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Liquid flooding in tower internals significantly impairs separation efficiency, causing operational disruptions and reduced productivity. To address this, targeted strategies focusing on packing, distribution, and operation are essential. First, optimize packing selection and structure. High-efficiency, low-hold-up packings like metal wire mesh or structured ceramic packings reduce liquid retention and pressure drop, lowering the risk of flooding. Avoid random packings with irregular voids, as they trap liquid and hinder gas flow. Second, enhance liquid distribution. Implement precision liquid distributors, such as槽式分布器 (tray-type distributors) or pressure-balanced莲蓬头分布器 (shower head distributors), to ensure uniform liquid spreading across the tower cross-section. Uneven distribution leads to localized liquid accumulation, a primary flood trigger. Third, adjust operational parameters. Maintain gas velocity below the flood limit by calculating flood points using correlations like the O'Conner or Sherwood equations. Gradually reduce liquid flow rates if flooding occurs, and avoid sudden changes in feed conditions. Additionally, regular maintenance—cleaning packings to remove fouling and inspecting distributors for blockages—prevents performance degradation. By combining these methods, tower internals can operate at higher capacities with minimized flooding, boosting overall separation process reliability and efficiency.
