Additively manufactured monolithic structures for containing and directing flows of fluids are described herein, which can achieve high contact area between fluids and solids while maintaining uniform flow conditions and requiring low applied pressures to yield desired flow rates, for use in heat exchangers, chromatography columns, catalytic converters, etc. An exemplary monolithic structure comprises a plurality of tiled unit cells having a same shape, where the tiled unit cells are integrally formed as a single component. The tiled unit cells are arranged to define one or more interior regions of fluid flow, one or more inlets to each interior region of fluid flow, and one or more outlets to each interior region of fluid flow. The structures and methods of tiling herein are suited to additive manufacturing technologies such as projection stereolithography, multiphoton lithography, etc.

The packing has one or more thin-layer packing elements that are installed upright, the packing element having a main body portion with a planar liquid film formation surface, and one or more wall portions that are provided upright relative to the liquid film formation surface along a linear direction. The side surface of each wall portion has a curved portion at the base thereof connected to the liquid film formation surface, the curved portion curbing so as to continue into the liquid film formation surface.

A method of manufacturing packing includes: determining types of a gas and a liquid which are brought into gas-liquid contact and a main plate to be used; calculating a relationship between a contact angle and a liquid film length ratio; determining the arrangement (intervals) of a rib; determining rib conditions; calculating the minimum value of the flow direction length of the rib satisfying the contact angle and a strength requirement; confirming whether or not a liquid film length is greater than the minimum value; and determining the flow direction length of the rib within a range from the minimum value to the liquid film length.

The present invention relates to a structured packing element (21) having the shape of a rectangular flat plate, provided with slots (23) and recesses (22). The slots (23) are intended for assembly by interlocking the structured packing elements together in order to form the structured packing. The recesses (22) are provided in order to form channels within the structured packing.

The present invention also relates to a packing structure obtained by assembling such packing elements (21), the use of such a packing for an operation of bringing a gas and a catalyst into contact, and a manufacturing process of such a structured packing.

A method of attaching/detaching a catalytic unit according to an embodiment is a method of attaching/detaching a catalytic unit accommodated in a reactor housing of a catalytic reactor, including a step of passing the catalytic unit through a gas inlet formed at a top portion of the reactor housing to attach or detach the catalytic unit to or from the reactor housing having a cylindrical shape extending in a vertical direction and configured such that a gas having a gauge pressure of 0.2 Mpa or more is introduced thereto.

A jig for inserting a packing into a flow passage of a reactor extending in one direction or for removing the packing from the flow passage, includes: a pair of strip portions extending in parallel with each other, having a length longer than the flow passage; and link portions arranged in an extending direction of the pair of strip portions, linking the pair of strip portions and having lengths with which the pair of strip portions sandwich the packing therebetween.

An apparatus and process for distillation column fabrication can include forming multiple distillation column packing units that are positionable in a column to define a single packing section so that multiple columns of packing can be positioned in parallel with each other within a single distillation pressure vessel. Each of these multiple columns can have a pre-selected cross-sectional shape, such as a hexagonal shape, and each packing unit can have the same cross-sectional shape (e.g. hexagonal). Each column can include a riser, or distributor, attached to its upper or top portion. A plurality of outer jigsaw seal elements can be arranged between the outer portion of the columns and the inner wall of the pressure vessel. Each packing unit can include a plurality of layered corrugated sheets that are provided in a pre-selected arrangement to facilitate gas and liquid separation via the packing.

A method of manufacturing packing includes: determining types of a gas and a liquid which are brought into gas-liquid contact and a main plate to be used; calculating a relationship between a contact angle and a liquid film length ratio; determining the arrangement (intervals) of a rib; determining rib conditions; calculating the minimum value of the flow direction length of the rib satisfying the contact angle and a strength requirement; confirming whether or not a liquid film length is greater than the minimum value; and determining the flow direction length of the rib within a range from the minimum value to the liquid film length.

A contactor media includes continuous surface segments, wherein a first continuous surface segment has at least 50% of its surface area follow at least one of: (a) a contour of a first zero-thickness surface having a Gaussian curvature (G.sub.c) of 400 mm.sup.2G.sub.c<0.01 mm.sup.2; and (b) a contour of a second zero-thickness surface having at least one principal curvature (k.sub.i) of 20 mm.sup.1k.sub.i<0.1 mm.sup.1; and wherein the first continuous surface segment provides at least: (a) a total liquid hold-up of between about 1 kg/m.sup.3 to about 800 kg/m.sup.3 or (b) a static liquid hold-up of about 0.1 kg/m.sup.3 to about 800 kg/m.sup.3.

An apparatus and process for distillation column fabrication can include forming multiple distillation column packing units that are positionable in a column to define a single packing section so that multiple columns of packing can be positioned in parallel with each other within a single distillation pressure vessel. Each of these multiple columns can have a pre-selected cross-sectional shape, such as a hexagonal shape, and each packing unit can have the same cross-sectional shape (e.g. hexagonal). Each column can include a riser, or distributor, attached to its upper or top portion. A plurality of outer jigsaw seal elements can be arranged between the outer portion of the columns and the inner wall of the pressure vessel. Each packing unit can include a plurality of layered corrugated sheets that are provided in a pre-selected arrangement to facilitate gas and liquid separation via the packing.