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CN1318130C - 具有不对称卷曲形状的规整填料 - Google Patents

具有不对称卷曲形状的规整填料 Download PDF

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CN1318130C
CN1318130C CNB011325836A CN01132583A CN1318130C CN 1318130 C CN1318130 C CN 1318130C CN B011325836 A CNB011325836 A CN B011325836A CN 01132583 A CN01132583 A CN 01132583A CN 1318130 C CN1318130 C CN 1318130C
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CN1347753A (zh
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M·J·洛克
J·F·比林哈姆
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Praxair Technology Inc
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Abstract

一种波纹规整填料，可以组合成组件在精馏塔中使用，其具有卷曲形状，它相对于与规整填料板中心线相垂直且经过波纹峰或波纹谷顶点的线是不对称的，从所述一个波谷的顶点到相邻波峰的顶点沿中心线的轴向距离，不能被所述卷曲形状与介于所述波谷和波峰间中心线相交点所平分，使用该填料能够减少对提高传质无效的压力损失，从而降低塔的必要高度。

Description

具有不对称卷曲形状的规整填料
技术领域
本发明主要涉及一种规整填料，它特别用于精馏操作，尤其是低温精馏。
背景技术
交叉波纹状薄板金属的规整填料，自从大约15年前开始其广泛的工业应用以来，已经赢得了精馏塔内部构件业务的相当大的份额。这些规整填料因为在分离的每个理论板的压力降较小，所以通常认为它们比无规填料更为有效。它们在一些应用领域内还替代塔盘，这主要因为在给定塔直径的条件下，至少在液体流速为低等或中等时，它们的处理能力更大。
规整填料对其具有重要影响的一个工业是低温空气分离工业。在低温空气分离中使用规整填料的主要优点是：与低温空气分离塔中先前选用的塔内部构件-塔盘相比，全塔的压力降可降低一个数量级，这可降低所述塔的操作压力，它反过来会降低空气必须压缩到的压力，这样就可以降低工厂对能量的需求。
Meier(US4296050)所描述市售的规整填料中的大部分是交叉波纹状金属板，包括空隙和凹槽(一种表面结构的形式)。在这篇专利以后的近20年里，公开了大量有关规整填料基本结构的改进。但是，直到Billingham等人(US5632934)才对工业应用方面具有重大的影响。这篇专利认识到规整填料在层界面处开始发生液泛，而通过减小每堆块填料基底处的气体压力降就可以克服这一瓶颈。自从这篇专利公开以后，使用该专利中提出的概念制成的两种产品开始工业化。
人们希望获得这样的规整填料，它对于给定的压力降，可促进传质，这是通过使对于促进传质无效的压力损失最小化而实现的，这样就可以使用更小型的精馏塔。
因此，本发明的目的在于，提供一种在传统波纹状的规整填料基础上改进的波纹状的规整填料，它能使分离，例如低温精馏，在一个降低的塔高度下实施。
发明内容
上述的和其他的发明目的，对于所属领域技术人员来说，在阅读了本申请后可以清楚地了解，它们可由本发明获得，本发明一方面是：
一种具有卷曲形状的规整填料板，它相对于与规整填料板中心线相垂直且经过波纹峰或波纹谷顶点的线是不对称的，从所述一个波谷的顶点到相邻波峰的顶点沿中心线的距离，不能被所述卷曲形状与介于所述波谷和波峰间中心线相交点所平分。
本发明的另一方面是：
一种进行精馏的方法，其包括：
(A)将含有易挥发组分和比较不易挥发组分的混合物加入到含有多个组件的塔中，每个组件包括许多垂直取向的波纹规整填料板，每个填料板外形卷曲，它相对于与规整填料板中心线相垂直且经过波纹峰或波纹谷顶点的线是不对称的，从所述一个波谷的顶点到相邻波峰的顶点沿中心线的距离，不能被所述卷曲形状与介于所述波谷和波峰间中心线相交点所平分；
(B)在塔内进行精馏操作时，气体通过组件向上流动，液体通过组件向下流动，导致易挥发组分在向上流动的气体中浓集，比较不易挥发组分在向下流动的液体中浓集；和
(C)从塔的上部排出第一流体，所说的第一流体中易挥发组分的浓度比进料混合物的高，从塔的下部排出第二流体，所说的第二流体中比较不易挥发组分的浓度比进料混合物的高。
本文中所用的术语“塔”是指精馏或分馏塔或区，即一种接触塔或区，液相和气相在其中进行逆流接触以进行分离流体混合物，例如，气相和液相在填料元件上接触。有关蒸馏塔的更深入的论述可以参见R.H.Perry和C.H.Chilton主编、纽约McGraw-Hill图书公司出版的第五版的化学工程师手册(“the Chemical Engineers’Handbook”)第13章B.D.Smith等人编著的蒸馏(“Distillation”)第13-3页连续蒸馏过程(“The Continuous DistillationProcess”)。气液接触分离过程取决于组分的蒸汽压差。蒸汽压高(或易挥发或低沸点)的组分倾向于浓集在气相中，而蒸汽压低(或比较不易挥发或高沸点)的组分倾向于浓集在液相中。蒸馏是这样一种分离过程，通过加热液体混合物，使易挥发组分浓集在气相中，比较不易挥发组分浓集在液相中。部分冷凝是这样一种分离过程，通过冷却气体混合物，使易挥发组分浓集在气相中，比较不易挥发组分浓集在液相中。精馏，或连续蒸馏是这样一种分离过程，通过气相和液相逆流接触，将连续的部分汽化和冷凝组合起来。气相和液相的逆流接触可以是绝热的或非绝热的；包括相间积分的(逐板的)或微分的(连续的)接触。应用精馏原理来分离混合物的分离装置通常可互换地称为精馏塔、蒸馏塔或分馏塔。低温精馏是至少部分在温度低于150°K以下进行的精馏过程。
本文中所用的术语“填料”是指具有预定结构、尺寸和形状的实心体或空心体，用作为塔内构件，当两相逆流流动时，它为液体在液-气界面上传质提供表面积。
本文中所用的术语“规整填料”是指对角方向交叉的波纹状的填料，其中每个构件相互之间、构件与塔轴线之间都具有特定的取向。
本文中所用的术语塔的“上部”和“下部”分别是指在塔中点以上或以下的部分。
本文中所用的术语“波纹”是指填料板上有折叠，或有突起峰，或有凹谷。
本文中所用的术语“中心线”是指如果将波纹状的规整填料板展平，除去所有的波纹以后，所形成的中心线。
本文中所用的术语“顶点”是指波纹与填料板中心线的最大垂直距离。
附图说明
附图1、2和3是自与已知的规整填料的波纹方向垂直的平面获得的视图。
附图4是自与本发明一个实施方案的规整填料的波纹方向垂直的平面获得的视图。
附图5是自与本发明另一个实施方案的规整填料的波纹方向垂直的平面获得的视图。
附图6是一个使用本发明的方法进行操作的塔的简化示意图。
具体实施方式
下面将参照附图详细地描述本发明。
交叉波纹规整填料板形成堆块或组件。每个堆块包括多个竖直取向的、对角交叉波纹的填料板。这些填料板并排地堆放起来，相邻的填料板上波纹方向是反转的。这样做，填料板就可以形成多个能使上升气体流动的交叉通道。由填料组成的堆块作为层安放在塔内，填满塔的横截面。每层可以是单独一个堆块，或者，在大型塔内，多个堆块并排安放，填满塔的圆形横截面。这些填料层一层在另一层的上方堆积起来，达到所需的填料高度。相邻的层转角摆放，这样就可以使这些层的堆块里的板不平行。上述旋转角度介于45°到90°之间，更通常为90°。
在两种流体逆向流动中使用交叉波纹规整填料可以影响传热和传质。典型的流体物流是气体和液体，也可以是两个液相。板式换热器也采用相似的几何形状。在这些应用中，流体通常是单相的。现已证明，在单相流动中存在两种流动形式：一种是交叉流，其中气体物流以对应于净流动方向相反的朝向，沿着第一、第二板的波纹方向流动。另一种是曲折流，其中气体在向上流过填料时是从一个板横向到另一个板。
第一种流动形式在使用小角度(从垂直方向测量)波纹时占优势，第二种流动方式在使用大角度波纹时占优势。实际流动形式因采用居中间的波纹角度(30°＜θ＜60°)是两种流动形式的混合。所说的波纹角度是填料板的对角线与垂直方向所成的角度。
将表面网纹与卷曲形状加以区分，是非常重要的。表面网纹应用于所有市售的金属规整填料板。该网纹的作用在于促进液体分散，这样就可以使用填料中所有可用的面积来传质。有许多形式的表面网纹。最普通的形式是凹槽形，其中材料板一般包含正弦形的波纹。先经滚轧或压轧，在基材上形成了网纹，然后再制出构成填料基本结构的卷曲。既然该网纹是为了扩散液体，那么它的尺寸与液膜的厚度是在同一个数量级。这样，网纹的尺寸比卷曲形状的尺寸明显小得多。我们可以认为网纹是被叠加在实际的卷曲形状上。而后者确定了规整填料宏观几何形状以及气体流路。
图1、2和3是传统的规整填料的卷曲形式。这些是从与波纹方向垂直平面获得的视图。图1显示为三角形的卷曲状，图2显示为正弦曲线形，图3显示为锯齿形。有关波纹金属板的研究证明，在填料表面上，各局部的传质系数与传热系数一样会有变化。尤其是，在波峰的迎流面的传热、传质系数比背流面的大。波峰的迎流面是指波纹波峰面向横向气体流的一侧。而背流面是其反面，是波峰的被遮蔽侧。
当流体通过填料时产生压力降，这种压力降主要由两种因素造成：粘滞阻力和形状阻力。粘滞阻力是流体和填料或液膜表面之间产生的表面摩擦力。形状阻力是由流体冲撞到固体表面上形成环流旋涡所引起的。该形状阻力的大小在很大程度上取决于障碍物的形状和流动方向。由形状阻力引起的压力损失造成传热和传质系数增加的效应要小于由粘滞阻力引起的压力损失造成的效应。所以，在设计传热和传质设备时，通常认为形状阻力是无效的。
参见图3的规整填料，在相邻板之间横向流体的流动方向都用箭头表示。我们可以看到，两种流动经过的填料表面的形状不同。看上部分流路(图的上侧)，在迎流面的斜面陡，在背流面下降坡度较缓。若看下部分的横向流路，结果正好相反。我们认为这两部分流路对流体的阻力不同。这是因为形状阻力在很大程度上取决于障碍物的形状和流动的方向。实际上，在不考虑气体在板的那一边流动的前提下，通过填料前后的压力降大致相等。对流体的阻力不同将导致气体流动偏向填料一侧而非另一侧。在传热和传质的设备中，均匀流的任何偏离称作分布不均匀。流动分布不均匀对于整个的传质和传热的性能是有害的，这是本领域的公知常识。在实际中，穿过一个面上的形状阻力小，而另一个面上的形状阻力大。
图4是本发明的一个实施方案。这是从与波纹方向垂直的平面绘制的一个单一填料板的形状。该填料板的特点是：波纹的迎流面与波纹的背流面形状不同；而且当横向流体的流动方向给定时，填料板任何一侧的形状都(基本上)相同。
图1和图2的形状不能满足上述的两个标准，图3只能满足第一个标准，而不能满足第二个标准。
参照附图4的卷曲形状，可以看到，它相对于与填料板中心线相垂直且经过板的波峰或波谷顶点的线是不对称的，另外，从所述一个波谷的顶点到相邻波峰的顶点沿中心线的距离，不能被所述卷曲形状与介于所述波谷和波峰间中心线相交点所平分。优选地，如图4所示，填料板基本上关于填料的中心线对称，尽管它们相位相差180°。这样，横向流体在板的任何一侧都受到填料相同的阻力，流体就不会偏向填料的任何一侧流动。
这种填料的一个特点是，板两侧的横向流体遭遇的表面有相同形状，如果气体反向流动(例如将填料按照反方向安装)，就会有不同的结果。气体反向流动时的情况见图5。与图3的填料相比，我们可以看出，横向流体穿过两个侧面时遇到相同的形状，而且压力降也相同。此外，预计在流体运动的某一个方向上的形状阻力可以比传统填料上的形状阻力要小，因而产生优良的性能。取决于具体的应用、气体和液体的速率、气体和液体的物理参数、θ、和b/h等，任意取向都可能是优良的。实际上，我们可以从两个方向检测填料，(仅须将填料“倒过来”重新安装)，就可以找出哪个是适合该具体应用的方向。
参照附图5，对所述的形状进行数学定义，沿着填料中心线的下列位置定义为：
x1波谷顶点的位置
x2相邻波峰顶点的位置
x3下一个波谷顶点的位置
填料的基线长b，是相邻波谷之间的距离(或等于相邻波峰之间的距离)，这样，
b＝x3-x1                        (1)
尽管波纹的形状是不对称的，但是，两个波谷之间的波峰的轴向位置是两个波谷位置的平均值，
x2＝(x1+x3)/2                   (2)
我们现在再定义另外两个点：
x4在第一个波谷顶点和相邻波峰顶点之间，卷曲形状与填料中心线交叉点的位置
x5在波峰顶点和第二个波谷顶点之间，卷曲形状与填料中心线交叉点的位置
在本发明中，使用下列不等式
x4-x1≠x2-x4                    (3)
x5-x2≠x3-x5                    (4)
与现有技术相比，图1、图2中传统的卷曲形状能够满足方程1和2，却不满足关系式3和4(在这些形状的任何一侧上述表达式都是等式)。与图3中锯齿形状相比，能够满足方程1，却不能满足方程2、3、4。
已预期：按照本发明制造的填料会有较高的处理能力，且与相似的对称卷曲状填料相比，没有传质性能损失。根据系统的具体情况，处理能力提高幅度是2-15％。
该填料的特性可用比例数R描述并定义如下；
R＝(x4-x1)/(x2-x4)                      (5)
其中x1与前述的定义相同，是沿着中心线的距离，测定中正方向的选择应使R大于或等于1(R≥1)。
对于附图1、2、3所示的传统形状，R的值为1。按本发明制造的填料的R的范围是6＞R＞1.05，优选范围是3＞R＞1.2，估计最优值是约2。预期该R值作为填料表面密度和填料基线长度与卷曲高度之比b/h的函数而变化。波纹的角度期望在20-70°的范围内，更通常用的范围是30-55°。
与传统的卷曲形状的填料不同，按照本发明制造的填料的性能，对其与气体和液体流动的取向敏感。如前所述，根据具体的应用，任意取向都可能是优良的，我们可以从两个方向都检测填料(仅需将填料“倒过来”重新安装)，就可以找出哪个是能够适用于具体应用的方向。我们认为在多数应用中的最佳的取向如图4所示，其中流体接近波峰顶前先经过一个倾斜面，过峰顶后再沿着不太陡的斜面下降。
图6是一个低温空气分离装置的简化示意图，其中，进料空气被分离成一种或多种产品。进料空气包括，特别有，氧气、氮气和氩气。氮气比氩气和氧气更易挥发，而氩气比氧气易挥发。按照图6所示的方案，采用低温的空气分离装置，包括高压塔50、低压塔51和侧支氩塔52，可产出氮气、氧气和粗的氩气。在塔50、51、52中的一个或多个塔内垂直堆放本发明的填料组件。优选是在三个塔内都垂直堆放本发明的填料组件。
参照附图6，进料空气53进入塔50中，被低温精馏分离成富氮气体和富氧液体。富氮气体作为物流54进入到主冷凝器55，在主冷凝器中，通过与塔51底部液体的间接换热而被冷凝。生成的富氮液体56，一部分作为回流液57进入塔50中，另一部分作为回流液58进入到塔51中。富氧液体在物流59中进到氩冷凝器60，在其中至少部分蒸发，然后以物流61进入到塔51中。在塔51中，不同的进料被低温精馏分离，得到产品氮气作为物流62被回收，得到的产品氧气在物流63中被回收。侧线馏分64从塔51进入到塔52中，在此被分离成富氩流体和富氧流体。富氧流体在物流65中进入到塔51中，富氩流体在冷凝器60中经过全部或部分处理后，作为粗氩气在物流66中回收被回收。
虽然本发明参照一些优选的实施方案作了详细的说明，然而本领域的技术人员会认识到，在权利要求的实质和范围内本发明尚有一些其它的实施方案。

Claims (8)

1.一种规整填料组件，其包含许多垂直定向的、对角方向交叉的波纹状的填料板，所述板并排地堆放起来，从而使相邻的板上波纹方向反转，每个波纹规整填料板具有卷曲形状，其相对于与规整填料板中心线相垂直且经过波纹峰或波纹谷顶点的线是不对称的，且其中从所述一个波谷的顶点到相邻波峰的顶点沿中心线的距离，不能被所述卷曲形状与介于所述波谷和波峰间中心线相交点所平分。
2.权利要求1的具有波纹规整填料板的组件，其中所述的长段距离与所述的短段距离之比为1.2到3。
3.权利要求1的组件，其中每个波纹规整填料相对于填料板的中心线是对称的。
4.一种进行精馏的方法，其包括：
(A)将一种包含易挥发组分和比较不易挥发组分的进料混合物加入到含有多个组件的塔中，每个组件包括多个垂直定向的对角方向交叉的波纹规整填料板，所述板并排地堆放起来，从而使相邻的板上波纹方向反转，每个规整填料板具有卷曲形状，其相对于与规整填料板中心线相垂直且经过波纹峰或波纹谷顶点的线是不对称的，且其中从所述一个波谷的顶点到相邻波峰的顶点沿中心线的距离，不能被所述卷曲形状与介于所述波谷和波峰间中心线相交点所平分；
(B)在塔内进行精馏操作时，其中气体通过组件向上流动，且液体通过组件向下流动，导致所述的易挥发性的组分在向上流动的气体中浓集，所述的比较不易挥发组分在向下流动的液体中浓集；
(C)从塔的上部排出第一流体，所述的第一流体中易挥发组分的浓度比进料混合物的高，且从塔的下部排出第二流体，所述的第二流体中比较不易挥发组分的浓度比进料混合物的高。
5.权利要求4的方法，其中的精馏是低温精馏。
6.权利要求5的方法，其中的混合物包括氧气、氮气和氩气中的至少两种，其中氮气比氩气或氧气更易挥发，而氩气比氧气更易挥发。
7.权利要求4的方法，其中每个所述的规整填料板中所述的长段距离与所述的短段距离之比为1.2到3。
8.权利要求4的方法，其中所述的规整填料板相对于其各自的中心线是对称的。
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