flow within a small packing height. The maldistribution effect on the scale of a packing element is largely on (D a r,L compensated large scale as by radial mixing of gas and liquid. However, the well radial as mixing for the is small for the liquid r,G = 0.4 mm ) . In

= 0.3 mm )

gas ( D

practical

applications large scale irregularities will persist in

the packing for a long distance. Both wall phases The show a deviation from the average velocity in the liquid wall flow rate develops from the initial 32

zone.

wall

flow

rate to an equilibrium value, which is higher than the rate. This development is accelerated by higher gas the equilibrium value is lower. The relative gas is independent of gas or liquid flow and equals

average

flow

velocities, wall flow

but rate

1.1-1.7 times the superficial velocity. The increase in the spreading cofficint of gas and liquid and decrease of liquid wall flow in the loading region could be an

explanation for the minimum in HETP as observed in small columns. The and data as presented in this article can be used to model gas flow patterns below and above the loading point, in-

liquid

cluding wall flow , maldistribution and radial spreading.

Acknowledgements

We would like to thank Norton Ltd. and Raschig GmbH for supplying us with packing, the Koninklijke/Shell-Laboratorium for the and all students involved for their zest of

financial work.

support

Symbols

d f(z,r) D Mf n Q Q x'

diameter velocity at position (z,r) radial spreading cofficint maldistribution factor number of samples total flow rate of the point source the flow rate passing through a circular area with radius r at a depth z

[m] [m/s] [m] [-] [-] [m 3 /s]

[m3/s] [m] [-] [m/s] [m]

r Wf u z

radial coordinate wall flow factor superficial velocity packing height/depth

subscripts: b G L p bottom of packing gas phase liquid phase packing element 33

t w = >

top of packing wall at infinite height/depth

Greek symbols: 9 polar angle [rad]

References 1 K.E.Porter and M.C.Jones I. Chem. E. Symposium Series No.104 (1987) A245-258 2 F.J.Zuiderweg I. Chem. E. Symposium Series No.104 (1987) A589-596 3 P.J.Hoek Ph.D. Thesis, Technische Hogeschool Delft, 1983 4 F.Moore and F.Rukovena Chemical Plants & Processing, No.8 (1987) 11-15 5 Q.H.Ali Ph.D. Thesis, Univesity of Aston, 1984 6 R.M.Stikkelman and J.A.Wesselingh I. Chem. E. Symposium Series No.104 (1987) B155-164 7 G.Speek Ph.D. Thesis, Technische Hochschule Dresden, 1955 9 C.Krebs Chem. Eng. Process., 19 (1985) 129-142 9 P.L.Spedding, M.T.Jones and G.R.Lightsey Chem. Eng. J., 32 (1986) 151-163 10 M.Choudhary, J.Szekely and S.W.Weller AICHE journal, 22, No.6 (1979) 1021-1032 11 R.J.Kouri and J.J.Sohlo I. Chem. E. Symposium Series No.104 (1987) B193-211 12 T.Baker, T.H.Chilton and H.C.Vernon Trans. Am. Inst. Chem. Engrs., 31 (1935) 296 13 E.Dutkai and E.Ruckenstein Chem. Eng. Sci., 25 (1970) 483-488 14 G.Baldi and V.Specchia Ing. Chim. Ital., 12 (1976) 107-111 15 J.Stichlmair and A.Stemmer I. Chem. E. Symposium Series No.104 (1987) B213-224 16 P.J.Hoek, J.A.Wesselingh and F.J.Zuiderweg Chem. Eng. Res. Des., 64 (1986) 431-449 17 B.Lespinasse and P.le Goff Rev. Inst. Fr. Pt., 17 (1962) 1,21,41 18 H.C.Groenhof Ph.D. Thesis, Rijksuniversiteit Groningen, 1972 19 M.A.Albright Hydrocarbon Processing, 63 (1984) No.9 173-177 20 F.J.Zuiderweg and P.J.Hoek I. Chem. E. Symposium Series No.104 (1987) B247-254 21 F.Hurter J. Soc. Chem. Ind., 12 (1893) 227 22 A.M.Scott Trans. Ind. Che. Engng., 13 (1935) 211 23 R.S.Tour and F.Lehrman Trans. Am. Inst. Chem. Eng., 40 (1944) 79 24 Z.Cihla and O.Schmidt Coll. Czech. Chem. Comm., 22 (1957) 896 25 K.E.Porter and M.C.Jones 34

Trans. Inst. Chem. Eng., 41 (1963) 240 26 E.Dutkai and E.Ruckenstein Chem. Eng. Sci., 23 (1968) 1365 27 V.Stanek and V.Kolar Distribution of liquid over a random packing I to X : I Coll. Czech. Chem. Comm., 30 (1965) 1054-1059 X Coll. Czech. Chem. Comm., 42 (1977) 1129-1140 28 K.E.Porter Trans. Inst. Chem. Eng., 46 (1968) T69 29 G.G.Bemer and F.J.Zuiderweg Chem. Eng. Sci., 33 (1978) 1637 30 E.A.Brignole Chem. Eng. Sci., 28 (1973) 1225 31 P.J.Hoftyzer Trans. Instn. Chem. Engrs., 42 (1964) T09-117 32 H.G.Groenhof Chem. Eng. J., 14 (1977) 193 33 R.M.Stikkelman, L.Feenstra, J.de Graauw and J.A.Wesselingh Submitted for publication in Chem. Eng. Res. Des. 34 K.Y.Wu and G.K.Chen I. Chem. E. Symposium Series No.104 (1987) B225-245 35 F.J.Zuiderweg personal communications

35

CHAPTER IV

Simulation of the gas and liquid distribution in a column with a random packlng

Introduction

For

the

large of gas

scale

application

of

random packings a good

understanding effects studied 0.5 the the m. of

the liquid flow in the column is desirable. The loading on the liquid distribution have been

experimentally The

in a water/air column with a diameter of

column has been equipped with 332 flow detectors for

liquid as well as for the gas to determine a precise image of flow distributions. The results were evaluated in terms of a factor Mf, a wall flow factor Wf, and a radial

maldistribution spreading tion of

cofficint D . These global parameters give an indicathe small and large scale maldistribution and the

spreading capabillties of the packing. Flow However, patterns such can be simulated using the diffusion equation. cannot simulate small scale

equations Also

maldistribution. boundary models

it is difficult to stipulate a good set of These shortcomings can be avoided with cell

conditions. i.e.

the column is built up with a three dimensional net-

work of coupled cells. In capable wall this of paper a Monte Carlo cell model is presented which is

simulating small scale maldistribution of the liquid, and spreading a of both phases. It includes loading

flow

effects. basics

After of the will

survey of the literature on flow modelling the model will be explained. The Mf, Wf and D r to local parameters for a unit

cell be

parameters cell. The

transformed

model will be applied to the simulation of profiles as experimentally in the water/air column. Furthermore,

determined the effect

of the number of drip points per square meter and the

effect

of a wall wiper on the quality of the distribution will be

discussed. The model is not llmited to speclfic sizes of the cell or the

column. A method to extend the model to any cell dimension will be presented at the end of the paper.

37

Literature Several workers

9 -1 ft

have investigated the liquid flow in packed

columns and tried to model the distribution of liquid. In most of the slmulation models the liquid is thought to flow as a continum or to flow as rivulets, following speciflc paths through the packing elements. Both mechanisms lead to a diffusion

equation analogous to Fick's Law:

df^) . D x ( *gl + m^l

dz r dr 2 rdr

(1)

D -values have been calculated from spreading experiments using r . n ., . . . .n _ , . . . . 6-8,11,12,14-19 n. single liquid jet as nitial distribution (1) has been solved for several types of initial dis20

Equation The

tribution with a radial symmetry. A survey is given by Prchlik

boundary condition for the liquid flow near the wall is an 4 important factor of the diffusion based model. Cihla and Schmidt considered liquid the wall of the column to be a total reflector where is forced back into the packing. This allows the construc

tion of a model of finite dimensions, but it does not predict wall 9 flow. Porter assumed that the wall flow is proportional to the liquid wall wall liquid packing. flow flow rate was Dutkai into the in and the bulk of the packing near the wall. The to be over-estimated for small depths of introduced an annulus near the place via an "adsorption14 presented Ruckenstein region found

with a thichness S. They assumed that the penetration of the wall cakes 17

desorption" mechanism. Onda et.al the equilibrium and wall flow rate

and Brignole et.al

independently a mechanism which is based on the difference between and the actual wall flow rate. denotes the ratio between wall Stanek Kolar introduced a radial transfer cofficint and a which

distribution

cofficint,

flow and bulk flow at an infinite packing depth. Another way to simulate the liquid distribution is given by 21 Jameson . He divided the column into layers. Each layer consists of concentric rings. The thickness as well as the height of a ring is the equal is to the diameter of a packing element. The spread of liquid controled as the by a dimensionless factor P and weighted to diffusion models, no complex mathematics is

circumference of a ring. Although the model predicts the same

tendencies required.

38

Albright model the which flow

and is

Hoek

et.al

used

a random number numerical

not based on diffusion theories. It accounts for and to a from each individual piece of packing. Every "natural" flow distribution i.e. the equi-

onto tends

packing

librium flow in the bulk of the packing without external effects. The solving flows. small more into models radial based on the diffusion equation are capable in problems for the liquid

symmetrie

distribution

However, they need complex mathematics and do not simulate scale maldistribution. but and it The numerical method of Jameson is

powerful, account

it does not take small scale maldistribution contains some simplifications. The random

number numerical method simulates small scale maldistribution, but misses links to other packing characteristics. Gas flow 1 2 data have only been published recently ' , and model

simulations of the gas have not yet been reported.

The simulation model The aim of the present model is to predict all the observed characteristics simulation of the liquid and gas flow patterns. This implies

of spreading and wall flow of both phases and of small

scale maldistribution of the liquid. The simulation of small scale maldistribution of the gas will be omitted because it was found to be negllgible. The of model consists of an orthogonal network of stacked layers

small cells. Each cell has a width, w, of 25 mm and a variable

height, h. The height will be chosen in such a way as to produce a proper liquid spreading. The flow model for one cell is outlined

in Figure 1.

39

>sfe Osi^
<1-S G )*G*

1 i
0.E5*SQ*G gas spllttlng

I
<I-S L )*L\-S
L

liquid spllt-tlng

:z_

Figure 1 The flow splitting model for liquid (L) and gas (G) .

Liquid bulk flow

Small scale maldistribution is introduced by a random splitting mechanism in a cell. A fraction S T , of the liquid flow L through a cell, leaves the cel randomly to one of the four neighbours of the cell below. The rest of the liquid, (1-S.) L is conducted to the

underlying the each

cell. A smoothing effect is caused by the splitting of

liquid: deviations with a relative high flow are reduced with split. On the other hand maldistribution is promoted by

coalescense

of the flows: it may happen that a number of side-way

flows melt together in one cell, introducing a high flow. With variance, flow and has this model a theoretical prediction of the relative

also called the maldistribution factor Mf.for "natural" been calculated by simulations using various S -values

various layer dimensions. From these calculations two conclu-

sions can be made: The calculated on of the cells Mf values of show cells some scatter. The scatter

depends number

number

in a layer. The higher the

the less the scatter. For a layer with about

300 cells the calculated Mf-values fluctuate within 10 % of the

40

average

value.

The

average

Mf-value

is

independent of the

number of cells in a layer. The average maldistribution can be fitted with formula (2): SL
T

Mf

- 0.42 x

(2)

For ting flow and

very small S -values the smoothing character of the split dominates. For an S -value near one the "natural" consists the of a few cells contaxning all liquid of cells without flow. The coalescing effect is needed. Equation (2) can be rewritdistribution

mechanism the rest

dominates. The result is a very high Mf-value. For the simulations an explicit function for S ten as: = _ 0.42 + Mf

\ This

(3) (i>

equation relates a measured global packing characteristic to I.t-only_ho.lds_if the cell width

a1-oca-lparameterofacell based. The Per over S -value is

equals the width of the measuring modules on which the Mf-value is a measure for the average fraction of liquid

that spreads in a horizontal direction over the surface of a cell. layer the the liquid is also transported in a vertical direction height of a cell. This results in a random-walk type can be calculated from:

spreading of the liquid. The spreading cofficint, D

rf
D

r,L

4 x z x ln(l-'x)'

(4)

Here x is the fraction of the liquid flowing through a circle with radius model r around the axis at a packing depth z. For the simulation the depth z is equal to the number of layers n multiplied

with the height h of one layer z - n x h (5)

41

The
vertical flow ) (5)

D -value i s a raeasure for the r a t i o between h o r i z o n t a l and r

flow. The distance travelled by the liquid ( vertical From equation (4) and is proportional to the cell height.

it can be seen that for a constant number of layers the D

value is inversely proportional to the cell height. Reniinding that the S -factor spreads over a surface ( in the order of w 2 ) in a and the ratio

horizontal direction, a linear relation between D S /h is to be expected:

r.L
The

<*
values The

(6)

S /h.

of D , have been calculated for many ratios of J r.L results, presented in Figure 2, show that equation (6) -4 is satisfactory. The constant C has a value of 1.56x10 [m2]

0.010

0.005

0.000

Sl/h
Figure 2 The the relation radial between spreading

(l/m)

the splitting per cell height and cofficint for unit cells with a

width of 25 mm.

42

The c e l l model r e q u i r e s a v a l u e for h. Rearranging e q u a t i o n (6) gives:

= C x g-ir,L
is already fixed and D h-values

(7)

-values can be found in literature.

Typical 20

for a cell wldth of 25 mm are in the range from

to 50 mm for packings with a diameter of 25 mm, i.e. about the

height of a packing element, which is satisfactory from a physical point of view.

Gas bulk flow

It of a

was observed that the gas flow maldistribution on the scale packing For element this is very the small compared with that of the gas flow model does not contain

liquid .

reason

random aspects; small scale maldistribution is not simulated. In~Figure 1 the~principle~ofthegas-spreadingi-s-outs-l-lnedtoo. A fraction S the four of the gas flow G through a cell is divided equally neighbours upwards. the of the cell above. The rest (l-S)xG (6) can also be applied for a and the gas r, G splitting factor S . Substituting and rearranging results in:

over flows

straigth between

Formula

relation

gas spreading cofficint D

r G

The constant C has the same value as in formula (6). A limitation of the gas model is that it only simulates gas

mixing correctly if the Initlal distribution resembles the natural flow caused shown natural diameter profile. by that The model cannot compensate for radial gas flows

horizontal a severely wlthin

pressure differences. However, it has been maldistributed inlet gas is converted to packing height of one-half a column

flow 25

43

Wall flow

In the

this work the wall flow factor, Wf, is arbitrary defined as between the average velocity in a peripheral ring,

ratio

adjacent

to the wall, with a thickness of 0.0127 m and the super-

ficial velocity. At the column radius the square cells are intersected by the

wall. Any liquid flow directed to the wall is deflected downwards. An annulus with a thickness S forms the wall zone ( Figure 3 ). In this factor chosen smaller wall zone W the splitting factor S is replaced by a splitting

This W to the

serves the same function as the S , but can be predict the wall flow. When the W -value is

freely than

S -value the liquid tends to accumulate in the of W causes the development of a

zone.

The

introduction at

constant factors

wall are

flow weighted

an infinite packing depth. The splitting

by the area they occupy in cells that fall

partly in the bulk ,in the wall zone or outside the column. Analogous to the liquid model an W -factor is used for the gas
G

flow in the wall zone instead of an S -factor.

excluded area wall a r e a bulk a r e a

Figure 3 The zone near the column w a l l . w i s the element width, S i s the wall r i n g t h i c k n e s s

44

Results

The column written

unit

cell

as

presented above is the building block of a

configuration. A computer program in Turbo Pascal has been to manage input, layer to layer calculations, output and Although the program is able to handle all kinds

interpretation. of

configurations, the cells used in this chapter have dimensions

equal to those of the measuring equipment . A layer of 20x20 cells of 25 mm width is used to enclose a

circular are

column cross-section with a diameter of 0.5 m. 332 cells covered by the column, the remaining cells are ex-

(partly)

cluded from the calculations. The wall zone covers 10% of the total cross-sectional area of

the column. This results in an annulus thichness of 12.7 mm. For this configuration several simulations up to the

equilibrium profile were performed using various S /W ratios. The G G resultlng wall flow factors are presented in Figure 4. This figure can also be used the other way around. Knowing the wall flow at an ihihte in the packing bulk and depth-yi-elds-the-rafei-o-o-ffehe-spli-tting-fac.tors_ in the wall zone. Figure (4) is also valid to

predict the average wall flow of the liquid.

r-

3 -

^ ^ ^ ^

Wf
2 -

/ ^
Jf

Q 3i

11

10

15

20

S/W
Figure 4 The equilibrium wall flow as a function of the ratio between splitting factors in the bulk and wall zone. 45

The

following

three

examples

compare

measurments

with

simulations.

Liquid spreading

Maldistribution known the for

factors and liquid spreading coefficients are 2 various types of random packings . With this knowledge can be used to simulate the liquid flow distribution

model

resulting and and a

from a point source. As an example an S -value of 0.576

cell height of 48 mm are obtained by applying equation (3) on

the Mf-value of 0.57 and the D .-value of 1.8 mm as r, 1 measured for the Intalox Metal Tower Packing (IMTP no.25) in the 2 absence of gas flow . In Figure 5 the results are presented for a liquid spreading the m. simulation Both for IMTP no.25 in a bed with a show small scale

(7)

experiment height of

and 1.72

velocity

profiles

irregularities. The overall distributions are similar.

Measured
o o

Profile

Simulated
oo ooooo o o o

Profile

o o o o oo o o O O O Offl0 o o o o o o o o o 0 0 OOOffiOO O O O O o oooo O OffiOO0 O OO O o o o o o o oo o ooo

ooo o o o oo ooooeoooo O ffi00ffiffi O O O O O 0ffiffiO00 000000 o o o o o o o o

OOOOO ffiOffi O OOO O OOO OOOffiO OO O O OO

ffiffifflO

ooo
O0.3-1.5 1.5-3.0 m m / s } 3.0

Figure 5 Measured and simulated results for the spread of a single liquid jet for 1.72 m of IMTP packing.

46

8 r

Column axis Initial liquid distribution

Liquid Velocity (mm/s)

Relative Area

V^/lT^V
ji ii i iii i

0.21 m
-1 1 1 L_

0.43 m
i ' i i i i1_

\J^^\J.
J 1 1 1 1 1 1 L.

0.86 m
,.,!, ,.i

1.72 m

Simulations
Figure 6 Results for

Measurements
3.4 mm/s

the profile developement of a flat in..-_

distribution for 1" pall rings. u_ - 0 m/s. u

47

Liquid profiles The prediction for a of large scale effects is illustrated in

Figure 6 profiles lated annuli needs This

column of 0.5 m diameter filled with 25 mm metal

Pall rings (S =0.659, W - 0.146, h = 39.5 mm). The liquid velocity are given for several packing depths. The initial liquid show of a comparable increase of the wall flow. The flow causes a shortage of liquid in the distribution is almost uniform. The measured as well as the calcuprofiles up close a fast built wall

to the wall. The liquid in the centre of the column column height to equilibrate with the wall flow.

large

is because of the low spreading capacity of random packings.

All profiles show local irregularities.

Gas flow effect on liquid wall flow The wall flow of the liquid phase decreases at higher gas loads 2 for various types of random packings . For 25 mm metal Pall rings simulations liquid packing The from value The wall wall have been performed to predict the development of the flow with and without gas flow as a function of the Figure 7 the measuring results are presented ) and 2.54 ( needs ) m/s. of global packing has a model input In

height.

for a gas velocity of 0 ( simulation characteristics. the Spreading

and maldistribution data are obtained a zero gas velocity D equals 3.7

experimental

work. At

of 2.5 mm and at a gas velocity of 2.54 m/s D equilibrium of

mm. The maldistribution factor for natural flow is 0.81. wall flow factors of 2.1 and 1.4 are found by the measured data in Figure 7. The equilibrium extrapolation lated from :

flow factor for the case without gas flow can also be calcu-

gr=
For 25 mm hand

U + O^]-1
P Pall side rings of the

(9)

in a column with a diameter of 0.5 m the equation takes the value of 0.122.

right

Remembering that the wall zone thickness, S, is 12.7 mm leads to a Wf -value of 2.1.

48

Now the global packing characteristics are known the local cell parameters results
G

can be

determined.

Applying

equation

(3) and (7)

in

an S -value

of 0.659 and a cell height of 39.5 mm

t i

(u - 0 m/s) or that

26.7 mm (u = 2.54 m/s). From Figure 4 it follows

the splitting factor for the wall zone is: W - 0.146 (u = 0

m/s ) or W = 0.347 (u - 2.54 m/s).

Wf

Packing Depth
the packing height for 1" metal

(m)

Figure 7 The developement of the liquid wall flow as a function of pall rings with and
G

without

gas loading. Measurements ( J > , u -2.5 m/s ) and Result of one simulation (
) and

( O u =0 m/s )). average result (

-).

The to be In aspect solid

initial equal

liquid distribution for the simulation was chosen to that used for the measurements. The superficial

liquid velocity is 3.4 mm/s. Figure 7 two types of simulation results are presented. The of the model curves introduces a scatter in the Wf-factor. The dotted curves show the results for a single simulation. The random give the average value of the Wf-factor. The curves

are in agreement with measurements.

49

In

the

following

two

examples

the model will be applied to

predict the effect of tower internals:

Drip point density

A choice

practical of the

problem number

with the design of packed columns is the of drip points per square meter of the

initial there on a

distributor.

A high number of drip points is desired but

are constructional limits: it hard to obtain a flat profile large scale. Also fouling can destroy the quality of the

distribution. A low number of drip points however could wrsen the separation efficiency of the packing. The simulation model has been used to study the development of

the quality of the distribution as a function of the packing depth for eight different initial distributions. The number of drip

points per square meter has been varied between 40/m 2 and 1600/m2. The for spreading cofficint of the liquid is 3 mm and the Mf-value

natural flow was chosen to be 0.6. These are realistic values

for 25 mm packings. The wall effect has been neglected.

10

\ \

Mf

\h

w
\c\
T'

IV

\ ) \ \ \ \ \

\ \

0.0

0.5

1 . 0

Packing Depth
Figure 8 The tion

(m)

effect of the drip point density on the maldistribuas a function of the packing height. a=1600, b=800,

c=400, d=200, e=100, f=80, g=60 and h=40 drip points/m2

50

Figure 8 shows the behaviour of the maldistribution factor as a function the high more of the packing depth. The lower the drip point density depth is needed to reach natural flow. A very

packing

density

hardly improves the quality of the distribution. On

the other hand a poor density penetrates deeply into a packed bed.

Wall wiper

Wall is

wipers due

are said to be required when the tower efficiency to a large percentage of liquid flowing down the

reduced

column wall. Their principal function is to remove the liquid from the column wall and transport it to the interior of the bed. This

problem occurs most often in small diameter towers. In this example the effect of a wall wiper on the wall flow is The 0.5 column has a packing height of 6 m and a

investigated. diameter of

m. The initial liquid distribution has 100 drip

points per square meter. The wall wiper is located at three meters front the top wall of the bed\ The dimensions~cTf~the modeT~8"5"8 me tal26 wipper as manufactured by Norton Ltd . were used for the redistribution of the liquid. The wall

"Rosette" as an

indication

flow 6 cm

is spread over 16 regulary orientated points which are about from the wall. The same values were chosen for the liquid

spreading

cofficint, the "natural" flow maldistribution and the

equilibrium wall flow as in the previous example. Figure gives the 9 shows the results of the simulation. The solid line

wall at

flow factor as a function of the packing height.

Starting 1 m of

the top of the packing the Wf-factor develops within from zero to about 1.5. After the wall wiper has

packing

reduced kind of

the wall flow to zero at a packing depth of 3 m, the same development is calculated again. This means that the

effect of this wall wiper lasts for about 1 m of packing. It should the wall This From a be emphasized that a Wf-factor of one is ideal. ideal wall flow and

Therefore simulated effect. figure. only

absolute flow

difference

between

should is

be regarded as a measure for a wall represented by a dashed line in the

difference this small an line

it can be concluded that the wall wiper

gives

improvement in the total wall effect of the increased maldistribution factor for some

column. layers

Moreover, just below

the wall wiper, caused by the 16 points, also

diminishes the improvement. 51

Wf
1

Packing Depth
Figure 9 The wall flow (

(m)

) as a function of packing depth with

a wall wiper for a typical 25 mm packing. Column height = 6 m. Diameter - 0.5 m. The deviation from the ideal value is denoted by ( ).

Other cell dimensions The size tion simulations 25 mm. presented above were all based on a unit cell This size corresponds to the dimensions of the

of

experimental applied directly to

collectors. For large columns the number of simulaavoid'time and memory consuming simulations. However, the flow maldistributions are smaller with larger

cells per layer increases rapidly. A larger unit cell can be

the measured maldistrlbution factor on a scale of 25 mm cannot be used; unit cells. The maldistribution factor for a unit cell with the size of w,

Mf , can be calculated from: w

Mf

"

Mf

0.025* < ^

>*

<10)

where

Mf. n _ s

is the maldistribution factor as measured on an 25

mm scale. and w is an integer multiple of 0.025 m. w must always be 52

smaller than the column diameter. The Mf -value can be substituted w in equation (3) to find the S -value of the larger unit cell. A ing of over second problem to be solved is the dependency of the spreadcofficint the a flow in upon the cell width. As stated before a fraction each cell is spreaded in a horizontal direction in the order of the cell area ( w 2 ) . The total

surface

amount S

of sideward flow is proportional to the splitting factors,

and S . During this spreading the flow is also transported in a direction is over a distance of the cell height, h. Radial to the ratio between horizontal and

vertical spreading vertical

proportional

transportation.

If the constant C is replaced by C'xw2,

then C'= 0.25. Equation (6) can now be rewritten as:

D

r,L " - 2 5 * T x S L
constant more C

(11)

The give

can be substituted in equation (7) and (8) to formulae for the determination of the cell

general

height and S Attemps were A made to derive the new constant from theoretical value of 0.25 was thought to be equal to the

considerations. probability of

flow in one of the four horizontal directions. An

acceptable explanation has not yet been found. The the use of larger cells implicates a loss in the accuracy of on a small scale. However, the spreading

flow

description

behaviour

and maldistribution on the scale of the unit cell still

agree with practice.

Conclusions

Monte

Carlo

cell model based on simple principles has been

developed packing. spreading formed to

to simulate flow distributions in columns with a random Measured quantities such as the maldistribution factor, and wall flow at equilibrium are trans-

coefficients

parameters for a unit cell. The column to be simulated

is formed by a three dimensional network of cells. The agreement of flow between simulations and measurements of radial

spreading of wall

liquid, of velocity profiles and of the development as a function of packing height and gas velocity

demonstrates the capabilities of the model.

53

The of a

model initial are

can also be used to evaluate the drip point density distributor, some the redistribution caused by a wall

wiper, etc. There radial may limitations. The model cannot compensate for gas flow caused by horizontal pressure differences as they in the lower part of the packing. Also axial mixing is

occur

not taken into account.

Note The simulation is program suitable for IBM compatible personal

computers subject.

available

for people who are interested in this

Svmbols C d c d D h Mf Qtot Qwall r S u w W Wf x z constant used in equation (6) column diameter nominal packing diameter radial spreading cofficint height of a unit cell maldistribution factor total liquid flow wall flow radius splitting factor for the bulk zone velocity cell width splitting factor for the wall zone Wall flow factor fraction of the flow through a circle with radius r packing depth [ ] [m] [m2] [ml [m] [m] [m] [ ] [m3/s] [m3/s] [m] [ ] [m/s] [m] [ ] [ ]

subscripts:
G L w
00

gas phase liquid phase for cells with a width of w at equilibrium

54

References R.M.Stikkelman -this thesis chapter 3 -Chem. Eng. Res. Des. submitted for publication R.S.Tour, F.Lerman Trans. Am. Inst. Chem. Engrs. , 35 (1939) 719-42 R.S.Tour, F.Lerman

Trans. Am. I n s t . Chem. Engrs. , 40 (1944) 79-103 Z.Cihla, O.Schmidt

Coll. Czech. Chem. Comm. 22 (1957) 896-907 5 Z.Cihla, O.Schmidt Coll. Czech. Chem. Comm. 23 (1958) 569-578 6 V.Stanek and V.Kolar Distribution of liquid over a random packing I - X I Coll. Czech. Chem. Comm., 30 (1965) 1054-1059 X Coll. Czech. Chem. Comm.. 42 (1977) 1129-1140 7 E.Dutkai, E.Ruckenstein Chem. Eng. Sci., 23 (1968) 1365-1373 8 E.Dutkai, E.Ruckenstein Chem. Eng. Sci., 25 (1970) 483-488 9 K.E.Porter, M.C.Jones Trans. Instn. Chem. Engrs., 41 (1963) 240-47 10 J.J.Templeman, K.E.Porter Chem. Eng. Sci., 20 (1965) 1139-40 11 K.E.Porter, J.J.Templeman Trans. Instn. Chem. Engrs. 46 (1968) t86 12-P-. J-.Hofty z er Trans. Instn. CHem. Engrs. 42 (1964) tl09-17 13 D.J.Gunn Chem. Eng. Sci., 33 (1978) 1211-19 14 E.A.Brignole, G.Zacharonek, J.Mangosio Chem. Eng. Sci. , 28 (1973) 1225-29 15 P.J.Hoek Ph.D. Thesis, Technische Hogeschool Delft, 1983 16 P.J.Hoek, J.A.Wesselingh and F.J.Zuiderweg Chem. Eng. Res. Des., 64 (1986) 431-49 17 K.Onda, H.Takeuchi, Y.Maeda, N.Takeuchi Chem. Eng. Sci., 28 (1973) 1677-83 18 G.G.Bemer F.J.Zuiderweg Chem. Eng. Sci. 33 (1978) 1637-43 19 D.E.Nutter I. Chem. E Symposium Series No.104 (1987) A129-42 20 J.Prchlik, J.Soukop, V.Zapletal, V.Ruzicka Coll. Czech. Chem. Comm., 40 (1975) 845-55 21 G.J.Jameson Trans. Instn. Chem. Engrs., 45 (1967), T44

22 M.A.Albright
Hydrocarbon Processing, 9 (1984) 173 23 Q.H.Ali Ph.D. Thesis, University of Aston, 1984 24 Packed Tower internals Norton, Bulletin TA-80R, revised december 1976

55

CHAPTER V

Measurement and simulation of the influence of maldistribution on distillation in a column with a random packing

Introduction

Vfhen

a column with a random packing is designed some important

choices have to be made concerning the type of packing, the dimensions Insight to of the column, the liquid distributor, redistributors, etc. in the development of flow in a packed bed can contribute

an optimal design. Malperformance can be predicted or possibly

diminished. The effect of liquid flow patterns on the performance of packed columns has been studied in the literature mostly using an artifij;ially studies Kunesh . zones of defined by maldistribution an adjustable . Controlled maldistribution were performed by

using

distributor

Discontinuities or step changes in the flow from various the distributor have the most severe impact on ef

ficiency, be ing

while modest amounts of tilting and sagging are said to

tolerable. The separating efficiency of beds of a random pack as influenced by large scale liquid maldistribtuion has been by radial Zuiderweg in a zone-stage mass transfer model in-

described cluding relative column plied

spreading. The model can calculate the effects of concentrations, reflux ratio, packing size, height and redistribution. It has been apof the
Q

volatility, diameter, bed

to

simulate

results

controlled

maldistribution

studies by Fractionation Research Ine . The Delft study on maldistribution effects in packed columns at the One in 9 water/air second column, has been presented in a previous paper . The project deals with the effects of a severe initial liquid on the separation efficiency of a pilot distilla a

Unlversity of Technology is divided into two projects. concerning the liquid and gas flow patterns

project,

maldistribution tion plant.

57

Figure 1 The distillation unit: and condensor (3).

packed column (1), reboiler (2)

58

After results will Carlo already be

a of

short description of the pilot plant the experimental distillations with and without liquid maldistribution These The results will be simulated by a Monte part of this model has

presented. model.

cell

flow

simulation

been described

. By including simple mass transfer equa-

tions the model is capable of simulating concentration profiles. A practical of the example of the model is given in a study of the

effect

drip point density of a liquid distributor on the

overall separation efficiency.

The distillation unit

In scale mm

pilot

plant

distillation column the influence of large

initial liquid maldistribution has been investigated for 25

plastic hydrofilized Ralu rings (RALU) and the no.25 stainless

steel Intalox Metal Tower Packing (IMTP). The plant is situated at the Laboratory of Process Equipment at the Delft University of

Technology. It consists of the following major parts ( Figure 1 ) :

an

isolated of

column, made of stainless steel, with an internal 0.45 m. The height of the packing is 2.65 m. An

diameter

adjustable liquid distributor is situated at a distance of 2 cm above of the packing. a reboiler, where heating is supplied by steam with a maximum

pressure of 0.5 MPa. a condensor, where the vapour phase is condensed with water

from a cooling tower.

The at

distillations atmospheric in

were performed with a methanol/ethanol mixture

pressure and at total reflux. During each run the

pressure

the column was measured and temperatures ( top, bot-

tom, cooling water in, cooling water out ) were recorded. Also the cooling liquid water flow was measured. When the whole system was stable samples were taken at the bottom of the column and at the

reflux pipe. The meter a liquid samples have been analyzed by a refractive index

ABBE 60 at 20 "C. The maximuin error in the determination of fraction results is 0.01. Some samples have also been checked by fall within the error of the refractive index

mole The

GLC.

analysis. 59

The loading of the column ( the F-factor ) can be obtained from a heat The troughs. ideal balance liquid The over the condensor. Experiments were perforraed used evenly ( Figure 2 ) consists of eight distributed over 52 drip points feed is introduced by twice for several F-factors between 0.5 and 1.6 Pa ' . distributor liquid is

(330/m2 on the column crossectional area). This will be called the distribution. The maldistributed covering the left four of the eight troughs. Then only one half of the top of the packing is irrigated.

configuration

drip points in the O maldistributed feed ideal distributor

. 1

o cm

Figure 2 The

of

the

drip

points

of the liquid

distributor. Ideal (). Maldistributed feed ( O ) .

Determination of the HTU

OG

-value

The number of over-all gas-phase transfer units, Nn, is given

by:

OG

-i

t
(

dy yeq- y >
(i)

where: (2)

eq

1 + (a-1) x

60

The of a The

relative is almost

volatility, constant were

Q, can be obtained be applying the the whole composition range and total reflux so the overall

Van Laar

and Antoine equations. At a pressure of 10s Pa the value over all

equals 1.72. experiments under operating line is given by: y x liquid compositions (3) as measured at the bottom and the

Therefore top of

the packing height

can be used in equation (1) instead of the

vapour compositions. The of a transfer unit based on the over-all gas-phase , is calculated according to: resistance, HTU

The

relative

error in the determination of the HTU--value_is

less than 10 %.

~" Uu

Distillation results The Table packed The average results for at the two types of packing are summarized in ) and at the bottom ( x, ) of the

I for a packing height of 2.65 m. For several F-factors the the top ( x bed have been determined. Applying equation (4) results in effect
UG

concentrations

the height of an over-all gas-phase transfer unit. of the maldistributed feed is considerable: the HTU.-value is 2.7 (IMTP) or 1.6 (RALU) times higher than - value in the case of the ideal distributor. The is more sensitive to initial liquid maldistribution

the average HTU IMTP packing

than the RALU packing. Increasing the F-factor leads in general to lower values of the height of a transfer unit. Due to practical limitations, it was not possible to apply higher F-fact< F-factors than 1.6 Pa ' so all experiments are without loading effects.

61

01 m on r-l r-t 01
I

X> dl N i-t
i-l

i-I 4-1 O IJ

o H -P O

Ui

M-l 01

o ra o r-l
00 ai

01 o R

T) d

ra
P

ra o. o 4J
ai 43 4J (3
r-l

O O X '

u o o o n P O

o >!
43 O
-H

ra
Ol ra
PH

ra

ra
I-I

OvOVDinoOCfirHOO vomor~ooi-ir--CT> romrOCMCMrotMcM o o o o o o o o

n p i o i N c i v o i / i o O O O M S O H O O i n CAoooo%c^oor^r^ O O i - I O O O O O

oocrvcNini-i<foa\ O l O O i n N C l O M N o o o o o o o o

y w H r i m c g i n n

>

e p
T3 C

e ra 43
4-1
1 i-H

4J 01 r-l O.

ra

H T\
t-i
i-l

01 o

c
l-i 43 O

r-l

Tl (11
0)

m Ol 4-1 o

o o u UI 01 01 o r-l rH

ra
(3 O r-l 4-> i-i

C
43
P

P O 4-1 r-l O

43

CAvorHtnr^t-icNin ? ( n i o m r o \ o o o CNCV4CMC*JCMCMr-ICN

i n i - t c M t n c M r ^ o ^ ? l O i n M T l l O f i l M N O O O O O O O O

i n m o o - ^ - ^ c o c A N U N N H r i O O o o o o o o o o

t n p ^ O N i n m i n c M O OOVOVOtMCMONOO nc-lCMCMCMCsliHi-H O O O O O O O O

ra
O

ra u

o o o o o o o o

ra 01
u o ip v o a \ c o c s i c o o m o P CTiC^CT*CJ\CAOCACT* o \ o i e o o \ o i t N m M iir-ir^cOr-imm<r O O O O O O O O OCM^ti-HCMCTiCMr-f O < J i o i o i n n H M 0003000000000000 r--inooooinrorHoo m t n o o O i - i r H O r - * r - r ^ r ^ r - * r ^ r * i ^ O O O O O O O O

Ifl 43 P H

ra
3

a
E
p

C
1 < i > M-l w C p

4J
0]

a ra

00 w 1H o o

01 01

c ra 43
P 01 E o 43 H 01

c 01
H 00 01 in o

ra

e
33

^ co
e
in v> CSI 4-1 43 00
fl

>

o o o o o o o o

o o o o o o o o

in CM o

ra
M-l 0 P 43 on H 0) 43 Cl

<11 O

I-I 0 u

u ra

c
T>

3
43 r-l U P 01 H Tl 01 43 p 4-1 O

c
o H P i-l

mal distri buted feed

01

I-I

on c r-l
U

01 43

c 0

4->

o r-i u o 43 O.

X
0 p p o 43

on
H

s> 01 ra

H Q 01 d I-I

ra m
H

I-I

4<! O 04

* H

X.

ra o. os

ra

04

P < J

43

ra

mal distri buted feed

p oi H 01 < U

c ra

/"
TJ

ra
04

CTiOvOOOr-ltnCNCTl < r m o o o o c M < N i n m O O O O r - 4 r - l r - l r - l

N t n f n i o - J i o i s p i 4 > 0 0 H H ^ i n
O O O O I H I - I I - I I - I

O ^ O l l / l l O H H C M O O O O O r H l H r - l r H

M ^ l O O \ H O H l ^ o t o H o j m i n O O O O r H i - l i - l i H

e ra

c ra

Simulation of mass transfer

Monte

Carlo The

cell

model

has

been

used

to simulate mass

transfer. sions the model

column is thought to be built of cells with dimen-

in the order of a packing element. The flows of the gas and liquid through these boxes are calculated by a flow splitting capable of predicting wall spreading and mal-

flow, 9 distribution as determined experimentally . Small scale

maldistribution in the liquid phase is introduced

by a random splitting mechanism. A fraction S , of the liquid flow through a cell, leaves the cell randomly to one of the four neighbours of of the cell below. Maldistribution is caused by coalescense The height of the box is chosen to produce a proper

flows.

liquid spreading. Gas fraction over the spreading Sp of is descrlbed by a gas splitting factor S . A

the gas flow G through a cell is divided equally neighbours of the cell above. The rest (1-S )xG
Cr

four

flows straigth upwards. An annulus forms near the the wall with a thickness of half a packing

diameter

wall zone in which the splitting factors are

adjusted to correctly predict wall flows.

Measurement

Simulation

Figure 3 Measurement and simulation of the liquid velocity profile leaving the bottom of 2.16 m IMTP with the maldistributed f eed.

63

The the

flow

simulation model is illustrated for 2.16 m IMTP with feed. Figure 3 shows a measured as well as a

maldistributed

simulated velocity profile of the liquid leaving the bottom of the packing. The velocity measurements were performed in an air/water

column with a diameter of 0.5 m. Both over liquid profiles show .that the liquid is not equally distributed

the

column cross section. About 78 % of the total amount of remains in the half of the cross section which was This would be 50 % in the ideal case. From

still

originally this

irrigated.

it can be concluded that a low performance of a distillation

column with such a configuration is to be expected. The Monte Carlo model has been extended to include mass

transfer. For each cell the incoming flows are known from the flow simulation. When the mole fractions of these flows are also known, the mole fractions entering the cell, x. and y. , can be calcuy in in

lated applying mixing rules. The fractions which leave x out ,_ and 'out y , are found by J using b two r e l a t i o n s : The material balance over a cell
y -- y. = TT ( x. - x )

the c e l l ,

(5)

'out and

-'m

in

out'

An estimation of mass transfer in a cell W

in and
y

in

" HT- ^ e q - ^in'

UG

(6)

which

h is the height of a cell. For a mixture of methanol at atmospheric con conditions the y -value can be ap

ethanol

proximated by formula (2) using x Substracting

out equation (6) from (5) and substituting equation (2), which can

with a 1.72, results in a quadratic expression in x be solved analytically. Y

can be calculated using the material

balance. Many correlations are known for the HTU is fairly . In general the HTU

insensitive to the gas and liquid velocities. For this on a local scale OG

reason

it was decided to introduc a flxed HTU

for all cells. No the correlations such local transfer units are known. Therefore local HTU OG has been fitted to experiments with the ideal

64

distributor produce tal

i.e.

the

height

of

the transfer unit is chosen to

top and bottom concentrations corresponding to experimenThe resulting HTU is then applied to the case of

results.

the maldistributed feed.

The simulation procedure is as follows:

- The

initial distributions for the liquid as well as the gas are

chosen according to the experimental set up. - The correct parameters of the splitting model are entered and

the flow profiles are calculated - The composition of the liquid in the distributor is used to make a first guess of the concentration profiles of both phases. The of the liquid at the top is known from the

composition experiments.

- Better estimates for the concentrations are calculated using the simulated eqation bottonn - In the case of total reflux the amount of each component leaving the packing as liquid should equal the amount of that component the packing as gas. The average initial gas concentra flow profiles column and is the mass transfer according to from the top to the

(6). The

simulated

entering

tion can be calculated. - Even better estimates are calculated. The column is simulated

from the bottom to the top.

The mass tion value.

last balance the

three steps of this procedure are repeated until the at the top of column is correct. During the simula concentration can be slowly converges to a constant

bottom value

This

compared

to the experimental bottom

concentration.

65

H
o
ft

0.5

0.0

Packing Depth
Figure 4 Simulated RALU () gas with and without

(m)
) and an initial liquid

concentration profiles for IMTP ( The measured

maldistribution.

top and bottom fractions

are denoted by ($) for IMTP and ( ) for RALU.

r-

N 2
1 1
\

N \

^"V

'.
V

\ maldis

\
~* ~ ~ ^v * *

\
0

ideal
1

"--^*5rs-^.

- ^ ~

Packing Depth
Figure 5 Simulated with and HETP(z) values

(m)
) and RALU ( )

for IMTP (

without an initial liquid maldistribution as a

function of the packing depth, z. 66

Simulation results Mass packing tranfer simulations were performed for both types of

with and without covering the distributor for an F-factor

of about 1.5 Pa ' . Figure 4 shows the radially averaged simulated gas concentration profiles as a function of the packing depth. The measured top and bottom top for values the of concentrations are presented on the Yare forced to correspond to the axis' . The experimental centrations equals these It IMTP 0.19 values is concentrations

by the simulation procedure. The bottom con case of the ideal distributor are fitted by an over-all gas-phase transfer unit. This

the local height

m for the IMTP and 0.31 m for the RALU packing. With the separation with the maldistributed feed has now that the calculated bottom concentration for the the same as the measured value. For the RALU

been calculated. found is exactly

packing the calculated value is 5 % higher. Figure effectively and very liquid The depth 4 shows that in the top of the packing only one half is irrigated. little This part operates in a pinch condition, is achieved. Further downwards the. separation

distribution improves and the methanol concentration falls performance can be of the packing as a function of the packing by an HETP-value than by a con

more rapidly. better expressed

centration decrease. The HETP-value can be derived from the Fenske Equation: H * ln(a) _ _ ^

HETP

(7)

ln( [

! riH* ir^ > t *b

1 x

This HETP(z):

relation can also be applied on a small height of packing in a local height equivalent to a theoretical plate

resulting

HETP(z) =

h * ln(a) j z z+h

(8)

These

l o c a l HETP-values a r e given in Figure 5. The s i m u l a t i o n s

67

Figure 6 Longitudinal distributor m.

cross-sections and RALU

of simulated gas concentraIMTP (B) vith the IMTP ideal (D) with the mal-

tion profiles. RALU

(A) and (C) and

distributed feed. Column height - 2.65 m. Diameter 0.45

68

with the ideal distributor rapidly reach a stable HETP-value. Only in the first 0.2 m of the packing the initial liquid distrlbution a by malperformance the of the column. The large scale effect penetrates deeply into the

causes caused

maldistributed

feed

packing. The HETP-value slowly improves. The difference of the HETP development between the RALU and the IMTP higher packing with the maldistributed feed is remarkably. Due to a 9 liquid spreading cofficint ( Dr - 3.4 mm ) the RALU gives a better smoothing of the maldistribution than the The liquid spreading cofficint for IMTP packing

packing IMTP equals

packing. 1.9 mm.

Also the difference in gas spreading cofficint

contributes to this difference. IMTP: Dr = 2.4 mm, RALU: Dr = 4 . 0 mm. The concentration of the profiles of the gas over a longitudinal

cross-section

simulated column are presented in Figure 6

for both types of packing. For the case of the ideal distributor the profiles contain some irregularities flow. The caused by for small the scale maldistribution and wall feed show that the

profiles

maldistributed

concentration in a part of the gas hardly changes. This by-pass of gas lines RALU is more profound in the top of the packing: iso-concentration are almost is vertical. The higher spreading capacity of the illustrated by the more regular transition from

packing

vertical to horizontal iso-concentration lines.

Influence of the drip point densitv

The

number

of

drip

points

per square meter is an important

parameter for the design of a packed column. In the ideal case the initial liquid profile is flat, but then an distributor is needed

with a high drip point denslty. Such a distributor is difficult to manufacture. A low number of drip points could worsen the tion separa-

efficiency of the packing. A large packing depth is required

before the jets properly overlap. The mass with effect of the drip point density has been studied with the tranfer a height have simulation of model for random packings. For a column

l m and a diameter of 0.5 m the concentration calculated of for different distributor

profiles

been The

configurations. been varied

number

drip points per square meter has

between 220/m2 and 5/m2. The drip points were evenly 69

distributed cint equals

over 3

the column cross section. The spreading coffi mm for the liquid and 4 mm for the gas. The

maldistribution factor, Mf, is 0.6. These parameters are realistic for 25 mm packings. Wall flow has not been taken into account. For all simulations a constant local HTU -value of 0.3 m has been

used. The relative volatility a is also constant and equals 1.725. The packing calculated depth has concentration been profile as a function of the

transformed

into the local HETP-values

using equation (8). These values are given in Figure 7.

EW

Packing Depth
Figure 7 The depth development and of drip the HETP point

(m)
as a function of packing density: a = 200 dp/ra2;

b = 60 dp/m 2 ; c - 30 dp/m2; d = 15 dp/m2; e = 5 dp/m 2

For

the

simulations
2

with

drip

point density equal to or

higher than 15/m of

the local HETP reaches a stable value within 1 m

packing. The simulation with 5 drip points per square meter is developing by the The after liquid height from value 1 m. Here large scale maldistribution

still caused

distributor results in an inferior column of packing lost to stabilize the liquid 0.2 m for 200 dp/m2 to 0.4 m for 30

performance. distribution dp/m2. This

varies last

is low compared to the common number of

100/m2 in practical applications. 70

Figure Packings

holds lower

only

for

the

parameters

mentioned

above.

with

spreading capacities, like no.25 IMTP, will

need more packing depth to stabilize.

Discussion

The when

experiments with 50 % of the distributor covered show that maldistribution is large the column performance is primarily

controlled by flow parameters and not by mass transfer parameters. Although RALU, feed. the the potential HETP value of IMTP is lower than that of result is worse for the maldistributed

distillation

Kunesh

did comparable experiments for a column with 3.7 m

of 1 inch Pall rings and a diameter of 1.2 m. In the case in which liquid flow to one-half of the bed was shut off no recovery of the potential separation efficiency was found. The cross sections as presented in Figure 6 show that con-

centration These

profiles are

are not flat even for the ideal distributor. very simular to the temperature profiles

profiles

measured by Stichlmair

. Due to the irregularities one should not

evaluate the performance of a column by taking samples at a single point in the packing. The proposed model is capable of simulating all types of random packing examples. and The column configurations. This paper only gives some

mass transfer model can be easily replaced by more

elaborate models to simulate less ideal mixtures. The tions model are has however one serious disadvantage. The calculaconsuming. about The simulation of one distillation

time took

experiment

16 hours on an 8086 Personal Computer. No

extra effort was given to speed up the convergence so improvements are possible.

Conclusions

Experiments distribution tion model

have on

shown

that the effect of the initial liquid

distillation can be considerable. A flow simula

combined with simple mass transfer equations has been for two distillations with an extreme initial

verified

maldistribution. example

Calculated and experimental results agree. As an

the model has been used to predict the packing efficiency 71

of only

common 0.4 m

25 mm of

packings.

For a drip point density of 30 dp/m2

the top of the packing is lost compared with the

ideal initial distribution. The model can A be used for is all kinds of packed column

configurations.

disadvantage

the long time needed for the

simulation to converge.

Acknowledgements

This

work

was

made

possible

by

the

support

of

the

Koninklijke/Shell-laboratorium, Amsterdam and the Delft Laboratory for Process Equipment. We would also like to thank Norton Ltd. and Raschig GmbH for providing us with packings.

Svmbols

d Dr Dr h H HETP

packing diameter gas spreading factor liquid spreading factor height of a simulation cell height of packing height equivalent to one theoretical plate

[m] [m] [m] [m] [m]

[m]

HTU n

height of a transfer unit based on over-all gas-phase resistance [m] [mol/s] [-]

L Mf N

molar liquid flow maldistribution factor number of over-all gas-phase transfer units

[-] [-] [-] [mol/s] [-] [-] [m]

ST S V x y z

liquid split factor gas split factor molar gas flow liquid mole fraction gas mole fraction packing depth

relative volatility

[-]

72

subscripts

b eq t

bottom at equilibrium top

References 1 J.W.Mullin Ind. Chemist., 33 (1957) 408 2 R.E.Manning, M.R.Cannon Ind. Engng. Chem. 49 (1957) 347 3 G.A.Morris Proc. Int. Symp. Dist. London (1960) 146 4 M.Huber, R.Hiltbrunner Chem. Engng. Sci. 21 (1966) 819 5 H.C.Yuan, L.Spiegel, Proc. 2nd. World Congr. Chem. Engng. Montreal 4 (1981) 274 6 J.G.Kunesh, L.L.Lahm, T.Yanigi Ind. Eng. Chem. Res. 26 (1987) 1845-1850 7 F.J.Zuiderweg, P.J.Hoek and L.L.Lahm I. Chem. E. Symposium Series No.104 (1987) A217-231 8 J.G.Kunesh, L.L.Lahm, T.Yanigi IChem7-ET-Symposium-Series-No-.-104-(1987-)-A233^24_4 I 9 R.M.Stikkelman, J.de Graauw, J.A.Wesselingh - this thesis chapter 3 - chem. eng. res. des. submitted for publication 10 R.M.Stikkelman, J.de Graauw, R.F.de Ruiter, J.A.Wesselingh - this thesis chapter 4 - chem. end .res. des. submitted for publication 11 J.Stichlmair and A.Stemmer I. Chem. E. Symposium Series No.104 (1987) B213-224

73

CHAPTER VI

A study of gas and liquid distributions in structured packings

Tntroduction

Structured large flow liquid little decided liquid

packings

are being used in separation columns on a

scale. Even so their behaviour is not fully understood. The in such and is to using in known columns the gas appears phase the the to be fairly ideal, both in the

up to the loading point. However region. Therefore, it was

about

loading flow

determine a

profile in both the gas and the with a diameter of 0.5 m. The

water/air enables

column

measuring flow rates

equipment

the detection of the gas and liquid in about 300 measuring sections of

simultaneously

25x25 mm 2 in both the top and the bottom of the column. A detailed description Stikkelman . The liquid tured aim of the present work was to study in detail the gas and flows and their interaction for the varous types of struc packings listed in Table I. The results of the measurements of the equipment is given in the Ph.D. thesis of

will be discussed in terms of two parameters: the maldistribution factor Mf the wall flow factor Wf The maldistribution factor, which is a measure for small scale is equal to the relative Standard variation of

maldistribution, the flows

in the bulk of the packing. For a uniform distribution

it has a value of zero. The wall flow factor is defined as the ratio between the flow

rate in an annulus near the wall and the average flow rate. For an ideal distribution this factor equals one. Also attention of will be given to the occurrence of large scale liquid flows and spreading of both phases in

segregation the column.

the

75

Table I

The structured packings used.

Type of packing

Material

Code

Sulzer Mellapak 250Y Sulzer Mellapak 500Y Sulzer plastic BX

perforated metal sheet perforated metal sheet plastic gauze metal sheet gauze-like metal sheet slitted metal sheet

250Y 500Y BX Bl-250 BS-450 Rpak

Julius Montz BI-250 Julius Montz BS-450 Raschig Ralupak 250YC

Literature survey

The equipped

major part of the literature on maldistribution in columns with structured packing has been produced by the

coworkers of Sulzer Brothers Ltd. Dealing gauze theory bitrary with the fractionation of heavy water they designed a 2 3 4 5 Huber and Hiltbrunner results results and Flatt developed a

packing ' . to obtain

quantitative These

for columns with an arhave been confirmed

maldistribution.

experimentally by Meier and Huber artificially 4 influence of

in a column with BX packing and

generated maldistribution at total reflux. Huber and showed that in a column with a small diameter the

Hiltbrunner

maldistribution is compensated by lateral mixing in

the vapour phase. The total reflux experiments with BX packing are summarized maintained separation by in Meier the and Huber . An initial maldistribution is

top of the packing, causing a decrease in the

efficiency. If the initial liquid distribution is good

enough the packing will keep the liquid evenly distributed, except when the liquid does not wet the packing. No substantial influence o of the column diameter was found. Experiments by Zogg showd that the gas-side height partial in mass and reflux transfer column cofficint diameter. is independent of the

packing under

Low pressure distillation

resulted

using an artificial liquid maldistribution 9 a complex system of relationships. Yuan and Spiegel

76

indicated

that the influence of maldistribution on column perfor

mance is less at partial reflux than at total reflux. The corrugated metal sheet packing "Mellapak" was introduced in 1977 . The HETP seems to be almost independent of the column

diameter, the it by HETP

packing

height and reflux ratio. For the Mellapak 250Y

is fairly constant up to a F-factor of 2.8, above which . The lateral mixing of the gas was studied of carbon dioxide in the column axis

increases rapidly adding one of

percent

upstream

the packing. Lateral mixing of the gas is said to be 12 much better than in dumped packing In rect data general working the Sulzer coworkers concluded that, assuming cor conditions and no initial maldistribution, design

obtained from calculations or pilot tests can be transferred

to industrial scale with a large degree of certainty. Measurements liquid, The 250Y in of the flow distribution on a small scale for the 13 the absence of gas loading, have been made by Hoek of the distribution was found to be better for BX,

quality

and 500Y packings than for random packings. The natural flow assuming a reasonable initial distribution, was establithree elements. Liquid was spread rapidly in the 14

profile, shed

within

direction parallel to the sheet orientation. Gas-only studies were performed by Stikkelman and Wesselingh

The maldistribution of the gas was found to be negligible compared to that of the liquid. However, initial maldistribution of the gas phase was retained longer in structured packings than in random

packings. Interaction between gas and liquid has been the subject of

studies by Kouri and Sohlo concentric rings as

. For their investigations they used 5 sections in a column with a

collecting

diameter of 0.5 m. Gas distribution was found to be close to ideal for the BX packing, unless a poor initial liquid distribution was Liquid distribution was uniform at moderate gas loads,

employed.

but it deteriorated at gas velocities above 1.7 m/s. From the the literature it can be concluded that the influence of

gas flow near or in the loading region on maldistribution has

sofar received little attention.

77

Gas profiles
t

Measurements distribution well an the as order in factor

for the gas phase

showed

that the local flow The maldistribution

over a cross section is almost uniform at the top as the bottom of the packing.

, Mf, based on about 300 measuring areas of 25x25 mm2, is of magnitude smaller than the average value of 0.25 for phase. Values for the packings tested are given in

liquid

Table II. The relative gas flow rate near the wall, Wf, in the bottom of wall the The flow at the gas inlet is partially caused by the around the packing element, one can discuss the packing is about 1.25 times the average bulk flow rate. In the equipment reduced due to whether element. flowing packing. area of the measuring elements at the periphery. However, sleeves the wall flow is constant over the height of one packing two sleeves per element form obstacles for the gas through the annulus between the wall and the upwards

Table II Maldistribution and wall flow factors for the gas and the liquid
b

phase
b

at

the top ( Mf , Wf

) and in the bottom

( Mf, , Wf, ) of a 0.5 m diameter column with 4 elements of structured packing (BX 5 elements).

Code

Gas

Liquid

Mf b

Wf b

Mf
t

Wf
t

Mf b

u Gmax [m/s]

u Lmin [mm/s]

250Y 500Y BX Bl-250 BS-450 Rpak

0.016 0.020 0.014 0.013 0.019 0.023

1.25 1.33 1.35 1.18 1.24 1.30

0.011 0.011 0.015 0.006 0.011 0.018

1.3 78

0.24 0.21 0.22 0.23 0.44 0.71

2.6 2.1 2.4 2.6 2.2 >3.2

3 1.5 1.5 3 <0.8 5

Figure 1 The

gas

velocity on

near

the

wall

as a function of~the

location dinate a,

the circumference, denoted by a polar coor-

for Montz BI-250 packing.

Furthermore, variation example, is higher of for at

the orientation of the sheets plays a role in the

wall flow over the cross section of the column. For the BI-250 packing the gas flow through the annulus the open ends of the sheets perpendicular to the

column wall. This is illustrated in Figure 1.

79

Gas snreading

Gas spreading has to be determined by means of a tracer gas due to the fact of gas being the continuous phase. Quantitative investigations have been performed for one element of each of the

packings in Table I. A relative small amount of carbon dioxide was injected The at a point in the center of the bottom of the packing. profile leaving the sheet upright of the point

concentration

source

was analyzed channel by channel, thus providing a detailed

picture of the mixing pattern of the gas. Two adjacent show sheets, mirror having opposite orientations of their

channels,

image concentration profiles. The average

result for each type of packing is presented in Figure 2. Two flow to mechanisms of gas transport, both independent of the gas

rate, can be distinguished: lateral transport of the gas due the flow of through two while one channel, and mixing- of the gas between sheets. For 500Y the mixing effect

channels dominates,

adjacent

for the other packings lateral transport is the

most important mechanisra. Lateral deviation transport in one alone does not flatten a gas concentration However, it results in large scale

element.

mixing because successive elements are rotated 90 degrees.

Liquid profiles

The the from used

"natural" flow of the liquid, with a gas flow rate beneath point, is almost established after the third element

loading the had

top, as illustrated in Figure 3. The liquid distributor 760 the drip points/m2 and had a Mf .value of 1.01. This is number of drip points - although large - is smaller

because

than the number of measuring elements. The limits. down to "natural" flow maldistribution is constant within certain

No influence of the superficial liquid veiocity was found a critical veiocity, u. . . Beneath this value the disJ Lmin

tribution quality deteriorates. The "natural" flow maldistribution factors, together with the critical liquid veiocity, are presented in Table II.

80

X cd u o o cd

u CU o cd u

25

r
element, measured one sheet.

(cm)
channel by channel over the length of

Figure 2 The relative tracer concentration profile, resulting from a central point source injection up stream of one packing

1 . 0

Mf
0 . 5

ir

0.0

Number of Elements
Figure 3 The maldistribution of distributor 250Y factor and for the liquid phase as a of the packing for (superficial gas function liquid Sulzer the number of packing elements between the the bottom () and Montz Bl-250 (*)

velocity 1.8 m/s, superficial liquid velocity 3.4 mm/s). 81

Gas Velocity
Figure 4 The (), maldistribution of of Sulzer (o) Sulzer BS-450 factors 250Y BX of elements elements

(m/s)
the liquid phase for 4

( ) , 500Y ( O ) , Montz Bl-250 ( ) as a function of the gas

and Raschig RaluPak 250YC ( ) and 5

velocity at a superficial liquid velocity of 3.4 mm/s.

In

Figure

the Mf

values

of the liquid distributions are

plotted as a function of the superficial gas velocity. The packing height is about 0.8 m. For all packings except Rpak the quality of the distributions deteriorates rapidly above a critical gas velocity, u G m a x . It was sleeve through packings observed Rpak that and partial flooding started at the bottom BX. The liquid is prevented to flow of the elements at a gas velocity of about 1.7 m/s for all except the sleeves. This results in a decrease of the wall flow

factor, from 1.1 down to about 0.5. The effect of partial flooding deteriorates the overall distribution and is intensified at higher gas rates. The sleeves of Rpak are highly permeable to the liquid and may are not folded round the bottom of the packing element. This we have measured that the wall flow for four explain why

elements varies from 3 in the absence of flowing gas, down to 1 at a gas velocity of 3 m/s. 82

Above shown liquid for

the load

critical gas velocity liquid segregation occurs, as In Figure 5. Near the wall two areas with a high can be distinguished. About 70 percent of the total

250Y

flow passes through these areas. Perhaps to element. degrees changed. Only unexpectedly, the orientation of the areas is parallel (and not perpendicular to) the sheet orientation of the bottom Moreover, the areas with a high liquid flow rotate by 90 as the orientation a flow of successive of packing elements is However, rotation 90 degrees between each

element is impossible, because liquid cannot flow through a sheet. spreading parallel to the sheets is allowed. This "paradox" by assuming liquid migration over the sleeves can be explained

around an element.

Figure 5 Three

dimensional leaving

presentation the bottom of

of

liquid packing

velocity at a gas

profile

the

velocity of 2.0 m/s (upper part of the figure, Mf 0.26) and of 3.2 m/s (Mf = 1.74) for 4 elements of Sulzer 250Y. 83

This sleeves

assumption and by

has

been the

checked packing

by

removing the Standard

wrapping

with tape to prevent any

horizontal

migration along the wall. This resulted in an improved

liquid distribution, as illustrated in Figure 6.

Figure 6 Three profile

dimensional leaving

presentation the bottom of

of the

liquid packing

velocity at a gas

velocity of 3.1 m/s (Mf = 0.43) for 4 elements of wrapped Montz BI-250.

Liquid spreadine

Liquid single jet

spreading of

experiments

were

performed

by injecting a

liquid

in the centre of one element, so that the

spreading between the sheets could be studied. Two mechanisms of spreading, simular to those for gas spread

ing, are proposed to explain the observed phenomena. The the to first mechanism only translates liquid: a jet remains in

channel the

through which it is flowing, without liquid crossing sheet. This mechanism is thought to be the main

adjacent

cause of spreading in Rpak, 250Y and 500Y (Figure 7 ) . The second mechanism redistributes the liquid to some extent at each contact point of adjacent sheets. This mechanism may explain

the profiles measured for BX, BS-450 and Bl-250 (Figure 7 ) . Because successive elements are rotated by 90 degrees both

mechanisms lead to large scale mixing. - 84

Figure 7 Three profile liquid

dimensional after point one

presentation element

of

liquid

velocity

of packing resulting from a

source for Sulzer Mellapak 500Y (left) and

Montz BI-250 (right).

Discussion

low maldistribution of the gas agrees well with 14 15 previous studies ' . Gas spreading profiles comparable to the 12 results of Meier are found for 500Y, but for the other types of packing of the a different spreading mechanism can be involved. Because of mixing and translation inside the packing

The

observed

combination and

element

large scale mixing between the rotated elements, one

should be careful to use the diffusion model to express the mixing performance of the packing. The assumption flow of Hoek 13 that below the loading point the

"natural"

is not influenced by the gas was confirmed by our

experiments. The "natural" flow is rapidly established, provided a properly designed liquid distributor is used. Also an increase of was found when applying low liquid loadings. A 85

maldistribution

reduction point.

of wall flow by gas flow was observed below the loading

The results for the liquid spreading show the same behaviour as 13 the measurements of Hoek . The gas has a negligible effect on the spreading. mechanisms, For the various with types of packing two spreading

comparable

the gas phase, are suggested. Again

the definition of the radial spreading cofficint, as used in the diffusion packings. The origin of the large scale liquid segregation is related to model, is not appropriate for low height of structured

the nature of the sleeves between the packing and the column wall. The precise flow paths of both phases are as yet not known.

However, tion open

local

flooding on the sleeves, horizontal liquid migrathe annulus and an excess of gas wall flow at the

through

sides of the sheets are thought to be the main contributions

to the development of this large scale maldistribution. A Figure that similar 4 the with break point F-factor is observed when comparing . It seems probable

HETP-curves in

from literature is

increase

HETP-value

caused by the large scale

liquid segregation.

Conclusions

Gas compared

maldistribution to the liquid

can

be

ignored at all gas velocities as The flow through the

maldistribution.

annulus between packing and column wall is about 1.25 times higher than inside the an superficial gas flow. Gas spreading is caused by mixing element (between adjacent sheets) and by a combination

of translation and rotation between two elements. Up the the to the loading point no severe disturbances were found in

liquid. Only a reduction of the wall flow was observed. Above loading by point large of the the maldistribution increased rapidly, accomscale liquid segregation for some packings. The liquid is a result of translation and mixing

panied

spreading

between adjacent channels. Although not quit well understod, the sleeves around the

packing . elements play an important role in the formation of large scale the maldistributions sleeve performance above the loading point. Optimization of

can result in a higher loading limit for

structured packings. 86

Acknowledgements We research cial would like to thank Julius Montz GmbH, Raschig GmbH and

Gebrder Sulzer AG for supplying us with packing. Furthermore this project would not have been possible without the finansupport of the Koninklijke/Shell-Laboratorium, Amsterdam and

the zest for work of all students involved.

References 1 R.M.Stikkelman, This thesis chapter II 2 M.Huber, A.Sperandio Chem. Ing. Tech., 36 (1964) 221-227 3 A.Sperandio, M.Richard, M.Huber Chem. Ing. Tech., 37 (1965) 322-328 4 M.Huber, R.Hiltbrunner Chem. Eng. Sci., 21 (1966) 819-831 5 P.Flatt Chem. Ing. Tech., 38 (1966) 254-259 6 W.Meier, M.Huber Cnei7~IngTTcT7~3 9~( 19 6 7 )^7 9 7 ^ 8 0 2 7 W.Meier, M.Huber I . Chem. E. Symposium S e r i e s No.32 (1969) 4.31-37 8 M.Zogg Chem. Ing. Tech., 45 (1973) 67-74 9 H.C.Yuan, L.Spiegel Chem. Ing. Tech., 54 (1982) 774-775 10 W.Meier, W.D.Stcker, B.Weinstein Chem. Eng. Progr., 73 (1977) Vol.11 71-77 11 W.Meier, R.Hunkelar, W.D.Stcker Chem. Ing. Tech., 51 (1979) 119 12 W.Meier, R.Hunkelar, W.D.Stcker I. Chem. E. Symposium Series No.56 (1979) 3.3/1 13 P.J.Hoek Ph.D. Thesis, Technische Hogeschool Delft, 1983 14 R.M.Stikkelman, J.A.Wesselingh I. Chem. E. Symposium Series No.104 (1987) B155-164 15 R.J.Kouri, J.J.Sohlo I. Chem. E. Symposium Series No.104 (1987) B193-211 16 H.G.Groenhof, S.Stemerding Chem. Eng. J., 14 (1977) 193 17 L.Spiegel, W.Meier I. Chem. E. Symposium Series No.104 (1987) A203-215

APPENDIX A Characterization of the flow distributions in a cross section of a packed column

Introduction Designers often assume plug flow for both the gas and liquid in packed columns1"4. However non-ideal flow of both phases^has often been observed and described as wall flow and channeling Ideal industrial packed columns. Better account. made design procedures will have to take the non-ideality in This requires a description of the flow, preferably in . Nonflow is also thought to contribute to the malfunctioning of

terms of only a few parameters. In the past measurements have been in which the flow rates , *[j], in a cross section have been in a large number ofraeasuringelements . The maldetermined

"^Jj^^^^TwIs^delcHbd^by" araTlditFibltior"faceor^(Mf)~:

M f

- i *s ( ~i$; )
Mf is related to the Standard deviation of the flows in elements. It has a value of zero if all elements flow; its value increases rapidly as the flow beone the serious disadvantage; it does not convay any pattern of the distribution. As an example a the same has on

This

the measuring have

comes less regular. The Mf information tions

number of cross sections are shown in Figure 1. In these illustrathe black elements all have a flow twice the average, while elements have no flow. It should be obvious that the the white

flow distribution deteriorates going from pattern E to pattern A. Yet the Mf's of all these pattems are equal! A better description of the maldistribution is developed in

this paper. The proposed such as those in Figure 1.

method discriminates between patterns

89

Figure 1 Five

"checkerboard"

distributions having an equal value

of the maldistribution factor (Kf=l).

Figure 2 A

typical

measuring

grid.

The enlargeraent of the wall

section shows superimposed point sources (.) and excluded points (o) 90

Channel and overall distribution Consider section these each The is a cylindrical column with a diameter D. The cross

divided

into a large number of square measuring ele

ments with a side of length b (Figure 2). The flow $[j] in each of elements is assumed to be known. For calculational purposes element flow is considered to contain a number (here sixteen) of

equal point sources. Some elements fall partly outside the column. in the elements that fall partly outside the column is over those point sources in the element which lie distributed We with value

inside the column boundary. define a between a channel as the circular part of the cross section d the ( see Figure 3 ). This diameter may have any and the column diameter. Each channel is coordinates (x,y) of its centre and by its through a channel *(x,y,d) is the sum of the zero by flow diameter

characterized diameter. The

point sources inside the channel.

Figure 3 Possible

(x,y)-positions

for

channel of size d in a

column of diameter D.

91

For

each

channel The

size

d,

a channel maldistribution ra(d) is

determined. from which point the

centre of the channel is moved in discrete steps to point source. All positions are covered in does not intersect the column wall. At each

source channel

position

(there

are

n(d)

of them) the channel flow tf(x,y,d) is

calculated. A channel maldistribution is then defined as:

m(d)

= [ S( *(x,v d) - < * ( d ) <*(d)> * (n(d)-l) in

]0 .5

* _A_ A(d)

2)

The Standard chosen

left-most

contribution

formula

(2)

is the relative

deviation of the channel flows. The right hand factor is such that the m(d)'s of different channel sizes are all

based on the same area. In been the calculations in presented equal here the channel diameter has to the side b of the measuring

increased The channel

steps

elements. D-b. A

smallest channel has a diameter b, and the largest with a diameter 0 has no physical meaning, and a

channel with diameter D always yields m(D)=0. An overall channel factor is defined as:

b - - * S m(d) D diameter ratio in this factor

( 4)

The

makes the value relatively

insensitive to the choice of the size b of the measuring element. Two main concepts have been introduced in this paper:

the

channel

maldistribution

of

different

channel diameters

m(d) and the overall maldistribution M

As are

will the

be shown m(d) gives an impression of which channel sizes major contributors can this be used to the maldistribution. The overall to rank the quality of diffrents

maldistribution distributions:

ranking

generally agrees well with what one

would decide on the basis of visual observations.

92

Sample distributions and discussion

A number of more or less regular distributions will be analysed to see what this method of characterization yields. A relative diameter, d , expressed in units of one measuring

element length, is introduced.

A checkerboard distribution

This distribution is shown in Figure 4. The flow carrying areas have fewer wall. dimensions measuring of 5*5 measuring elements. Some areas contain

elements

because they are cut off by the column

10

20

Relative Channel Diameter

Figure 4 Channel maldistributions as a function of a relative channel diameter for a "checker board" distribution

The

channel

maldistributions

are shown for different channel

diameters. These are given in terms of the diameter of the measur ing from elements. As is to be expected, there is a major contribution channels of of of five or less element diameters. Channels with a about "black" nine and elements "white". contain approximately equal

diameter amounts

They hardly contribute to the 93

maldistribution.

Relatively

large

contributions

are

found for

channels of around 12 and 17 element diameters. In the previous case all elements have either twice the average flow with of or all the no flow. Figure 4 also shows the same distribution but

elements having either one and a half times or one half average flow. As to be expected the distribution of the

channel maldistributions is the same, but their values are lower.

A column with an irrigated outer ring

The aspects

distributions, of

shown

in

Figure

5, simulate some of the

wall flow. The outer ring has a width from one to ten elements. In the last case there is a uniform flow over of the column. To obtain an understanding of the be-

measuring the whole

haviour of this example first consider the case with an outer ring one element wide. There are then two channel sizes contributing

largely to the maldistribution: channels with a diameter of 18 elements (the inner circle) channels ring). with a diameter of 1 element (portions of the outer

10

15

20

Relative Channel Diameter

Figure 5 Channel radius maldistribution for rings with a different inner

94

As sizes

the move

width

of

the outer ring is increased the two channel each other and the overall maldistribution with a diameter larger than the

towards Note

decreases.

that

channels

inner circle do not contribute to the maldistribution.

A point source

Figure

gives

the overall maldistribution of a single point

source as a function of its position. First of all notice the very high values of the overall maldistribution. A single point is of

course

a very poor distribution. Note also that this distribution

is termed best if the point source is in the centre of the column.

10

Relative Displacement
Figure 6 Overall maldistributions for a point source as a function of its position

95

A series of checkerboard dlstributions

The overall maldistributions of the checkerboard distributions as presented in Figure 1 are:

Distribution

Overall Maldistribution M

A B C D E

3.027 0.847 0.490 0.268 0.127

What

one

percieves

to be a good distribution does indeed have a

low value of M.

Conclusions

Two

entities have been constructed to describe the ideality of

a distribution: the nel the channel maldistribution m(d), which depends on the size chosen and overall maldistribution, M, which is a summation of chan-

contributions from the different channel sizes. The of channel maldistribution function m(d) gives an impression

which channel sizes give the major contribution to the overall M. The latter parameter permits different flow

maldistribution

distributions to be ranked. Thls method is not restricted to flow distributions but can

also be applied to other distributions such as those of concentration or temperature. We are currently evaluatlng maldistributions for different

types of packing, different packing heights, initial distributions and operating conditions on a pilot plant scale in a column with a diameter of 0.5 m. It is hoped that such figures will contribute

to a more rational design of packed columns.

96

Svmbols A A(d) b D d i M m(d) n <$> $[i] <*(d) Area of column cross section Summation of all the areas of used channels size of measurlng element column diameter relative channel size relative distance overall maldistribution factor maldistribution factor for a channel with size d number of areas average flow through the measuring areas flow through the i-th measuring area Average flow through all channels with size d References 1 W.H.Walker, W.K.Lewis and W.H.McAdams Principles of Chemical Engineering (1927) McGraw-Hill Book Co., New York 2 T.H.Chilton and A.P.Colburn Ind. Eng. Chem., 27 (1935) 255 3 R.H.Perry and D.Green Perry's Chemical Engineers' Handbook (1985) 13-96/97 and references therein McGraw-Hill Book Co., Singapore 4 T.Baker, T.H.Chilton and H.C.Vernon Trans. AIChE., 31 (1935) 296 5 J.C.Charpentier. Ph.D. Thesis, University of Nancy, 1968 6 K.E.Porter, V.D.Barnett and J.J.Templeman Trans. I. Chem. E., 46 (1968) 69 7 H.G.Groenhof Chem. Eng. J., 14 (1977) 193 8 G.G.Bemer and F.J.Zuiderweg Chem. Eng. Sci., 33 (1978) 1637 9 P.J.Hoek Ph.D. Thesis, Technische Hogeschool Delft, 1983 10 J.Szekely and J.J.Poveromo AIChE. Journal, 21 (1975) 769 11 Q.H.Ali Ph.D. Thesis, University of Aston, 1984 12 C.Krebs Chem. Eng. Process., 19 (1985) 129-142 13 P.L.Speddlng and G.R.Llghtsey Chem. Eng. J., 32 (1986) 151-163 [-] 3 -1 [m s ] 3 -1 [m s ] 3 -1 [m s ] [m] [m] [ [? [ [ 2 [m ] 2 [m ]

97

14 F.J.Zuiderweg, P.J.Hoek and L.Lahm Jr. I. Chem. E. Symposium. Series No.104 (1987) A217 15 J.G.Kunesh, L.L.Lahu and T.Yonagi I. Chem. E. Symposium. Series No.104 (1987) A233 16 R.M.Stikkelman and J.A.Wesselingh I. Chem. E. Symposium. Series No.104 (1987) B155 17 R.J.Kuri and J.J.Sohlo I. Chem. E. Symposium. Series No.104 (1987) B193 18 J.Stichlmair and A.Stemmer I. Chem. E. Symposium. Series No.104 (1987) B213 19 F.J.Zuiderweg and P.J.Hoek I. Chem. E. Symposium. Series No.104 (1987) B247 20 P.J.Hoek, F.J.Zuiderweg, J.A.Wesselingh Chem. Eng. Res. Des., 64 (1986) 431-449 21 H.C.Groenhof Chem. Eng. J., 14 (1977) 193

98

APPENDIX B

Descriptlon of the computer programs used

General information

This pearing described Pascal

appendix

provides

a global reference to the options ap-

within the programs that were used for the simulations as in code, chapter are IV and V. Three programs, written in Turbo available: FLOWSIM.PAS, MASSSIM.PAS and

ANALYZE.PAS.

The most important parts of these programs are docu-

mented in the source code. The compiled can be versions, FL0WSIM.COM, MASSSIM.COM and

ANALYZE.COM,

used within the MSdos environment. However,

there are some limitations: - A IBM compatible computer with 8087 processor is needed -A-c:driye^is_assumed (preferably a virtual disk) The 21. number of cells on the column diameter should be lower than This limitation can be changed by adjusting the first lines

of the source code of all programs.

The flow simulation program

After column to

starting

the program information is gathered to fix the and packing characteristics. First you have of simulation by highlighting a option. The

configuration the type

choose

following message appears:

iquid flow simulation as flow simulation ass transfer preparation

C ontinue

Make your choice and press fc] to continue.

99

Enter all data needed for the simulation

Column diameter Number of element on radius Thickness of wall zone Mf on 0.025 m scale Liquid D -value W.-value Gas D -value r W-value Column height The constants can

[m]

[m]

[m]

[m]

[m]

be found in chapter III. Automatically the factors S , S and cell heigth h are

corresponding calculated. Next saved created the

splitting

initial

distributions can be loaded.

have New

to be entered. Earlier distributions can be

distributions with the

Edit option and eventually saved on disk. Just

select your option.

oad data dit data c:all_zero.liq ave data

C ontinue

In keys. integer tion

the editing mode you can move the active cell by the cursor The active cell points the place where you can enter an

value be

of the flow or velocity (press [x]). The distribualtered quickly by using the [Tjrace option; the

can

active value shadows the active cell, or by using the [XJdjust all option. After the editing sessions the program asks for the filenames

to store simulations results. Finally all values can be printed. The simulation Typical starts, showing all intermediate results on the

screen.

run times are in the order of 10 minutes. Top or

bottom distributions can be saved on disk. The calculated profiles can be used in MASSSIM.COM to simulated mass transfer or can be

analyzed with ANALYZE.COM.

100

The mass transfer simulation program

This

program uses the data produced by the flow simulation. It

starts with a questionnaire which is partially filled in. With the average the ratio flow can liquid and gas densities and the average molecular weigth profiles are transformed to moles. Eventually the L/V

be forced to unity by adjusting the molar gas flows to total reflux. Up to now the program only handles total After entering the volatility, the local

guarantee reflux HETP,

distillation. the

top concentration of the liquid and some filenames the profiles 10 are calculated. The simulation time is in The results can be visualized with

concentration the order of

hours.

ANALYZE.COM.

The evaluation program

The

ANALYZE.COM

program is a powerful tooi to study the simu-

lated profiles. The options are:

[cjrnf-factor

The

channel

maldistribution

of different channel

diameters and the overall maldistribution M conform the definition in Appendix A. [F]requencies [S]f-factor Histogram of the distribution. The relative variancy ( maldistribution factor ) of the distribution. [R]ings The a average velocity through concentric rings with constant thickness or area and the Wall flow

factor Wf. |s|egments []hree-D [vjalues The average velocity through segments. A three dimensional presentation. The simulated values of a cross section scaled by a factor [Y] .

The

programs

are available for people who are interested in this

subject.

101