Packing and Distributor Technology Sulzer Chemtech

Dan Summers | March 8, 2011

Sulzer Chemtech

Packing and Distributors 2

 Sulzer Chemtech

Thin Sheet Metal

Angled Corrugation

Textured & Perforated

Layers are Segmented & Rotated

Varied Crimp Size (Surface Area)

Packing and Distributors 3

 Sulzer Chemtech

Sheet Metal Typically 0.004” - 0.008”

Larger Crimp Packings May Require More Thickness

Essentially No Corrosion Allowance

– Material Selection is Critical

Gauze Packings Made From Woven Metal Cloth

Usually for Very High Efficiency Applications

Sheets Cut 8 - 12” tall

Packing and Distributors 4

Sulzer Chemtech

Packing and Distributors 5

 Sulzer Chemtech

Typically Textured & Perforated

Texturing Promotes Spreading of Liquid on Surface

Perforation Allows Equalization of Flows and Pressures Between

Sheets

Lack of Texture and/or Perforation Reduces Efficiency

Some Specialized Packings Do Have No Surface Treatment

– Mellagrid - For Coking Resistance

– SMV - For Extraction Applications

Packing and Distributors 6

 Sulzer Chemtech

non-perforated sheet metal, 30ml/min perforated sheet metal, 30ml/min

Packing and Distributors 7

 Sulzer Chemtech

Structured Packing Has its Greatest Advantage with Low

Liquid Rates and High Vapor Velocities

In Distillation Systems, Low Pressure Means Low Liquid

Rates and High Vapor Velocities. Ideal for Structured
Packing

Conversely, High Pressure Distillation Systems are

Usually Better Served by Random Packing or Trays

High Pressure Absorption with Low Liquid Rates are also

Good Structured Packing Applications

Packing and Distributors 8

 Sulzer Chemtech

Most Thermal Degradation Prone Processes Favor

Structured Packing

Advantages of Structured Packing’s Lower Pressure Drop

Low ∆P Means

– Lower Liquid Holdup = Lower Residence Time

– Lower Column Bottom Pressure = Lower Temperature

Packing and Distributors 9

MellapakPlus Sulzer Chemtech

MellapakPlus a new Generation of Structured Packings

up to 40% more capacity, depending on pressure

Mellapak
packing
elements

Hold-up above Mellapak MellapakPlus

intersectional
loading point
typical for Mellapak

The hold-up profile of Mellapak above intersectional loading point is

reduced by the smooth change of flow direction achieved by the new
MellapakPlus structure. This suppresses the local flooding at intersection
points and increases the overall packing capacity.

Packing and Distributors 10

 Sulzer Chemtech
MellapakPlus: FRI Testing
Figure 4. Mellapak Plus 252.Y Efficiency
o/p Xylene System, 100 mm Hg (FRI)
&
Chloro/Ethyl Benzene, 77 mm Hg (Sulzer CT)
Capacity Factor Cs, m/s
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18
32 0.80

30 0.75
M252Y (FRI) M250Y (FRI)
28 0.70
M250Y (WT) M252Y (WT)
26 0.65

24 0.60
HETP, inches

HETP, m
22 0.55

20 0.50

18 0.45

16 0.40

14 0.35

12 0.30

10 0.25
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60
Capacity Factor Cs, ft/s

Packing and Distributors 11

Wire Gauze Packing Sulzer Chemtech

Preferred applications:
• Minimum pressure drop requirement
• Large number of theoretical stages
• In high vacuum for degradable products

Application examples:
• Pharmaceutical products (vitamins, etc.)
• Flavors and fragrances (e.g. Geraniol)
• Monomers (Caprolactam, MDI, DMT, etc.)
• Fatty acids, fatty alcohols, esters of fatty acids
• Mono-, Di-, Tri-, Tetraethylene glycol

Packing and Distributors 12

 Sulzer Chemtech

The new gauze packing benefits from the various

features of the MellapakPlus product line

• Lower pressure drop

due to smooth change
in gas flow direction
• Increased open area
for gas flow due to
smaller liquid hold-up at
element transition

Concept of the
Plus type packings Vertical Hold-up Profile

Packing and Distributors 13

 Sulzer Chemtech
Mellagrid – Sulzer Structured Grid Packings

Special features:
• Resists coking and fouling due to its smooth surface
• Geometric structure efficiently dissipates temperature and concentration gradients
• Much better de-entrainment and separation efficiency than conventional grids
• The low element height and its smooth surface structure allow for easy cleaning
• Mechanically robust structure

Application examples:
• Atmospheric or Vacuum Tower
- Wash section
- Pumparound section with high liquid and
gas loadings
• FCC Main Fractionator
Slurry pumparound section
• Coker or Visbreaker Fractionator
Wash section
• Oil and Water Quench Tower

Packing and Distributors 14

 Sulzer Chemtech

Nutter Ring Advantages

Efficiency enhanced by lateral liquid
spreading and surface renewal.
Superior surface utilization in mass and
heat transfer, allowing shorter packed bed
heights.
A high performance random packing
verified by tests conducted at Fractionation
Research Institute (FRI).
Mechanical form provides maximum
randomness with minimal nesting.

Material and Sizes

Available in most metals
Sizes in #0.7, #1.0, #1.5, #2.0, #2.5 & #3.0

Packing and Distributors 15

 Sulzer Chemtech

I-Ring Advantages
I-Rings provide over 30% lower pressure
drop than Pall® Rings.
Revolutionary design enhances greater
capacity and efficiency than other random
packings.
Geometric design minimizes liquid hold-up.
Direct replacement of the widely used
IMTP®.

Material and Sizes

Available in most metals
Sizes in #15, #25, #40, #50 & #70

Packing and Distributors 16

 Sulzer Chemtech

P-Ring Advantages
Highest industry experience and
extensively tested by research institutes
worldwide.
Material thickness overcomes mechanical
weaknesses, and can be used in extremely
corrosive services enabling cheaper
materials to be used.
Strength-to-weight ration stronger than
most other random packings.
Direct replacement of the well known
Pall®Ring.

Material and Sizes

Available in most metals
Sizes in 5/8”, 1”, 1.5”, 2” & 3.5”

Packing and Distributors 17

 Sulzer Chemtech

R-Ring Advantages
First generation of random packings,
industry experience outperforms
fractionation trays.
Great strength-to-weight ratio.
Direct replacement of the well known
Raschig Ring.

Material and Sizes

Available in most metals
Sizes in 5/8”, 1”, 1.5”, 2” & 3.5”

Packing and Distributors 18

 Sulzer Chemtech

C-Ring Advantages
Rounds out Sulzer's Portfolio.
Unique Diameter to Height ratio.
Direct replacement of the well known
Cascade Mini Ring®.

Material and Sizes

Available in most metals
Sizes in #1.5, #2.0, #2.5, #3.0, & #4.0

Packing and Distributors 19

 Sulzer Chemtech

Packed Towers

Liquid Distributor - Must Distribute Liquid Uniformly

Packing - Vapor/Liquid Contact and Spreading

Vapor Distribution

Anything that keeps these from functioning will cause problems

Packing and Distributors 20

 Sulzer Chemtech
! " #$ % &

&

Packing and Distributors 21

Types of Distributors Sulzer Chemtech

Sulzer Classification of Distributors

Ground hole G

VK type
Elevated hole P, H, R

Ground hole G
VE type
Elevated hole P, H, R

VR type

VSI type Packing and Distributors 22

Types of Distributors Sulzer Chemtech

VK distributor

•Single Level Main Channel

•Communicating Channels
•Shorter Elevation Requirement
•More Costly than VE
•For Smaller Diameters: < 4 m (13 ft)

Packing and Distributors 23

Types of Distributors Sulzer Chemtech

VE distributor

•Dual Element – Arm & Main Channel

•Less Expensive, Less Welding
•Simpler Construction Than VK
•For Larger Diameters
•Arm Channels Do Not Communicate
Packing and Distributors 24
Distributor Outflow Systems Sulzer Chemtech

Ground holes Drip Splash plate Distributing

G tubes P pans
R PW

Packing and Distributors 25

Types of Distributors Sulzer Chemtech

G - Ground Hole

• Simple design

• Not Resistant to fouling

Packing and Distributors 26

Types of Distributors Sulzer Chemtech

P,H,R - Elevated Hole

• Fouling resistant

• More complex design

Packing and Distributors 27

Types of Distributors Sulzer Chemtech

VKG/VKGF

Integral channel with ground holes

Packing and Distributors 28
Types of Distributors Sulzer Chemtech

VKR/VKRF/VKRFPW

Integral channel with tubes

Packing and Distributors 29
Types of Distributors Sulzer Chemtech

VKR2/VKRF2

Integral channel with external curl tubes

Packing and Distributors 30
Types of Distributors Sulzer Chemtech

VKH

Integral channel with high outflow

Packing and Distributors 31
Types of Distributors Sulzer Chemtech

VEG/VEG2

Element design with ground holes

Packing and Distributors 32
Types of Distributors Sulzer Chemtech

VER2

Element design with external curl tubes

Packing and Distributors 33
Types of Distributors Sulzer Chemtech

VEP

Element design with splash baffle

Packing and Distributors 34
Types of Distributors Sulzer Chemtech

VRD

Spray Header Distributor

Packing and Distributors 35
VRD ' Sulzer Chemtech

90°
120°

Packing and Distributors 36

Types of Distributors Sulzer Chemtech

VSI

Orifice Pan Distributor

Packing and Distributors 37
 Sulzer Chemtech
( % &

• Orifices Must be Arranged Uniformly & Evenly

• Zonal Analysis

• Coefficient of Variation, Cv Should be < 10%

• Drip Point Density Must Match Packing Type

Packing and Distributors 38

 Sulzer Chemtech
) %

Quadrant Partitioning:

All Four Areas Are Equal

Packing and Distributors 39

 Sulzer Chemtech
) %

D(25%) = 0.5*D(100%)
D(50%) = 0.707 * D(100%)
D(75%) = 0.866 * D(100%)

Concentric Partitioning:

All Four Areas Are Equal

Packing and Distributors 40

 Sulzer Chemtech
% %

• Typical Value 10 points/ft2.

• Ranges from 6 to 20 points/ft2 in Refinery Services

• Varies Depending Upon Service and Packing

• Smaller Packing Sizes (High Surface Area)

Require Higher Drip Point Density.

Packing and Distributors 41

 Sulzer Chemtech
% & *

Function of Design & Head Available

Typical Turndowns 3-5:1

Head Varies as a Square Function

Packing and Distributors 42

 Sulzer Chemtech
+ % &

Flow through Orifice Openings

H = C (GPM/AO)n
Where,
H = Head Required, inches Liquid
C = Hole Coefficient (0.027 round holes)
AO = Open Area, in2
n = constant, 2.15

Based on Bernoulli’s Principle

Packing and Distributors 43

Distributor Testing Sulzer Chemtech

# , -

Packing and Distributors 44

Distributor Testing Sulzer Chemtech

Packing and Distributors 45

Distributor Testing Sulzer Chemtech

Packing and Distributors 46

 Sulzer Chemtech
- % &

The design of an adequate

vapor inlet system is important
to obtain the best results from
packed columns, which are
sensitive to both liquid and
vapor maldistribution

The design geometry is

derived from computational
fluid dynamics studies

Packing and Distributors 47

 Sulzer Chemtech
- % &

• Most Important In Vacuum Services

• Packings are Excellent Redistributors of Fluids
• Momentum Criteria
• Chimney Trays
• Vapor Horns & Schoepentoeters

Packing and Distributors 48

 Sulzer Chemtech
- .

Packing and Distributors 49

 Sulzer Chemtech
- % & /#

Packing and Distributors 50

 Sulzer Chemtech
Supports / Collectors

Support grid TSB for

structured packing
Gas injection support plate
for random packing GIS

Liquid collector SLR Chimney tray SKI

Packing and Distributors 51