3D printed structured packings - analysis of the influence of morphological changes and anisotropical structures induced by the printing process on wetting behavior and mass transfer

• Applicants: Professor Dr.-Ing. Thomas Grützner; Professor Dr.-Ing. Jens-Uwe Repke
• Subject Area: Chemical and Thermal Process Engineering
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 533252297

A large part of the energy consumption in the process industry is consumed in thermal separation units, especially distillation or desorption columns. Structured packings offer good separation efficiency as well as a low pressure drop. However, distillation offers huge potential for saved resources by improving structured packings. Conventional manufacturing of structured packings made from metal sheets by bending and punching limits the degree of freedom regarding the development of more efficient designs. However, current developments in the field of additive manufacturing can partially overcome these obstacles in the manufacturing process of established manufacturing methods. Above all, this includes new degrees of freedom in the design of packings. An open question here is the extent to which parameters, such as the alignment of the packing to the axis of the printer, influence the texture and thus also the properties when the packing is used. This project addresses the fundamental question of how orientation in the printing chamber during 3D printing of structured packings affects separation performance. Preliminary studies have shown that both the fluid distribution and the HETP value change when the orientation is varied during the printing process. In this project, two approaches will be taken to generate an understanding of the observed phenomena: First, systematic experimental studies of surface properties, contact angle, fluid distribution, and separation performance will be conducted to shed light on individual phenomena. The influence of a distribution of contact angles, stemming from the anisotropic surface structure generated during the printing process will also be investigated. On the other hand, numerical flow simulations will be performed to characterize the influence of the surface structure on the flow regime and to generate an understanding of how a possible manipulation of the surface could be used to improve the separation performance in the future.

• DFG Programme: Research Grants