Distillation column trays are the unsung hero when separating mixtures in the chemical and petrochemical industries. When constructed and implemented correctly, they provide an avenue for optimal vapor-liquid contact.
When enhancing the separation process, you must invest in reliable materials. Woven wire mesh, for example, has improved separation efficiency by delivering peak contact point surface area, enabling even liquid distribution, and optimizing mass transfer.
With over 150 years of wire mesh experience, W.S. Tyler strives to deliver high-performing solutions that optimize the efficiency and durability of your distribution column trays, driving your operational success.
In this article, we will explain what woven wire mesh is and its role when integrated into distribution column trays. You will learn:
- What a distillation column tray is
- What woven wire mesh is
- How woven wire mesh functions in a distillation column tray
- The benefits of using woven wire mesh
- What you need to consider when selecting a woven wire mesh solution
Understanding Distillation Column Trays
A distillation column tray, also known as a fractionating column tray, facilitates the separation of liquid mixtures by providing numerous vapor-liquid contact points. Using various trays, volatile components of the liquid are vaporized while the less volatile components become condensed and fall. The following are all distillation column trays that are used:
- Sieve
- Valve
- Bubble-cap
These trays are integral in crude oil refining, high-purity chemical production, and chemical feedstock separation.
What Is Woven Wire Mesh?
Woven wire mesh, or simply wire mesh, is a versatile material consisting of hundreds of metal wires interwoven to form specific patterns that facilitate peak filtration, separation, or structural support. Its high open surface area and uniform porosity allow optimal mass transfer and fluid distribution.
However, what truly makes wire mesh stand out among similar solutions is its ability to be customized. Virtually every parameter of the weave, including the percentage of open area, wire diameter, and weave pattern, can be tailored to meet your exact requirements.
Note: Your mesh can be constructed using a wide range of alloys, such as stainless steel, Inconel, and Hastelloy.
Are you curious as to how woven wire mesh is made? Read the article below:
How Woven Wire Mesh Functions in Distillation Column Trays
When integrated into a distillation column tray, wove wire provides a structured surface to increase the number of contact points for vapor-liquid separation. It also allows liquid to be distributed evenly, which creates a uniform flow that prevents channeling or flooding.
Another key function of wire mesh is facilitating liquid retention. This is important to the overall function of the distillation column as it controls how well vapor passes through and interacts with liquids.
Ultimately, this optimizes mass transfer and separation efficiency, especially when working with components with varying boiling points.
The final key function of woven wire mesh is that it is a physical barrier that retains finer droplets, minimizing the amount of droplets transferred into the vapor phase.
The Benefits of Woven Wire Mesh in Distillation Column Trays
Woven wire mesh is proven to improve separation efficiency when integrated into a distillation column tray. Its increased percentage of open area allows for the maximum number of vapor-liquid contact points.
This, in turn, enhances how well components transfer from the liquid and vapor phases. As a result, you will find that component separation is more effective.
It should also be noted that the unique structure of wire mesh promotes the uniform distribution of liquids. This helps minimize pitfalls, like channeling and entrainment, that hinder separation effectiveness.
To that end, wire mesh balances durability and corrosion resistance, allowing the material to operate under high pressures and high temperatures associated with distillation columns without performance dips. This means you can always count on the material to deliver industry-leading results.
Consideration for Choosing Woven Wire Mesh for Distillation Column Trays
The woven wire mesh solution you select will ultimately determine the level of separation efficiency your process can achieve. Specifications like mesh size and weave pattern control the vapor-liquid contact throughout the tray.
It should be noted that finer mesh specifications offer an increased surface area for enhanced mass transfer. However, finer weaves can also cause increased pressure drops.
Conversely, coarser specifications offer properties that can improve vapor flow. However, the coarser a mesh specification gets, the fewer contact points for separation.
You must also be mindful of the alloy you select. The alloy of your wire mesh is directly responsible for how well it can withstand the operational conditions of your process, specifically high temperatures and corrosive atmospheres.
Alloys you should consider include 304 stainless steel, 316 stainless steel, Inconel, Hastelloy, and duplex.
NOTE: The alloy you select will also play a key role in the durability of your mesh. A durable mesh will ensure it can withstand the mechanical stresses present within the column.
Become a Woven Wire Mesh Expert to Maximize Distillation Performance
Woven wire mesh is a key component when optimizing the performance of your distribution tray. By selecting the right specifications, you can use the versatile material to improve vapor-liquid contact, minimize entrainment, and improve peak separation efficiency.
However, to ensure you properly integrate wire mesh into your process, you must gain a comprehensive understanding of the material. This knowledge will allow you to understand what can be done fully and what cannot, ensuring you handpick a solution that meets your expectations.
Backed by over 150 years of wire weaving experience, W.S. Tyler dedicates itself to helping customers leverage innovative wire mesh solutions to achieve desirable separation performance.
Read and download our technical wire mesh brochure to unlock valuable insight that will allow you to make the informed decision needed to elevate your process: