Vapor-liquid contact tray including interlocking joint

A separation system can include one or more vapor-liquid contact trays. A vapor-liquid contact tray can include a set of panels. Two adjacent panels can be connected at a joint at overlapping edges of the panels. The first panel can include slots extending through the first panel proximal to a first offset bend. Tabs of the first panel can extend downward toward an underside of the first panel. The tabs can originate from an edge of the slots proximal to the deck and extend downward relative to a horizontal plane of the deck. The second panel can include a plurality of strips that have a second offset bend extending from a deck of the second panel extending through a slot and to underlie the first panel. A strip of the plurality of strips can define an opening through which a tab of the first panel can extend.

FIELD OF THE DISCLOSURE

This disclosure, in general, relates to vapor-liquid contact trays including panels connected at interlocking joints, separation systems including such vapor-liquid contact trays, and methods of assembling such vapor-liquid contact trays.

BACKGROUND

There is a large worldwide demand for refined chemicals and products made using such refined chemicals. In an effort to refine or separate compounds from undesirable byproducts or impurities, chemical facilities often use vapor-liquid separations processes, such as distillation, stripping, or absorption. Such separations processes can utilize vapor-liquid contact trays, among other equipment. As such, there is a large demand for vapor-liquid contact equipment, including vapor-liquid contact trays.

Vapor-liquid contact trays are oftentimes deployed in cylindrical column structures. As such, the contact trays are assembled within rigid columns, providing limited space and flexibility for maneuvering panels and equipment. Moreover, owing to the remote locations of many chemical facilities, the assembly of vapor-liquid contact trays within columns is subject to outdoor environmental conditions, often in inhospitable climates. Accordingly, assembling vapor-liquid contact trays in limited spaces under harsh conditions is a difficult undertaking.

As such, an improved vapor-liquid contact tray would be desirable.

SUMMARY

In an exemplary embodiment, a separation system, such as a separation column, can include one or more vapor-liquid contact trays. Each of the vapor-liquid contact trays can include a set of panels. In an example, two adjacent panels can be connected at a joint at overlapping edges of the panels. The panels can include vapor flow elements, such as vapor flow valves, bubble caps, sieve tray perforations, or a combination thereof. Proximal to the joint, a first panel can include an offset bend extending from a deck to a support portion that is to extend to underlie a second panel. The first panel can include slots extending through the first panel proximal to the first offset bend. In addition, tabs of the first panel can extend downward toward an underside of the first panel. The tabs can be associated with the slots. For example, the tabs can originate from an edge of the slots proximal to the deck and extend downward relative to a horizontal plane of the deck. The second panel can include a plurality of strips that have a second offset bend extending from a deck of the second panel to a distal portion extending through a slot and to underlie the first panel. Each strip can define an opening through which a tab of the first panel can extend when the joint is assembled.

To assemble an exemplary contact tray, the first panel can be secured within a column. For example, the first panel can be secured to a wall of the column. The first panel, at an edge away from the column wall, can include the offset bend extending from the deck of the first panel to the support portion. The first panel can include slots extending through the panel proximal to the offset bend, and a plurality of tabs can extend downward toward an underside of the first panel. The tabs can be associated with the slots. The second panel can include an edge having a plurality of strips extending from the deck of the second panel to a distal portion of the strips. The second panel can be tilted, and the strips can be applied through the slots of the first panel, and, with maneuvering, openings defined by the strips can engage the tabs of the first panel. The second panel can be secured to additional panels or can be secured to a wall of the column. A liquid receiving panel or downcomer panel can be applied to other edges of the first or second panels.

DETAILED DESCRIPTION

In an exemplary embodiment, a separation system, such as a separation column, can include one or more vapor-liquid contact trays. Each of the vapor-liquid contact trays can include a set of panels. In an example, two adjacent panels can be connected at a joint at overlapping edges of the panels. The panels can include vapor flow elements, such as vapor flow valves, bubble caps, sieve tray perforations, or a combination thereof, which can assist with vapor-liquid contact. Proximal to the joint, a first panel can include an offset bend extending from a deck to a support portion that is to extend to underlie a second panel. The first panel can include slots extending through the first panel proximal to the first offset bend. In addition, tabs of the first panel can extend downward toward an underside of the first panel. The tabs can be associated with the slots. For example, the tabs can originate from an edge of the slots proximal to the deck and extend downward relative to a horizontal plane of the deck. The second panel can include a plurality of strips that have a second offset bend extending from a deck of the second panel to a distal portion extending through a slot and to underlie the first panel. Each strip can define an opening through which a tab of the first panel can extend when the joint is assembled.

To assemble an exemplary contact tray, the first panel can be secured within a column. For example, the first panel can be secured to a support ring welded to a wall of the column. The first panel, at an edge away from the column wall, can include the offset bend extending from the deck of the first panel to the support portion. The first panel can include slots extending through the panel proximal to the offset bend, and a plurality of tabs can extend downward toward an underside of the first panel. The tabs can be associated with the slots. The second panel can include an edge having a plurality of strips extending from the deck of the second panel to a distal portion of the strips. The strips can be applied through the slots of the first panel, and openings defined by the strips can engage the tabs of the first panel. The second panel can be secured to additional panels or can be secured to a wall of the column. A liquid receiving panel or downcomer panel can be applied to other edges of the first or second panels.

The exemplary separation system and contact tray can be used in vapor-liquid separations processes. For example, in practice, a multicomponent stream can be fed to the separation system or separation column. As the liquid flows down the column from tray to tray and vapor or gas flows up through trays, components of the multicomponent stream concentrate either at the top or at the bottom of the column. A concentrated compound can be drawn from the column, for example, from a reflux container, a condenser, or from a boiler.

As illustrated inFIG. 1, a separation device100can include a column102. The column102at the top can be in fluid communication with a condenser106. In particular, vapor or gas from the column102flows to the condenser106to be condensed into a liquid which flows into a reflux container108, and optionally, a portion of the reflux flows back to the column102as a liquid. The column102, for example, can be in fluid communication with a boiler104. For example, liquid flows from the bottom of the column102to the boiler104where at least a portion of the liquid can be vaporized and returned to the column102as a gas or vapor.

The column102can include a plurality of trays110. Each tray110can optionally include a downcomer112in which liquid flows from the tray to the liquid receiving area of a lower tray. In further example, the tray110can also include a weir114that defines a liquid height for retaining liquid on the tray. Alternatively, the tray can be designed without a weir114.

Each of the trays110can be formed from one or more panels that include perforations and, optionally elements applied over the perforations. Panels of the trays110can connect to one another at a joint.FIG. 2includes an illustration of an exemplary vapor-liquid contact tray200. The vapor-liquid contact tray200can include panels that include vapor flow elements214, such as vapor flow valves, bubble caps, sieve tray perforations, the like, or a combination thereof, which can assist with vapor liquid contact, such as through the formation of vapor-liquid interface surface area, e.g., with bubbles. In a particular example, the vapor-liquid contact tray200includes a panel202and a panel204. One or both of the panels (202or204) can include vapor flow elements214. As illustrated, the panel204is secured to a tray support208. The tray support208can be a tray ring or ledge and, in an example, can be welded to a tower shell. In addition, the panel204can be secured to the panel202at overlapping edges218of the panels202or204that form a joint206.

In addition, a liquid receiving panel210can be secured to an edge216of the panels202or204. For example, the liquid receiving panel210can be secured to an edge216that is orthogonal to the overlapping edges218of the joint206. In further example, a downcomer212can be secured to an edge220of one or both of the panels202or204, for example, at an edge220orthogonal to the overlapping edges218associated with the joint206. The liquid received at the liquid receiving panel210can flow across the vapor-liquid contact panel202to the downcomer212. As the liquid crosses the panels (e.g., panels202or204), liquid is contacted with vapor flowing through the vapor flow elements214.

FIG. 3,FIG. 4, andFIG. 5include illustrations of an exemplary joint between two panels302and304. The panel302includes a deck318. In an example, the deck318can include vapor flow elements, such as vapor flow valves, bubble caps, sieve tray perforations, the like, or a combination thereof. The panel304can also include a deck320. In an example, the deck320can include vapor flow elements, such as vapor flow valves, bubble caps, sieve tray perforations, the like, or a combination thereof.

The panel302includes a support portion324connected to the deck318by an offset bend306. Proximal to the offset bend306, slots308are formed in the panel302that open through the panel302. In addition, each slot can be associated with one or more tabs310extending downward toward an underside of the panel302. In a particular example, the one or more tabs310initiate at an edge of the slot308proximal to the deck318and extend downward relative to a plane of the deck318. While the tabs and slots are illustrated in a 1:1 relationship, more than one tab can be associated with a slot. The panel302can also include a cross support316extending along the edge of the panel302and extending downward from the support portion324.

The panel304can include strips312connected to the deck320of the panel304by offset bends322. Proximal to a distal end326, the strips312can define openings314. While the openings and strips are illustrated in a 1:1 relationship, more than one opening can be defined by a strip. In an example, the number of openings associated with a strip corresponds to the number of tabs associated with a slot.

As illustrated inFIG. 4andFIG. 5, when the strips312of the panel304are inserted into the slots308of the panel302, the tabs310engage the openings314of the strips312. For example, the tabs310can extend into the openings314defined by the strips312. As such, the strips312extend under the panel302, and the support portion324extends under the panel304, for example, extending under the deck320of the panel304.

When joined, the decks318and320of the respective panels302and304can be coplanar, depending on the nature of the offset bends306and322. For example, the depth of the offset bend306can provide for the top of the deck318to be approximately 1 panel thickness higher than the top of the support portion324. As illustrated, the depth (d) extending between respective center planes of the deck318and the support portion324is in a range of 0.8 to 1.2 times the thickness of the second panel304, such as a range of 0.9 to 1.1, or a range of 0.99 to 1.01.

As illustrated inFIG. 5, the tab310of the panel302extends downward relative to a plane of the deck318. In particular, relative to a reference plane of the deck318, the tab310can extend downward at an angle a in a range of 30° to 120°, such as a range of 45° to 100°, or a range of 70° to 90°. Optionally, the tab310can have a distal end that extends at least to the center plane of the support portion324. In a particular example, the distal end of the tab310can extend downward beyond the center plane of the support portion324. For example, the difference (e) between the height of the center plane of the support portion324and the distal end of the tab310can be in a range of 0.1 to 1 times the thickness of the first panel302.

During assembly, a panel can be secured to a support ring. The panel can include a first portion of a joint at an edge distal from the column wall. A second panel can be secured to the first panel and can include a second portion of the joint. Strips defined at an edge of one of the panels can be inserted into slots disposed at an edge of the other panel. Openings defined by the strips can engage tabs of the opposite panel. Additional panels can be secured at other edges of the panels. Further, a liquid receiving panel can be secured to an orthogonal edge of one or both panels and a downcomer can be secured to another orthogonal edge of one or both panels.

In an example, sheets can be cut and shaped to form the panels. In particular, metal sheets can be cut and shaped in a stamp press. The sheet can be perforated for associated vapor flow elements prior to stamping to cut and shape the sheet into a panel. Alternatively, the panel can be formed in a single stamp press process.

While providing a secure interface between two panels, the joint further provides technical advantages useful vapor-liquid contact systems. For example, owing to the nature of the joint, the open area at the joint is limited, preventing excessive weeping at the joint and preventing uncontrolled vapor flow through the joint. Further, embodiments of the tray and panels including the described joint provides for easier installation, in-column manipulation, maintenance, and replacement. In particular, the trays including panels with the described joint are easier to dismantle for maintenance or for panel replacement.

In a first aspect, a vapor-liquid contact tray includes first and second panels having coplanar respective first and second decks and releasably joinable at a joint formed along overlapping edges of the first and second panels. A plurality of vapor flow elements is disposed in at least one of the first or second decks. The joint can include the first panel including a first offset bend extending from the first deck to a support portion, the support portion to extend to underlie the second panel. A plurality of slots extends through the first panel proximal to the first offset bend. A plurality of tabs are each associated with a slot of the plurality of slots and can extend downward toward an underside of the first panel and can initiate from an edge of the associated slot proximal to the first deck. The second panel includes a plurality of strips. A strip of the plurality of strips has a second offset bend extending from the second deck to a distal portion that is to extend through a slot of the plurality of slots to underlie the first panel. The strip defines an opening. A tab of the plurality of tabs extends through the opening.

In an example of the first aspect, at least a subset of the plurality of vapor flow elements is disposed in the first deck.

In another example of the first aspect and the above examples, at least a subset of the plurality of vapor flow elements is disposed in the second deck.

In a further example of the first aspect and the above examples, a first subset of the plurality of vapor flow elements is disposed in the first deck and a second subset of the plurality of vapor flow elements is disposed in the second deck.

In an additional example of the first aspect and the above examples, a distal end of a tab of the plurality of tabs extends below a plane of the support portion.

In another example of the first aspect and the above examples, the tab extends downward at an angle relative to a plane of the deck in a range of 30° to 120°. For example, the angle is in a range of 70° to 90°.

In a further example of the first aspect and the above examples, the first panel further includes a cross support extending along the overlapping edge and extending downward from an edge of the support portion opposite the first deck.

In an additional example of the first aspect and the above examples, the vapor-liquid contact tray further includes a downcomer positioned at an edge of the first or second panels, optionally, orthogonal to the overlapping edge.

In another example of the first aspect and the above examples, the vapor-liquid contact tray further includes a liquid receiving panel secured to the first or second panels along an edge of the first or second panels, optionally, orthogonal to the overlapping edge.

In a second aspect, a mass transfer column includes a plurality of horizontally extending vapor-liquid contact trays vertically spaced apart relative to one another. At least one contact tray of the plurality of contact trays includes at least two panels and a downcomer. The at least two panels includes first and second panels having coplanar respective first and second decks and releasably joined at a joint formed along overlapping edges of the first and second panels. A plurality of vapor flow elements is disposed in at least one of the first or second decks. The joint includes the first panel including a first offset bend extending from the first deck to a support portion, the support portion to extend to underlie the second panel. A plurality of slots extends through the first panel proximal to the first offset bend. A plurality of tabs are each associated with a slot of the plurality of slots and extend downward toward an underside of the first panel and initiate from an edge of the associated slot proximal to the first deck. The second panel includes a plurality of strips. A strip of the plurality of strips has a second offset bend extending from the second deck to a distal portion that is to extend through a slot of the plurality of slots to underlie the first panel. The strip defines an opening. A tab of the plurality of tabs extends through the opening.

In an example of the second aspect, at least a subset of the plurality of vapor flow elements is disposed in the first deck.

In another example of the second aspect and the above examples, at least a subset of the plurality of vapor flow elements is disposed in the second deck.

In a further example of the second aspect and the above examples, a first subset of the plurality of vapor flow elements is disposed in the first deck and a second subset of the plurality of vapor flow elements is disposed in the second deck.

In an additional example of the second aspect and the above examples, a distal end of a tab of the plurality of tabs extends below a plane of the support portion.

In another example of the second aspect and the above examples, the tab extends downward at an angle relative to a plane of the deck in a range of 30° to 120°.

In a further example of the second aspect and the above examples, the first panel further includes a cross support extending along the overlapping edge and extending downward from an edge of the support portion opposite the first deck.

In an additional example of the second aspect and the above examples, the downcomer is positioned at an edge of the first or second panels, optionally, orthogonal to the overlapping edges.

In another example of the second aspect and the above examples, the mass transfer column further includes a liquid receiving panel secured to the first or second panels along an edge of the first or second panels, optionally, orthogonal to the overlapping edges.

In a third aspect, a method of forming a vapor-liquid contact tray includes tilting a second panel at an angle in relation to a first panel and inserting a plurality of strips of the second panel into a plurality of slots of the first panel. The first panel includes a first offset bend extending from a first deck to a support portion. The plurality of slots extends through the first panel proximal to the first offset bend. A plurality of tabs are each associated with a slot of the plurality of slots and extend downward toward an underside of the first panel and initiate from an edge of the associated slot proximal to the first deck. The second panel includes the plurality of strips. A strip of the plurality of strips has a second offset bend extending from the second deck to a distal portion. The strip defines an opening. A tab of the plurality of tabs extends through the opening. The method further includes maneuvering the first and second panels to place the first and second decks in coplanar relationship to form a joint. Distal ends of the strips of the second panel extend under the first panel. The support portion of the first panel extends under the second panel. The tabs of the first panel engage the openings in the strips of second panel.

In an example of the third aspect, the method further includes securing an edge of the first or second panels to a wall of the column.

In another example of the third aspect and the above examples, the method further includes attaching a downcomer to an edge of the first or second panels, optionally, orthogonal to the joint.

In a further example of the third aspect and the above examples, the method further includes attaching a liquid receiving panel to an edge of the first or second panels, optionally, orthogonal to the joint.

In an additional example of the third aspect and the above examples, the contact tray of the method can include features of the first or second aspects and associated examples.

Benefits, other advantages, and solutions to problems have bend described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.