Random Packing from Competitive Products to Advanced Solutions Sulzer Chemtech

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, High performance high performance trays big thing in combined with large never equaled liquid/liquid ever tested at FRI random packing 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 established 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

70 NXR#1 800

60 NXR#2 NXR#1.5 600 NXR#1.5 NXR#1.2 50 NXR#2

HETP (mm) NXR#1 NXR#1.2 400 NXR#3 NXR#0.7 40 NXR#0.6 KGa, kg-mol / (h m³ atm)

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 10080 60 40 20 80 60 40 20 10 1.22 10 1.22 0 m3/ m2h 0 m3/ m2h ft ft / / m m

/ / O O 2 2 H H mbar mbar

/∆z, 1.0 0.12 /∆z, 1.0 0.12 /∆z, in /∆z, in ∆p ∆p ∆p ∆p

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 120100 80 20 120 100 80 40 20 60 40 60 10 1.22 10 1.22 ft ft / / m m

/ / 3/ 2 0 m m h O O 2 0 m3/ m2h 2 H H mbar mbar

/∆z, 1.0 0.12 /∆z, 1.0 0.12 /∆z, in /∆z, in ∆p ∆p ∆p ∆p

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 ft ft / / m m

/ / O O 0 m3/ m2h 2 2 H 0 m3/ m2h H mbar mbar

/∆z, 1.0 0.12 /∆z, 1.0 0.12 /∆z, in /∆z, in ∆p ∆p ∆p ∆p

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 100 3 2 120 80 40 Load l, m /m h 60

10 20 1.22 0 ft / m 20 / O 2 40 H

mbar 60 3/ 2 0 m m h 80

/∆z, 1.0 0.12 /∆z, in 100 ∆p ∆p 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#0.7 160% PR#1 P-Ring™ 150% 140% NXR#1 130% PR#1.5 IR#40 NXR#1.2 120% NXR#1.5 110%

Efﬁciency increase % 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 m2/m3 226 170 124 96 85 66

ft2/ft3 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 6 1100 90 40 (NR #0.7) 1000 80 5 NR #3 900

atm) 70 NR #1 3 800 NR #2.5 4 30 60 700 NR #2

(NR #1.5) atm) 3 600 NR #1.5 50 NR #2 3 500 NR #1 20 NR #2.5 HETP, mm HETP,

NR #0.7 inches HETP, 40 400 (NR #3) 300

35 a, lb-mol/(h ft 10 G KGa, kg-mol / (h m

2 K 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 ft ft / / m

/ / O O 2 2 mbar mbar

/∆z, 0.12

/∆z, 0.12 1.0

1.0 /∆z, in H /∆z, in H ∆p ∆p ∆p ∆p

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

3 NR #1.5 F, ft / s √lb / ft3 NR #2 F, ft / s √lb / ft 1.0 2.0 3.0 4.0 1.0 2.0 3.0 4.0 2.45 20 2.45 20 Liquid Load l, m3/m2 h 10 1.22 10 1.22 ft ft /

0 m

/ m /

/ O 2 O 20 2 40 mbar mbar 60

/∆z, 1.0 0.12 80 /∆z, in H /∆z, 1.0 0.12 /∆z, in H ∆p ∆p

∆p 100 ∆p 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 ft ft / / m m

/ / O O 2 2 mbar mbar /∆z, /∆z, 1.0 0.12 1.0 0.12 /∆z, in H /∆z, in H ∆p ∆p ∆p ∆p

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 m2/m3 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 m2/m3 315 250 180 150 120 100 80

ft2/ft3 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 m2/m3 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 m2/m3 350 222 144 112 64

ft2/ft3 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

Standard-Load

VKGF VER2 10

VKR2 Specific liquid load l [m3/m2 h]

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.