Structured packing module for use in a mass transfer column and method of assembly

1. A structured packing module comprising:

a plurality of individual structured packing sheets that are arranged sequentially in an upright, parallel relationship to each other, wherein a front face of a first one of the structured packing sheets forms one side of the structured packing module and a rear face of a last one of the structured packing sheets forms a second side of the structured packing module that is opposite from said first side; and

fasteners that extend into the structured packing sheets from the first and second sides of the structured packing module at an angle of inclination with respect to the first and second sides of the structured packing module.

2. The structured packing module of claim 1 , wherein each of the structured packing sheets is corrugated with parallel corrugations and the structured packing sheets are arranged so that the corrugations of each one of the structured packing modules extend at an oblique angle to the corrugations of adjacent ones of the structured packing modules.

3. The structured packing module of claim 2 , wherein the fasteners that extend into the structured packing sheets from the first side of the structured packing module do not extend to the second side of the structured packing module and the fasteners that extend into the structured packing sheets from the second side of the structured packing module do not extend to the first side of the structured packing module.

4. The structured packing module of claim 2 , wherein at least one of the fasteners extending into the structured packing module from the first side of the structured packing module is paired with another one of the fasteners that extends into the structured packing module from the second side of the structured packing module.

5. The structured packing module of claim 4 , wherein multiple ones of the fasteners extend into the structured packing module from spaced apart locations at the first side of the structured packing module and multiple ones of the fasteners extend into the structured packing module from spaced apart locations at the second side of the structured packing module.

6. The structured packing module of claim 2 , wherein each of the fasteners comprises a shank extending from a head.

7. The structured packing module of claim 6 , wherein said shanks have an outer surface with protrusions or indentations that resist removal of the fasteners from the structured packing sheets.

8. The structured packing module of claim 7 , wherein the structured packing sheets are arranged so that the structured packing module forms a six-sided polyhedron shape.

9. The structured packing module of claim 8 , wherein the six-sided polyhedron shape is a cube, a rectangular cuboid or a parallelepiped.

10. The structured packing module of claim 8 , wherein the angle of inclination is between 30 and 80 degrees.

11. A structured packing layer comprising a plurality of structured packing modules positioned in end-to-end and side-to-side relationship, each of the structured packing modules comprising:

a plurality of individual structured packing sheets that are arranged sequentially in an upright, parallel relationship to each other, wherein a front face of a first one of the structured packing sheets forms one side of the structured packing module and a rear face of a last one of the structured packing sheets forms a second side of the structured packing module that is opposite from said first side,

wherein each of the structured packing sheets is corrugated with parallel corrugations and the structured packing sheets are arranged so that the corrugations of each one of the structured packing modules extend at an oblique angle to the corrugations of adjacent ones of the structured packing modules; and

fasteners that extend into the structured packing sheets from the first and second sides of the structured packing module at an angle of inclination with respect to the first and second sides of the structured packing module.

12. The structured packing layer of claim 11 , wherein the fasteners that extend into the structured packing module from the first side of the structured packing module do not extend to the second side of the structured packing module and the fasteners that extend into the structured packing module from the second side of the structured packing module do not extend to the first side of the structured packing module.

13. The structured packing layer of claim 12 , wherein at least one of the fasteners extending into the structured packing module from the first side of the structured packing module is paired with another one of the fasteners that extends into the structured packing module from the second side of the structured packing module.

14. The structured packing layer of claim 13 , wherein multiple ones of the fasteners extend into the structured packing module from spaced apart locations at the first side of the structured packing module and multiple ones of the fasteners extend into the structured packing module from spaced apart locations at the second side of the structured packing module.

15. The structured packing layer of claim 14 , wherein each of the fasteners comprises a shank extending from a head.

16. The structured packing layer of claim 15 , wherein said shanks have an outer surface with protrusions or indentations that resist removal of the fasteners from the structured packing sheets.

17. The structured packing layer of claim 16 , wherein the structured packing sheets are arranged so that at least some of the structured packing modules each forms a six-sided polyhedron shape.

18. The structured packing layer of claim 17 , wherein the six-sided polyhedron shape is a cube, a rectangular cuboid or a parallelepiped.

19. The structured packing layer of claim 17 , wherein the angle of inclination is between 30 and 80 degrees.

20. A method of forming the structured packing module of claim 1 , comprising:

assembling the structured packing sheets together in a sequential arrangement in an upright, parallel relationship to each other, wherein a front face of a first one of the structured packing sheets forms one side of the structured packing module and a rear face of a last one of the structured packing sheets forms a second side of the structured packing module that is opposite from said first side; and

inserting fasteners into the structured packing sheets from the first and second sides of the structured packing module at an angle of inclination with respect to the first and second sides of the structured packing module.

21. A structured packing module comprising:

a plurality of individual structured packing sheets that are arranged sequentially in an upright, parallel relationship to each other, wherein a front face of a first one of the structured packing sheets forms one side of the structured packing module and a rear face of a last one of the structured packing sheets forms a second side of the structured packing module that is opposite from said first side,

wherein each of the structured packing sheets is corrugated with parallel corrugations and the structured packing sheets are arranged so that the corrugations of each one of the structured packing modules extend at an oblique angle to the corrugations of adjacent ones of the structured packing modules,

wherein the structured packing sheets are arranged so that the structured packing module is in the form of a cube, a rectangular cuboid or a parallelepiped; and

fasteners that extend into the structured packing sheets from the first and second sides of the structured packing module at an angle of inclination of between 30 and 80 degrees with respect to the first and second sides of the structured packing module.

22. The structured packing module of claim 21 , wherein the fasteners that extend into the structured packing module from the first side of the structured packing module do not extend to the second side of the structured packing module and the fasteners that extend into the structured packing module from the second side of the structured packing module do not extend to the first side of the structured packing module.

23. The structured packing module of claim 21 , wherein at least one of the fasteners extending into the structured packing module from the first side of the structured packing module is paired with another one of the fasteners that extends into the structured packing module from the second side of the structured packing module.

24. The structured packing module of claim 23 , wherein multiple ones of the fasteners extend into the structured packing module from spaced apart locations at the first side of the structured packing module and multiple ones of the fasteners extend into the structured packing module from spaced apart locations at the second side of the structured packing module.

25. The structured packing module of claim 21 , wherein each of the fasteners comprises a shank extending from a head.

26. The structured packing module of claim 25 , wherein each of said shanks has an outer surface with protrusions or indentations that resist removal of the fastener from the structured packing sheets.