PLASTIC

Packing and Column Internals

YOU CAN RELY ON US.™

Introduction
For more than 70 years, random packings in ceramic, metal, and plastic have been used successfully as an inexpensive
but efficient means to increase a tower’s capacity and/or efficiency. The original Raschig Rings have been superseded by
new generations of improved products. Today, Koch-Glitsch offers the widest spectrum of random packings available
worldwide. For more demanding applications, structured packing offers even lower pressure drop and higher efficiency.
Structured packing is offered in both standard- and high-capacity versions to meet any performance specification.

There are numerous process advantages that can be realized by using packings in various applications. The predominant
reasons for using tower packings are to reduce pressure drop throughout the column, to increase the capacity compared
to trays at the same efficiency, and/or to reduce liquid holdup in the column. Plastic random packings are not as bulky as
their ceramic equivalents and, therefore, offer higher capacity and lower pressure drop.

From an engineering point of view, plastics are materials that will permanently deform when stress (force) is applied
at common temperatures. The rate at which a plastic will deform depends on the amount of stress, temperature, and
time. Compression at the bottom of a packed bed reduces the void fraction and can lead to increased pressure drop and
premature flooding. Koch-Glitsch has developed a proprietary database of allowable operating loads for plastic packing
based on creep modulus data that is used to ensure the structural integrity of your packed beds.

This booklet provides information for quick sizing of

packed columns using plastic structured and random
packings. The charts provide hydraulic ratings and
relative packing efficiencies (in terms of the KGa
value for the absorption of CO2 into a standard caustic
solution). In addition, Koch-Glitsch offers the hydraulic
rating program, KG-TOWER® software, which may be
downloaded from its website: www.koch-glitsch.com.

Koch-Glitsch is unsurpassed in offering the widest range of

sizes and styles of traditional and high performance plastic
structured and random packings. To enable the process
engineer to optimize the system for cost and performance,
several sizes are offered within each packing family. As the
packing size increases within the family, the packing offers
greater capacity and lower pressure drop at the expense of
GRP Flue Gas Condensing Scrubber. lower efficiency.

Koch-Glitsch and its sister companies deliver innovative process and pollution control equipment designed to optimize
plant operations and manage the constant changes in environmental standards.
n State-of-the-art ceramic and plastic products from Koch Knight are applied in demanding corrosive applications.
n With over 35 years’ experience and 400 plants in operation, Eta Process Plant is the world’s leading supplier of
turnkey deaeration plants.
n Combined with Koch-Glitsch, Koch Specialty Plant Services offers the single supplier/installer benefits of turnkey
solutions, which provides faster, safer revamps with minimum downtime.
n Precision membrane technologies from Koch Membrane Systems include ultrafiltration and reverse osmosis (RO)
membrane systems to help purify the world’s water.

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Column Internals
Koch-Glitsch plastic column internals are available in both thermoplastic and thermoset (e.g. Fiberglass-Reinforced
Plastic – FRP) materials. Occasionally, thermoplastic internals have different temperature limits than packing of the same
material. Koch-Glitsch has an unsurpassed knowledge in recognizing these instances and can provide designs specific to
any application.

FRP column internals use different designs than thermoplastic internals. FRP has better structural properties but greater
fabrication restrictions. The Koch-Glitsch standard thermoset is one of the DERAKANE® brand resins, although other
resins are available to suit a wide range of chemical and thermal requirements.

Model TP 286 Thermoplastic Trough Model TS 236 FRP Liquid Distributor Model TP 804 Support Grid,
Distributor with Drip Tubes. with Side Orifices. PTFE/Carbon-Carbon.

Koch-Glitsch process engineers will help select the appropriate style of packing and match that packing with the
optimum tower internals to create the INTALOX® Packed Tower System that best satisfies your specific requirements.
For more information on liquid and vapor distribution technology as well as other column internals in thermoplastic or
FRP, consult our brochure, Plastic Packed Tower Internals (KGPTIG-1).

Materials of Construction
Plastic packings are often preferred because of their lightweight construction Available Materials
and resistance to breakage. The availability of numerous types of plastic ■ General grade polypropylene
resins provides the designer with a broad range of chemical and thermal ■ LTHA polypropylene
resistant materials. Koch-Glitsch plastic packings are made in a wide variety of ■ LTHA polypropylene
thermoplastic materials. Most of the Koch-Glitsch packings are available in the (10% glass filled)
materials shown in the Available Materials list. Other plastics are available by ■ High density polyethylene
special request. ■ Low density polyethylene
■ PVC
The mechanical strength of a plastic material decreases over time. Temperature ■ CPVC
limits for long-term service life depend on the load the packing must bear from ■ PVDF
its own weight and from liquid holdup. The maximum operating temperature ■ E-CTFE
depends on system environment, packing size, and bed height. In general, ■ ETFE
deep packed beds, weaker packing shapes, and high liquid loads result in ■ ETFE (25% glass filled)
lower temperature limits. Packed heights can be increased by using specially ■ PFA
formulated filled resins. Typical fillers include glass fibers, carbon fibers, and
chalk. Contact Koch-Glitsch to determine a specific load limit for a particular
Koch-Glitsch product at a certain temperature.

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Applications
Plastic packings are used in Absorbers
■ CO2 absorption
corrosive applications with low to ■ SO2, HCL, and HF absorption or stripping
■ Chlorine absorption in water or caustic
moderate operating temperature ■ Chlorine dioxide absorption
■ Hydrogen sulfide and mercaptan removal
and can offer an economic ■ Air pollution control scrubbers
Fume scrubbing
advantage over metal materials.
■

■ Odor control

Where temperatures permit, ■ VOC removal

plastic packings perform better Degassing

■ Decarbonation
than ceramic packings and are ■ Deaeration

often less expensive than metals, Water treatment

■ Waste water treatment
particularly when exotic metals and ■ Drinking water preparation
Fish farming
alloys are required. Consequently,
■

plastic packings are used mainly in Heat transfer

■ Humidification
absorption, scrubbing, stripping, ■ Dehumidification
■ Direct contact cooler
and heat transfer services. ■ Water chiller

Super INTALOX® Saddles random packing

n Enhance internal gas and liquid distribution
n Scalloped edges
− Provide more interstitial transfer points per unit of
volume than standard saddle packings
− Immobilize the packing within the bed, which
reduces settling
n Saddle shape ensures complete randomness of packed bed

Nominal size 1 2 3
Void fraction % 90 93 94
Bulk weight lb/ft3 5.2 3.8 3.1
(polypropylene) kg/m3 83 61 50

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5
FLEXIRING® random packing
An economical and versatile industry standard with well-known
performance characteristics.
n Openings in cylinder provide more use of internal mass transfer
area and lower pressure drop compared to Raschig Rings
n Extensively used; therefore, performance is widely known
n Industry standard for many designers
n 2 in [50 mm] and 4 in [100 mm] versions are available with
extra internal vanes to produce higher efficiency compared
to the standard versions

High Performance

Nominal
size 5/8 1 1.5 2 3.5 2 4
mm 16 25 38 50 90 50 100
inch 5/8 1 1.5 2 3.5 2 4
Void fraction % 87 92 91 93 95 93 96
Bulk weight lb/ft 3
5.9 4.4 4.3 3.8 2.7 3.8 2.2
(polypropylene) kg/m3 95 71 70 60 43 60 36

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7
CASCADE MINI-RINGS® random packing
High capacity and low pressure drop with high mechanical strength that allows use in deep beds.
n Achieves better efficiency and capacity than FLEXIRING® random
packing as a result of the low aspect ratio
n In a packed bed, a significant portion of the rings lie with their axes
nearly vertical
n The preferred orientation exposes both the interior and exterior
surfaces to liquid and vapor flow
n Geometry provides more efficient use of the packing surface
n Largest opening is in the direction of vapor flow, resulting in lower
pressure drop and higher capacity
n Orientation with cylindrical axis in the vertical position increases
the mechanical strength of the packed bed

Nominal
1A size 2 2A 3A
Void fraction % 97 97 97 98
Bulk weight lb/ft 3
3.3 2.7 2.9 2.5
(polypropylene) kg/m3 53 43 46 40

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BETA RING® random packing
High vapor capacity and efficiency with high liquid handling capacity.

n Strategic placement of slots and tabs provides an extremely effective use

of packing surface area
n Variation in the length of the internal tabs ensures high efficiency and
optimal distribution
n Uninterrupted flow of gas and liquid
n Provides additional drip points to enhance liquid film surface
renewal for improved mass and heat transfer
n Well suited for applications where low pressure drop and high liquid
handling capacity are important

Nominal
size 1 2 3
Void fraction % 94 94 96
Bulk weight lb/ft 3
3.3 3.4 2.4
(polypropylene) kg/m3 53 54 38

Seawater Deaeration
Seawater can be injected
into hydrocarbon reservoirs
to maintain pressure and
production. It is desirable to
remove oxygen from the
seawater because it
promotes corrosion and
growth of certain bacteria
that produce hydrogen
sulfide. The oxygen can be
removed using a stripping
gas or vacuum system.
ETA Process Plant, a division
of Koch-Glitsch UK, provides
packed tower designs for
both options using very
economical plastic BETA
RING® random packing.
The low pressure drop of
this packing reduces
operating costs while the good liquid phase mass transfer performance reduces capital expenditure. Additional
deaeration applications include soft drink production, beer brewing, potable water treatment, boiler feed, and volatile
organic compound removal.

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 BETA RING #2
Liquid Loading
Top Curve to Bottom BETA RING #3
gpm/ft2 m3/m2h
80 196
60 147
44 106
22 53
10 24
5 12
0 0

System Air-Water, Ambient

Tower: 29.5in. Diameter

KGa BETA RING

BETA RING #1

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INTALOX® SNOWFLAKE® random packing
Versatile standard packing with good capacity and low pressure drop combined with higher liquid
hold-up and residence time.
n Superior separation efficiency and capacity
n Superior performance over a wide operating range
n Independent testing confirms removal efficiencies
greater than 99% for groundwater air stripping
n Low pressure drop reduces energy consumption in
applications requiring blowers or compressors
n In typical system designs, INTALOX® SNOWFLAKE®
random packing can save more than 50% in energy
cost compared to #1 plastic saddle
n Strong shape allows deep beds for multiple transfer
unit absorption
n Widely used in chlorine and bromine production;
environmental applications

Void fraction % 97
Bulk weight lb/ft 3.2
3

(polypropylene) kg/m3 51

Liquid Loading
Top Curve to Bottom
gpm/ft2 m3/m2h
70 171
50 122
30 73
11 26
4 10
0 0
System Air-Water, Ambient
Tower: 29.5in. Diameter

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FLEXIPAC® and FLEXIPAC® HC® structured packing
Excellent performance in chemically corrosive applications.

Plastic FLEXIPAC® and FLEXIPAC® HC® structured

packings provide the same combination of high
efficiency, high capacity, and low pressure drop as their
metal counterparts. The variety of plastics available
makes this product suitable for some of the most
demanding corrosive applications. NOTE: The wetting
characteristics of plastic combined with any unique
attributes of the specific material of construction may
cause the actual HETP to vary significantly.

Efficiency FLEXIPAC® 2Y structured packing in polypropylene (white)

Plastic Structured Packing and FLEXIPAC® 500Z HC® structured packing in PFA (black).
Size HETP*

500Z HC 9.8 in (250 mm)

Materials of Construction Applications
1Y 11.4 in (290 mm) Polypropylene
■ ■ Air separation plant direct
2Y 19.2 in (485 mm)
■ Glass-filled polypropylene contact cooler
CPVC
■ ■ Flue gas cooler
2Y HC 19.2 in (485 mm)
PVDF
■ ■ Seawater scrubber
3Y 43.3 in (1100 mm) HCI absorber
ECTFE
■ ■

3X 76.8 in (1950 mm)

■ Glass-filled ECTFE ■ SO2 absorber

* HETP values are estimates and are for PFA

■ ■ CI2/CIO2 scrubber
reference only. Contact Kosh-Glitsch for
■ Glass-filled PFA ■ HNO3
additional information.
■ Deaerators

Chlorine Dioxide
Absorption
Chlorine dioxide (ClO2) is a very important
chemical compound used as a bleaching agent in
the pulp and paper industry. ClO2 is produced by
reducing sodium chlorate in a strong acid solution
with a suitable reducing agent. The ClO2 gas that
is discharged from the generator is fed to the
bottom of a packed bed absorber where a
ClO2 solution is made using chilled water.
The excellent chemical resistance of plastic
INTALOX® SNOWFLAKE® random packing,
Super INTALOX® Saddles random packing,
or FLEXIPAC® structured packing provides a
lower-cost alternative to exotic metals, such as
titanium. These packings are often applied in
processes using CIO2 for bleaching to avoid
escape in the atmosphere.

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ETAPAK random packing
Specifically designed for biological waste water treatment.

The size and shape of ETAPAK random packing is designed for

superior biological filtration.

n The maximum exposed surface area allows growth of

microorganisms and enhances biological activity, liquid
distribution, oxygen transfer, and low sludge production.
n The open nature of the packing and high void radius
ensures flow patterns that allow continual contact
between effluent, biomass, and circulating air.
n The open area enhances sloughing characteristics and
minimizes potential blockages.

Size 120 210

Void fraction % 95 96
Dimensions in 4.5 x 3.5 1.8 x 1.6
mm 115 x 90 45 x 40

Surface Area ft2/ft3 30.5 70.0

m2/m3 100 200

Two sizes provide the ability to optimize capacity and efficiency based on application requirements. Both sizes are well
suited for treatment of high strength effluents, either aerobically or anaerobically, in applications including domestic,
industrial, and refinery wastes. High mechanical strength provides excellent performance in deep beds.

Constructed of thermoplastic resin, the material is fully stabilized to UV light and is chemically inert. The material
is non-toxic to microorganisms and is immune to fungal or bacteriological degradation. The preferred operating
temperature is 32 – 194 °F [0 – 90 °C].

With the ability to remove up to 95% biochemical oxygen demand (BOD),

ETAPAK 120 random packing is widely used in single- or two-stage high rate
filters. It is often used for new, roughing first-stage filters where the existing
plant is overloaded or underperforming.

ETAPAK 220 random packing is highly effective in polishing applications

and nitrification processes, including fish farming. Achieving over 85% BOD
removal plus nitrification, it is frequently used on mixed industrial and
domestic waste streams.

Engineers at Eta Process Plant, a division of Koch-Glitsch UK, can

calculate the optimum volume of media necessary and recommend
the number of stages, vessel diameters, bed heights load, irrigation
rates, recycle flows, and clarifier dimensions.
Water treatment facility.

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PROVALVE® Trays
Plastic trays are used in a wide variety of applications, such as acid stripping, gas washing, distillation of corrosive
components, and gas drying using sulfuric acid. For corrosive distillations, Koch-Glitsch plastic trays can be a more
cost-effective solution than trays constructed of exotic metals or graphite. Combining plastic composites technology
with fluoropolymer technology allows trays to be produced for relatively large
diameter columns that operate at temperatures up to 392 °F [200 °C]. For columns
with diameters less than 42 in [1066 mm], Koch-Glitsch can manufacture trays in
cartridge-style construction.

Koch-Glitsch supplies bubble cap, tunnel cap, sieve, and PROVALVE® valve
trays in plastic materials.

The PROVALVE unit (pictured) is also available in fluoroplastics and graphite for
highly corrosive applications where a suitable metallic material is not available.
PROVALVE trays are used in a wide variety of services – from severely
fouling refinery applications to petrochemicals to fine chemical separations. PROVALVE® tray in PTFE material.

Mist Eliminators
When vessel size is not set by the mist eliminator, the practical starting point is often the knitted wire mesh mist
eliminator. DEMISTER® mist eliminators provide high separation efficiency with a low pressure drop at the lowest
installed cost. They are custom manufactured to any size and shape from a wide selection of plastics and fluoroplastics
to perform in corrosive environments.

FLEXICHEVRON® mist eliminators are characterized by smooth blade profiles and wide blade spacing that provide
additional fouling resistance. Koch‐Glitsch offers an extensive line of FLEXICHEVRON mist eliminators to meet the
demanding requirements of applications where
undissolved solids can be present or droplets can be
sticky or viscous. Vapor flow paths that are more open
provide higher capacity and lower pressure drop than
other mist eliminators. They are a good selection for use
in scrubbers, cooling towers, and evaporators.

FLEXIFIBER® mist eliminators are applied to achieve

high efficiency removal of sub-micron liquid droplets.
Typical applications include sulfuric acid, chlorine, and
turbine lube oil tank vents. Plastics, fluoroplastics, and
FRP materials are available for element (cage) construction.

In most process industries, it is common for two

immiscible liquids to mix with each other to create a
dispersion. Products such as KY-FLEX® liquid-liquid
settling media and KY-MESH liquid-liquid coalescing Left (FLEXIFIBER® mist eliminators), center (DEMISTER® mist
media are applied to separate the liquids. Both products eliminators), and right (FLEXICHEVRON® mist eliminators).
are available in plastic and fluoroplastic materials.

Refer to the Koch-Glitsch brochure, Mist Elimination – Liquid-Liquid Coalescing (MELLC-01), for more information
on Koch-Glitsch mist elimination and separation technologies.

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Koch-Glitsch Corporate Offices
Worldwide Headquarters
Koch-Glitsch, LP
4111 East 37th Street North Wichita, KS 67220 – United States tel: 316-828-5110 fax: 316-828-7985

Europe
Koch-Glitsch Italia S.r.l.
Via Torri Bianche, 3A 20871 Vimercate MB – Italy tel: +39-039-638-6010 fax: +39-039-638-6011

Asia
Koch Chemical Technology Group Singapore Pte. Ltd.
260 Orchard Road, #11-01/09 Singapore 238855 tel: +65-6831-6500 fax: +65-6835-2031
The Heeren

Koch-Glitsch (a division of Koch Chemical Technology Group India Pvt. Ltd.)

Seawoods Grand Central Navi, Mumbai - 400 706
F901 to F904, Tower-2 tel: +91-22-6771-7171 fax: +91-22-6771-7161
Maharashtra - India
Nerul Road, Nr. Seawoods Railway Station

For a complete list of our offices and facilities, visit us on the Web at www.koch-glitsch.com.

Emergency Numbers
United States/Latin America: 1-888-KOCH-911 (mass transfer), 1-316-207-7935 (mist elimination),
or your local Koch-Glitsch office.

Canada: 1-905-852-3381 (Uxbridge, Ontario).

Europe/Middle East/Africa: +39-06-928-911 (Italy), +44-1782-744561 (United Kingdom),

or your local Koch-Glitsch office.

Asia: +65-6831-6500 (Singapore) or your local Koch-Glitsch office.

Trademarks Patents
The following registered trademarks are owned by Koch-Glitsch, LP in the The following technologies are protected by one or more patents
United States and may be registered in other jurisdictions: BETA RING® random in the USA; other foreign patents may be relevant: FLEXILOCK®
packing, CASCADE MINI-RINGS® random packing, DEMISTER® mist eliminator, tray construction (US6592106), FLEXIPAC® HC® structured packing
FLEXICHEVRON® mist eliminator, FLEXIFIBER® mist eliminator, FLEXIPAC® structured (US5632934, US6478290), INTALOX® ULTRA random packing (US7722945),
packing, FLEXIPAC® HC® structured packing, FLEXIRING® random packing, KFBE fluidized bed structured packing (US6224833), Model 758
INTALOX® Packed Tower Systems technology, INTALOX® Saddles random Enhanced Vapor Horn (US5605654, US5632933, US6889961, US66889962,
packing, INTALOX® SNOWFLAKE® random packing, KG-TOWER® software, US7104529), PROFLUX® severe service grid (US8298412), PROVALVE® tray
KOCH-GLITSCH®, “K” KOCH-GLITSCH (logo), KY-FLEX® liquid-liquid coalescing (US5762834), and SUPERFLUX® tray (US5895608). Available exclusively
media, and PROVALVE® tray. The following trademarks are owned by Koch- from Koch-Glitsch, FLEXIPAC® HC® structured packing is protected by
Glitsch, LP in the United States and may be registered in other jurisdictions: US Patent 5,632,934 and other patents worldwide assigned to Praxair
ETAPAK random packing, KY-MESH liquid-liquid coalescing media, and YOU CAN Technology, Inc. Koch-Glitsch, LP is the exclusive worldwide licensee of
RELY ON US. All other trademarks, service marks, or registered trademarks that Praxair Technology, Inc. for the manufacture and sale of this packing
appear in this document are the trademarks or service marks of their respective in all markets except for industrial gas separation.
owners.
Legal Notice
For related trademark information, visit http://www.koch-glitsch.com/trademarks. The information contained in this bulletin is believed to be accurate
and reliable, but is not to be construed as implying any warranty or
guarantee of performance.

Bulletin KGPPCI-1.1 Rev. 05-2019. Printed in USA.

© 2018-2019 Koch-Glitsch, LP. All rights reserved.