Metal_Random_Packing

1 Sulzer Chemtech 0699 2527-1 Metal Random Packing Superior random packings combined with innovative mass transfer technology � Sulzer Chemtech is dedicated to developing solutions that optimize the performance of industrial processes and plants through greater energy efficiency, higher product quality, and increased capacity. Our application know- how, dedication to exacting fabrication standards and rigorous quality management characterize all our pro- ducts. Our steadfast commitment to providing the right mass transfer equipment is supported by an in-house develop- ment group and a state of the art research facility with multiple pilot and industrial scale columns. This innovati- on and commitment to our customers has taken existing random packing technologies beyond its past threshold and created a new outlook in a conventional product. Random Packing Random packings have been used for separations in chemical and refining plants for many years. The practical, chemical process and commercial benefits of random packing are well-established in many applications and is a mainstay in the area of mass transfer equipment. For example at high liquid load and in high pressure applications, random packings improve distillation or absorption efficiency and reduce pressure drop compared to other mass transfer contacting devices. Sulzer Chemtech‘s portfolio of random packing includes standard and latest generation random packings, comprising the Nutter Ring, I-Ring, C-Ring, P-Ring and R-Ring. The I-Ring, C-Ring, P-Ring and R-Ring are similar to the widely accepted IMTP®, CMR™, Pall Ring® and Raschig Ring respectively. The Pall Ring is a second-generation random packing, and except for the Raschig Ring, it has been on the market longer than any of the others. The P-Ring can be used as a replacement of the Pall Ring and in applications where performance needs are not sufficient to warrant a third-generation packing, such as the Nutter Ring or I-Ring. The revolutionary geometric design of the third-generation Nutter Ring, I-Ring and C-Ring minimize pressure drop and liquid hold-up while main- taining efficiency. All three types of Nutter Ring, I-Ring and C-Ring can handle greater capacity than the P-Ring. They all provide up to 30% lower pressure drop than the P-Ring. Nutter Ring I-Ring C-Ring P-Ring R-Ring 0603 2535-2 0603 2532-1 0606 2501-2 0603 2533-2 0603 2534-1 3 Colum Internals Liquid distribution is critical to en- sure optimal tower performance. Attributes such as distribution qua- lity, drip point density and operating range are important parameters to a well designed distributor. Our extensive experience in designing and fabricating both high perfor- mance and fit-for-purpose internals will ensure that you will get the pro- per equipment for your application. Emergency delivery Sulzer Chemtech has the random packing for optimal perfor- mance of your application. For urgent deliveries, we have on stock common stainless steel random packing of various sizes in our warehouses to get you back onstream. For emergencies, contact your nearest Sulzer Chemtech office at our website: www.sulzerchemtech.com Customer Benefits - We offer our customers the world- wide presence, extensive techni- cal services, and recognized lea- dership in the design of column internals. - We offer a wide range of random packing types and sizes that ope- rators and process licensors are familiar with. - At Sulzer Chemtech, decades of design, construction and manuf- acturing experience combine to ensure our column internals meet the requirements of your applica- tion. - Each individual product offered by Sulzer Chemtech has been thoroughly researched at our test facilities, and consistently provides superior reproducible results no matter the worldwide location your purchase from. Materials of Construction Metal random packings are availa- ble in various materials of construc- tion such as: - Carbon Steel - Stainless Steel - Titanium and Zirconium - Copper - Aluminum Contents Nutter Ring™ ............................................................. 4 - 5 I-Ring™ ...................................................................... 6 - 7 C-Ring™ ..................................................................... 8 P-Ring™ ..................................................................... 8 R-Ring™ ..................................................................... 9 Separation Technology Test Facilities .................... 10 Colum Internals ......................................................... 11 - 13 Applications .............................................................. 140693 2505 4 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 0 0.5 1.51.0 2.0 2.5 0.50 1.5 2.5 3.52.0 3.01.0 40 30 20 10 0 1100 1000 900 800 700 600 500 400 300 200 100 0 0.5 1.51.0 2.0 2.5 NR #3 NR #2 NR #1 NR #2.5 NR #1.5 NR #0.7 10 15 20 25 30 40 50 60 80 100 150 7 6 5 4 3 2 100 110 90 80 70 60 50 40 35 30 25 4 8 10 20 30 40 50 60 (NR #0.7) (NR #1.5) NR #2.5 NR #1 NR #2 (NR #3 ) Mechanical Specifications No. 0.7 No. 1 No. 1.5 No. 2 No. 2.5 No. 3 Pieces (m3) 167,400 67,100 26,800 13,600 8,800 4,200 Surface Area (m2/m3) 226 168 124 96 83 66 Weight (kg/m3)* 177 179 181 144 121 133 Void (%) 97.8 97.8 97.8 97.9 98.2 98.4 KGa of Nutter Ring Liquid Load l, m3/m� h Liquid Load, gpm/ft� K G a, k g- m ol / (h m 3 a tm ) K G a, lb -m ol /( h ft3 a tm ) H E T P, m m H E T P, in ch es F, ft/s �lb/ft3 HETP of Nutter Ring * For stainless steel with standard material thickness. Other thicknesses are available upon request. The technical data are average values and approximate sizes. Subject to changes and improvements. No claims may be derived from information given. F, �Pa Conditions Valid for atmospheric distillation with standard organic test mixture at total reflux. Nutter Ring Nutter Ring Advantages • Efficiency enhanced by lateral liquid spreading and surface film 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. Conditions Diameter: 0.3 m, Bed height: 2.25 m Liquid concentration: 4% NaOH Conversion to carbonate (Na�CO3): < 1% Inlet gas concentration: 400ppm CO� Temperature: 25 oC F = 1.5 √Pa Bracket indicates extrapolated data 0603 2535-3 5 F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 20 10 1.0 0.1 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t 20 10 1.0 0.1 F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t 20 10 1.0 0.1 F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t 20 10 1.0 0.1 F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t 20 10 1.0 0.1 F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t 20 10 1.0 0.1 F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t 0 20 40 60 80 100 120 150 NR #0.7 NR #1 NR #1.5 NR #2 NR #2.5 NR #3 Liquid Load l, m3/m� h Air-water system, ambient conditions � 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 0 0.5 1.51.0 2.0 2.5 0.50 1.5 2.5 3.52.0 3.01.0 40 30 20 10 0 1100 1000 900 800 700 600 500 400 300 200 100 0 0.5 1.51.0 2.0 2.5 IR #70 IR #50 IR #40 IR #25 IR #15 0603 2532-3 10 15 20 25 30 40 50 60 80 100 150 7 6 5 4 3 2 100 110 90 80 70 60 50 40 35 30 25 4 8 10 20 30 40 50 60 (IR #15) IR #25 IR #40 IR #50 (IR # 70) Mechanical Specifications No. 15 No. 25 No. 40 No. 50 No. 70 Pieces (m3) 347,500 135,000 50,000 15,000 4,600 Surface Area (m2/m3) 291 226 151 100 60 Weight (kg/m3)* 336 252 180 163 116 Void (%) 95.6 96.6 97.7 98.0 98.5 I-Ring KGa of I-Ring H E T P, m m H E T P, in ch es HETP of I-Ring * For stainless steel with standard material thickness. Other thicknesses are available upon request. The technical data are average values and approximate sizes. Subject to changes and improvements. No claims may be derived from information given. Conditions Diameter: 0.3 m, Bed height: 2.25 m Liquid concentration: 4% NaOH Conversion to carbonate (Na�CO3): < 1% Inlet gas concentration: 400ppm CO� Temperature: 25 oC F = 1.5 √Pa Bracket indicates extrapolated data Conditions Valid for atmospheric distillation with standard organic test mixture at total reflux. I-Ring Advantages • I-Rings provide over 30% lower pressure drop than the 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. F, ft/s �lb/ft3 F, �PaLiquid Load l, m3/m� h Liquid Load, gpm/ft� K G a, k g- m ol / (h m 3 a tm ) K G a, lb -m ol /( h ft3 a tm ) 7 0 20 40 60 80 100 120 150 F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 20 10 1.0 0.1 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 20 10 1.0 0.1 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 20 10 1.0 0.1 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 20 10 1.0 0.1 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t F, ft/s √lb/ft3 1.0 2.0 3.0 4.0 20 10 1.0 0.1 2.45 1.22 0.12 0.5 1.0 5.0 F, √Pa ∆p /∆ z, m ba r/ m ∆p /∆ z, in H 2O /f t IR #15 IR #25 IR #40 IR #50 IR #70 Liquid Load l, m3/m� h Air-water system, ambient conditions 8 C-Ring Advantages • First commercially successful third-generation ran- dom packing replacing the widely used Pall® Ring. • Low aspect ratio (element height : element diameter is 1:3) favors a packing orientation that results in hig- her capacity, lower pressure drop and better fouling resistance. • The arrangement of tabs provides more drip points per element offering better liquid distribution and higher efficiency. • Direct replacement of the widely used CMR. Mechanical Specifications No. 1.5 No. 2 No. 2.5 No. 3 No. 4 Pieces (m3) 71,000 29,500 20,500 10,200 4,300 Surface Area (m2/m3) 187 144 126 103 74 Weight (kg/m3)* 207 162 205 149 108 Void (%) 97.0 97.5 97.5 98.0 98.5 P-Ring Advantages • Highest industry experience and extensively tested by research institutes worldwide. • Material thickness overcomes mechanical weak- nesses, and can be used in extremely corrosive ser- vices enabling cheaper materials to be used. • Strength-to-weight ratio stronger than most other random packings. • Direct replacement of the well known Pall Ring. Mechanical Specifications No. 5/8 No. 1 No. 1.5 No. 2 No. 3.5 Pieces (m3) 214,000 50,000 14,000 6,100 1,100 Surface Area (m2/m3) 360 215 135 105 66 Weight (kg/m3)* 560 320 208 213 158 Void (%) 95.0 95.0 96.0 97.0 97.0 0606 2501-2 0603 2533-2 9 R-Ring Advantages • First generation of random packings, industry expe- rience outperforms fractionation trays. • Great strength-to-weight ratio. • Direct replacement of the well known Raschig Ring. Mechanical Specifications No. 5/8 No. 1 No. 1.5 No. 2 No. 3.5 Pieces (m3) 214,000 50,000 14,000 6,100 1,100 Surface Area (m2/m3) 350 220 130 110 66 Weight (kg/m3)* 560 400 260 256 220 Void (%) 86.0 88.0 90.0 92.0 95.0 * For stainless steel with standard material thickness. Other thicknesses are available upon request. The technical data are average values and approximate sizes. Subject to changes and improvements. No claims may be derived from information given. 0603 2534-1 10 Distributor Test Facility Uniform liquid distribution is deci- sive in securing good separation performance from a rectification/ absorption column incorporating packings especially for columns of large diameter. This requirement was recognized early on in the development of the Sulzer structured packings. Hence a whole series of liquid distributors has been developed, which are op- timally matched for column diam- eter, packing type and operating conditions. Separation Technology Laboratory Comprehensive customer service The distributor test facility has pro- vided results which have contribut- ed significantly to the construction of large distributors with diameters ranging from 3 m up to 15 m. Sul- zer Chemtech is certified in accor- dance to ISO 9001:2000 and ISO 14001. Distributors on the Sulzer Chemtech distributor test facility Laboratories Sulzer Chemtech has set up a process engineering laboratory in Winterthur, Switzerland. In addition to the further develop- ment and testing of packings, column internals and trays, this laboratory carries out customer trials and pilot tests. An analytical laboratory and trained personnel are available. Multi-purpose pilot plant for the separation of mixtures by distillation, using Sulzer packings of various designs. 0600 2566-1 0682 2026 Separation Technology Test Facilities 0600 2566-1 0682 2026-1 11 Column Internals Welded column, monoblock type All internals in segments for in- stallation and removal through manhole, nominal diameter 500 up to 1000 mm Sulzer packing 1 in various types and different materials Support plate 2 for the packing Liquid collector 3 Feed pipe 4 to distributor Liquid distributor 5 Retaining grid 6 Collector / distributor 7 Nozzle with inlet baffle 8 Column sump 9 Variations on the above design Feed: • vapor • two phases with flash box Side stream: • liquid from collector • vapor collector Sulzer columns of sectional design All internals can be installed through the column flange openings 0606 2503-1 0606 2503-2 5 1 3 4 2 6 1 4 5 2 8 9 6 9 5 7 0690 2532-1 1� 0606 2504-4 0606 2506-1 0606 2504-1 0606 2504-2 0606 2504-3 2506 2505 Independent arm & main channels VEG2 Channel-type distributor VKG21) or VKR21) Collector/distributor, VS Column Internals 200 50 0.5 1.0 10 Li qu id loa d l, m 3 /m � h Liquid distributors Discharge systems Type VEG2 Type VKR2 Type VES 1) Can be supplied in a flanged version, also for diameters > 0.8 m Column diameter, m 0.25 13 0600 2509-2 0600 2506-1 0600 2513-5 0600 2513-6 Support plates Collectors Chimney trays Retaining grid for random packing Type EMS GIS SLR/SLM SK RPB Features The EMS and GIS grids are used as support grids for random packing, as well as gas injecton devices to distribu- te vapor to the bottom layers of the packing. Both grids have an open cross sectional area of between 80 to 100%. 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 flanges in smaller flanged columns. 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. The collector SK can also serve as a liquid draw off tray. Retaining grids, consisting of wire mesh welded to the underside of grid frames, are required above random packing beds. Such grids may be either suspended from a liquid distributor above it or bolted to wall support angles welded to the column wall. Column diameter 250 - 1200 mm 1200 - 9000 mm from 0.3 m from 1 m 0604 2507 0600256601 14 Applications Acid Gas Removal Gas streams containing H�S, CO� and mercaptans are sweetened by contact with solvents in an absorp- tion tower. Afterwards, the solvent is restored in a regenerator. Tradi- tional natural gas sweetening plants are based on MEA, DEA, DGA, DIPA or MDEA solvents. Several proprietary solvents use activated formulations of potassium carbon- ate (or MDEA) based solvents to en- hance its performance. Examples of such proprietary solvents are the Benfield™, Catacarb®, aMDEA® and UCARSOL® processes. Similar operations in the petrochemical in- dustry, such as ethylene oxide and ammonia production plants, utilize proprietary solvents that address specific requirements of these ap- plications. Due to the typical high liquid load and high pressure na- ture of these systems, you will find Sulzer‘s random packing particular- ly well suited. Our random packing are therefore often specified and extensively applied. Some natural gas absorbers are specially designed using MDEA or DIPA to selectively remove H�S and slip CO�. The majority of grass- roots acid gas removal plants are equipped with trays owing to past design experience. A significant number of such plants however, are now being specified new or retrofit- ted with packing to take advantage of the unique benefits offered here. Random packing such as the Nut- ter Ring or I-Ring have one third the liquid hold-up compared to trays, a benefit which can boast the slip- page of CO� in selective MDEA gas treatment plants. Due to the foam- ing tendency of these systems, some trayed units are limited by capacity. Sulzer‘s latest genera- tion random packing such as Nutter Ring, I-Ring or C-Ring, offers about one-third the pressure drop of trays and hence the higher capacity de- sired. You will also reap significant saving in energy consumption from this change. Combined with our extensive expe- rience in column internals design and fabrication, you will be ensured optimal performance from your gas treating unit. Treated Gas Absorber Regenerator Off Gas Raw Gas 15 Natural Gas Liquids (NGL) Treating. Natural gas liquids produced from liquids recovery plants contain H�S, CO� and mercaptans, which must be removed to satisfy contract pu- rity requirements. Some of these impurities can be removed by con- tacting the NGL with amine solvent in a liquid treater. Liquid treaters are frequently equipped with ran- dom packing owing to the higher mass transfer efficiency, ability to decrease droplet size, increase dis- persed phase hold-up, and reduce the effect of back-mixing compared to trays. The heavy amine solu- tion is introduced at the top of the column, and the light natural gas liquids are introduced at the bot- tom. To achieve intimate contact between both solvents, one liquid must be dispersed into the other. The amine solution is usually the continuous phase, and the hydro- carbons are the dispersed phase. Formula Notation Metric Units Imperial Units l Liquid load m3/m�h gpm/ft� HETP Height equivalent to a theoretical plate mm inches ∆p/∆z Pressure drop per unit height mbar/m in H�O/ft KGa Volumetric mass transfer coefficient kg-mol / (h m3 atm) lb-mol/(h ft3 atm) F F factor √Pa ft/s �lb/ft3 aMDEA® and Pall Ring® are registered trademarks of BASF AG. Benfield™ and UCARSOL® are registered trademarks of UOP LLC. Catacarb® is a registered trademark of Eickmeyer & Associates. IMTP® and CMR™ are registered trademarks of Koch-Glitsch, LP. As droplets of the dispersed phase rise through the column, the drop- lets are sheared by the edges of the packing, providing thorough mixing of the phases and helping maximize mass transfer. At the top and bot- tom of the column, the difference in density allow for the separation of the two ph