Novel design approach based on triply periodic minimal surfaces (TPMS) for gas–liquid contactor packing

• A novel packing design for gas–liquid contactors is derived from triply periodic minimal surfaces (TPMS). • Adaptation of the characteristic surface equation leads to new complex shapes and control of the structural dimensions. • Gas-solid pressure drop of the new TPMS-based prototypes was evaluated through CFD. • Larger strut diameter is expected to promote better gas–liquid contact with good gas distribution. Additive manufacturing has facilitated new design possibilities for gas–liquid contactors by enabling the creation of complex geometries to enhance performance. A novel design approach is introduced for column packing, based on triply periodic minimal surfaces (TPMS). This approach combines the unique properties of these surfaces with the advantageous features of wire-based structures. As an initial step, canonical TPMS were integrated to develop a new surface design. The equation representing this surface was subsequently adjusted to control packing dimensions, such as the strut diameter and other characteristics. Three prototypes based on TPMS, each with distinct dimensions, were evaluated through CFD simulation. A small-scale domain of the packing (DN25) was found to align with experimental results for gas–solid pressure drop. When comparing the prototypes, pressure drop exhibited a stronger dependency on strut diameter, higher for larger diameters. Additionally, the gas velocity profile within the packing section suggested that a larger strut diameter may lead to better gas–liquid contact.