Structured packing

RELATED APPLICATIONS

[0001] This application is a continuation-in-part of pending U.S. patent application Ser. No. 09/344,647, entitled “Structured Packing,” filed Jun. 25, 1999, and of pending U.S. patent application Ser. No. 09/593,051, entitled “Structured Packing,” filed Jun. 13, 2000, both of which are herein incorporated by reference in their entirety.

FIELD OF THE INVENTION

[0002] The present invention relates generally to structured packings, and more particularly, to structured packing elements and applications to method of cryogenic separation.

BACKGROUND OF THE INVENTION

[0003] Structured packings have found widespread use in a variety of distillations including those involved in the separation of air into its component parts. Distillations are conducted within distillation columns filled with mass transfer elements to bring ascending vapor phases into intimate contact with descending liquid phases of mixtures to be separated. As the ascending phase rises and contacts the descending liquid phase, it becomes evermore enriched in the more volatile components of the mixture to be separated. At the same time, the descending liquid phase becomes ever more concentrated in the less volatile components of the mixture to be separated. In such fashion, systems of distillation columns can be used to separate various mixture components. For instance, in case of air separation, nitrogen is separated from oxygen in a double distillation column unit. Argon is then separated from oxygen in an argon column that is attached to a lower pressure column of such a double distillation column unit.

[0004] Structured packings are widely used as mass transfer elements within distillation columns due to their low pressure drop characteristics. Structured packings generally include a series of structured packing elements that are made up of a number of corrugated sheets of material, in which the sheets are placed in a side by side relationship with the corrugations of adjacent sheets crisscrossing one another. In use, the liquid phase of the mixture to be separated is distributed to the top of the packing and spreads out throughout the packing as a descending film. The vapor phase of such a mixture rises through the corrugations contacting the liquid film as it descends.

[0005] There have been many attempts in the prior art to increase the efficiency of structured packings, that is, to decrease the height of packing equal to a theoretical plate (HETP). Obviously, the lower the height, the more efficient the packing. At the same time, a structured packing with a low HETP inherently has an increased pressure drop over less efficient packings. One such structured packing is disclosed in U.S. Pat. No. 4,597,916 in which the corrugated sheets are separated from one another by flat, perforated sheets that extend throughout the packing. It is believed that the flat perforated sheets of this prior packing increase efficiency by both providing additional interfacial area for vapor-liquid contact and by increasing turbulence in the vapor flow and therefore the degree of mixing between vapor and liquid phases. Other approaches to improving the performance of structured packings have also been disclosed in U.S. Pat. No. 5,632,934 and EP 858,366B1, which involve modifying the configurations of corrugations close to the interfaces between adjacent structured packing elements. It is believed that such modifications lead to improved performance by reducing the pressure drop between adjacent packing elements. However, there is still an ongoing need for alternative designs of structured packings for improving capacity without significant sacrifice in the separation efficiency, and vice versa.

SUMMARY OF THE INVENTION

[0006] The present invention provides generally a structured packing with improved capacity without significant loss of separation efficiency and a method of cryogenic separation using the structured packing. In one embodiment, a structured packing of the present invention contains packing elements comprising an array of vertically oriented corrugated sheets, and one or more planar members located between at least one pair of adjacent corrugated sheets. At least some of the corrugated sheets have corrugations in the middle portion with angles of inclination from horizontal that are smaller than angles of inclination in at least one of the top and bottom portions of the corrugated sheets. The one or more planar members and the corrugated sheets are positioned such that at least one outermost horizontal edge of each planar member is proximal to a horizontal edge of the adjacent corrugated sheets. Another aspect of the invention provides a method of cryogenic separation using such a structured packing.

[0007] Other embodiments relate to structured packing elements comprising corrugated sheets that have differences in configurations between a middle portion and at least a top or a bottom portion of the corrugated sheet, and one or more planar members positioned between at least one pair of adjacent corrugated sheets. Corrugations in the middle portion of each corrugated sheet are characterized by a corrugation height and a corrugation width. The planar members are positioned such that an outermost horizontal edge of each planar member is proximal to a horizontal edge of the adjacent corrugated sheets, and each planar member has a length that is equal to at least two times the corrugation width of adjacent corrugated sheets.

[0008] One specific embodiment relates to a structured packing element with planar members used in conjunction with corrugated sheets having corrugations whose angles of inclination at the middle portion of the corrugated sheet are less than 90 degrees, while those at the top and bottom portions increase progressively to about 90 degrees. Another specific embodiment relates to a structured packing element with planar members used in conjunction with corrugated sheets having rectilinear corrugations at the middle portions with angles of inclination less than 90° (typically from about 30° to about 60°), while those at the bottom portions have angles of inclination about 90°. In both embodiments, the two planar members located between each pair of adjacent corrugated sheets both have a length that is equal to at least two times the corrugation width of an adjacent corrugated sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] While the specification concludes with claims distinctly pointing out the subject matter that the applicants regard as their invention, it is believed the invention would be better understood when taken in connection with the accompanying drawings in which:

[0010]FIG. 1 is a schematic view of an air separation plant utilizing a structured packing comprising structured packing elements in accordance with the present invention;

[0011]FIG. 2 is a fragmentary view of a structured packing element in accordance with one embodiment of the present invention for use in the air separation plant illustrated in FIG. 1;

[0012]FIG. 3 is a fragmentary, side elevational view of the structured packing element shown in FIG. 2.;

[0013]FIG. 4<i>a </i>is a partial exploded view of an alternative embodiment of a structured packing element incorporating one planar member in accordance with the present invention;

[0014]FIG. 4<i>b </i>is a side elevational view of the embodiment of FIG. 4<i>a; </i>

[0015]FIG. 5 is a partial perspective view of an alternative embodiment of a structured packing element incorporating a single planar member between corrugated sheets;

[0016]FIG. 6 is a schematic view of an alternative embodiment of a planar member for use in a structured packing element according to the present invention;

[0017]FIG. 7<i>a </i>is a partial exploded view of a corrugation sheet with varying corrugation angles that can be used with planar members for practicing embodiments of the invention;

[0018]FIG. 7<i>b </i>is a side elevational view of the embodiment of FIG. 7<i>a; </i>

[0019]FIG. 8 is a schematic illustration of a corrugated sheet with different corrugation angles that can be used with planar members according to embodiments of the invention;

[0020]FIG. 9 is a schematic illustration of a side view of one embodiment incorporating two planar members between corrugated sheets with reduced corrugation heights;

[0021]FIG. 10<i>a </i>is a schematic front view of another corrugated sheet with a modified bottom portion that can be used with planar members according to embodiments of the invention; and

[0022]FIG. 10<i>b </i>is a side view of an embodiment comprising a planar member and corrugated sheets of FIG. 10<i>a. </i>

DETAILED DESCRIPTION

[0023] The present invention relates to an improved structured packing designed for increased capacity by reducing turbulent vapor flows. Such a structured packing can be used in a more efficient, cost effective manner in cryogenic separations because the improvement in capacity can be achieved without significant decrease in separation efficiency. Although various aspects of the structured packing will be illustrated as they pertain to air separation, the improved structured packing is generally applicable to a variety of other distillation applications.

[0024]FIG. 1 is a schematic illustration of an air separation plant <b>1</b>. Air separation plant <b>1</b> has a double distillation column unit <b>10</b> and an argon column <b>12</b>. Although not illustrated, but as would be known by those skilled in the art, air separation plant <b>1</b> would additionally have a main heat exchanger to cool the air to a rectification temperature against warming product streams to ambient temperatures. Additionally, a main air compressor and a pre-purification unit would also be provided to compress the air and then to purify the compressed air of impurities such as carbon dioxide and moisture.

[0025] Air as a feed stream <b>14</b> enters a higher pressure column <b>16</b> of double distillation column unit <b>10</b> where it is rectified to produce a nitrogen rich tower overhead and a crude liquid oxygen column bottoms. Stream <b>18</b> of the crude liquid oxygen column bottoms is subcooled within a subcooling unit <b>20</b> and then expanded across an expansion valve <b>22</b>. The expansion reduces the temperature of stream <b>18</b> so that it can serve as coolant for a head condenser <b>24</b> used to form reflux for an argon column <b>12</b>. The crude liquid oxygen obtained within stream <b>18</b> is vaporized within head condenser <b>24</b> and then fed into a lower pressure column <b>26</b> (of double distillation column unit <b>10</b>) for further refinement. The further refinement produces an oxygen-enriched column bottoms and a nitrogen vapor tower overhead within the lower pressure column <b>26</b>.

[0026] Reflux for both the higher and lower pressure columns <b>16</b> and <b>26</b> is provided by condensing the nitrogen-rich tower overhead within a condenser reboiler <b>30</b> to produce higher and lower pressure column reflux streams <b>32</b> and <b>34</b>. Lower pressure reflux stream <b>34</b> is subcooled within subcooling unit <b>20</b> and reduced in pressure by expansion valve <b>36</b> prior to its introduction into lower pressure column <b>26</b>. The nitrogen vapor tower overhead is removed as a nitrogen stream <b>38</b> which serves in subcooling unit <b>22</b> to subcool stream <b>18</b> and lower pressure column reflux stream <b>34</b>. An oxygen product stream <b>40</b> may be removed as a liquid from a bottom region of lower pressure column <b>26</b>. Both the nitrogen stream <b>38</b> and the oxygen product stream <b>40</b> may be introduced into the main heat exchanger for cooling the incoming air.

[0027] At an intermediate location of lower pressure column <b>26</b>, an argon rich vapor stream <b>42</b> maybe removed and introduced into argon column <b>12</b>. An argon rich tower overhead is produced within argon column <b>12</b>. An oxygen rich column bottoms is also produced which is returned as a liquid stream <b>44</b> back to lower pressure column <b>26</b>. An argon product stream <b>46</b> may be removed from part of the condensate of head condenser <b>24</b>.

[0028] In order to effectuate the distillation, ascending vapor phases and descending liquid phases must be brought into contact with one another by mass transfer elements. For instance, higher pressure column <b>16</b> is provided with transfer elements <b>48</b> which may be trays or structured packings. As vapor rises within mass transfer elements <b>48</b>, it becomes ever more rich in nitrogen until it reaches the top of higher pressure column <b>16</b>. There, the vapor is condensed and in part returned as higher pressure column reflux stream <b>32</b> to higher pressure column <b>16</b>. The nitrogen rich tower overhead, as a liquid, descends within higher pressure column <b>16</b> and becomes ever more richer in oxygen, through contact with the ascending vapor, to produce the crude liquid oxygen column bottoms.

[0029] Vapor rising within lower pressure column <b>26</b> passes through beds <b>50</b>, <b>52</b>, <b>56</b> and <b>58</b> which are formed of structured packing. The ascending vapor phase, initiated by boiling the oxygen rich liquid, rises through the column and becomes ever more rich in nitrogen to form the nitrogen vapor tower overhead. The descending liquid phase is initiated by the reflux of higher pressure column stream <b>34</b>. This liquid becomes ever more rich in oxygen as it descends.

[0030] Argon column <b>12</b> is provided with mass transfer elements <b>60</b> which again, are a structured packing. The vapor phase initiated by introduction of argon rich vapor stream <b>42</b> becomes ever more rich in argon. The reflux introduced into the top of argon column <b>12</b> becomes ever more rich in oxygen as it descends.

[0031] FIGS. <b>2</b>-<b>3</b> illustrate two fragmentary views—a perspective view and a side elevational view, of a structured packing element <b>2</b> in accordance with one embodiment of the present invention. The structured packing element <b>2</b> comprises a plurality of corrugated sheets <b>62</b> and <b>64</b> arranged in a face to face relationship with each other, which may also be referred to as an array of corrugated sheets, and two planar members <b>70</b> and <b>72</b> disposed between and in contact with adjacent corrugated sheets <b>62</b> and <b>64</b>. As used herein, the planes of the corrugated sheets <b>62</b> and <b>64</b> define a vertical orientation, which corresponds to one as viewed when the structured packing element <b>2</b> is in use within a distillation column. While the structured packing element <b>2</b> shown in FIGS. <b>2</b>-<b>3</b> is fabricated from rectangular corrugated sheets, other shapes can be used as evident to one skilled in the art. The repetition of corrugated sheets <b>62</b> and <b>64</b> and planar members <b>70</b> and <b>72</b> produce a structured packing element within a bed of packing. In general, planar members <b>70</b> and <b>72</b> may be held in place within the structured packing element <b>2</b> by a variety of means such as welding, fastening with the aid of pins or clips, or through frictional forces between the planar members <b>70</b> and <b>72</b> and the adjacent corrugated sheets <b>62</b> and <b>64</b> which occur when the packing element <b>2</b> is compressed either by pins or a metal band around the perimeter of the packing element <b>2</b>. Each of the corrugated sheets <b>62</b> and <b>64</b> contains a plurality of corrugations, some of which are shown as corrugations <b>66</b> and <b>68</b>, respectively.

[0032] In general, corrugations within one corrugated sheets of the structured packing element <b>2</b> have similar cross-sectional shapes, dimensions and angular orientations. Referring to FIG. 3, corrugations <b>68</b> may be characterized by a corrugation height h, representing the distance between a peak and a trough of corrugations <b>68</b>, as measured perpendicular to a vertical plane of the corrugated sheet. In addition, each corrugation is characterized by a corrugation width (CW), defined as the distance between two successive peaks or two successive troughs of the corrugation, as measured perpendicular to the longitudinal axis of the corrugation. Furthermore, corrugations <b>66</b> and <b>68</b> have longitudinal axes inclined at an angle with respect to a horizontal axis HH′, defining an angle of inclination or a slope θ, as shown in FIG. 2. This angle of inclination θ, may for instance be about 60° or 45°, or even smaller in other appropriate applications. In forming the structured packing element <b>2</b>, corrugated sheets <b>62</b> and <b>64</b> are positioned so that corrugations <b>66</b> and <b>68</b> criss-cross one another.

[0033] As shown in FIGS. <b>2</b>-<b>3</b>, planar members <b>70</b> and <b>72</b> alternate with and are positioned between corrugated sheets <b>62</b> and <b>64</b>. In one embodiment, each of the planar members <b>70</b> and <b>72</b> has a width “W” (alternatively, a horizontal extent) equal to the widths of corrugated sheets <b>62</b> and <b>64</b> and a length “1” (alternatively, a vertical extent) less than those of corrugated sheets <b>62</b> and <b>64</b>. As used herein, the length dimension is measured parallel to a longitudinal axis of the distillation column in which the structured packing element is used, i.e., along a vertical direction.

[0034] While at least one planar member must be present, this embodiment illustrates the use of two planar members in an upper and lower strip configuration as viewed when the structured packing element <b>2</b> is in use—i.e., with the planes of the corrugated sheets <b>62</b> and <b>64</b> defining a substantially vertical orientation. In a preferred embodiment, the planar members <b>70</b> and <b>72</b> have the same dimensions as each other. Furthermore, planar members <b>70</b> and <b>72</b> are preferably arranged symmetrically in the vertical direction, e.g., about equidistant from a horizontal plane containing central points of the corrugated sheets <b>62</b> and <b>64</b>.

[0035] The side view in FIG. 3 shows that lowermost horizontal edges <b>71</b> of the lower planar members <b>72</b> are generally aligned to be proximal to the lower horizontal edges <b>74</b> of corrugated sheets <b>62</b> and <b>64</b>, while the uppermost horizontal edges <b>73</b> of the upper planar members <b>70</b> are generally aligned to be proximal to the upper horizontal edges <b>75</b> of corrugated sheets <b>62</b> and <b>64</b>. It is understood, however, that such alignment includes situations where the horizontal edges of adjacent planar members and corrugated sheets are flush with each other, as well as those in which there might be some misalignment, e.g., in the nature of about 5 mm. As such, the lowermost and uppermost horizontal edges (alternatively referred to as outermost horizontal edges) of the planar members in any embodiment are situated at least near or proximal to those of corrugated sheets <b>62</b> and <b>64</b>, and the words “proximal to” includes an alignment in which the horizontal edges of the planar members and the corrugated sheets are either flush with or near each other.

[0036] Generally, the widths of the planar members <b>70</b> and <b>72</b> will be substantially the same as the corrugated sheets <b>66</b> and <b>68</b>. However, depending on the specific applications, it is also possible that planar members may have widths that are different from those of the corrugated sheets. Furthermore, the lengths of the planar members <b>70</b> and <b>72</b> are preferably less than about one third, more preferably less than about one fifth, of those of the corrugated sheets. According to embodiments of the invention, planar members <b>70</b> and <b>72</b> have a length ranging from about 2 to about 8 times the corrugation width CW of adjacent corrugated sheets. The corrugation width may generally range from about 5 mm to about 15 mm. Preferably, the planar members <b>70</b> and <b>72</b> have lengths that are about 5 times the corrugation width.

[0037] As shown in FIG. 2, corrugated sheets <b>62</b> and <b>64</b> and planar members <b>70</b> and <b>72</b> are provided with perforations <b>76</b>. However, depending on the lengths of the planar members <b>70</b> and <b>72</b>, perforations <b>76</b> may or may not be present. For example, when the lengths of planar members <b>70</b> and <b>72</b> are less than about one-third the lengths of adjacent corrugates sheets <b>62</b> and <b>64</b>, perforations <b>76</b> are normally not necessary. These perforations are employed to prevent or minimize transverse vapor and liquid flows while allowing pressure equalization across planar members <b>70</b> and <b>72</b> and corrugated sheets. That is, perforations <b>76</b> have diameters that are small enough to minimize bulk fluid flows in the horizontal direction across the planar members, but are sufficiently large to allow a small amount of vapor flow necessary to achieve pressure equalization across planar members and corrugated sheets. For example, in typical air separation applications, perforations <b>76</b> may have diameters ranging from about 1 mm to about 5 mm.

[0038] According to embodiments of the invention, perforations within each planar member or within each corrugated sheet are designed to have the same dimensions. Although the perforations are usually arranged in some regular or periodic manner, such an arrangement is not absolutely necessary. In one embodiment, perforations in the corrugated sheets <b>62</b> and <b>64</b> have the same dimensions as those provided in planar members <b>70</b> and <b>72</b>. However, the use of differently sized perforations in the upper planar member <b>70</b> and the lower planar member <b>72</b> is not precluded. Perforations in the planar members may also have dimensions different from those provided in the corrugated sheets <b>62</b> and <b>64</b>.

[0039] In addition, perforations <b>76</b> provided in planar members <b>70</b> and <b>72</b> or in corrugated sheets <b>62</b> and <b>64</b> are designed in the present invention to minimize turbulent vapor flows. For example, turbulence can be minimized by limiting the size of the perforations and by providing perforations with relatively smooth edges. As such, protrusions above the plane of the planar members or corrugated sheets beyond that of residual burr from the manufacture process should be avoided. As previously mentioned, the perforations are also designed to allow pressure equalization across the planar members or corrugated sheets while minimizing or preventing bulk fluid flows in a transverse direction. Thus, the present invention allows the use of single-sized perforations to accomplish different desired flow characteristics within a structured packing element. The feasibility of using single-sized perforations for all planar members and corrugated sheets provide a benefit in ease of fabrication and reduced cost. It is noted that the use of circular perforations in the figures is meant for illustrative purposes, and that perforations of different shapes, e.g., rectangular, square or triangular, may also be used for practicing embodiments of the invention.

[0040] Although two planar members <b>72</b> and <b>70</b> are illustrated in FIG. 2, the present invention further encompasses embodiments in which either upper planar members <b>70</b> or lower planar members <b>72</b> are omitted. FIGS. 4<i>a</i>-<i>b </i>show respectively a partial exploded view and a side elevational view of such a structured packing element <b>4</b> in which the planar members <b>472</b> are positioned so that the lowermost horizontal edges thereof, i.e., horizontal edges <b>471</b>, are aligned proximal to the lower horizontal edges <b>74</b> of adjacent corrugated sheets <b>62</b> and <b>64</b>. Although this embodiment shows planar members <b>472</b> as not having any perforations, the use of planar members having perforations is also acceptable. The planar members <b>472</b> generally have a length (<b>1</b>) less than those of adjacent corrugated sheets <b>62</b> and <b>64</b>. Preferably, the length of the planar members is less than about one third, and more preferably less than about one fifth, of those of adjacent corrugated sheets <b>62</b> and <b>64</b>. In some applications, the use of planar members in the upper configuration (not shown)—i.e., having an uppermost horizontal edge proximal to the upper horizontal edges <b>73</b> of corrugated sheets <b>62</b> and <b>64</b>, may also be desirable.

[0041]FIG. 5 is a schematic illustration of yet another embodiment of the invention, showing a partial perspective view of a structured packing element <b>5</b>. Specifically, the structured packing element <b>5</b> is of the type having repeating pairs of corrugated sheets <b>77</b> and <b>78</b> separated by or alternating with a planar member <b>80</b>, which has uppermost and lowermost edges <b>82</b> and <b>84</b> that are proximal to the uppermost and lowermost edges of corrugated sheets <b>77</b> and <b>78</b>. The planar member <b>80</b> have lengths and widths substantially equal to those of corrugated sheets <b>77</b> and <b>78</b>. Additionally, corrugated sheets <b>77</b> and <b>78</b> and planar members <b>80</b> are provided with perforations <b>86</b>, <b>88</b> and <b>90</b>. In this embodiment, perforations <b>86</b>, <b>88</b> and <b>90</b> must be present. As previously discussed, these perforations <b>86</b>, <b>88</b> and <b>90</b> are sized to prevent or minimize undesirable transverse liquid and vapor flows or bulk fluid flows across the structured packing element <b>5</b>, while permitting pressure equalization. In such manner, smooth rather than turbulent vapor flows are promoted to produce the advantageous operation described above. In case of air separation, each of the perforations <b>86</b>, <b>88</b> and <b>90</b> can be designed to have a diameter in a range of between about 5% and about 40% of a channel width or corrugation width “CW” as shown in FIG. 2. (The channel width is the distance between the corrugations from trough to trough or from peak to peak, measured perpendicularly to the longitudinal axis of the corrugations.) The perforation diameter is more preferably between about 10% and about 25% of the channel width CW and is most preferably about 15% of the channel width CW. For example, perforations <b>86</b>, <b>88</b> and <b>90</b> having diameters between about 1mm and about 5mm have been used in a structured packing element in an argon separation column.

[0042] The planar members and corrugated sheets can be made from several different materials including metals and metal alloys, plastics, ceramics, or composite materials, depending on the application of use. For air separation applications, the materials should also be compatible with the low temperature environment such that they do not become brittle upon being cooled to cryogenic temperatures. Examples of suitable materials of construction include aluminum, copper, stainless steel, nickel and copper-nickel alloys, among others. In addition, the planar members can be textured or smooth and made from solid sheets, woven materials or knitted materials. Generally, the planar members are made from the same materials as the corrugated sheets.

[0043] A further optimization for air separation is to control the number of perforations and therefore, their open area contribution. Preferably, perforations <b>86</b>, <b>88</b> and <b>90</b> can constitute an open area of the corrugated sheets <b>77</b> and <b>78</b> and the planar member <b>80</b> in a range of between about 5% and about 20% of a total area thereof. More preferably such open area can be between about 7% and about 15% of the total area and most preferably, the open area is about 10% of the total area.

[0044] Aside from varying the number of perforations, the open area of the planar member may further be adjusted by using a variety of appropriate shapes or designs. FIG. 6 is a schematic illustration of another embodiment of a planar member <b>600</b> that can be used with corrugated sheets in forming a structured packing element. The planar member <b>600</b> has an I-shaped design, and comprises generally of an upper portion <b>602</b> and a lower portion <b>606</b> both adjoining a middle portion <b>604</b>. For example, the upper and the lower portions <b>602</b> and <b>606</b> may have widths W approximately equal to those of adjacent corrugated sheets, and lengths L<b>1</b> and L<b>2</b> that are each preferably less than about one third, more preferably less than about one fifth, of the lengths of adjacent corrugated sheets. The middle portion <b>604</b>, delineated from the upper and lower portions <b>602</b> and <b>606</b> by dotted lines in FIG. 6, is characterized by a length L<b>3</b> and a width W<b>3</b>. The open area of planar member <b>600</b> is thus given by the total contributions from the areas of all perforations <b>608</b> and the area given by the product of (W−W<b>3</b>)×L<b>3</b>.

[0045] In the illustration of FIG. 6, perforations <b>608</b> are provided for all three portions <b>602</b>, <b>604</b> and <b>606</b> of the planar member <b>600</b>. In another embodiment, the planar member <b>600</b> may be imperforated—i.e., without any perforations. Furthermore, the number of perforations <b>608</b> may also be distributed differently in different portions of the planar member <b>600</b> in order to achieve various flow characteristics. For example, it may be desirable to provide perforations <b>608</b> only in the middle portion <b>604</b> of the planar member <b>600</b>, with few perforations, if any, in the upper and lower portions <b>602</b> and <b>606</b>. Such an embodiment, with a relatively large open area between the upper and lower portions <b>602</b> and <b>606</b>, can be designed to resemble the embodiment previously shown in FIGS. <b>2</b>-<b>3</b>. One advantage of this design is that the single-piece construction of the planar member <b>600</b> can facilitate assembly of the structured packing element because it is not necessary to perform separate alignments of the upper and lower planar members with respect to adjacent corrugated sheets. In one embodiment, for example, the planar member <b>600</b> preferably has a total length L that is substantially equal to the length of adjacent corrugated sheets, and is positioned between adjacent corrugated sheets such that its uppermost horizontal edge <b>612</b> and lowermost horizontal edge <b>614</b> (also referred to as outermost horizontal edges) are respectively proximal to upper and lower horizontal edges of the adjacent corrugated sheets. The embodiment of FIG. 6 is meant to be illustrative of alternative designs that may be useful for both improved performance and ease of fabrication or assembly of the structured packing element. Other designs can include more than one middle portion in the single-piece planar member, which may provide additional structural stability in cases where the ratio of W:W<b>3</b> is relatively large.

[0046] In addition to the packing elements having linear corrugations described above, the present invention can also be practiced with corrugated sheets of varying configurations. For example, corrugated sheets with curved corrugations near the top and bottom of the sheets but straight corrugations near the middle, or those having other nonlinear corrugations, may also be used in practicing embodiments of the present invention.

[0047]FIGS. 7<i>a</i>-<i>b </i>show a partial exploded view and a side view of a structured packing element <b>7</b> comprising planar members <b>702</b> and <b>704</b> disposed adjacent to corrugated sheets such as those found in MELLAPAKPLUS™ 752.Y packing. Various versions of MELLAPAKPLUS packings are available from Sulzer Chemtech Ltd., Winterthur, Switzerland. Details of a MELLAPAKPLUS packing have been disclosed in a PCT International Patent Application, WO 97/16247, published on May 9, 1997, and in European Patent Specification EP 858,366B1, granted on Jul. 26, 2000, both of which are incorporated herein by reference.

[0048]FIG. 7<i>a </i>shows corrugated sheets <b>706</b> and <b>708</b> each having a series of corrugations <b>710</b> disposed at an angle that is different between a middle portion <b>714</b> and the terminal portions <b>712</b> and <b>716</b> (or upper and lower portions) of the corrugated sheets <b>706</b> and <b>708</b>. In general, corrugations <b>710</b> can be characterized by an angle of inclination α, which is the acute angle between corrugations <b>710</b> and a horizontal axis HH′. Within the middle portion <b>714</b>, this angle of inclination has a uniform or constant value less than 90°, e.g., 45° or 60°, but increases progressively within the upper and lower portions <b>712</b> and <b>716</b> such that the corrugations <b>710</b> intersect an upper horizontal edge <b>720</b> and a lower horizontal edge <b>722</b> of the corrugated sheet <b>706</b> substantially perpendicularly, i.e., with angle of inclination α at about 90°. However, it is also acceptable to have corrugations <b>710</b> intersecting the upper and/or lower horizontal edges <b>720</b> and <b>722</b> at an angle ranging from about 80° to about 90°.

[0049] As shown in FIG. 7<i>b</i>, planar members <b>702</b> and <b>704</b> are held in place, within the same vertical plane as each other, by contact with adjacent corrugated sheets <b>706</b> and <b>708</b>, and are respectively positioned adjacent to the upper and lower portions <b>712</b> and <b>716</b>, with outermost horizontal edges <b>732</b> and <b>736</b> proximal to horizontal edges <b>720</b> and <b>722</b> of corrugated sheets <b>706</b> and <b>708</b>. In one embodiment, both planar members <b>702</b> and <b>704</b> have a length of about 35 mm, such that their innermost edges <b>734</b> and <b>738</b> extend beyond the upper and lower portions <b>712</b> and <b>716</b> of corrugated sheets <b>706</b> and <b>708</b>. In general, the length (<b>1</b>) of the planar members <b>702</b> and <b>704</b> should at least be about two times the corrugation width CW of corrugations <b>710</b>, and preferably less than about one third, more preferably less than about one fifth, of the length of the corrugated sheets <b>706</b> and <b>708</b>. Although FIGS. 7<i>a</i>-<i>b </i>show the use of two planar members <b>702</b> and <b>704</b> in an upper and lower configuration, it is also possible to use only one planar member, preferably adjacent to the lower portions <b>716</b> of the corrugated sheets <b>706</b> and <b>708</b>.

[0050] Aside from the specific embodiments illustrated above, many other possible variations in the corrugated sheets may be used for practicing embodiments of the present invention. For example, it is possible to have corrugations <b>710</b> with angles of inclination that vary progressively within substantially the entire length of the corrugated sheet, or corrugations <b>710</b> intersecting the upper or lower edges <b>720</b> and <b>722</b> with angles of inclination less than 90°, e.g., from about 80° to about 90°. Although corrugations <b>710</b> usually have uniform height (h, shown in FIG. 7<i>b</i>) from the top to bottom portions <b>712</b> and <b>716</b>, those having non-uniform heights may also be acceptable. Furthermore, in the vicinity of at least one of the upper or lower edges <b>720</b> and <b>722</b> of the structured packing element <b>7</b>, corrugations <b>710</b> may have reduced cross-sections (not shown) for reducing the surface area and pressure drop at these locations, i.e., close to the interfaces with adjacent structured packing elements. Such reduced cross-sections may be accomplished, for example, by reducing the height or depth of the corrugations <b>710</b>, or by changing the cross-sectional shape of the corrugations. In sum, different modifications of the configuration of corrugated sheets, including for example, the angle of inclination of corrugations, corrugation height, corrugation width, cross-sections of the corrugations, or surface texture, may be advantageously used in conjunction with planar members according to the present invention for improved performance in the structured packings.

[0051] According to embodiments of the invention, it is generally preferable that at least one planar member be positioned between each pair of adjacent corrugated sheets, e.g., at least one planar member alternating with each corrugated sheet. However, it is understood that improved performance in the structured packing can still be achieved even if planar members are missing between some pairs of adjacent corrugated sheets. Thus, it is possible to practice embodiments of the present invention using a structured packing element having planar members positioned between at least a majority of pairs of adjacent corrugated sheets.

[0052] FIGS. <b>8</b>-<b>10</b> illustrate schematically other corrugated sheets that may be used with one or more planar members as previously described to practice embodiments of the present invention. Details of other configurations of corrugated sheets are disclosed in U.S. Pat. No. 5,632,934, issued May 27, 1997, and in U.S. Pat. No. 5,921,109, issued Jul. 13, 1999; both of which are herein incorporated by reference in their entirety. One structured packing element incorporating these corrugated sheets is the FLEXIPAC®HC™ packing, which is available from Koch-Glitsch, Inc., of Wichita, Kans. These various designs of corrugations in the corrugated sheets are directed towards reducing pressure drops near the interface between adjacent packing elements.

[0053]FIG. 8 illustrates a schematic front view of a corrugated sheet <b>810</b> having rectilinear corrugations <b>812</b> made up of linear segments in different portions of the corrugated sheet <b>810</b>. Each of the rectilinear corrugations <b>812</b> is characterized by at least one angle of inclination θ, which is the acute angle between a longitudinal axis of the rectilinear corrugation <b>812</b> and a horizontal axis AA′. In this embodiment, the corrugations <b>812</b> have a first angle of inclination less than <b>900</b>, which remains constant within a first portion <b>816</b> of the corrugated sheet <b>810</b>. There is a relatively abrupt change in the angle of inclination of some of the rectilinear corrugations <b>812</b> between the first portion <b>816</b> and the lower portion <b>814</b> of the corrugated sheet <b>810</b>. At the lower portion <b>814</b>, rectilinear corrugations <b>812</b> are oriented substantially perpendicular to the lower horizontal edge <b>818</b> of the corrugated sheet <b>810</b>. Such a configuration also reduces the gas velocity, and thus the pressure drop, at the interface between a structured packing element containing these corrugated sheets <b>810</b> and an adjacent packing element (not shown) that is positioned below the structured packing element with corrugated sheets <b>810</b>. It is further understood that there are also other corrugations on the corrugated sheet <b>810</b>, e.g., those labelled as <b>830</b>, that neither show an abrupt change in the angle of inclination, nor extend to the lower portion <b>814</b>.

[0054] In practicing embodiments of the present invention, structured packing elements are preferably formed by using corrugated sheets <b>810</b> in conjunction with either a single planar member adjacent to the lower portion <b>814</b> of the corrugated sheets, or two planar members in an upper and lower configuration. When two planar members are employed in the upper and lower configuration, the upper planar member is aligned with its upper horizontal edge proximal to upper horizontal edges <b>828</b> of two adjacent corrugated sheets <b>810</b>, while the lower planar member is aligned with its lower horizontal edge proximal to lower horizontal edges <b>818</b> of the adjacent corrugated sheets <b>810</b>. In either embodiment, the planar member located adjacent the lower portion <b>814</b> should preferably have a minimum length (in a vertical direction) equal to at least about two times the corrugation width (CW) for the rectilinear corrugations <b>812</b> at the lower portion <b>814</b>. Note that due to the difference in angles of inclinations, the rectilinear corrugations <b>812</b> in portions <b>814</b> and <b>816</b> are characterized by slightly different corrugation widths (CW), each of which corresponds to the distance defined from peak to peak or trough to trough, as measured perpendicular to the respective longitudinal axes of the corrugations. In yet another embodiment, rectilinear corrugations <b>812</b> may also have an angle of inclination in an upper portion <b>820</b> that is equal to about 90° (not shown), with the angle of inclination in a middle portion <b>822</b> remaining constant at some angle of inclination less than 90°.

[0055]FIG. 9 illustrates a schematic side view of another embodiment of the present invention, in which upper and lower planar members <b>902</b> and <b>904</b> are disposed between and in contact with corrugated sheets <b>910</b> and <b>920</b>. In this configuration, linear corrugations <b>912</b>, <b>922</b> have constant angles of inclination throughout the entire corrugated sheets <b>910</b> and <b>920</b>, but are provided with reduced corrugation heights h<b>2</b> at the lower portions <b>914</b>, <b>924</b> compared to the corrugation heights h<b>1</b> at the remaining portions <b>916</b>, <b>926</b> of the corrugated sheets <b>910</b> and <b>920</b>. If a single planar member is used, it is preferable that the planar member be disposed adjacent to the lower portions <b>914</b>, <b>924</b> of corrugated sheets <b>910</b> and <b>920</b>. In either embodiments, the lower planar member <b>904</b> should be sufficiently long (in vertical direction) so as to extend between and in contact with corrugations in the remaining portions <b>916</b> and <b>926</b> of the corrugated sheets. The length of the planar member <b>904</b> extending above the lower portions <b>914</b> and <b>914</b> (L<b>1</b>) should preferably be equal to at least about two times the corrugation width for the linear corrugations <b>912</b> and <b>922</b>.

[0056]FIGS. 10<i>a</i>-<i>b </i>illustrate a schematic front view and a side view of yet another configuration of a corrugated sheet <b>110</b>, in which the corrugations <b>112</b> terminate above a bottom portion <b>114</b>. As such, the bottom portion <b>114</b> has a flat configuration, i.e., without any corrugations. One or more planar members such as those previously described may be used with corrugated sheets <b>110</b> to form structured packing elements for use in various distillation applications. Again, if only one planar member is used, it is preferably positioned adjacent to the bottom portions <b>114</b> of adjacent corrugated sheets <b>110</b>, as shown in FIG. 10<i>b</i>. The lower planar member <b>120</b> should be sufficiently long (in the vertical direction) to extend between and be in contact with corrugations <b>112</b>, and the length of the lower planar member <b>120</b> extending above the bottom portion <b>114</b> (indicated as L<b>1</b> in FIG. 10) should again be equal to at least two times the corrugation width for the corrugations <b>112</b>.

[0057] Finally, embodiments of the present invention may further be practiced by incorporating planar members previously described with other variations of corrugated sheet designs, such as MONTZ™-Pak B1-350 and MONTZ™-Pak B1-350M, available from Julius Montz, of GmbH, Hilden, Germany, described by Olujic et al. in “Stretching the Capacity of Structured Packings”, presented at the Annual Meeting of the American Institute of Chemical Engineers, Nov. 14, 2000, in Los Angeles, Calif.

[0058] It has been found that a structured packing, such as packings with structured packing elements <b>2</b>, <b>5</b> and <b>7</b> designed in the manner set forth above, functions with the same or a higher HETP than structured packings of the prior art. This is surprising considering the fact that the packing with the intermediate planar members has a greater surface area than similar packing not incorporating such planar members, and as such, would be expected to have a lower HETP. A further unexpected feature is that packings of structured packing elements <b>2</b>, <b>5</b> and <b>7</b> of the present invention flood at higher vapor rates. There are various criteria that are used to describe the flooding condition, for instance, excessive pressure drop. In all cases if HETP is plotted against F-Factor (where F-Factor is a product of the superficial vapor velocity and the square root of the vapor density) flooding is evidenced by a rapid rise of the slope of the curve. Such a rise in HETP is indicative of the vapor supporting the descending liquid thereby choking the column and disrupting the separation. This increase in the flooding point allows higher flow rates through the column and therefore for a given volume of packing, greater production. This allows for thinner columns using less packings or columns that can handle a greater throughput. The reason for such operation is that the planar members of the present invention are believed to inhibit turbulence in the vapor flow ascending through the structured packing. In addition, the planar members provide both additional surface area near the bottom of a packing layer for the descending liquid to spread out upon and additional contact points between the upper and lower layers of packing at their common interface. These attributes of the planar members are believed to lessen the resistance to liquid flow from the upper to the lower packing layers. This decreases the hold-up of liquid at the interface and allows the column to operate at a higher capacity.

[0059] Structured packings comprising packing elements <b>2</b> and <b>5</b> (shown in FIGS. <b>2</b>-<b>3</b> and FIG. 5 respectively) were tested against structured packing obtained from Sulzer Chemtech Ltd, Winterthur, Switzerland, as model MELLAPAK™ 500.YL. This packing has a density of about 500 m²/m³. The structured packings <b>2</b> and <b>5</b> were then fabricated out of corrugated sheets that would otherwise have had the same density but for planar members <b>70</b>, <b>72</b>, and <b>80</b>, respectively, and therefore were of slightly greater density. A greater separation efficiency was therefore to have been expected.

[0060] Testing, however, showed that with the type of mixtures to be separated in an air separation plant, either in a lower pressure column, such as lower pressure column <b>26</b>, or in an argon column, such as argon column <b>12</b>, at operational ranges of F-Factor prior to flooding, structured packing <b>2</b> had an HETP of about 15% greater than the MELLAPAK 500.YL packing. Structured packing <b>5</b> (more dense than structured packing <b>2</b>) had an HETP of about 25% greater than the MELLAPAK 500.YL packing. Moreover the flooding points of structured packings <b>2</b> and <b>5</b> were about 25% and about 40% greater than the MELLAPAK 500.YL packing.

[0061] For both structured packing elements <b>2</b> and <b>5</b>, the addition of planar members to MELLAPAK 500.YL increased the structured packing's capacity at the expense of a loss in separation efficiency. Those skilled in the art will recognize this as an accepted tradeoff in packing design, i.e., higher capacity packings generally have lower separation efficiencies and vice versa.

[0062] However, a surprising result was obtained when planar members were incorporated into MELLAPAKPLUS 752Y packing to obtain structured packing element <b>7</b>. For the separation of argon from a mixture of argon and oxygen at 1.6 bara using structured packings comprising packing element <b>7</b>, the capacity was found to increase by about 20% above that of MELLAPAKPLUS 752Y, without any appreciable loss in separation efficiency. This result is surprising especially in light of the results obtained with structured packing elements <b>2</b> and <b>5</b>, and might suggest the presence of a synergy between the corrugation channels with end geometry modifications (e.g., configurational changes near the terminal portions of the corrugated sheets) and the use of planar members. Based on the results obtained with structured packing element <b>7</b>, similar results would thus be expected for other embodiments described herein which incorporate other end geometry modifications.

[0063] In addition to the obvious advantage of allowing smaller distillation columns to be used to achieve a specified production rate in the design of new commercial plants, this packing has the added advantage of being useful in retrofit applications. For example, the production rate of a commercial plant which uses a distillation column packed with MELLAPAKPLUS 752Y could be increased by about 20% simply by replacing the packing with structured packing comprising packing elements <b>7</b>. In retrofit applications, only a packing with the same or lower HETP could be used to enhance the capacity of the distillation column. Thus, unlike packings with structured packing elements <b>7</b>, those with structured packing elements <b>2</b> and <b>5</b> would not be suitable candidates for such applications.

[0064] The structured packing elements of the present invention have been illustrated for use in air separation applications. These structured packing elements can also be used for the separation of argon and oxygen in a distillation column. Details of a cryogenic process for argon and oxygen recovery using a distillation column with structured packings have been disclosed in U.S. Pat. No. 4,871,382, issued Oct. 3, 1989, which is incorporated herein by reference. However, these structured packings can also be employed in numerous distillation applications such as in chemical and petroleum separations. while the present invention has been described with reference to several embodiments, as will occur to those skilled in the art, numerous changes, additions and omissions may be made without departing from the spirit and scope of the present invention.