Innovative packing centrifugal tray: hydrodynamics and performance analysis using CFD and experimental validation

Abstract In this study, a new innovative tray called packing centrifugal tray is introduced, which provides a very effective mixing process between phases using centrifugal and packing technologies simultaneously. This paper investigates the hydrodynamics and the gas-liquid flow distribution pattern on the tray. This study employed computational fluid dynamics (CFD), utilizing a two-phase Eulerian–Eulerian approach. An air-water simulator rig in a rectangular cross section flow domain (30×50 cm) has been used to validate the CFD modeling of the present tray. The gas-phase Reynolds number in the simulations ranged from approximately 5,000 to 30,000, depending on the inlet superficial velocity, while the liquid-phase Reynolds number ranged from 1,000 to 5,000. To capture the complex swirling and rotational flows, the RNG k−ε turbulence model with enhanced wall functions was applied. Dry tray pressure drop, total pressure drop, volume fraction of liquid, and velocity vectors have been investigated. The simulation results clearly demonstrate the effects of centrifugal force generated by the gas flow momentum, effective gas–liquid contact, and the beneficial role of packing in promoting film flow and reducing entrainment. This work addresses the research gap between centrifugal trays and packing-assisted trays by integrating both mechanisms in a single three-dimensional design, offering higher capacity, reduced entrainment, and suitability for retrofitting and debottlenecking process towers.