Process Gas Flow:

We could now trace the process gas flow inside the converter.  Within the AB cooled converter of that was show in the figure, the process gas enters one end of the converter at the middle and is directed to the outside of the shell through a series of baffles. It flows by the gas cooler and is directed to the outer section, or pass, of the barrier tubes.  Whole of the flow enters the outer or first pass, and flows by the tubes.  Elements of the flow diffuse by the barrier tube walls and the remainder of the flow passes by the tubes and is way through a crossover to the second pass of tubes. This crossover is sometimes known as a doughnut since of its shape. The procedure gas flow that does not diffuse by the barrier tube walls of the second pass is directed through a second crossover for the third pass.  The first crossover is sometimes referred to as the 1-2 crossovers since it directs gas flow from the first pass to the second pass.  As same, the second crossover is known as the 2-3 crossovers. An undiffused procedure gas that passes by the third pass is directed to the "B" outlet of the converter and flows to the stage below.  The process gas that was diffused by the barrier tubes in all three passes is collected and flows to the "A" outlet and on to the level above.

Because a few of the process gas flowing within the first pass will diffuse by the tube walls, a decreased amount of process gas flow will enter the second pass.  Sequence to manage the similar flow velocity, the second pass holds fewer tubes than the first pass. As same, the third pass will hold still fewer tubes.  The velocity of process gas by the tubes affects the flow by the tube walls and therefore affects the separation effectiveness. The effectiveness is highest while the flow velocity is the similar in all of the tubes.

Within the Badger stage, about 50 percent of the process gas entering a converter diffuses by the tubing and flows to the stage above. That fraction is known as the "cut." A cut of 50 percent has been found to yield the best separation. As mentioned previously, the "cut" in a Badger Cluster stage might be more or less than 50 percent depending upon its position in the cluster.