Wetted-wire columns: a potential alternative to packed or spray columns

Christopher Wagstaff; Mohammed Al-Juaied; Deoras Prabhudharwadkar; William L. Roberts

doi:10.1515/revce-2023-0008

Published online by De Gruyter November 8, 2023

Wetted-wire columns: a potential alternative to packed or spray columns

Christopher Wagstaff , Mohammed Al-Juaied , Deoras Prabhudharwadkar and William L. Roberts

From the journal Reviews in Chemical Engineering

https://doi.org/10.1515/revce-2023-0008

Showing a limited preview of this publication:

Abstract

Wetted wires are a unique column internal with several advantages compared to spray and packed columns. These include near-perfect liquid distribution, extremely low pressure drops, and better heat or mass transfer due to droplet circulation. Currently, wetted-wire columns remain within the laboratory prototyping stage. The primary goal of this review is to present the current research on wetted-wire columns and to highlight the gaps that impede scale-up and commercialization. Initially, wetted-wire columns were proposed as an alternative to spray towers. However, wetted-wire columns occupy a space in between spray towers and packed columns. Therefore, wetted-wire columns should also be analyzed more like packed columns to increase the speed of technological translation. Wetted-wire column literature is presented by defining features (wire diameter, nozzle diameter, pitch, and material) and by performance indicators (operating range, pressure drop, hold-up, and separation efficiency). In addition, adjacent literature on wire-like structures is discussed.

Keywords: heat exchange; packed column; spray tower; structured packing; wetted wires

Corresponding author: Christopher Wagstaff, Clean Combustion Research Center, Physical Sciences and Engineering Division, King Abdullah University of Science and Technology (KAUST), Thuwal 23955-6900, Saudi Arabia, E-mail: christopher.wagstaff@kaust.edu.sa

Acknowledgments

Supplementary Videos provided with permission by Dr. Dilip Maity and Prof. Tadd Truscott (King Abdullah University of Science and Technology).

Research ethics: Not applicable.
Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.
Competing interests: Christopher Wagstaff, Deoras Prabhudarwadkar, and William L. Roberts hold two applications for patents related to this work (Wagstaff et al. 2022a,b). Mohammed Al-Juaied declares no conflicts of interest.
Research funding: None declared.
Data availability: Not applicable.

Nomenclature

a _c: interfacial specific area, m²/m³
a _g: dry specific area, m²/m³
a _p: packing interfacial area (wet, unless unavailable), m²/m
a _Nu: interfacial specific area constructed from the Nusselt thickness, m²/m³
B: base length for triangular cross-section for crimp geometry of structured packing, mm
C: coefficient in Sherwood relation
COV: coefficient of temperature variation, dimensionless
C _XY: coefficient for the angle of inclination, dimensionless
d: diameter of Raschig ring, mm
dA: liquid–gas interfacial area for an element, m²
d _n: diameter of nozzle (outer if wetted), mm
D _Nu: diameter of a cylinder constructed from the Nusselt thickness, mm
d _w: diameter of a single wire, mm
F _p: packing factor, m⁻¹
g: acceleration due to gravity on earth’s surface, m/s²
g _m: mass transfer conductance, kg/m²s
Ga: Galilei number, dimensionless
Go: Goucher number, dimensionless
GOR: gained output ratio, dimensionless (Eq. (5.1) Sedighi 2023)
HETP: height equivalent to a theoretical plate, m
h: height of triangular cross-section for crimp geometry of structured packing, mm
h _bead-to-air: heat transfer coefficient for the bead to air, W/m²K
h _Nu: Nusselt thickness, mm
HTU_L: height of a liquid-side transfer unit, m
HTU_I: height of a vapor-side transfer unit, m
K _g a: overall capacity coefficient for the gas, mol/m³s (two variables treated as a lumped variable)
k _L: liquid-side mass transfer coefficient, m/s
L: length of Raschig ring, mm
l _w: length of a tetragonal wire section, mm
n _t/H: number of trays per theoretical height (inverse of HETP), m⁻¹
m: slope (dimensionless in the case of Figure 11)
Nu: the Nusselt number is not used in this work. See h _Nu and Section 3.1.2.
ΔP _L: Laplace pressure, Pa
Q: liquid volumetric flow rate down a single wire, m³/s
r _w: radius of the wire, mm
R ₁: first orthogonal radius of curvature of interface, mm
R ₂: second orthogonal radius of curvature of interface, mm
Re: Reynolds number of liquid flowing down a single wire, dimensionless
Re_L: Reynolds number of the liquid flowing down a planar surface, dimensionless
RR: recovery ratio, dimensionless (Eq. (5.1) Sedighi 2023)
s: pitch, center-to-center distance between two wires within an array, mm
S: side length of triangular cross section for crimp geometry of structured packing, mm
Sc_L: liquid-side Schmidt number, dimensionless
Sh_G: liquid-side Sherwood number, dimensionless
Sh_L: liquid-side Sherwood number, dimensionless
t: thickness of Raschig ring, mm
U: overall heat transfer coefficient, W/m²K
WPUV: water productivity per unit volume, kg/m³h

Greek letters

α: aspect ratio for a wetted wire, h _Nu/r _w, dimensionless
β *: saturation number (generalized), dimensionless
γ: surface tension, N/m
ɛ _A: overall liquid-side absorption effectiveness, dimensionless
ɛ _T: overall liquid-side temperature effectiveness, dimensionless
η: energy efficiency, dimensionless
θ: dimensionless temperature
λ c: capillary length, λ c = γ ρ g , mm
μ g: dynamic viscosity of the gas, N s/m²
μ l: dynamic viscosity of the liquid, N s/m²
ν: kinematic viscosity of the liquid, m²/s
ρ g: density of gas, kg/m³
ρ l: density of liquid, kg/m³
τ _a: advection timescale, s
τ _g: linear instability timescale, s

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