Structured Packings Energy Efficient Innovative
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Summary
Structured PackingsEnergy-efficient, innovative & profitable 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 state-of-the art We don’t shut-down, when you We provide a full scope of expert know-how for more than shut-down. You can rely on Sulzer associated engineering and 500 applications in 100 processes, professionals, expertise and technology services to optimize this enables us to optimize the procedures to get you back and or trouble-shoot your installation
performance and your installation. running in the shortest possible time
Naphtha Kero Diesel A Broad Range of Innovative and High-performing Products Our more than 200 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, 40,000 gas / liquid separators and 100,000 mixers in operation worldwide
0602 2510 0605 2504 0603 2535-3 0694 2720 MellapakPlus™ VGPlus™ Trays NeXRing™ SMV™ static mixer Dusec Plus™ Packing One of the best The next big High mixing efficiency Coalescer Often copied, high performance trays thing in random combined with large High performance never equaled ever tested at FRI packing turn-down processing with minimum capabilities pressure drop2 Metal Sheet Packings 4 Gauze Packings 8 Special Packing Types 11 Column Internals 16 Services 18Sulzer Structured Packing Portfolio – The complete rangeStructured packing is one of our core abilities. Over 50 years of experience in development, design, and fabricationof this type of packing makes us your best partner to find the optimum solution for your application. This brochureprovides an overview of all Sulzer structured packing types and their applications
Sulzer’s complete structured packing portfolio ranges from the conventional BX gauze packing, developed by us50 years ago, to the MellapakPlus high capacity packing. We offer packing types for all kind of applications, madein almost all types of metal and also other corrosion resistant materials
BX™ and BXPlus™ CY™ and CYPlus™ MellapakPlus™ Mellapak™ AYPlus™ DC for gauze packings gauze packings for improved the allrounder aqueous solutions for high separation for even higher capacity packing and low liquid loads efficiency efficiency Mellacarbon™ Mellapak™ and Mellagrid™, F-Grid™ Katapak™-SP Laboratory for demanding MellapakPlus™ in and Nutter Grid™ for for reactive Packings for corrosive plastic for corrosive fouling conditions distillation small columns applications applications 3 MellapakPlus For improved capacity MellapakPlus is a capacity enhanced structured packing
Separation Efficiency It combines all advantages of the metal sheet packing Mellapak with new geometrical features
Features of MellapakPlus At the lower and upper end of each packing element, the orientation of the corrugation gradually approaches the vertical axis
Advantages of this geometrical modification: • The vapor flow smoothly changes direction at the interface between two packing elements • At the interface vapor flow is nearly parallel to the vertical axis of the column. The gas velocity is therefore reduced by about 25% 0699 2522−4 compared to the velocity inside the packing element parameter = head pressure p /mbar Both factors reduce the pressure drop and the shear forces, which are especially critical at the inter-face due to the presence of thicker and less Pressure Drop stable liquid films. As a result, premature flooding at the interface is no longer of concern
In the interior part of the packing element the geometrical features of MellapakPlus and Mellapak are identical. Hence, separation efficiency is similar – but with a significant increase in capacity and a reduction in pressure drop
All other MellapakPlus properties – including installation procedure, mechanical strength and corrosion resistance – are identical to Mellapak
MellapakPlus performance has been confirmed in category 1 tests at F.R.I
Internals The close resemblance between MellapakPlus and Mellapak guarantees continued use of the whole range of well known and reliable internals
Internals are now able to handle the increased gas load typical for the high capacity of MellapakPlus. Sulzer Chemtech is committed to the ongoing, focused development of novel designs
MellapakPlus 252.Y vs
Mellapak 250.Y4 Separation Efficiency Separation Efficiency Separation Efficiency parameter = head pressure p /mbar parameter = head pressure p /mbar parameter = head pressure p /mbar Pressure Drop Pressure Drop Pressure Drop 0.1MellapakPlus 202.Y MellapakPlus 352.Y MellapakPlus 452.Y MellapakPlus 602.Y MellapakPlus 752.Y 5 Mellapak The allrounder packing Separation Efficiency 0602 2510 Mellapak is the most widely used structured packing worldwide. It has proven excellent performance in columns with diameters up to 15 m. It is supplied in sheet metal thicknesses from 0.1 mm up. parameter = head pressure p /mbar Special features Pressure Drop • Pressure drop per theoretical stage 0.3‑1.0 mbar • Pressure drop at 70‑80% flooding about 2 mbar/m • Minimum liquid load approx. 0.2 m3/m2h • Maximum liquid load up to more than 200 m3/m2h (typically in desorption columns) Preferred applications • Vacuum to moderate pressure • High pressure in selected applications • Increasing capacity of existing tray and packed columns Typical applications Chemical industry: Ethylbenzene/styrene, tall oil, cyclohexonone/‑ol, air separation Petrochemical industry: Quench columns, C3‑ and C4‑ splitters, xylene splitters Refineries: Vacuum and atmospheric columns Absorption: Natural gas drying, CO2‑ and H2S‑absorbers and strippers, ethyleneoxide absorbers and strippers, acrylonitrile absorbers Mellapak 250.Y Mellapak 250.X6 Separation Efficiency Separation Efficiency Separation Efficiency parameter = head pressure p /mbar parameter = head pressure p /mbar parameter = head pressure p /mbar Pressure Drop Pressure Drop Pressure DropMellapak 125.Y Mellapak 170.Y Mellapak 2YMellapak 125.X Mellapak 170.X Mellapak 2X 7 BX and BXPlus Gauze Packings For high separation efficiency Separation Efficiency 0682 2017 This packing has been successfully employed in the industry for over 40 years. Largest diameter supplied to date: 6 m
Special features • High number of theoretical stages per unit height • Pressure drop per theoretical stage 0.1 – 0.5 mbar • Most economical load range: F factor 1-2.5 √Pa • Minimum liquid load approx. 0.05 m3/m2h • Small hold‑up parameter = head pressure p /mbar Preferred applications Pressure Drop • Large number of theoretical stages • Vacuum from 1 mbar to atmospheric pressure • Where minimum pressure drop per theoretical stage is important Product applications • Monomers from plastics (MDI, DMT, etc.) • Fatty acids, fatty alcohols, fatty acid esters • Mono‑, di‑, tri‑, and tetraethylene glycols • Fine chemicals BXPlus BXPlus is a further development of the well proven gauze packing BX. Its geometry is similar to MellapakPlus. BXPlus offers the same efficiency as BX with a 20% lower pressure drop. It is recommended for gentle distillation at higher capacity
Gauze packing BX Gauze packing BXPlus8 CY and CYPlus Gauze PackingsFor even higher separation efficiency Separation Efficiency4588 3043This packing was developed for separations thatrequire a large number of theoretical stages. Largestdiameter supplied to date: 1.8 m
Special features• Maximum number of theoretical stages per meter• Most economical load range: F factor 1.5 – 2 √Pa• Minimum liquid load approx. 0.05 m3/m2h• Small hold‑upPreferred applications parameter = head pressure p /mbar• For a very large number of theoretical stages Pressure Drop• Vacuum from 1 mbar to atmospheric pressure• Small overall height• Batch and continuous columns• Pilot and laboratory columns (reliable scale up)Limited suitability for:• Fouling substances• Non‑wetting liquidsProduct applications• Pharmaceutical products (vitamins, etc.)• Fragrances (menthol, geraniol, etc.)• Separation of isomersCYPlusThe traditional CY structure was modified usingthe know-how from the MellapakPlus and BXPlusconcept for more capacity, resulting in the newCYPlus packing. The Plus structure allows for 15%more capacity while keeping the same efficiency asthe traditional CY gauze packing. Gauze packing CY 9 AYPlus DC For aqueous solutions and low liquid loads Pressure Drop AYPlus DC MellapakPlus 252.Y AYPlus DC is based on a newly developed hybrid gauze 20 20 material combination and the geometry of MellapakPlus 10 10 Wet Wet 252.Y. AYPlus DC has a distinctly increased separation Parameter: Specific liquid load / m3 / (m2h) efficiency compared to MellapakPlus 252.Y, in particular System: Air-water Column Diameter: 1000mm at low liquid loads and with aqueous systems
Special features • Excellent wettability for organic and aqueous Efficiency for Absorption Systems Test: DMF absoprtion with water systems even at very low liquid loads such as below 0.1 m3/(m2h) • Low HETP, depending on the system • More than twice as efficient as comparable sheet metal or plastic packings in aqueous applications with low liquid load • Pressure drop comparable to MellapakPlus 252.Y and for aqueous systems even lower Separation Efficiency • Most economical liquid load range < 1 m3/(m2h) • Maximum operating temperature about 300°C Product applications Aqueous systems • Dimethyl acetamide / water • Dimethyl formamide / water • Gas sweetening wash sections • Glycol dehydrations • High-boiling alcohols / water AYPlus DC MellapakPlus 252.Y 100 100 • Wash sections in CO2 absorbers 10 Parameter: Head Pressure p / mbar System: Trans-/cis-Decalin10 MellacarbonFor demanding corrosive applications Separation Efficiency 0697 2522Carbon does not react with most solvents, acids or lyes
Sulzer Chemtech offers various Mellacarbon types. head pressure p /mbar• Corrosion‑proof against caustic solutions, non‑oxidizing inorganic acids including hydrofluoric acid and carboxylic acids• Excellent wettability, also in aqueous systems• Specific surface area of 125 – 1700 m2/m3 Pressure Drop• High thermal stability (> 400˚C)Product applications• HCI separation for production and for HCI recovery (typically in the production of polycarbonate)• MCA / DCA distillation• Production of phosphoric acid• Concentration of hydrofluoric acid• Separation of chlorophenols Mellacarbon 11 Mellapak and MellapakPlus from plastics For corrosive applications Separation Efficiency Acetone / H 2O SO2 / H2O 0682 2021 The MELLAPAK 125.X, 125.Y, 250.X and 250.Y and MellapakPlus 252.Y are also available in different kinds of thermoplastics
Separation efficiency of Mellapak 250.Y PP Packings made of polypropylene (PP), postchlorated polyvinylchloride (PVC-C), polyvinylide-nedifluoride (PVDF), Teflon® PFA and polyether ether ketone (PEEK) Pressure Drop can be supplied
The plastic versions of MELLAPAK have proven operational record in various types of absorption and desorption columns
Special features 75 m3/(m2h) • Large number of transfer units per meter, low HTU, depending on the system • Small pressure drop per meter packed height • Most economical load range up to F factor 4 √Pa • Maximum operating temperatures: approx. 110 ˚C for polypropylene approx. 150˚C for PVDF Product applications • HCI absorbers • SO2 absorbers dry • Flue gas cleaning columns • Sea water deaerators MellapakPlus 252.Y has the same efficiency as Mellapak PP Mellapak 250.Y and same capacity as Mellapak 250.X atmospheric pressure12
Structured packing is one of our core abilities. Over 50 years of experience in development, design, and fabrication of this type of packing makes us your best partner to find the optimum …
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Frequently Asked Questions
What is structured packing?
Structured packing elements are composed of grids (metal or plastic) or woven mesh (metal or plastic) or of thin vertical crimped sheets (metal, plastic, or ceramic) stacked parallel to each other. Figure 6.9 shows examples of the vertical crimped sheet style of structured packing. Figure 6.9.
Do structured packings perform well in dehydration service?
They concluded 1. A number of commercial structured packings perform well in dehydration service. 2. The design gas velocity in a structured packing tower is approximately twice the normal velocity in a trayed tower. 3. Because of the high gas velocity, a high efficiency mist eliminator is required. 4.
Is structured packing better than bubble cap packing?
Structured packing, which is offered by several vendors, is claimed to offer greatly increased throughput, lower pressure drop, and lower column height than bubble-cap trays for the same service.
What are the different types of sulzer structured packing?
provides an overview of all Sulzer structured packing types and their applications. Sulzer’s complete structured packing portfolio ranges from the conventional BX gauze packing, developed by us 50 years ago, to the MellapakPlus high capacity packing. We offer packing types for all kind of applications, made