Sulzer Chemtech
Structured Packings for Distillation, Absorption and Reactive Distillation
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 mass transfer 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
Me a l/H2 0.05 1 2 m3/m2