Demercury Tower-Reasons for not using layered partitions and supports in the packing layer

Time:2025-05-25 20:19:17

Detail Introduction

Demercury Tower-Reasons for not using layered partitions and supports in the packing layer

demercuration processing equipment fabrication drawing with layered partitions and supports

(demercuration processing equipment fabrication drawing with layered partitions and supports)

( demercury tower system without layered partition for packing fillers)

Natural gas mercury removal tower pressure vessel with an inner diameter of 2600 mm, body and head made of Q345R, working pressure of 6.3 MPa, design pressure of 7.6 MPa, working temperature ≤ 49 degrees, design temperature 100 degrees, processing gas volume 23600 Nm³/h, inlet gas mercury content ≤ 0.07 μg/m³, finished product mercury content ≤ 0.01 μg/m³, mercury removal agent volume 27 m³, skirt body DN2680x20, length L=875, bottom plate thickness 24 mm. Why is layered partition and support not used for the packing? After filling the entire 27 cubic meters of packing, is there data on the natural gas mercury removal efficiency, gas flow, and pressure drop effects?

Regarding the design of the natural gas mercury removal tower and the packing layer structure, the analysis is as follows based on technical specifications, process characteristics, and relevant information:

1. Reasons for not using layered partitions and supports in the packing layer

- Process characteristics and packing properties

The natural gas mercury removal tower typically uses activated carbon or sulfur-loaded activated carbon as the mercury removal agent, with the adsorption/reaction process primarily relying on uniform contact. If the packing particles are uniform and have good flow, layered partitions may disrupt the gas flow distribution, increasing pressure drop instead. The mercury removal reaction is a gas-solid heterogeneous reaction, and overall packing ensures sufficient contact between the gas flow and packing, avoiding local short-circuiting caused by layering.

- Structural simplification and maintenance convenience

Layered partitions and supports increase internal structural complexity, potentially making packing replacement difficult (especially when frequent replacement of the mercury removal agent is required). For example, the design of environmentally friendly discharge devices emphasizes sealing and automation, and overall packing is more compatible with such discharge processes, avoiding reduced discharge efficiency due to obstruction from supports.

- Pressure drop control requirements

The void fraction of the packing tower (approximately 0.45-0.95) directly affects the pressure drop. Layered structures may reduce effective void fraction, while uniform packing can maintain a higher overall void fraction, thereby reducing gas flow resistance. The design of the packing tower needs to balance specific surface area and void fraction, and a design without partitions is more conducive to uniform gas flow distribution.

2. Performance impact analysis after filling 27 m³ of packing

- Mercury removal efficiency

Theoretical calculation: processing gas volume 23600 Nm³/h, inlet mercury content ≤ 0.07 μg/m³, outlet requirement ≤ 0.01 μg/m³, removal efficiency must reach over 85.7%.

- Actual factors: mercury removal efficiency is related to the specific surface area of the packing, contact time, and adsorption kinetics. The 27 m³ packing volume must ensure sufficient residence time (usually from seconds to tens of seconds), and the adsorption capacity of activated carbon must meet the inlet mercury load (approximately 1.652 μg/h). In similar processes, the catalyst life and regeneration capability of the mercury removal tower are key; if non-regenerative packing is used, regular replacement is necessary to maintain efficiency.

- Gas flow distribution and pressure drop

Gas flow uniformity: without partitions, the gas flow distribution needs to be optimized through the design of the inlet pipe (such as tangential inlet or distributor). When the tower diameter is large, gas phase end effects must be avoided; overall packing combined with a uniform gas distribution structure can reduce bypass risks.

- Pressure drop estimation: depending on the type of packing (such as random or structured packing), the pressure drop typically ranges from 50-200 Pa/m. Assuming a packing layer height of 10 m, the total pressure drop is approximately 0.5-2 kPa, which needs to be verified against process allowable values (such as the smaller pressure drop mentioned for floating valve towers).

- Economic and operational stability

Overall packing can reduce manufacturing costs (less internal component welding and installation) while minimizing the risk of failures due to support corrosion or blockage. Similar mercury removal towers use Q345R material, with a design pressure of 7.6 MPa, and structural strength can meet the requirements for support-free packing.

3. Additional recommendations

- Simulation validation: it is recommended to verify gas flow distribution and pressure drop through CFD simulations or pilot experiments to ensure design parameters match actual operating conditions.

- Packing selection optimization: if the pressure drop is too high, high porosity structured packing (such as honeycomb activated carbon) can be selected, or particle size distribution can be adjusted to balance efficiency and pressure drop.
- Monitoring and maintenance: regularly check the pressure drop changes in the packing layer, and combine the discharge device design to achieve automated maintenance, extending packing life.

Summary

The decision not to use layered partitions and supports is primarily based on process simplification, pressure drop control, and maintenance convenience. After filling 27 m³ of packing, mercury removal efficiency can be achieved by optimizing contact time and packing performance, while gas flow distribution and pressure drop rely on the design of the inlet pipe and packing characteristics for a comprehensive balance. Specific data needs to be further verified through experiments or industry cases, but the existing design framework (such as the strength of Q345R containers and automated discharge systems) already supports the feasibility of this solution.

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