structured packings - ntnu
TRANSCRIPT
Sulzer Chemtech
Structured Packingsfor Distillation, Absorption and Reactive Distillation
0699 2501
2
Structured packings for separation and reactive distillation
- Internals for Packed Columns Thebrochurecontainsacompre-hensivesummaryoftheselectionof internals supplied by SulzerChemtech, and a description ofthe most important features ofthedistributortechnology.
- Gas Processing- Chemical Processing Industry- Process Technology and
Equipment for Oil Refineries and Crude Oil Production
Three brochures which illustratethewidespectrumofapplicationofstructuredpackings.
Sulcol Design ProgramA program that enables usersto carry out hydraulic design ofcolumns featuring every type ofpacking Sulzer Chemtech offers.The program is based on our ex-perience with several thousandindustrial columns and from ex-perimental data measured in ourowntestcolumnwithadiameterof1m.
Considering the broad selectionof products and widely provenapplication know-how, SulzerChemtech is in a position to offerthe suitable solution even for themostdifficultseparationtasks.
Contents Structured packings• Overview 4-5
• Laboratorypackings 6
• Rombopak 7
• Mellapak® 8-10+15
• MellapakPlus® 11-12
• Gauzepackings 13-14+16
• Mellacarbon® 17
• Mellagrid® 18
• Katapak®-SP 19
Internals and erection• Distributors 20
• Collectors 21
• Supportgrids 22
• Revamping 23
• Installation 24
• Sulzercolumns 25
Test facilities• Distributortestfacility 26
• Pilotplants 26
Column design
• Formulanotation 27
This brochure was reviewed andsupplementedrecently.Itthereforeprovides a complete, up-to-dateoverview of packings availablefromSulzerChemtech.Also included isasummarycove-ringtheessentialcolumninternalsandourtechnicalservices.
Forfurtherinformationandtodown-load our brochures as well asdesigntools,pleaserefertowww.sulzerchemtech.com
More detailed product information,you will find in the followingbrochures:
0693 2504-14
3
SulzerChemtechhasbeenactiveasequipmentsuppliertothechemicalindustry since the nineteen fourties. In the early days the engineeringdesign was completely dependent on the specification provided bycustomers. At the end of the fifties Sulzer was ready to offer its ownsolutionstospecificchemicalprocessengineeringproblems.Theseearlyactivitieslaidthecornerstoneforsustainedinnovationbyestablishinganin-housedevelopmentgroupandawellequippedpilotfacility.
50 years of experience in mass transfer technology
Gauze packingsTheinventionofthegauzepackingsBX and CY in the early sixtiesresultedinadecisivebreakthroughindistillationtechnology.Thespecialadvantages of these packingsallowed difficult separation tasksto be accomplished for the veryfirst time, and thermally sensitivesubstances to be separated bymeansofdistillation.
MellapakA furthermilestonewas thedeve-lopmentofthestructuredpackingsMellapakintheseventies.Originallyconceived to cover the moderatevacuum range up to atmosphericpressure,Mellapakopenedupnewandunforeseenperspectivesinallareasofthermalmasstransfer.
ApplicationsThe eighties were marked by thewidening of the application rangeof Mellapak in the petrochemical,oil and gas industries as well asin exhaust air cleaning and in thestrippping of volatile constituentsfromwastewater.Typicalexamplesarevacuumtowersinrefineriesandhigh-pressure absorption columns
test data gathered in our processengineering laboratory as well asexperience gained in numerousindustrialapplications,weareableto offer the best possible solutionforyourapplicationrequirements.
Column InternalsWith the concept of advancedinternals, Sulzer Chemtech hasdefined the standard for gasand liquid distribution in packedcolumns.Distributorsareavailablefor a wide range of applicationsandoperatingconditions.
MellapakPlus• MellapakPlusrepresentsthenovel,highcapacitystructuredpacking(typically25to30%morecapacitycomparedwithconventionalstructuredpacking)
• MellapakPlusofferssignificantlylowerpressuredrop
• MellapakPlusoffersawiderangeoftechnicalandcommercialadvantages
•MellapakPluscanbeusedfromlowvacuumuptohighpressureapplications
•EverythingonealreadyknowsaboutMellapakremainsvalidforMellapakPlus
for natural gas drying. In compa-rison to conventional technology,Mellapakofferssubstantialbenefitsin many process applications.Duringthepast40years,thousandsofcolumns,originallyequippedwithtrays or random packings, havebeen revamped with Mellapak inordertoimproveyieldorpurityortoincreasecapacity.Duetoextensive
0678 2057
0693 2505
4588 3003
0603 2516
Type of packing Material
4
Structured packings from Sulzer Chemtech
Mellapak64.X/64.YMellapak125.X/125.YMellapak170.X/170.YMellapak2X/2YMellapak250.X/250.YMellapak350.Y
MellapakPlus202.YMellapakPlus252.YMellapakPlus352.YMellapakPlus452.YMellapakPlus602YMellapakPlus752.Y
Mellapak125.X/YMellapak250.X/YfromplasticsMellapakPlus252.Yfromplastics
Mellagrid40.YMellagrid64.XMellagrid64.YMellagrid90.X
BXgauzepackingBXPlusgauzepackingCYgauzepacking
BXgauzepackingfromplastics
Mellacarbon125.YMellacarbon250.YMellacarbon350.YMellacarbon500.Y
RombopakS4MRombopak 9MRombopak 6MRombopak12Mlaboratorypacking
DXlaboratorypackingEXlaboratorypackingDXM,DYMlaboratorypackingmadefromsheetmetal
Katapak-SP11Katapak-SP12Katapak-SP13
Mellapak500.X/500.YMellapak750.YFurthertypesonrequest
Furthertypesonrequest
Furthertypesonrequest
StainlesssteelsCarbonsteelHastelloy,monel,aluminum,copper-bronze,brass,titanium,nickelOthermaterialsavailableonrequest
StainlesssteelsCarbonsteelHastelloy,monel,aluminum,copper-bronze,brass,titanium,nickel,Othermaterialsavailableonrequest
PP,PVC-C,PVDF,Teflon®PFA,PEEK
StainlesssteelsCarbonsteelOthermaterialsavailableonrequest
StainlesssteelsCopper-bronze,monel,hastelloy,nickel,titaniumOthermaterialsavailableonrequestGauze-madeofpolypropylene/polyacrylonitrilemixture(PP/PAN)
Carbon(CFC)
Stainlesssteel,carbonsteel,Hastelloy,copper,aluminium,titan,niobium
CrNiMosteelAlloyC22Carbon(CFC)
StainlesssteelsOthersteelsavailableonrequest
5
Basicchemicalsandpetrochemicals,ethylbenzene/styrene,fattyacids,talloil,cyclohexanone/-ol,caprolactam,refineryoperations,absorption/desorptioncolumns,naturalgasdrying
Basicchemicalsandpetrochemicals,ethylbenzene/styrene,fattyacids,talloil,cyclohexanone/-ol,caprolactam,refineryoperations,absorption/desorptioncolumns,naturalgasdrying
Absorption/desorptioncolumns
RefineriesandpetrochemicalindustryCrudeoildistillationQuenchcolumns
FinechemicalsIsomersFragrancesFlavoursLowliquidloadswithaqueoussolutions
Hydrofluoricacid,carboxylicacid,causticsolutions
PharmaceuticalandfinechemicalsAlcohols,esters,fattyacidsandderivativesFlagranciesandflavoursSolventrecoveryFoulingservicesPilotplants
Laboratoryandpilotcolumns
Acetates,methylacetatehydrolysis,fattyacidestersAcetalsMTBE,ETBE,TAME
From80mmupto17m(dependingontype)VacuumtohighpressureLiquidload0.2tomorethan200m3/m2h
From80mmupto12m(dependingontype)VacuumtohighpressureLiquidload0.2tomorethan200m3/m2h
From200mmupto15m(dependingontype)VacuumtohighpressureTemperature:PPmax.110oC,PVDFmax.150oC
Minimumdiameter900mmVacuumtohighpressure
From40mmupto6m(dependingontype)Pressure1mbartoatmosphericpressure,optimum:1-100mbarFrom100mmupto4m(dependingonmaterial)Pressure1mbartomoderatepressureTemperaturemax.80oC
From30mmVacuumtomoderatepressureTemperaturesuptomorethan400oC
From28mmupto4mVacuumtomoderatepressure
DX,DXM,DYM30-125mm,EX20-85mmVacuumtoatmosphericpressure
From50mmVacuumtomoderatepressure
Universalpackingtype,suitableforawiderangeofapplicationsLowtoveryhighliquidloads
UniversalpackingtypeBoostsusefulcapacity
ResistanttomanychemicalsSmallpressuredropSeparationefficiencesimilartoMellapakmadefrommetal
RobustconstructionSmoothsurfaceNoblockage,notsensitivetofoulingExcellentflowstabiliserEfficientde-entrainmentdevice
Highseparationefficiency,evenatsmallliquidloadsLowpressuredrop,Smallhold-upBXPlus:SameefficiencyasBX,lowerpressuredropSelf-wetting,evenwithaqueoussolutionsLargenumberoftransferunitspermeter,evenwithsmallliquidloadsLowpressuredrop
HighseparationperformanceBestchemicalresistanceandthermalstabilityLowpressuredrop
Gridstructure:SurfacedividedinalargenumberofstreamlinedlamellasUniquedistributioneffectfortheliquidandgooddistributionofvaporflowConstantseparationperformanceindependentofvaporload
SmallesthydraulicdiameterEX,DX:Veryhighnumberoftheoreticalstagespermeter,lowpressuredropDXM,DYM:ConstantHETPoverthewholeFfactorrange
Packingforreactivedistillationandtrickle-bedreactorsHighseparationefficiencyandhighreactioncapacityModularconcept
Applications Diameter and operation range Characteristics
0.1
0.08
0.06
0.04
0.02
00
0 1 2 3
0.5 1 1.5 2 2.5 3
HE
TP
/m
p
/ z
/m
ba
r/m
F / Pa
F / Pa
20
1
10
EX DX
6
Standard structured packings are hardly suitable foruseinlaboratorycolumnsoflessthan50mmdiameter.Sulzerlaboratorypackingsareespeciallydesignedforthispurpose.
Preferred applications:• Laboratorycolumnsfrom20to80mm• Vacuumfrom1mbar• Whereahighnumberoftheoreticalstagesisrequired(DX,EX)
• Distillationofcomponentspronetodecomposition• Preliminaryassessementofaseparatontask• Derivingofreliablescale-uprules
Special features:SmallpressuredropTypeEX:• Highestpossiblenumberoftheoreticalstages,evenwithverylowliquidloadings
• SamepressuredroppertheoreticalstageasSulzerBXpacking
• Smallhold-up• Capacitynearlydoublethatofwiremeshrings (3x3mm)
TypeDX:Thispackinghasacoarserstructureandhencealowernumberoftheoreticalstages.Suitableforlaboratorycolumnswhereamodestnum-beroftheoreticalstagesisrequired,togetherwithlowpressuredropandhighcapacity.TypeDXM/DYM:These packing types, made of sheet metal, have alower number of theoretical stages compared toDX.HETP or NTSM remain constant over a wide rangeof F factors and liquid loads. This makes scale-upsignificantlyeasier.
Laboratory packingHighestnumberoftheoreticalstagesperunitheight
pressuredrop
separationefficiency
Laboratory packings Headpressure=50mbar
0691 2532-2
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separationefficiency
Rombopak
The unique open structure has been specificallydevelopedfortheambitiousdistillationrequirementsofthefinechemical industry.Ithasbeenwidelyusedinthemostdiverseapplicationsandhasbecomeawellestablished preferred choice of the pharmaceuticalindustryandspecialtychemistry.
Special features• Gridstructure:Surfacedividedinalargenumberofstreamlinedlamellas
• Uniquedistributioneffectfortheliquidandgooddistributionofvaporflow
• Maximizedopenareaforthevaportoflowthroughresultinginareducedpressuredrop
• Constantseparationperformanceindependentofvaporload
• Pilotsizediametersavailabledownto28mm
Preferred applications• Highcapacityandseparationperformanceatminimumpressuredrop
• Idealforminiplantapplicationsduetoitsexceptionalscale-upproperties.EasyvalidationinGMPregulatedprocesses
• Highlyresistantagainstfoulingdueitsopenstructure• Goodperformancewithviscousliquids
Typical product applications• Pharmaceuticalandfinechemicals• Alcohols,esters,fattyacidsandderivatives• Flagranciesandflavours• Solventrecovery• Foulingservices• Pilotplants
Rombopak typesRombopak S4M 6M 9M 12MNTSM 2.4 3.7 6.0 8.0Rombopak12Monlyforlaborpilotplantupto150mmdiameter.
RombopakThepackingwiththeuniquestructureandperformance
pressuredrop
960 67
960 67
Rombopak R9M Rombopak R4M
1 2 650 3 4
1 2 650 3 4
0.7
0.4
0.6
0
F / Pa
0.3
0.2
0.5
0.1
F / Pa
HET
P /m
10
1
0.1
10
1
F
p/
z /m
bar/m
/ Pa
parameter=headpressurep/mbar
41 2 3 5 6
1
0.8
0.6
0.4
0.2
0
10
1
0.1
F / Pa
F / Pa
0
0 1 2 3 4 5 6
96040010050
96040010050
Mellapak 250.Y Mellapak 250.X
HE
TP /m
p
/ z
/mb
ar/m
8
Mellapak 250.Y/XAhighlyversatilepackingtype
Mellapak is themostwidely used structuredpackingworldwide. It has proven excellent performance incolumns with diameters up to 15m. It is supplied insheetmetalthicknessesfrom0.1mmup.
Special features • Pressuredroppertheoreticalstage0.3-1.0mbar• Pressuredropat70-80%floodingabout2mbar/m• Minimumliquidloadapprox.0.2m3/m2h• Maximumliquidloaduptomorethan200m3/m2h(typicallyindesorptioncolumns)
Preferred applications• Vacuumtomoderatepressure• Highpressureinselectedapplications• Increasingcapacityofexistingtrayandpackedcolumns
Typical applications• Chemical Ethylbenzene/styrene,talloil, industry: cyclohexonone/-ol,airseparation• Petrochemical Quenchcolumns, industry: C3-andC4-splitters,xylene
splitters• Refineries: Vacuumandatmosphericcolumns• Absorption: Naturalgasdrying, CO2-andH2S-absorbersand
strippers, ethyleneoxideabsorbersand
strippers,acrylonitrileabsorbers
separationefficiency
parameter=headpressurep/mbar
pressuredrop
0602 2510
Mellapak 250.YMellapak 250.X
Mellapak 125.YMellapak 125.X
Mellapak 170.YMellapak 170.X
Mellapak 2YMellapak 2X
1 2 3 4 5 6
1.0
0.8
0.6
0.4
0.2
0
10
1
0.1
0
0 1 2 3 4 5 66
96040010050
96040010050
Mellapak 170.Y Mellapak 170.X
0
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
F / Pa
1 2 3 4 5 6
1.5
1.0
0.5
0
10
1
0.1
0
0 1 2 3 4 5 6
96010050
96010050
Mellapak 125.Y Mellapak 125.X
F / Pa
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
1 2 3 4 5 6
1.0
0.8
0.6
0.4
0.2
0
10
1
0.1
0
0 1 2 3 4 5 6
96040010050
96040010050
Mellapak 2Y Mellapak 2X
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
F / Pa
9
MellapakAsolutionavailableforanyapplication
pressuredrop
separationefficiency
pressuredrop
separationefficiency
parameter=headpressurep/mbar
separationefficiency
pressuredrop
parameter=headpressurep/mbar parameter=headpressurep/mbar
Mellapak 350.Y Mellapak 500.YMellapak 500.X
Mellapak 750.Y
1 2 3 4
0.5
0.4
0.3
0.2
0.1
0
10
1
0.1
0
0 1 2 3 4
96040010050
Mellapak 350.Y
0
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
F / Pa
1 2 3 4
0.5
0.4
0.3
0.2
0.1
0
10
1
0.1
0
0 1 2 3 4
96040010050
96040010050
Mellapak 500.Y Mellapak 500.X
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
F / Pa
10
1
0.10 1 2 3
10
1
0.1
1 2 3
0.5
0.4
0.3
0.2
0.1
00
96010050
Mellapak 750.Y
0
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
F / Pa
10
Mellapak Asolutionavailableforanyapplication
pressuredrop
separationefficiency
pressuredrop
separationefficiency
pressuredrop
separationefficiency
parameter=headpressurep/mbar parameter=headpressurep/mbarparameter=headpressurep/mbar
0.6
0.5
0.4
0.3
0.2
0.1
0
10
1
0.10 1 2 3 4 5 6
0 1 2 3 4 5 6
960400100
960400100
MellapakPlus 252.Y Mellapak 250.Y
F / Pa
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
11
pressuredrop
separationefficiency
MellapakPlusAnewgenerationofstructuredpackings
MellapakPlusisacapacityenhan-cedstructuredpacking.Itcombinesalladvantagesof themetalsheetpacking Mellapak with new geo-metricalfeatures.
Features of MellapakPlusAtthelowerandupperendofeachpacking element, the orientationof the corrugation gradually ap-proaches the vertical axis.Advantages of this geometricalmodification:•The vapor flow smoothly chan-ges direction at the interfacebetweentwopackingelements
•At the interface vapor flow isnearlyparalleltotheverticalaxisof thecolumn.Thegasvelocityis therefore reduced by about25% compared to the velocityinsidethepackingelement
Both factors reduce the pressuredrop and the shear forces,whichareespecially critical at the inter-faceduetothepresenceofthickerand lessstable liquidfilms. Asaresult, premature flooding at theinterfaceisnolongerofconcern.
MellapakPlus 252.Y vs.Mellapak 250.Y
In the interior part of the packingelement the geometrical featuresof MellapakPlus and Mellapakare identical. Hence, separationefficiency is similar – but with asignificant increase in capacityandareduction inpressuredrop.All other MellapakPlus properties– including installation procedure,mechanicalstrengthandcorrosionresistance–areidenticaltoMellapak.
MellapakPlus performance hasbeenconfirmedincategory1testsatF.R.I.
InternalsThe close resemblance betweenMellapakPlus and Mellapak gua-ranteescontinueduseofthewholerange of well known and reliableinternals. Internals are now ableto handle the increased gas loadtypical for the high capacity ofMellapakPlus.SulzerChemtech iscommittedtotheon-going,focuseddevelopmentofnoveldesigns.
parameter=headpressurep/mbar
0699 2522−4
MellapakPlus 352.YMellapakPlus 602.Y
MellapakPlus 452.YMellapakPlus 752.Y
pressuredrop
separationefficiency
parameter=headpressurep/mbar
0.5
0.4
0.3
0.6
0.7
0.2
0.1
0
0
0 1 2 3 4
960
100
MellapakPlus 202.Y
65
10
1
0.11 2 3 4 65
F / Pa
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
0.5
0.4
0.3
0.2
0.1
0
0
0 1 2 3 4
960400100
MellapakPlus 352.Y960400100
MellapakPlus 602.Y
5
10
1
1 2 3 4 5
F / Pa
F / Pa
HET
P /m
p/
z /m
bar/m
0.1
0.5
0.4
0.3
0.2
0.1
0
0
0 1 2 3 4
960400100
MellapakPlus 452.Y
5
10
1
0.11 2 3 4 5
F / Pa
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
960400100
MellapakPlus 752.Y
12
pressuredrop
separationefficiency
pressuredrop
separationefficiency
parameter=headpressurep/mbar parameter=headpressurep/mbar
MellapakPlusAnewgenerationofstructuredpackings
MellapakPlus 202.Y
1 2 3 4 5 6
0.5
0.4
0.3
0.2
0.1
00
1 2 3 4 5 60
960
1005010
9604001005010
BXPlusBX
10
1
0.1
0
F / Pa
separation effciency of BXand BXPlus is identical
column diameterID = 250 mm
HE
TP /m
p
/ z
/mb
ar/m
F / Pa
13
This packing has been successfully employed in theindustry forover40years.Largestdiametersuppliedtodate:6m.
Special features• Highnumberoftheoreticalstagesperunitheight• Pressuredroppertheoreticalstage0.1–0.5mbar• Mosteconomicalloadrange: Ffactor1-2.5√Pa• Minimumliquidloadapprox.0.05m3/m2h• Smallhold-up
Preferred applications• Largenumberoftheoreticalstages• Vacuumfrom1mbartoatmosphericpressure• Whereminimumpressuredroppertheoreticalstageisimportant
• Smalloverallheight• Batchandcontinuouscolumns• Pilotcolumns(reliablescale-up)Limitedsuitabilityfor• Foulingsubstances• Non-wettingliquidsProduct applications• Monomersfromplastics(MDI,DMT,etc.)• Fattyacids,fattyalcohols,fattyacidesters• Mono-,di-,tri-,andtetraethyleneglycols• Finechemicals
BXPlusBXPlus isa furtherdevelopmentof thewellprovengauze packing BX. Its geometry is similar toMellapakPlus.BXPlusoffersthesameefficiencyasBXwitha20%lowerpressuredrop.Itisrecommendedforgentledistillationathighercapacity.
Gauze packingsSulzermetalgauzepacking,typeBXandBXPlus
pressuredrop
separationefficiency
Gauze packing BXGauze packing BXPlus
separationefficiencyofBXandBXPlusisidentical
parameter=headpressurep/mbar
columndiameterID=250mm
0682 2017
1 2 3 4
0.3
0.2
0.1
00
1 2 3 40
9604001005025
F / Pa
10
1
0.1
1 2 3 4
0.3
0.2
0.1
00
1 2 3 40
9604001005025
F / Pa
10
1
0.1
HE
TP /m
p
/ z
/mb
ar/m
F / Pa
14
pressuredrop
separationefficiency
This packing was developed for separations thatrequirea largenumberof theoreticalstages.Largestdiametersuppliedtodate:1.8m.
Special features• Maximumnumberoftheoreticalstagespermeter• Mosteconomicalloadrange: Ffactor1.5–2√Pa• Minimumliquidloadapprox.0.05m3/m2h• Smallhold-up
Preferred applications• Foraverylargenumberoftheoreticalstages• Vacuumfrom1mbartoatmosphericpressure• Smalloverallheight• Batchandcontinuouscolumns• Pilotandlaboratorycolumns(reliablescaleup)Limitedsuitabilityfor• Foulingsubstances• Non-wettingliquids
Product applications• Pharmaceuticalproducts(vitamins,etc.)• Fragrances(menthol,geraniol,etc.)• Separationofisomers
Gauze packing CY
Gauze packingsSulzermetalgauzepacking,typeCY
parameter=headpressurep/mbar
4588 3043
1 2 3 4
0.6
0.5
0.4
0.3
0.2
0.1
000
HTU
/m
F / Pa
10.10.01
1
0.1
10
100
10
250.X PP252.Y PP
250.Y PP
p
/ z
/mb
ar/m
F / Pa
dry
75m3/(m2h)
Acetone/H2O(10-20m3/m2h)SO2/H2O(20-40m3/m2h)
15
Mellapak and MellapakPlus from plastics
pressuredrop
separationefficiency
Mellapak PPatmosphericpressure
The MELLAPAK 125.X, 125.Y, 250.X and 250.Y andMellapakPlus252.Yarealsoavailableindifferentkindsof thermoplastics. Packings made of polypropylene(PP), postchlorated polyvinylchloride (PVC-C),polyvinylide-nedifluoride (PVDF), Teflon® PFA andpolyetheretherketone(PEEK)canbesupplied.
The plastic versions of MELLAPAK have provenoperational record invarious typesofabsorptionanddesorptioncolumns.
Special features• Largenumberoftransferunitspermeter,lowHTU,dependingonthesystem
• Smallpressuredroppermeterpackedheight• MosteconomicalloadrangeuptoFfactor4√Pa• Maximumoperatingtemperatures: approx.110oCforpolypropylene approx.150oCforPVDF
Product applications• HCIabsorbers• SO2absorbers• Fluegascleaningcolumns• Seawaterdeaerators
MellapakPlus252.YhasthesameefficiencyasMellapak250.YandsamecapacityasMellapak250.X
SeparationefficiencyofMellapak250.YPP
0682 2021
16
1 2 3
0.25
0.2
0.15
0.1
0.05
00
21 3 4 50
100
10
1
0.1
602050
F / Pa p
/ z
/mba
r/mH
TU /m
Methanol/H2O(1-2 m3/m2h)NH3/H2O(2.5-5 m3/m2h)
F / Pa
Theplasticgauzepackinghasbeenused industriallywithgreatsuccessformanyyears.Thespecialgauzestructure provides a very good wettability, even inaqueous systems. This packing is used primarily forcolumnswithlowliquidloads.
Special features• Largenumberoftransferunitspermeter,lowHTU, dependingonthesystem• Minimumpressuredrop,typically2–4mbar/m• Minimumliquidloadapprox.0.05m3/m2h• Self-wettingpackingsurface,evenforaqueoussolutions
• Operatingtemperaturesupto80oC, dependingonthechemicalcomponents
Preferred applications• Smallliquidloads• Increasingperformanceofexistingcolumns• Columnswithsmalloverallheight
Product applications• Methanolabsorbers• Isopropanolabsorbers• Dimethylformamideabsorbers• Formaldehydeabsorbers
Gauze packingsSulzerplasticgauzepacking,typeBX
pressuredrop
separationefficiency
parameter=liquidloadl/m3/m2h
Plastic gauze packing BXatmosphericpressure,ID=300mm
0682 2020
1 2 3 4
0.4
0.3
0.2
0.1
0
1 2 3 40
50
10
1
0.5
Mellacarbon 500.YMellacarbon 350.YMellacarbon 250.Y
960 100
0
F / Pa
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
17
Carbondoesnotreactwithmostsolvents,acidsorlyes.SulzerChemtechoffersvariousMellacarbontypes.
• Corrosion-proofagainstcausticsolutions,non-oxidizinginorganicacidsincludinghydrofluoricacidandcarboxylicacids
• Excellentwettability,alsoinaqueoussystems• Specificsurfaceareaof125–1700m2/m3
• Highthermalstability(>400oC)
Product applications• HCIseparationforproductionandforHCIrecovery(typicallyintheproductionofpolycarbonate)
• MCA/DCAdistillation• Productionofphosphoricacid• Concentrationofhydrofluoricacid• Separationofchlorophenols
Mellacarbon – pure carbon
pressuredrop
separationefficiency
Mellacarbon
headpressurep/mbar
0697 2522
18
1
0.1
0.01
64.X90.X
40.Y64.Y
0.01 0.1 1
0 2 4 6 8 10
100
10
1
0.1
p/
h /m
bar/m
F / Pa
40.
Y/64
.Y 6
4.X/
64.Y
variousliquidloads,air/water,T=30oC,atmosphericpressure
With Mellagrid, Sulzer Chemtechcombines the efficiency of struc-turedpackingswiththemechanicalresistanceofagrid.Mellagrid is used wherever themechanical strength of structuredpackings is a concern or wherecokingislikelytooccur.
MellagridSulzerstructuredgridpackings
Special features• Notsensitivetocokingandfoulingduetoitssmoothsurfaceandgeometricalstructure
• Efficientdissipationoftemperature
• Betterde-entrainmentandseparationefficiencythanatraditionalgrid
• Thelowelementheightanditsstructureallowforeasycleaning.Itcanberemoved,unscrewedandcleanedwithawaterjet
• Mechanicallyrobuststructure
Applications• Atmosphericorvacuumtower: Washsection• FCCMainFractionator:Slurrypumparoundsection
• Cokeror VisbreakerFractionator: Washsection
pressuredrop
capacity
loadfactorc
G /m
/s
Technical Data
Mellagrid 90.X 64.X 64.Y 40.YSpecificsurfacearea 90m2/m3 64m2/m3 64m2/m3 40m2/m3
Elementheight(approx.) 140mm 220mm 130mm 200mmSurfacestructure smoothMaterialthickness 0.5to2mmMaterial AISI410Sor316L,othermaterialsuponrequest
Mellagrid
0694 2506
0694 2506
19
Katapak-SP Sulzerreactivedistillationpacking
Thispackingwasdevelopedtobeappliedinreactivedistillationprocesses.Withthemodularconceptsepa-ration efficiency and catalyst volume fraction can bevariedtoperfectlyfittherequirementsofeachspecificprocess.Othertypesareavailableonrequest.Largestdiametersuppliedtodate:2m.
Special features:• FlexibledesigncombiningcatalystelementsandMellapakPluslayers
• Highseparationefficiency• Highreactioncapacity
Product applications:• Synthesisofacetates(e.g.butylacetate)• Hydrolysisofmethylacetate• Synthesisoffattyacidesters• Synthesisofacetals• MTBE,ETBE,TAME
pressuredrop
separationefficiency
Katapak
parameter=headpressurep/mbar
0600 2701-6
1 2 3 4
0.6
0.5
0.4
0.3
0.2
0.1
00
1 2 3 40
100
10
1
0.1
960400100
Katapak-SP 12
F / Pa
F / Pa
HE
TP /m
p
/ z
/mb
ar/m
VRGF
VSI
VKG
VKR2
VKPK VEPK
VKH
VKGF
VKR2F
VEH
VER2
VEP/VEPW
VSI/VSIR
300
100
50
10
1
0.050.25 0.8 3 20
20
Column internalsSp
ecificliquidloadl[m
3 /m2 h
]
Liquid distributors
High-Liquid-Load
Standard-Load
Low Liquid-Load
TubeDistributorsVR
Distributor/CollectorVS
Trough-DistributorVK Element-DistributorVE
Column-Diameter[m]
0609 2500-10609 2500-5
0610 2501-4
0610 2501-3
0610 2501-1
0610 2501-2
0609 2500-4
0609 2500-3
0609 2500-7 0609 2500-2
0600 2507-6
0609 2500-6
0610 2501-5
21
Collector support grids
Collectors
Chimney trays
Column internals
Type
SLRT/SLMT
SLR/SLM
SK
Features
ThecollectorSLTisbothapackingsupport and a vane collector. Asapacking support, it can supportthe direct load of packings withsurface areas up to 350 m2/m3.Forfinerpackings,additionaldripplatesareused.This non-welded collector SLT isoften used in applications wherespace between packed beds islimited. This collector requires asupportringinsidethecolumn.
ThevanecollectorSLisusedasaseparateunittoaccumulateliquidsfrom packed sections within acolumn. This collector requires aringchannelweldedtothecolumnwall.
The collector SLF is designed tobe installed between the columnflangesinsmallerflangedcolumns.
ThecollectorSKisanestablishedandversatiletraydesign,availableeither in bolted or seal-weldedconstruction.Itisgenerallyusedinlarge diameter columnswith highliquidloads.
Columndiameter
from0.3m
from0.3m
from1m
0600 2509-4
0600 2506-1
0600 2509-2
22
Column internals
Collector-distributor systems/Vapor distributor
Support grids
Type
VSI
Columndiameter
from0.25m
Thecollector/distributorVSisusedwhenevercollectionandredistribu-tion of liquid is required at veryhigh liquid loads. It resemblesa chimney tray; however thechimney arrangement is customdesigned for your application’sliquid distribution and pressuredroprequirements.For moderate liquid loads appli-cations,whereliquidmixingisim-portant, a separate accumulatortray must collect the liquid andfeedittoaliquiddistributorlocatedbelowit.
Inaddition,specialcollector-distributionsystemsareavailable,e.g.foruseatincreasedpressuresor-inconjunctionwithhighlycorrosion-resistantpackings-inprocesseswithagressivemedia.Supplementaryinformationistobefoundinourbrochure“InternalsforPackedColumns”.
TEB/TSB
TS/TE
0.5to10m
from0.1m
TEB and TSB are used withstructured packings. Both requiresupport rings tobewelded to thecolumnwall.TEBaresupportsforflanged columns. The segmentalgrids of the TSB pass throughmanholes and are clamped to-gether for convenient installation.Noweldingisrequired.TEB and TSB support grids areidealforapplicationsrequiringex-pensivehigh-alloys.Certainhighperformancepackingsrequireadditionaldripplates.
TEandTSareintendedforstruc-tured packings with surface areaover 350m2/m3 packing volume.Theyaredesignedwithdripplatesto prevent premature flooding ofthepacking.These support grids rest on sup-portringsorgussetsweldedtothecolumn shell. For columns over3m,additionalsupportsandmajorbeamsmayberequired.
0602 2511-2
0600 2513-4
0600 2513-2
23
Repacking the entire column cross-sectionAlong with other aspects, thismodificationservestoincreasethethroughput.
Revamping of existing columns
InstallationThe new column internals areinstalled through the manholes:support beam, support grid,packing, locating grid, distributorandcollector.
InstallationThecolumnhead is takenoffandthepre-assembledandpre-packedsleevesareloweredbycraneontothe relative beams fitted in thecolumn. The annular spaces aresealedofftopreventgasandliquidby-passing.
Repacking with column sleeveTo improve product purity withoutincreasing capacity. Due to thegood hydraulic performance ofthe Sulzer structured packings,the entire column cross-sectionis often not needed. The Sulzerpacking isfitted insideasleeveofsmallerdiameter.
Existingcolumn ItemssuppliedbySulzerChemtech
Installationeitherbythecus-tomerwithSulzeradvisingorcompleteinstallationservicebySulzerasthecustomerwishes.
1 Sulzer packing2 Support grid3 Support beam 4 Collector5 Support lugs (welded-in)6 Ring channel7 Liquid distributor8 Locating grid (hold-down grid)
9 Existing trays (incl. support rings)
Repacking work(Examplefortraytowers)• Removethetrays• Removetraysupportrings(whenrequired-dependingupontheinstallationmethodofthepacking)
• Weldinthesupportlugs,tie-barsandringchannelsfortheliquidcollectors
• Providemanholesandsightglassesatthelevelofeachliquiddistributor
• Fitnewfeedandinstrumentconnections,ifnecessary
• Cleanthecolumn
Repacking timeDependingonthecolumnsizeandpersonnel deployed,modificationstotheexistingcolumnmaytakeonetofourweeks,andseveraldaystotwoweeksforfittingthenewparts.
0682 2044 0682 2045
6
789
1
2345
45
6
8
9
12
7
Installation
24
Installation of packing
The packing is fitted inside the column sleeves at the preassembly site
Installation of the liquid distributor
The column sleeve is lowered into the column with two cranes. Weight: 100 tons
Revamping of a vacuum column with Mellapak
Inspecting packings after installation
0695 2510-13
0692 2512-18
0683 2006-2
0683 2006-1
0601 2505-2
0602 2509-39
25
Sulzer columns ofsectional designAllinternalscanbeinstalledthroughthecolumnflangeopenings
Sulzer columns – your solution
Welded column,monoblock typeAll internals in segments for in-stallation and removal throughmanhole,nominaldiameter500upto1000mm
Sulzer packing 1invarioustypesanddifferentmaterials
Support grid 2forthepacking
Liquid collector 3
Feed pipe 4todistributor
Liquid distributor 5mountedonlocatinggrid
Locating grid 6
Steam inlet pipe 7
Column sump 8
Circulation pipe 9to reboiler
Skirt 10
Anchorage 11
Variations on the above designFeed:• vapor• twophaseswithflashboxSidestream:• liquidfromcollector• vaporcollector
0694 2510 0694 2511
5
1
34
2
6
1
34
5
2
7
8
91011
Bottomproduct
Bottomproduct
Feed
Feed
Reflux
from
conden
ser
Reflux
from
conden
ser
26
Distributor test facilityUniform liquid distribution isdecisive in securing good sepa-ration performance from a rectifi-cation/absorption column incorpo-rating structured packingsespecially for columns of largediameter.This requirement was recognizedearlyoninthedevelopmentoftheSulzerstructuredpackings.Hencethegeometricalconfigurationofthepackings promotes liquid streamintersectionsand thus intermixing.Moreover, awhole seriesof liquiddistributors has been developed,which are optimally matched forcolumndiameter,packingtypeandoperatingconditions.
Separation technology laboratoryComprehensivecustomerservice
The distributor test facility hasprovided results which have con-tributed significantly to the con-struction of large distributors withdiameters ranging from3mup to15m.As part of integrated qualitycontrol, all distributor types arefully tested before delivery tocustomers. Sulzer Chemtech iscertified in accordance to ISO9001:2000andISO14001.
Distributors on the Sulzer Chemtech distributor test facility
LaboratoriesSulzer Chemtech has set up aprocess engineering laboratory inWinterthur,Switzerlandfordevelop-ment and testing of structuredpackings, column internals andtrays.AtSulzerChemtechAllschwilLtd, a laboratory carries outcustomertrialsandpilottests.Alsoananalyticallaboratoryandtrainedpersonnelareavailable.
Multi‑purpose pilot plant for the separation of mixtures by distillation, using Sulzer structured packings of various design
0600 2566-1 0682 2026
G Gasflow kg/h 2.205 lb/h
g Gasloadpersquaremeter kg/m2h 0.2048 lb/ft2h
(relatedtoemptycolumn)
L Liquidflow kg/h 2.205 lb/h
m³/h 4.403 gpm
l Specificliquidload m³/m²h 0.4090 gpm/ft2
(relatedtoemptycolumn)
NTS Numberoftheoreticalstages (–)
NTSM Numberoftheoreticalstages m-1 0.3048 ft-1
permeterpackedheight
NTUM Numberoftransferunits m-1 0.3048 ft-1
permeterpackedheight
HETP Heightequivalenttoa m 39.37 in
theoreticalplate
cG Loadfactor=wGρG/(ρL-ρG) m/s 3.281 ft/s
F Ffactor=wG.ρG m/skg/m³=Pa 0.8197 ft/slbm/ft3
wG Superficialgasvelocity m/s 3.281 ft/s
(relatedtoemptycolumn)
ρG Gasdensity kg/m3 0.06243 lb/ft3
ρL Liquiddensity kg/m3 0.06243 lb/ft3
M Molarmass kg/kmol 1.000 lb/lb-mol
p Operatingpressure mbar 0.7501 mmHg
bar 14.50 psia
∆p/∆z Pressuredropperunitheight mbar/m 0.1224 inH2O/ft
T Operatingtemperature K 1.800 R
Ac Columncross-section m2 10.76 ft2
dc Columndiameter m 3.281 ft
ψ Flowparameter=L/G.ρG/ρL (–)
27
Formula notation
MetricUnits Toconvert USUnits toUSUnits multiplyby
HeadquartersSulzerChemtechLtdP.O.Box658404Winterthur,SwitzerlandPhone+41522625028Fax [email protected]
22.13.06.40-II.10-50-PrintedinSwitzerland
Theactivityprogramcomprises:• Process components such as fractionation trays, structured andrandompackings,liquidandgasdistributors,gas-liquidseparators,andinternalsforseparationcolumns
• Engineeringservicesforseparationandreactiontechnologysuchasconceptualprocessdesign,feasibilitiesstudies,plantoptimizationsincludingprocessvalidationinthetestcenter
• Recoveryofvirtuallyanysolventsusedbythepharmaceuticalandchemicalindustry,ordifficultseparationsrequiringthecombinationof special techniques, such as thin film/short-path evaporation,distillation under high vacuum, liquid-liquid extraction,membranetechnologyorcrystallization.
• Complete separation process plants, in particularmodular plants(skids)
• Towerfieldservicesperformingtrayandpackinginstallation,towerand column maintenance, vessel welding, and plant turnaroundprojects
• Mixingandreactiontechnologywithstaticmixers• Cartridge-based metering, mixing and dispensing systems, anddisposablemixersforreactivemulti-componentmaterial
Distributedby:
North and South America SulzerChemtechUSA,Inc.8505E.NorthBeltDriveHumble,TX77396,USAPhone+12814415800Fax +12812910207
Asia, PacificSulzerChemtechPte.Ltd.10BenoiSectorSingapore629845Phone+6565155500Fax +6568627563
Sulzer Chemtech Ltd, a member of the Sulzer Corporation, withheadquartersinWinterthur,Switzerland,isactiveinthefieldofprocessengineeringandemployssome2500personsworldwide.SulzerChemtech is represented in all important industrial countriesandsetsstandardsinthefieldofmasstransferandstaticmixingwithitsadvancedandeconomicalsolutions.