A reactor for the synthesis of urea comprising a vertical shell and perforated baffles or trays (3) arranged to define compartments of the reactor, wherein each baffle comprises an array of individual perforated tiles (10) wherein each tile (101) comprises side walls (101A-101D) and a top face (101F), the side walls having first perforations for the liquid and said top face having second perforations for the gas, wherein said second perforations are smaller than said first perforations, and the tiles are distributed over the baffle with a two-dimensional pattern where adjacent tiles are separated by gaps (17).

A structured packing module for crossflow applications is provided and includes a plurality of corrugated structured packing sheets positioned in an upright, parallel relationship to each other. The corrugations of adjacent structured packing sheets are in contact with each other and extend at a crossing angle. Apertures and raised ridges may be positioned on sidewalls of the corrugations. The structured packing module may be used in a crossflow contactor, such as in a process for removing carbon dioxide from air.

A fill pack includes a first fill sheet defining an air intake edge, an air exit edge and an airflow axis extending between the air intake edge and the air exit edge. The first fill sheet defines a first flute section having a first inlet end, a first outlet end and a first peak extending between the first inlet end and the first outlet end. A second fill sheet defines a second flute section having a second inlet end, a second outlet end and a second peak extending between the second inlet end and the second outlet end. The first peak extends relative to the second peak such that a first flute portion defined by the first and second flute sections has a cross-sectional shape that changes between the first and second inlet ends and the first and second outlet ends.

A structured packing module for use in a mass transfer column. Corrugated sheets of structured packing in the structured packing module are held together by fasteners that extend into the corrugated sheets from opposite sides of the structured packing module at an angle of inclination or perpendicularly with respect to the sides of the structured packing module. The fasteners may have an outer surface with protrusions or indentations that resist removal of the fasteners from the structured packing sheets.

A fill pack includes a first fill sheet defining an air intake edge, an air exit edge and an airflow axis extending between the air intake edge and the air exit edge. The first fill sheet defines a first flute section having a first inlet end, a first outlet end and a first peak extending between the first inlet end and the first outlet end. A second fill sheet defines a second flute section having a second inlet end, a second outlet end and a second peak extending between the second inlet end and the second outlet end. The first peak extends relative to the second peak such that a first flute portion defined by the first and second flute sections has a cross-sectional shape that changes between the first and second inlet ends and the first and second outlet ends.

A structured packing bed for a column is provided. The structured packing bed comprises at least two layers stacked vertically above each other, and at least two of the layers each comprise at least one structured cross-channel packing element having a specific surface area of 60 to 500 m.sup.2/m.sup.3 and a height of 50 to less than 150 mm. At least 50% of the structured cross-channel packing elements are a block comprising a plurality of sheets with periodic deformations. The sheets are arranged in a longitudinal direction parallel and in touching contact with each other such that an open space is provided between them. Adjacent sheets are oriented such that their deformations intersect in crisscross fashion with each other, and a structured cross-channel packing element of a layer is rotated with regard to a structured cross-channel packing element of an adjacent layer by 70 to 110°.

Disclosed is a packing made up of a stack of plates, having been shaped to form corrugations in the plate and assembled to form a cross-corrugated packing block for a mass and/or heat transfer application, wherein the material of the packing plates is an open-pore metal foam, and in that the specific surface area of the packing is greater than 500 m2/m3 and in that the thickness (e) of the plate is less than 2 mm before the shaping operation.

The invention relates to a packing assembly for a material exchange column, comprising at least one structured packing plate and a container in which the at least one structured packing plate is arranged. The at least one structured packing plate has packing packets. Each packing packet has interconnected packing sheets. The packing sheets are corrugated and have corrugation peaks and corrugation valleys. Adjacent packing sheets contact each other at the corrugation peaks. Additional corrugated packing sheets are added between the packing packets such that the at least one packing plate is pretensioned against the container in a radial direction thereof. Both the corrugated packing sheets of the packing packets as well as the additional corrugated packing sheet added between the packing packets are arranged solely on a common preferred plane or parallel thereto.

A cross-corrugated structured packing element is provided for use in mass transfer or heat exchange columns. The packing element has a plurality of packing layers positioned in an upright, parallel relationship to each other and including corrugations formed of alternating peaks and valleys and corrugation sidewalls extending between the peaks and valleys. The packing element also includes a plurality of apertures each presenting an open area. The apertures are distributed such that the corrugation sidewalls have a greater density of open areas than any density of the open areas that may be present in the peaks and valleys. Some of the apertures may be present in the peaks and the valleys to facilitate liquid distribution. The apertures may also be placed in rows or other patterns that are aligned in a direction along a longitudinal length of the corrugations. Regions with a larger apex radius may be formed in the peaks, such as by depressing spaced-apart segments of the peaks to form spacers in the undepressed portions of the peaks. Some of the apertures may be positioned in the transitions from the depressed portions of the peaks to the unmodified apex sections.

A structured packing module for use in a mass transfer column. Corrugated sheets of structured packing in the structured packing module are held together by fasteners that extend into the corrugated sheets from opposite sides of the structured packing module at an angle of inclination or perpendicularly with respect to the sides of the structured packing module. The fasteners may have an outer surface with protrusions or indentations that resist removal of the fasteners from the structured packing sheets.