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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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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 9M Rombopak S4M

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

HE

TP /m

10

1

0.1

10

F

p

/ z

/mb

ar/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



pressuredrop

0602 2510

Mellapak 250.YMellapak 250.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


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


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


pressuredrop




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


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


pressuredrop


pressuredrop


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


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.


0699 2522−4

MellapakPlus 352.YMellapakPlus 602.Y

MellapakPlus 452.YMellapakPlus 752.Y

pressuredrop



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


pressuredrop


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


Gauze packing BXGauze packing BXPlus

separationefficiencyofBXandBXPlusisidentical


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


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


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


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


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


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


Katapak


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


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


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-IV.10

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.

structured packings - sulzer sulzer chemtech has been active as equipment supplier to the chemical...

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