Sulzer Chemtech

Structured Packings for , Absorption and

0699 2501 Structured packings for separation and reactive distillation

This brochure was reviewed and - Internals for Packed Columns Sulcol Design Program supplemented recently. It therefore The brochure contains a compre- A program that enables users provides a complete, up-to-date hensive summary of the selection to carry out hydraulic design of overview of packings available of internals supplied by Sulzer columns featuring every type of from Sulzer Chemtech. Chemtech, and a description of packing Sulzer Chemtech offers. Also included is a summary cove- the most important features of The program is based on our ex- ring the essential column internals the distributor technology. perience with several thousand and our technical services. industrial columns and from ex- perimental data measured in our For further information and to down‑ - Gas Processing own test column with a diameter of load our brochures as well as - Chemical Processing Industry 1 m. design tools, please refer to - Process Technology and www.sulzerchemtech.com Equipment for Oil Refineries Considering the broad selection and Crude Oil Production of products and widely proven More detailed product information, Three brochures which illustrate application know-how, Sulzer you will find in the following the wide spectrum of application Chemtech is in a position to offer brochures: of structured packings. the suitable solution even for the most difficult separation tasks.

Contents Structured packings • Overview 4‑5 • Laboratory packings 6 • Rombopak 7 • Mellapak® 8‑10+15 • MellapakPlus® 11-12 • Gauze packings 13‑14+16 • Mellacarbon® 17 • Mellagrid® 18 • Katapak®‑SP 19 Internals and erection • Distributors 20 • Collectors 21 • Support grids 22 • Revamping 23 • Installation 24 • Sulzer columns 25 Test facilities • Distributor test facility 26 • Pilot plants 26 Column design 0693 2504-14 • Formula notation 27

2 50 years of experience in technology

Sulzer Chemtech has been active as equipment supplier to the chemical test data gathered in our process industry since the nineteen fourties. In the early days the engineering engineering laboratory as well as design was completely dependent on the specification provided by experience gained in numerous customers. At the end of the fifties Sulzer was ready to offer its own industrial applications, we are able solutions to specific chemical process engineering problems.These early to offer the best possible solution activities laid the corner stone for sustained innovation by establishing an for your application requirements. in-house development group and a well equipped pilot facility. Column Internals Gauze packings With the concept of advanced The invention of the gauze packings for natural gas drying. In compa‑ internals, Sulzer Chemtech has BX and CY in the early sixties rison to conventional technology, defined the standard for gas resulted in a decisive breakthrough Mellapak offers substantial benefits and liquid distribution in packed in distillation technology. The special in many process applications. columns. Distributors are available advantages of these packings During the past 4 0 years, thousands for a wide range of applications allowed difficult separation tasks of columns, originally equipped with and operating conditions. to be accomplished for the very trays or random packings, have first time, and thermally sensitive been revamped with Mellapak in substances to be separated by order to improve yield or purity or to means of distillation. increase capacity. Due to extensive

0603 2516

0678 2057

Mellapak 0693 2505 A further milestone was the deve- lopment of the structured packings MellapakPlus Mellapak in the seventies. Originally • MellapakPlus represents the conceived to cover the moderate novel, high capacity structured vacuum range up to atmospheric packing (typically 25 to 30 % pressure, Mellapak opened up new more capacity compared with and unforeseen perspectives in all conventional structured packing) areas of thermal mass transfer. • MellapakPlus offers significantly lower pressure drop Applications The eighties were marked by the • MellapakPlus offers a wide widening of the application range range of technical and of Mellapak in the petrochemical, commercial advantages oil and gas industries as well as • MellapakPlus can be used from in exhaust air cleaning and in the low vacuum up to high pressure strippping of volatile constituents applications from wastewater. Typical examples • Everything one already knows are vacuum towers in refineries and about Mellapak remains valid for high-pressure absorption columns 4588 3003 MellapakPlus

3 Structured packings from Sulzer Chemtech

Type of packing Material

Mellapak 64.X/64.Y Mellapak 500.X/500.Y Stainless steels Mellapak125.X/125.Y Mellapak 750.Y Carbon steel Mellapak170.X/170.Y Further types on request Hastelloy, monel, aluminum, copper-bronze, Mellapak 2 X/2 Y brass, titanium, nickel Mellapak 250.X/250.Y Other materials available on request Mellapak 350.Y

MellapakPlus 202.Y Further types on request Stainless steels MellapakPlus 252.Y Carbon steel MellapakPlus 352.Y Hastelloy, monel, aluminum, copper-bronze, MellapakPlus 452.Y brass, titanium, nickel, MellapakPlus 602Y Other materials available on request MellapakPlus 752.Y

Mellapak 125.X/Y PP, PVC‑C, PVDF, Teflon® PFA, Mellapak 250.X/Y PEEK from plastics MellapakPlus 252.Y from plastics

Mellagrid 40.Y Stainless steels Mellagrid 64.X Carbon steel Mellagrid 64.Y Other materials available on request Mellagrid 90.X

BX gauze packing Stainless steels BXPlus gauze packing Copper-bronze, monel, hastelloy, nickel, CY gauze packing titanium Other materials available on request BX gauze packing Gauze ‑ made of polypropylene/polyacrylonitrile from plastics mixture (PP/PAN)

Mellacarbon 125.Y Carbon (CFC) Mellacarbon 250.Y Mellacarbon 350.Y Mellacarbon 500.Y

Rombopak S4M Further types on request Stainless steel, carbon steel, Hastelloy, Rombopak 9M copper, aluminium, titan, niobium Rombopak 6M Rombopak 12M laboratory packing

CrNiMo steel DX laboratory packing Alloy C22 EX laboratory packing Carbon (CFC) DXM, DYM laboratory packing made from sheet metal

Katapak‑SP 11 Stainless steels Katapak‑SP 12 Other steels available on request Katapak‑SP 13

4 Applications Diameter and operation range Characteristics

Basic chemicals and petrochemicals, From 80 mm up to 17 m Universal packing type, suitable for a wide ethylbenzene/styrene, fatty acids, (depending on type) range of applications tall oil, cyclohexanone/‑ol, caprolactam, Vacuum to high pressure Low to very high liquid loads refinery operations, Liquid load 0.2 to more than absorption/desorption columns, 200 m3/m2h natural gas drying

Basic chemicals and petrochemicals, From 80 mm up to 12 m Universal packing type ethylbenzene/styrene, fatty acids, (depending on type) Boosts useful capacity tall oil, cyclohexanone/‑ol, caprolactam, Vacuum to high pressure refinery operations, Liquid load 0.2 to more than absorption/desorption columns, 200 m3/m2h natural gas drying

Absorption/desorption columns From 200 mm up to 15 m Resistant to many chemicals (depending on type) Small pressure drop Vacuum to high pressure Temperature: PP Separation efficience similar to Mellapak max. 110 oC, made from metal PVDF max. 150 oC

Refineries and petrochemical industry Minimum diameter 900 mm Robust construction Crude oil distillation Vacuum to high pressure Smooth surface Quench columns No blockage, not sensitive to fouling Excellent flow stabiliser Efficient de‑entrainment device

Fine chemicals From 40 mm up to 6 m (depending on type) High separation efficiency, even at small liquid loads Isomers Pressure 1 mbar to atmospheric pressure, Low pressure drop, Small hold‑up Fragrances optimum: 1-100 mbar BXPlus: Same efficiency as BX, lower pressure drop Flavours From 100 mm up to 4 m (depending on Self-wetting, even with aqueous solutions Low liquid loads with aqueous solutions material) Large number of transfer units per meter, Pressure 1 mbar to moderate pressure even with small liquid loads Temperature max. 80 oC Low pressure drop

Hydrofluoric acid, carboxylic acid, From 30 mm High separation performance caustic solutions Vacuum to moderate pressure Best chemical resistance and Temperatures up to more thermal stability than 400 oC Low pressure drop

Pharmaceutical and fine chemicals From 28 mm up to 4 m Grid structure: Surface divided in a large number of Alcohols, esters, fatty acids and derivatives Vacuum to moderate pressure streamlined lamellas Flagrancies and flavours Unique distribution effect for the liquid and good Solvent recovery distribution of vapor flow Fouling services Constant separation performance independent of Pilot plants vapor load

Laboratory and pilot columns DX, DXM, DYM 30‑125 mm, Smallest hydraulic diameter EX 20‑85 mm EX, DX: Very high number of theoretical Vacuum to atmospheric pressure stages per meter, low pressure drop DXM, DYM: Constant HETP over the whole F factor range

Acetates, methyl acetate hydrolysis, From 50 mm Packing for reactive distillation and fatty acid esters Vacuum to moderate pressure trickle-bed reactors Acetals High separation efficiency and high MTBE, ETBE, TAME reaction capacity Modular concept

5 Laboratory packing Highest number of theoretical stages per unit height

separation efficiency 0.1

0.08

0.06 m /

HETP 0.04

0691 2532-2 0.02

Standard structured packings are hardly suitable for 0 use in laboratory columns of less than 50 mm diameter. 0 0.5 1 1.5 2 2.5 3 Sulzer laboratory packings are especially designed for F / Pa this purpose. EX DX Preferred applications: • Laboratory columns from 20 to 80 mm • Vacuum from 1 mbar • Where a high number of theoretical stages is required (DX, EX) • Distillation of components prone to decomposition pressure drop • Preliminary assessement of a separaton task 20 • Deriving of reliable scale‑up rules

Special features: Small pressure drop 10 Type EX: • Highest possible number of theoretical stages, even with very low liquid loadings • Same pressure drop per theoretical stage as Sulzer

BX packing mbar/m / • Small hold‑up

• Capacity nearly double that of wire mesh rings p/ z (3 x 3 mm)

Type DX: This packing has a coarser structure and hence a lower number of theoretical stages. Suitable for laboratory columns where a modest num- ber of theoretical stages is required, together with low pressure drop and high capacity. Type DXM/DYM: 1 These packing types, made of sheet metal, have a 0 1 2 3 lower number of theoretical stages compared to DX. F / Pa HETP or NTSM remain constant over a wide range Laboratory packings of F factors and liquid loads. This makes scale‑up Head pressure = 50 mbar significantly easier.

6 Rombopak The packing with the unique structure and performance

separation efficiency 0.7

0.6

0.5

m 0.4 /

0.3 HETP

0.2 The unique open structure has been specifically developed for the ambitious distillation requirements of 0.1 the fine chemical industry. It has been widely used in the most diverse applications and has become a well 0 established preferred choice of the pharmaceutical 0 1 2 3 4 5 6 industry and specialty chemistry. F / Pa

Special features Rombopak 9M Rombopak S4M • Grid structure: Surface divided in a large number of streamlined lamellas 67 67 960 960 • Unique distribution effect for the liquid and good parameter = head pressure p /mbar distribution of vapor flow • Maximized open area for the vapor to flow through resulting in a reduced pressure drop pressure drop • Constant separation performance independent of 10 vapor load • Pilot size diameters available down to 28 mm

Preferred applications • High capacity and separation performance at minimum pressure drop • Ideal for miniplant applications due to its exceptional scale‑up properties. Easy validation in GMP regulated processes mbar/m /

• Highly resistant against fouling due its open structure z 1

• Good performance with viscous liquids p/

Typical product applications • Pharmaceutical and fine chemicals • Alcohols, esters, fatty acids and derivatives • Flagrancies and flavours • Solvent recovery • Fouling services

• Pilot plants 0.1 0 1 2 3 4 5 6 Rombopak types F / Pa Rombopak S4M 6M 9M 12M Rombopak NTSM 2.4 3.7 6.0 8.0 Rombopak 12M only for lab or pilot plant up to 150 mm diameter.

7

Mellapak 250.Y/X A highly versatile packing type

separation efficiency 1

0.8

0.6 m /

HETP 0.4

0.2

0 0 1 2 3 4 5 6 F / Pa 0602 2510 Mellapak 250.Y Mellapak 250.X 960 960 Mellapak is the most widely used structured packing 400 400 worldwide. It has proven excellent performance in 100 100 50 50 columns with diameters up to 15 m. It is supplied in parameter = head pressure p /mbar sheet metal thicknesses from 0.1 mm up.

pressure drop Special features 10 • 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 mbar/m /

• Increasing capacity of existing tray and packed z 1

columns p/

Typical applications • Chemical Ethylbenzene/styrene, tall oil, industry: cyclohexonone/‑ol, air separation • Petrochemical Quench columns,

industry: C3- and C4- splitters, xylene splitters • Refineries: Vacuum and atmospheric columns 0.1 • Absorption: Natural gas drying, 0 1 2 3 4 5 6

CO2- and H2S-absorbers and F / Pa strippers, Mellapak 250.Y ethyleneoxide absorbers and Mellapak 250.X strippers, acrylonitrile absorbers

8 Mellapak A solution available for any application

separation efficiency separation efficiency separation efficiency 1.5 1.0 1.0

0.8 0.8

1.0 0.6 0.6 m m m / / / HETP HETP HETP 0.4 0.4 0.5

0.2 0.2

0 0 0 0 1 2 3 4 5 6 0 1 2 3 4 5 6 0 1 2 3 4 5 6 F / Pa F / Pa F / Pa

Mellapak 125.Y Mellapak 125.X Mellapak 170.Y Mellapak 170.X Mellapak 2Y Mellapak 2X 960 960 960 960 960 960 100 100 400 400 400 400 50 50 100 100 100 100 parameter = head pressure p /mbar 50 50 50 50 parameter = head pressure p /mbar parameter = head pressure p /mbar

pressure drop pressure drop pressure drop 10 10 10 mbar/m mbar/m mbar/m / / / z z

z 1 1 1

p/ p/ p/

0.1 0.1 0.1 0 1 2 3 4 5 6 0 1 2 3 4 5 6 0 1 2 3 4 5 6 F / Pa F / Pa F / Pa Mellapak 125.Y Mellapak 170.Y Mellapak 2Y Mellapak 125.X Mellapak 170.X Mellapak 2X

9

Mellapak A solution available for any application

separation efficiency separation efficiency separation efficiency 0.5 0.5 0.5

0.4 0.4 0.4

0.3 0.3 0.3 m m m / / / HETP HETP 0.2 HETP 0.2 0.2

0.1 0.1 0.1

0 0 0 0 1 2 3 4 0 1 2 3 4 0 1 2 3 F / Pa F / Pa F / Pa

Mellapak 350.Y Mellapak 500.Y Mellapak 500.X Mellapak 750.Y 960 960 960 960 400 400 400 100 100 100 100 50 50 50 50 parameter = head pressure p /mbar parameter = head pressure p /mbar parameter = head pressure p /mbar

pressure drop pressure drop pressure drop 10 10 10 mbar/m mbar/m mbar/m / / / z z 1 z 1 1

p/ p/ p/

0.1 0.1 0.1 0 1 2 3 4 0 1 2 3 4 0 1 2 3 F / Pa F / Pa F / Pa Mellapak 350.Y Mellapak 500.Y Mellapak 750.Y Mellapak 500.X

10 MellapakPlus A new generation of structured packings

separation efficiency 0.6

0.5

0.4 m / 0.3 HETP 0.2

0.1

0699 2522−4 0 0 1 2 3 4 5 6 F / Pa

MellapakPlus is a capacity enhan‑ In the interior part of the packing MellapakPlus 252.Y Mellapak 250.Y ced structured packing. It combines element the geometrical features 960 960 of MellapakPlus and Mellapak 400 400 all advantages of the metal sheet 100 100 packing Mellapak with new geo‑ are identical. Hence, separation parameter = head pressure p /mbar metrical features. efficiency is similar – but with a significant increase in capacity and a reduction in pressure drop. Features of MellapakPlus pressure drop At the lower and upper end of each All other MellapakPlus properties 10 packing element, the orientation – including installation procedure, of the corrugation gradually ap- mechanical strength and corrosion proaches the vertical axis. resistance – are identical to Mellapak. Advantages of this geometrical modification: MellapakPlus performance has • The vapor flow smoothly chan‑ been confirmed in category 1 tests ges direction at the interface at F.R.I. between two packing elements • At the interface vapor flow is Internals The close resemblance between

nearly parallel to the vertical axis mbar/m MellapakPlus and Mellapak gua‑ / of the column. The gas velocity z 1 rantees continued use of the whole

is therefore reduced by about p/ 25% compared to the velocity range of well known and reliable inside the packing element internals. Internals are now able to handle the increased gas load Both factors reduce the pressure typical for the high capacity of drop and the shear forces, which MellapakPlus. Sulzer Chemtech is are especially critical at the inter- committed to the on-going, focused face due to the presence of thicker development of novel designs. and less stable liquid films. As a result, premature flooding at the interface is no longer of concern. 0.1 0 1 2 3 4 5 6

F / Pa MellapakPlus 252.Y vs. Mellapak 250.Y

11 MellapakPlus A new generation of structured packings

separation efficiency separation efficiency separation efficiency 0.7 0.5 0.5

0.6 0.4 0.4 0.5

0.3

m 0.3 m m

0.4 / / /

0.3 HETP HETP HETP 0.2 0.2

0.2 0.1 0.1 0.1

0 0 0 0 1 2 3 4 65 0 1 2 3 4 5 0 1 2 3 4 5 F / Pa F / Pa F / Pa

MellapakPlus 202.Y MellapakPlus 352.Y MellapakPlus 602.Y MellapakPlus 452.Y MellapakPlus 752.Y 960 960 960 960 960 400 400 400 400 100 100 100 100 100 parameter = head pressure p /mbar parameter = head pressure p /mbar parameter = head pressure p /mbar

pressure drop pressure drop pressure drop 10 10 10 mbar/m mbar/m mbar/m / / / z z z 1 1 1

p/ p/ p/

0.1 0.1 0.1 0 1 2 3 4 65 0 1 2 3 4 5 0 1 2 3 4 5 F / Pa F / Pa F / Pa MellapakPlus 202.Y MellapakPlus 352.Y MellapakPlus 452.Y MellapakPlus 602.Y MellapakPlus 752.Y

12 Gauze packings Sulzer metal gauze packing, type BX and BXPlus

separation efficiency 0.5

0.4

0.3 m /

HETP 0.2

0682 2017 0.1 separation effciencyefficiency of ofBX BX This packing has been successfully employed in the and BXPlus is identical industry for over 40 years. Largest diameter supplied 0 to date: 6 m. 0 1 2 3 4 5 6 F / Pa Special features • High number of theoretical stages per unit height BX BXPlus • Pressure drop per theoretical stage 0.1 – 0.5 mbar 960 960 400 • Most economical load range: 100 100 F factor 1‑2.5 √Pa 50 50 10 10 3 2 • Minimum liquid load approx. 0.05 m /m h parameter = head pressure p /mbar • Small hold‑up pressure drop 10 Preferred applications • Large number of theoretical stages • Vacuum from 1 mbar to atmospheric pressure • Where minimum pressure drop per theoretical stage is important • Small overall height • Batch and continuous columns • Pilot columns (reliable scale‑up) mbar/m Limited suitability for / z 1 • Fouling substances p/ • Non‑wetting liquids

Product applications • Monomers from plastics (MDI, DMT, etc.) • Fatty acids, fatty alcohols, fatty acid esters • Mono‑, di‑, tri‑, and tetraethylene glycols ccolumnolumn diamdiametereter • Fine chemicals ID = 250 mm

BXPlus 0.1 BXPlus is a further development of the well proven 0 1 2 3 4 5 6 gauze packing BX. Its geometry is similar to F / Pa MellapakPlus. BXPlus offers the same efficiency as BX with a 20% lower pressure drop. It is recommended Gauze packing BX for gentle distillation at higher capacity. Gauze packing BXPlus

13 Gauze packings Sulzer metal gauze packing, type CY

separation efficiency 0.3

0.2 m / HETP 0.1

4588 3043

0 0 1 2 3 4 F / Pa

960 400 100 50 25 parameter = head pressur e p /mbar

This packing was developed for separations that pressure drop require a large number of theoretical stages. Largest 10 diameter 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‑up mbar/m /

z 1

Preferred applications p/

• For a very large number of theoretical stages • 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 liquids 0.1 0 1 2 3 4 Product applications F / Pa • Pharmaceutical products (vitamins, etc.) • Fragrances (menthol, geraniol, etc.) Gauze packing CY • Separation of isomers

14 Mellapak and MellapakPlus from plastics

separation efficiency 0.6

0.5

0.4 m / 0.3 HTU

0.2

Acetone/H2O (10-20 m3/m2h) 0.1 SO2/H2O (20‑40 m3/m2h) 0 0 1 2 3

0682 2021 F / Pa

Separation efficiency of Mellapak 250.Y PP

The MELLAPAK 125.X, 125.Y, 250.X and 250.Y and MellapakPlus 252.Y are also available in different kinds of thermoplastics. Packings made of polypropylene (PP), postchlorated polyvinylchloride (PVC‑C), pressure drop polyvinylide‑nedifluoride (PVDF), Teflon® PFA and 100 polyether ether ketone (PEEK) can be supplied.

The plastic versions of MELLAPAK have pro ven operational record in various types of absorption and 3 2 desorption columns. 75 m /(m h) 10 Special features • Large number of transfer units per meter, low HTU, depending on the system mbar/m

• Small pressure drop per meter packed height / z 1 • Most economical load range up to F factor 4 √Pa p/ • Maximum operating temperatures: approx. 110 oC for polypropylene approx. 150 oC for PVDF 0.1 Product applications • HCI absorbers dry 252.Y PP • SO2 absorbers 250.X PP • Flue gas cleaning columns 250.Y PP 0.01 • Sea water deaerators 0.1 1 F / Pa MellapakPlus 252.Y has the same efficiency as Mellapak 250.Y and same capacity as Mellapak Mellapak PP 250.X atmospheric pressure

15 Gauze packings Sulzer plastic gauze packing, type BX

separation efficiency 0.25

0.2

0.15 m / HT 0.1

Meal/H2 0.05 12 m3/m2

H3/H2 2.55 m3/m2 0682 2020 0 0 1 2 3 F / Pa

60 20 5 0 parameter = liquid load l /m3/m2h

The plastic gauze packing has been used industrially with great success for many years. The special gauze pressure drop 100 structure provides a very good wettability, even in aqueous systems. This packing is used primarily for columns with low liquid loads.

Special features • Large number of transfer units per meter, low HTU, depending on the system 10 • Minimum pressure drop, typically 2–4 mbar/m • Minimum liquid load approx. 0.05 m3/m2 h mbar/m • Self‑wetting packing surface, even for aqueous / z

solutions p/ • Operating temperatures up to 80 oC, depending on the chemical components 1

Preferred applications • Small liquid loads • Increasing performance of existing columns • Columns with small overall height

Product applications 0.1 0 1 2 3 4 5 • Methanol absorbers F Pa • Isopropanol absorbers / • Dimethylformamide absorbers Plastic gauze packing BX • Formaldehyde absorbers atmospheric pressure, ID = 300 mm

16 Mellacarbon – pure carbon

separation efficiency 0.4

0.3 m / 0.2 HETP

0.1

0 0 1 2 3 4 0697 2522 F / Pa

head pressure p /mbar 960 100 Mellacarbon 500.Y Mellacarbon 350.Y Mellacarbon 250.Y

Carbon does not react with most solvents, acids or lyes. pressure drop Sulzer Chemtech offers various Mellacarbon types. 50

• 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 o • High thermal stability (> 400 C) 10

Product applications mbar/m /

• HCI separation for production and for HCI recovery z

(typically in the production of polycarbonate) p/

• MCA / DCA distillation • Production of phosphoric acid • Concentration of hydrofluoric acid • Separation of chlorophenols

1

0.5 0 1 2 3 4 F / Pa

Mellacarbon

17 Mellagrid Sulzer structured grid packings

capacity 1 m/s /

G r c 0.1 acto d f loa 0694 2506

With Mellagrid, Sulzer Chemtech combines the effi ciency of struc‑ tured packings with the mechanical resistance of a grid. Mellagrid is used wherever the 0.01 mechanical strength of structured 0.01 0.1 1 packings is a concern or where 0694 2506 coking is likely to occur. 40.Y 64. 64.Y 90. pressure drop 100 Technical Data

Mellagrid 90.X 64.X 64.Y 40.Y Specific surface area 90 m2/m3 64 m 2/m3 64 m 2/m3 40 m 2/m3 Element height (approx.) 140 mm 220 mm 130 mm 200 mm

Surface structure smooth 10 Material thickness 0.5 to 2 mm Material AISI 410S or 316L, other materials upon request mbar/m /

Special features Applications p/ • Not sensitive to coking and • Atmospheric or vacuum tower: 1 fouling due to its smooth surface Wash section and geometrical structure • FCC Main Fractionator: 40.Y/64.Y 64./64.Y • Effi cient dissipation of Slurry pumparound section temperature • Coker or • Better de‑entrainment and Visbreaker Fractionator: separation effi ciency than a traditional grid Wash section 0.1 • The low element height and its 0 2 4 6 10 structure allow for easy cleaning. F / Pa It can be removed, unscrewed Mellagrid and cleaned with a water jet various liquid loads, air/water, • Mechanically robust structure T=30 oC, atmospheric pressure

18 Katapak-SP Sulzer reactive distillation packing

separation efficiency 0.6

0.5

0.4 m / 0.3 HETP 0.2

0.1

0 0 1 2 3 4 0600 2701-6 F / Pa

Katapak-SP 12 960 400 100 parameter = head pressure p /mbar

This packing was developed to be applied in reactive distillation processes. With the modular concept sepa- pressure drop ration efficiency and catalyst volume fraction can be 100 varied to perfectly fit the requirements of each specific process. Other types are available on request. Largest diameter supplied to date: 2 m.

Special features: • Flexible design combining catalyst elements and MellapakPlus layers 10 • High separation efficiency • High reaction capacity mbar/m / z

Product applications: p/

• Synthesis of acetates (e.g. butyl acetate) • Hydrolysis of methyl acetate 1 • Synthesis of fatty acid esters • Synthesis of acetals • MTBE, ETBE, TAME

0.1 0 1 2 3 4 F / Pa Katapak

19 Column internals

Liquid distributors

300 High-Liquid-Load Tube Distributors VR

VRGF

0610 2501-1 100 Distributor/Collector VS

VSI VSI/VSIR

0610 2501-3 0610 2501-2

Trough‑Distributor VK Element‑Distributor VE

50

VKH VEH

VKG

0600 2507-6 0609 2500-5 0609 2500-1 h] 2 /m 3 m [

l Standard-Load d

oa VKGF VER2 d l 10 iqui c l 0610 2501-4 0609 2500-4 VKR2 Specifi Specifi

VKR2F VEP/VEPW

0609 2500-6

0609 2500-7 0609 2500-2 1 Low Liquid-Load

VKPK VEPK

0610 2501-5 0609 2500-3 0.05 0.25 0.8 3 20 Column‑Diameter [m]

20 Column internals

Collector support grids

Type Column diameter Features

The collector SLT is both a packing support and a vane collector. As a packing support, it can support the direct load of packings with surface areas up to 350 m2/m3. For finer packings, additional drip plates are used.

0600 2509-4 This non‑welded collector SLT is often used in applications where space between packed beds is limited. This collector requires a SLRT/SLMT from 0.3 m support ring inside the column.

Collectors

The vane collector SL is used as a separate unit to accumulate liquids from packed sections within a column. This collector requires a ring channel welded to the column wall.

The collector SLF is designed to be installed between the column 0600 2509-2 flanges in smaller flanged columns.

SLR/SLM from 0.3 m

Chimney trays

The collector SK is an established and versatile tray design, available either in bolted or seal-welded construction. It is generally used in large diameter columns with high liquid loads.

0600 2506-1

SK from 1 m

21 Column internals

Collector-distributor systems/Vapor distributor

Type Column diameter

The collector/distributor VS is used whenever collection and redistribu- tion of liquid is required at very high liquid loads. It resembles a chimney tray; however the chimney arrangement is custom designed for your application’s liquid distribution and pressure 0602 2511-2 drop requirements. For moderate liquid loads appli‑ cations, where liquid mixing is im- portant, a separate accumulator tray must collect the liqui d and VSI from 0.25 m feed it to a liquid distributor located below it.

In addition, special collector‑distribution systems are available, e.g. for use at increased pressures or - in conjunction with highly corrosion-resistant packings - in processes with agressive media. Supplementary information is to be found in our brochure “Internals for Packed Columns”.

Support grids

TEB and TSB are used with structured packings. Both require support rings to be welded to the column wall. TEB are supports for flanged columns. The segmental grids of the TSB pass through manholes and are clamped to- 0600 2513-4 gether for convenient installation. No welding is required. TEB and TSB support grids are ideal for applications requiring ex- pensive high-alloys. Certain high performance packings TEB/TSB 0.5 to 10 m require additional drip plates.

TE and TS are intended for struc‑ tured packings with surface area over 350 m2/m3 packing volume. They are designed with drip plates to prevent premature flooding of the packing. These support grids rest on sup- port rings or gussets welded to the 0600 2513-2 column shell. For columns over 3 m, additional supports and major TS/TE from 0.1 m beams may be required.

22 Revamping of existing columns

Repacking the entire column Repacking with column sleeve cross-section To improve product purity without Along with other aspects, this increasing capacity. Due to the modification serves to increase the good hydraulic performance of throughput. the Sulzer structured packings, the entire column cross-section is often not needed. The Sulzer packing is fitted inside a sleeve of smaller diameter.

Existing column Items supplied by Sulzer 5 Chemtech 6 4 Installation either by the cus‑ tomer with Sulzer advising or 6 complete installation service by 7 Sulzer as the customer wishes. 7 8 8 9 1 Sulzer packing 2 Support grid 3 Support beam 4 Collector 9 5 Support lugs (welded-in) 6 Ring channel 7 Liquid distributor 8 Locating grid (hold-down grid) 9 Existing trays (incl. support rings)

Repacking work (Example for tray towers) • Remove the trays 1 • Remove tray support rings (when required - depending 1 upon the installation method of 2 the packing) 2 3 • Weld in the support lugs, 4 tie-bars and ring channels for 5 the liquid collectors • Provide manholes and sight glasses at the level of each liquid distributor • Fit new feed and instrument 0682 2044 0682 2045 connections, if necessary Installation Installation • Clean the column The new column internals are The column head is taken off and installed through the manholes: the pre-assembled and pre-packed Repacking time support beam, support grid, sleeves are lowered by crane onto Depending on the column size and packing, locating grid, distributor the relative beams fitted in the personnel deployed, modifications and collector. column. The annular spaces are to the existing column may take one sealed off to prevent gas and liquid to four weeks, and several days to by-passing. two weeks for fitting the new parts.

23 Installation

0695 2510-13 Installation of packing

0692 2512-18 Revamping of a vacuum column with Mellapak

0601 2505-2 Inspecting packings after installation

0602 2509-39 Installation of the liquid distributor

0683 2006-2 The packing is fitted inside the column sleeves at the preassembly site

0683 2006-1 The column sleeve is lowered into the column with two cranes. Weight: 100 tons

24 Sulzer columns – your solution

Sulzer columns of Welded column, sectional design monoblock type All internals can be installed through All internals in segments for in- the column flange openings stallation and removal through manhole, nominal diameter 500 up to 1000 mm

Sulzer packing 1 in various types and different materials

Support grid 2 for the packing

Liquid collector 3 Reflux from condenser from Feed pipe 4 condenser to distributor 6 5 Liquid distributor 5 1 mounted on locating grid

3 Locating grid 6 1 4 Feed Steam inlet pipe 7 5 Column sump 8 3 4 Circulation pipe 9 to reboiler Feed

Skirt 10 2

Anchorage 11 7

8 Variations on the above design Feed: 2 • vapor 9 • two phases with flash box Side stream: 10 • liquid from collector 11 • vapor collector Bottom product Bottom product

0694 2510 0694 2511

25 Separation technology laboratory Comprehensive customer service

Distributor test facility Laboratories Uniform liquid distribution is The distributor test facility has Sulzer Chemtech has set up a decisive in securing good sepa- provided results which have con- process engineering laboratory in ration performance from a rectifi‑ tributed significantly to the con‑ Winterthur, Switzerland for develop- cation/absorption column incorpo‑ struction of large distributors with ment and testing of structured rating structured packings diameters ranging from 3 m up to packings, column internals and especially for columns of large 15 m. As part of integrated quality trays. At Sulzer Chemtech Allschwil diameter. control, all distributor types are Ltd, a laboratory carries out This requirement was recognized fully tested before delivery to customer trials and pilot tests. Also early on in the development of the customers. Sulzer Chemtech is an analytical laboratory and trained Sulzer structured packings. Hence certified in accordance to ISO personnel are available. the geometrical configuration of the 9001 : 2000 and ISO 14001. packings promotes liquid stream intersections and thus intermixing. Moreover, a whole series of liquid distributors has been developed, which are optimally matched for column diameter, packing type and operating conditions.

0600 2566-1 0682 2026

Distributors on the Sulzer Chemtech Multi-purpose pilot plant for the separation distributor test facility of mixtures by distillation, using Sulzer structured packings of various design

26 Formula notation

Metric Units To convert US Units to US Units multiply by

G Gas flow kg/h 2.205 lb/h g Gas load per square meter kg/m2h 0.2048 lb/ft2h (related to empty column) L Liquid flow kg/h 2.205 lb/h m³/h 4.403 gpm l Specific liquid load m³/m²h 0.4090 gpm/ft2 (related to empty column) NTS Number of theoretical stages (–) NTSM Number of theoretical stages m-1 0.3048 ft-1 per meter packed height NTUM Number of transfer units m-1 0.3048 ft-1 per meter packed height HETP Height equivalent to a m 39.37 in theoretical plate cG Load factor = wG ρG /(ρL - ρG ) m/s 3.281 ft/s 3 F F factor = wG . ρG m/s kg/m³ = Pa 0.8197 ft/s lbm/ft wG Superficial gas velocity m/s 3.281 ft/s (related to empty column)

3 3 ρG Gas density kg/m 0.06243 lb/ft 3 3 ρL Liquid density kg/m 0.06243 lb/ft M Molar mass kg/kmol 1.000 lb/lb‑mol p Operating pressure mbar 0.7501 mm Hg bar 14.50 psia

∆p/∆z Pressure drop per unit height mbar/m 0.1224 in H2O/ft T Operating temperature K 1.800 R

2 2 Ac Column cross-section m 10.76 ft dc Column diameter m 3.281 ft . ψ Flow parameter = L/G ρG / ρL (–)

27 Headquarters North and South America Asia, Pacific P.O. Box 65 Sulzer Chemtech USA, Inc. Sulzer Chemtech Pte. Ltd. 8404 Winterthur, Switzerland 1 Sulzer Way 10 Benoi Sector Phone +41 52 262 50 28 Tulsa, OK 74107, USA 629845 Singapore Fax +41 52 262 01 82 Phone +1 918 446 6672 Phone +65 6515 5500 [email protected] Fax +1 918 446 5321 Fax +65 6862 7563 www.sulzer.com

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquar- The activity program comprises: ters in Winterthur, Switzerland, is active in the field of process engineering • Process components such as fractionation trays, structured and ran- and employs some 3500 persons worldwide. dom packings, liquid and gas distributors, gas-liquid separators, and Sulzer Chemtech is represented in all important industrial countries and internals for separation columns sets standards in the field of mass transfer and static mixing with its ad- • Engineering services for separation and reaction technology such as vanced and economical solutions. conceptual process design, feasibilities studies, plant optimizations in- cluding process validation in the test center • Recovery of virtually any solvents used by the pharmaceutical and chemical industry, or difficult separations requiring the combination of special technologies, such as thin film/short-path evaporation, distilla- tion under high vacuum, liquid-liquid extraction, membrane technology or crystallization. • Complete plants, in particular modular plants (skids) • Advanced polymerization technology for the production of PLA and EPS • Tower field services performing tray and packing installation, tower maintenance, welding, and plant turnaround projects • Mixing and reaction technology with static mixers • Cartridge-based metering, mixing and dispensing systems, and dis- posable mixers for reactive multi-component material

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Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any 22.13.06.40 - IX.12 - 10 - Printed in Switzerland warranty or guarantee of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.