The liquid spreading on structured packings plays an essential role in affecting gas–liquid mass transfer in separation columns, yet the synergistic mechanism of surface wettability and textured geometries remains insufficiently understood. This study integrates experimental and computational methods to systematically investigate the liquid spreading characteristics on textured surfaces. The synergistic combination of hydrophilic modification and surface textures markedly enhances liquid spreading performance. Compared with the hydrophilic plane surface, the spherical cap texture increases the interface area and wetted area by 25.2% and 49.6%, respectively, while the pyramid-shaped texture leads to improvements of 24.5% and 48.9%, respectively. Based on Weber number analysis, it is identified that the competition between inertial force and surface tension governs the evolution of liquid spreading regimes. In addition, the results suggest that variations in liquid viscosity and density may further influence spreading behavior by modifying the balance among inertial, viscous, and surface tension forces. The geometric parameters of spherical cap textures are systematically examined, and it is revealed that a spherical cap with a non-uniform staggered configuration (Mode III) enables the efficient liquid spreading. A new non-uniform spherical cap texture is designed to enhance liquid spreading, which enhances spreading performance compared with the original plate, increasing the interface area by 27.3% and the wetted area by 47.4%. Although the liquid film thickness increases slightly, the wetted area ratio is significantly improved, indicating enhanced effective surface coverage. Both simulations and experiments confirm that the new textured structure further enhances liquid spreading performance on the textured surface. This research unveils a strategy to improve liquid spreading through tailored surface textures, opening up new possibilities for the design of efficient packings.
Chen et al. (Sun,) studied this question.