16 February 1998

CHE 446
Dimensionless Groups Used in Bravo-Fair Correlations for Mass Transfer
Coefficients of Packed Towers (See handout from Kister)
1.

Reynolds No. = Re = V / ( ap) = Inertial Forces / Viscous Forces [ap=area/vol]

2.

Schmit No. = Sc = / ( D) = Momentum Transport / Diffusion [D is diffusivity]

3.

Sherwood No. = Sh = k / (D ap) = Convective MT / Diffusive MT [k is MT Coeff]

4.

Weber No. = We = V2 / (ap ) = Kinetic energy of fluid to surface tension stress

5.

Froude No. = Fr = V2 ap / g = Kinetic energy / potential energy

6.

Capillary No. = Ca = V / = Viscous forces (liquid-wall interaction) / cohesion

of liquid molecules

Random Versus Structured Packing

1.
At low liquid rates (<20 gpm/ft2), a higher ap for structured packings relative to
random packings makes them more efficient.
2.
For random and structured packings of the same ap values, the latter yield lower
values of the packing parameter, Fp. This indicates the latter yield a greater capacity
(<20 gpm/ft2).
3.
Structured packings yiled much lower pressure drop per unit length of tower
height.
4.
Structured packings do not perform well at high pressures and/or liquid flow rates:
> 10 gpm/ft2, > 100-200 psia.
5.
Structured packings perform less well with aqueous liquid systems and those
which possess high . The latter property indicates that larger droplets form, which
indicates that poorer wetting will occur on the surface of metal structured packings.
6.

Liquid holdup: similar values for structured and random packings.

7.

Structured packings are very susceptible to corrosion.

8.
Structured packings are much less sensitive to surges and plant upsets. A packed
tower operating in the loading region can be easily induced into the flooding region of
operation with plant upsets.

9.
Inspection and maintenance of structured packings are much more difficult than
random packings.
10.
Cost: A tradeoff exists. The cost per unit mass is 3-10 times more expensive for
structured compared to random packings; but, the former is more efficient (lower HETP)
due to lower pressure drop. Also, pumping costs are less for structured packings because
of the lower pressure drop and the shorter columns.
Tray Towers Versus Packed Towers
1.
Smaller pressure drops per unit length (lower pumping costs): PACKED (e.g.
0.04 psi/stage for packed; 0.15 psi/stage for tray; important issue for vacuum distillatn)
2.
Smaller liquid holdup (susceptibility to flooding):
issue for batch distillation)
3.

Higher L/G ratio (slope of operating line)

4.

Lower L/G ratio:

5.

Easier cooling of liquid:

PACKED (e.g., important

PACKED; or MULTIPASS TRAYS

TRAY
TRAY

6.
Easier side stream withdrawal (plus easier incorporation of other tower internals
such as inter-reboilers and cooling coils):
TRAY
7.

Better adaptation to L/G systems that foam: PACKED

8.

Better for L/G systems that corrode: PACKED (random)

9.

Easiest for cleaning: TRAY

10.

Operation for small column diameter: PACKED (maintenance issues)

11.
Operation for large column diameter: TRAY (packings have maldistribution
problems when DT / dp is too large)
12.

Presence of solids

TRAY (solids can clog void space of packed beds)

13.

Feed composition variation: TRAY (feed tray position can be varied)

14.

Ability to predict column performance/more accommodating of design errors

TRAY

15.

Chemical reactions

TRAY (Larger holdup, or residence time, of liquid)

16.

Lower weight: TRAY

17.
Effect of temperature gradient between ambient and internal: less significant for
TRAYS (expansion/contraction of shell can crush packings.)
18.

Lower capital costs (often): TRAY (Hairston article)