Random packing

From competitive products to advanced solutions

Sulzer Chemtech – Mass Transfer Technology

Your partner in separation and mixing technology

The highest level of Fast and reliable Comprehensive engineering

application know-how turnaround services and technology services
Our team provides expert knowledge We don’t shut-down, when you We provide a full scope of associated
for more than 500 applications in 100 shut-down. You can rely on Sulzer engineering and technology services
processes, enabling us to optimize the professionals, expertise and to optimize or trouble-shoot your
performance and your installation. procedures to get you back and installation.
running in the shortest possible time.

Naphtha

Kero

Diesel

A broad range of innovative and high-performing products

More than 200 of our products cover a wide range of needs in the field of separation and mixing technology.

They have proven their performance in more than 100’000 columns, 50’000 gas/liquid or liquid/liquid
separators and 100’000 static mixers in operations worldwide.

MellapakPlus™ UFMPlus™ trays NeXRing™ SMV™ static mixer Dusec Plus™

Packing Coalescer
One of the best The next High mixing efficiency
Often copied, big thing in High performance
high performance trays combined with large
never equaled random packing liquid/liquid
ever tested at FRI turn-down processing
coalescer
capabilities

2
Random packing

NeXRing random packing 4

NeXRing comparison 6

NeXRing applications 7

Other random packings 8

Column internals 13

Random packing has been used for fractionation, absorption With our NeXt evolution of random packing we bring the
and stripping operations in gas, refinery and chemical plants same or better performance of the established random
for may years and the benefits are well established. For packing types which when combined with Sulzer’s leading
example, in high liquid load and high pressure applications application know-how offers a reduction in both capital and
random packing has been historically preferred as it provides operation cost of even your most demanding processes.
improved distillation or absorption efficiency and a reduced
pressure drop.   Sulzer’s broad established random packing portfolio includes
Nutter Rings, I-Rings, C-Rings, P-Rings and R-Rings, and
Furthermore, ease of replacement and storage make random gives us the flexibility to offer the solution whatever your
packing the ideal choice for systems with heavy fouling or requirement.
corrosion where packing is frequently replaced.

NeXt Generation

3rd Generation

2nd Generation

1st Generation

3
NeXRing™

The NeXt generation random packing

The NeXRing is the latest high performance random packing

developed by Sulzer. The NeXRing provides extremely large
and uniform open area in every ring orientation allowing a
high surface exposure to liquid and vapor while minimizing
dry zones.

The NeXRing had been tested in both Sulzer’s leading in-

house R&D facilities and independently. NeXRing #1.2 had
been successfully tested in FRI in 2017. All results have
shown improved hydraulic performance compared to estab-
lished random packing types with the same efficiency.

The NeXRing has: The NeXRing enables you to:

• Reduced pressure drop • Reduce operating costs
• Increased capacity • Reduce column size (greenfield)
• Improved mechanical stability • Increase capacity (brownfield)
• Improved anti fouling feature • Increase efficiency
• Increase running time and reduce stoppage

KGa of NeXRing HETP of NeXRing

90 1200
NXR#0.6
80
NXR#0.7 1000
NXR#3
KGa, kg-mol / (h m³ atm)

70
NXR#1 800
HETP (mm)

60 NXR#2
NXR#1.5
600 NXR#1.5
NXR#2 NXR#1.2
50 NXR#1
NXR#1.2 400
NXR#3 NXR#0.7
40 NXR#0.6

200
30

20 0
10 100 0 0.5 1 1.5 2 2.5 3 3.5 4
Liquid Load l, m³/m² h F, √Pa
Conditions Conditions
Diameter: 0.3 m, Bed height: 2.25 m Valid for atmospheric distillation with
Liquid concentration: 4% NaOH standard organic test mixture at total reflux
Conversion to carbonate (Na2CO3): < 1%
Inlet gas concentration: 400ppm CO2
Temperature: 25˚C
F = 1.5 √Pa
Bracket indicates extrapolated data

4
Pressure drop performance curves

NXR #0.6 F, ft / s √lb / ft3 NXR #0.7 F, ft / s √lb / ft3

1.0 2.0 3.0 4.0 1.0 2.0 3.0 4.0
20 2.45 20 2.45
120
120 100
100 80 60 40 20 80 60 40 20

10 1.22 10 1.22
0m mh 3/ 2
0 m3/ m2h

∆p /∆z, in H2O / ft

∆p /∆z, in H2O / ft
∆p /∆z, mbar / m

∆p /∆z, mbar / m
1.0 0.12 1.0 0.12

0.1 0.1
0.5 1.0 5.0 0.5 1.0 5.0
F, √Pa F, √Pa

NXR #1 F, ft / s √lb / ft3 NXR #1.2 F, ft / s √lb / ft3

1.0 2.0 3.0 4.0 1.0 2.0 3.0 4.0
20 2.45 20 2.45
120 100 80 20 120 100 80 40 20
60 40
60
10 1.22 10 1.22
∆p /∆z, in H2O / ft

∆p /∆z, in H2O / ft
∆p /∆z, mbar / m

∆p /∆z, mbar / m
0 m3/ m2h
0 m3/ m2h

1.0 0.12 1.0 0.12

0.1 0.1
0.5 1.0 5.0 0.5 1.0 5.0
F, √Pa F, √Pa

NXR #1.5 F, ft / s √lb / ft3 NXR #2 F, ft / s √lb / ft3

1.0 2.0 3.0 4.0 1.0 2.0 3.0 4.0
20 2.45 20 2.45
100 80 60 40 20 6040 20
120 120 100 80

10 1.22 10 1.22
∆p /∆z, in H2O / ft

∆p /∆z, in H2O / ft
∆p /∆z, mbar / m

∆p /∆z, mbar / m

0 m3/ m2h
0 m3/ m2h

1.0 0.12 1.0 0.12

0.1 0.1
0.5 1.0 5.0 0.5 1.0 5.0
F, √Pa F, √Pa

NXR #3 F, ft / s √lb / ft3

1.0 2.0 3.0 4.0
20 2.45 Liquid
120 10080 40 Load l, m3/m2 h
60

10 20 1.22 0
∆p /∆z, in H2O / ft

20
∆p /∆z, mbar / m

40
60
0 m3/ m2h
1.0 0.12 80
100
120
150
Air-water system,
0.1 ambient conditions
0.5 1.0 5.0
F, √Pa

5
NeXRing™

The NeXt generation random packing

Sulzer’s NeXRing demonstrates an improvement of performance in comparison to the widely

used P-Ring (directly replace of Pall Ring) and I-Ring (directly replace of IMTP).
• Replacing P-Ring#2 with NeXRing#1.5 will give up to 10% increase in efficiency and a
25% increase in capacity. If NeXRing#2 is used up to a 35% increase capacity is obtained
with the same efficiency
• By replacing I-Ring #40 with NeXRing#1.2, more than 10% increase in capacity can be
achieved while keep same efficiency. For applications ask for more efficiency, NeXRing #1
can be a good choice while still bring certain capacity improvement.
• I-Ring #50 can be replaced by NeXRing #2 for a 10% increase in capacity with no
decrease in efficiency. NeXRing #1.5 can be used for a further increase in efficiency.

Influence of ring type and size to efficiency and capacity

200%
190% NXR#0.6
180%
170% IR#25 NXR#0.7
Efficiency increase %

160%
PR#1
P-Ring™ 150%
140%
NXR#1
130% PR#1.5
IR#40 NXR#1.2
120%
NXR#1.5
110%
PR#2 NXR#2
100%
IR#50
90%
80%
70% PR#3.5 NXR#3
IR#70
60%
70% 80% 90% 100% 110% 120% 130% 140% 150% 160% 170%
I-Ring™ Capacity increase %
PR = P-Ring
IR = I-Ring
NXR = NeXRing

Conditions of the test

Test mixture: Ethylbenzene and Chlorobenzene, at atmospheric pressure under
total reflux condition

The graphic shows relative efficiency values and relative capacity values for differ-
ent P-Rings, I-Rings and NeXRings. The P-Ring #2 is a standard in the industry.
That’s why it was set as a reference point (100% efficiency and 100% capacity).
NeXRing™

CMR™ is a trademark and IMTP® and Cascade Mini-Rings® are registered trademarks of Koch-Giitsch,
LP. Pall Ring® is a registered trademark of BASF AG. aMDEA® is a registered trademark of BASF AG.

6
Applications

Fertilizer, Acid NGL (Natural Gas Butadiene Demethanizers

Gas Removal, Gas Liquids) Treatment
In butadiene production Separation of methane from
Sweetening
NGL produced from liquids random packing is typically heavy hydrocarbons is done
Random packing is widely recovery plants contain used in the main wash, recti- at high operating pressure
used in the removal of CO2 H2S, CO2 and Mercaptans fier and degasser columns and low temperature. Due
and H2S from natural or which need to be removed due to their characteristically to the low surface tensions
bio-gas by contacting with to satisfy gas purity require- high specific liquid load. and small density differences
amine based solvents such ments. Random packing is leading to unstable liquid
as MEA, DEA, MDEA and the industry standard for this Replacing previous gen- films ensuring good contact
Activated MDEA. A common application and the Sulzer eration of random packing between the liquid and gas
characteristic of these sol- NeXRing with its uniform with the equivalent Sulzer phase is critical.
vents is the strong tendency surface area distribution and NeXRing can lead to higher
to foam. high open area helps to cre- capacities without loss of Due to these characteristics
ate a more uniform droplet efficiency. In these unit op- random packing has been
The Sulzer NeXRing can dispersal compared to erations it is fairly common historically preferred for on-
provide capital and op- previous generation random to use divided wall columns. shore applications in com-
erational cost reductions in packing while also minimiz- To prevent loss of efficiency parison to trays or structured
these applications by giving ing the potential for back- or hydraulic performance packing. The Sulzer NeXRing
a much lower pressure drop mixing. a good understanding a of with its higher capacity and
compared to older random liquid distribution is criti- lower pressure drop enables
packing types minimizing the Replacing existing older cal. With many divided wall a further increase in capacity
hydraulic impact of foam. types of random pack- columns in successful for existing columns or de-
Sulzer’s NeXRing can directly ing with Sulzer NeXRings operation and a track record creased diameters and bed
replace existing previous combined with Sulzer’s high of performance since the heights for new columns.
generations of random pack- performance VSX continu- 1960’s Sulzer can provide
ing either to hydraulically ous and dispersed phase this critical and often missed
debottleneck the column distributors provides either design know-how to get the
or to increase the column an increased efficiency or most out of your column.
efficiency by using a smaller increased capacity.
ring size while keeping the
same pressure drop.

7
Nutter Ring™

• High-performance random packing designed by

Dale Nutter in 1984
• Efficiency enhanced by lateral liquid spreading and
surface film renewal
• Superior surface utilization allows for shorter
packed beds
• Intensively tested by Fractionation Research Institute
(FRI) which makes the Nutter Ring the best-known
high-performance random packing in industry
• Geometry provides maximum randomness with
minimum nesting and maximum mechanical strength

Nutter Ring types NR #0.7 NR #1 NR #1.5 NR #2 NR #2.5 NR #3

Specific surface m /m 2 3
226 170 124 96 85 66

ft /ft
2 3
68.9 51.8 37.8 29.3 25.9 20.1

Void fraction % 98 98 98 98 98 98
Material thickness can be adjusted to clients’ needs. Other sizes are available on request.

KGa of Nutter Ring HETP of Nutter Ring

Liquid Load, gpm/ft² F, ft/s √lb/ft³
4 8 10 20 30 40 50 60 0 0.5 1.0 1.5 2.0 2.5
110 7 1200
100 1100
6
90 ) 40
(NR #0.7 1000
80 5 NR #3
KGa, kg-mol / (h m3 atm)

900
70 NR #1
800 NR #2.5

HETP, inches
4 30
KGa, lb-mol/(h ft3 atm)

.5)
60 (NR #1 700 NR #2
HETP, mm

2 600 NR #1.5
50 NR #
2.5 3 NR #1 20
N R # 500
NR #0.7
400
40 #3)
(NR 300
35 10
2 200
30
100

25 0 0
10 15 20 25 30 40 50 60 80 100 150 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5

Liquid Load l, m³/m² h F, √Pa

Conditions Conditions
Diameter: 0.3 m, Bed height: 2.25 m Valid for atmospheric distillation with standard organic test
Liquid concentration: 4% NaOH mixture at total reflux
Conversion to carbonate (Na2CO3): < 1%
Inlet gas concentration: 400ppm CO2
Temperature: 25 ºC
F = 1.0 √Pa
Bracket indicates extrapolated data

8
NR #0.7 F, ft / s √lb / ft3 NR #1 F, ft / s √lb / ft3
1.0 2.0 3.0 4.0 1.0 2.0 3.0 4.0
20 2.45 20 2.45

10 1.22 10 1.22

∆p /∆z, in H2O / ft
∆p /∆z, in H2O / ft

∆p /∆z, mbar / m
∆p /∆z, mbar / m

1.0 0.12 1.0 0.12

0.1 0.1
0.5 1.0 5.0 0.5 1.0 5.0
F, √Pa F, √Pa

NR #1.5 F, ft / s √lb / ft3 NR #2 F, ft / s √lb / ft3

1.0 2.0 3.0 4.0 1.0 2.0 3.0 4.0
20 2.45 20 2.45
Liquid
Load l, m3/m2 h
10 1.22 10 1.22
0

∆p /∆z, in H2O / ft
∆p /∆z, mbar / m
∆p /∆z, in H2O / ft
∆p /∆z, mbar / m

20
40
60
1.0 0.12 80 1.0 0.12
100
120
150
Air-water system, 0.1
0.1 ambient conditions
0.5 1.0 5.0 0.5 1.0 5.0
F, √Pa F, √Pa

NR #2.5 F, ft / s √lb / ft3 NR #3 F, ft / s √lb / ft3

1.0 2.0 3.0 4.0 1.0 2.0 3.0 4.0
20 2.45 20 2.45

10 1.22 10 1.22
∆p /∆z, in H2O / ft

∆p /∆z, in H2O / ft
∆p /∆z, mbar / m

∆p /∆z, mbar / m

1.0 0.12 1.0 0.12

0.1 0.1
0.5 1.0 5.0 0.5 1.0 5.0
F, √Pa F, √Pa

9
I-Ring™

• Equivalent to IMTP Rings - industry’s first and most

widely used high-performance random packing
introduced in the late 1970s
• Geometry ensures low liquid hold-up and a great
improvement in capacity compared to Pall Rings

I-Ring types IR #15 IR #25 IR #40 IR #50 IR #60 IR #70

Specific surface m /m
2 3
305 226 151 100 80 60

ft2/ft3 93.0 68.9 46.0 30.5 24.4 18.3

Void fraction % 97 97 98 98 98 98
Material thickness can be adjusted to clients’ needs. Other sizes are available on request.

S-Ring™

• Directly replace widely used Raschig Super Ring

• Improved performance compared to 3rd generation
random packings

S-Ring types SR #0.3 SR #0.5 SR #0.7 SR #1 SR #1.5 SR #2 SR #3

Specific surface m /m
2 3
315 250 180 150 120 100 80

ft /ft
2 3
96 76 54.5 45.7 36.5 30.5 24.4

Void fraction % 96 97 98 98 98 98 98
Material thickness can be adjusted to clients’ needs. Other sizes are available on request.

10
C-Ring™
Also available in Plastic, Materials available are PP, PVC/C, PE, PVDF, ETFE, PFA

• Equivalent to the widely used Cascade Mini-Rings (CMR)

• Evolution of Pall Ring employing a much lower
diameter-to-height ratio which favors orientation that
results in lower pressure drop and higher capacity
• Excellent mechanical strength
• C-Rings excel in fouling media

C-Ring types CR #1 CR #1.5 CR #2 CR #2.5 CR #3 CR #4 CR #5

Specific surface m /m
2 3
244 187 142 126 101 70 62

ft2/ft3 74.4 57.0 43.3 38.4 30.8 21.3 18.9

Void fraction % 97 97 98 98 98 98 99
Material thickness can be adjusted to clients’ needs. Other sizes are available on request.

P-Ring™
Also available in Plastic, Materials available are PP, PVC/C, PE, PVDF, ETFE, PFA

• Equivalent to the widely used Pall Ring

• Design by BASF AG around 1940 based on the
Raschig Ring
• Punched «shovels» leave «windows» on the outside
facilitating vapor flow and enhancing capacity versus
the R-Ring
• World‘s largest collection of performance data is
available for the Pall Ring

P-Ring types PR #5/8 PR #1 PR #1.5 PR #2 PR #3.5

Specific surface m /m
2 3
350 222 144 112 64

ft /ft
2 3
106.7 67.7 43.9 34.1 19.5

Void fraction % 95 95 97 97 98
Material thickness can be adjusted to clients’ needs. Other sizes are available on request.

11
 Column internals

Liquid distributors

300
High-Liquid-Load Tube Distributors VR

VRGF

100
Distributor / Collector VS

VSI
VSI/VSIR

Trough-Distributor VK Element-Distributor VE

50
VKH VEH

VKG
Specific liquid load l [m3/m2 h]

Standard-Load

VKGF VER2
10

VKR2

VKR2F VEP/VEPW

1
Low Liquid-Load

VKPK VEPK

0.05
0.25 0.8 3 20
Column-Diameter [m]
12
Internals for Random Packing Columns

Sulzer high performance liquid collector / re-distributor, VSR is designed with combination of high performance
liquid distributor and vane type liquid collector.

Compared to the conventional liquid collect/re-distributor, it has the following advantages:

• Lower pressure drop
• Excellent liquid distribution also to small liquid loads (from 1 m³/m².hr)
• Possible to have high distribution density
• Improved liquid-mixing compared to VS type
• Minimized liquid leakage
• Reduced space requirement

Distributor specifications:

Column Diameter 0.5~8 m

Liquid Load 1~80 m3/m².hr
Equivalent Drip Point Density 60 to 200 drip point per m² VSR

Turn Down Ratio 2.5 to 1 (max 10 to 1)

Support grids Collectors

GIS SLR/SLM

Collector-distributor systems/Vapor distributor Chimney trays

VSI/VSR SK

13
Internals for random packing columns

Column internal for NeXRing

Mist Eliminator
Remove liquid droplet
Liquid Feed Pipe from vapor entrainment

Liquid Distributor
Distribution liquid to Bed Limiter
the packing below, Required above random
a proper selection packing bed to stop
and design of liquid random packing being
distributor is important blow away
to overall efficiency

Random Packing
(Bed#1)
Gas Injection
Support Plate
Served as packing
support as well as to
distribute gas
from bottom,
high open area is
preferred

Liquid Collector
Used to accumulate
liquids of above beds,
Liquid Redistributor
side draw off can also
be realized with the
collector

Random Packing
(Bed#2)

14
Comprehensive engineering services markets

Development and technology

Sulzer makes every effort to support our customers and

continuously improve our design tools. Engineers in the
R&D lab develop new and improved products, analyze
and optimize processes.

We maintain close relationships to universities and

independent research organizations to support
these efforts.

Engineering and manufacturing 

Sulzer has a long-standing manufacturing tradition.

Sulzer owns dedicated factories in every region to
produce mixers, columns, reactors, and heat exchangers.

For certain sizes and certain countries, we work with

well-known and proven subcontractors who are bound by
Sulzer manufacturing policies and quality standards.

Capabilities

Manufacturing according to PED 97/23/EC, ASME VIII

Div.1, and ASME B31.3/U-Stamp, Gost (TR), China
Stamp, Norsok, or NACE

Design codes acc. to AD2000, EN 13445, ASME Broad

selection of material for construction available

Non-destructive testing (LPT, X-ray, pressure testing up

to 500 bar, PMI, MT, UT etc. acc. EN and ASME) Manufacturing / Service Centre
Sales offices
Designing with SolidWorks

Strength calculations, FEM analysis, nozzle loads etc.

Certification for ISO 9001, ISO 14001 and ISO 18001

Experienced project management team

CFD Analysis

CFD calculations done in advance of fabrication can

support the decision to go for a particular technology,
and can save on the time required for commissioning
and testing later. Sulzer uses CFD technology both for
the modeling of existing and the development of
new products.

15
www.sulzer.com

E10534 en 4.2019, Copyright © Sulzer Ltd 2019

This brochure is a general product presentation. It does not provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered
with our products. Directions for use and safety will be given separately. All information herein is subject to change without notice.