Random Packing
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this enables us to optimize the
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0602 2510
MellapakPlus
Packing
Often copied,
never equaled
0605 2504
VGPlus Trays
One of the best
high performance trays
ever tested at FRI
0603 2535-3
NeXRing
The next big
thing in random
packing
0694 2720
SMV static mixer
High mixing efficiency
combined with large
turn-down processing
capabilities
Dusec Plus
Coalescer
High performance
with minimum
pressure drop
NeXRing Random Packing
NeXRing Comparison
NeXRing Applications
Other Random Packings
Column Internals
13
Random Packing
Random packing has been used for fractionation,
absorption and stripping operations in gas, refinery
and chemical plants for may years and the benefits are
well established. For example, in high liquid load and
high pressure applications random packing has been
historically preferred as it provides improved distillation
or absorption efficiency and a reduced pressure drop.
Sulzers leading application know-how offers a
reduction in both capital and operation cost of even
your most demanding processes.
Sulzers broad established random packing portfolio
includes Nutter Rings, I-Rings, C-Rings, P-Rings and
R-Rings, and gives us the flexibility to offer the solution
whatever your requirement.
Furthermore, ease of replacement and storage
make random packing the ideal choice for systems
with heavy fouling or corrosion where packing is
frequently replaced.
With our NeXt evolution of random packing we bring
the same or better performance of the established
random packing types which when combined with
NeXt Generation
3rd Generation
2nd Generation
1st Generation
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 Sulzers leading
in-house R&D facilities and independently. All results
have shown improved hydraulic performance compared
to established random packing types with the same
efficiency.
Conditions
Diameter: 0.3 m, Bed height: 2.25 m
Liquid concentration: 4% NaOH
Conversion to carbonate (Na 2CO3): < 1%
Inlet gas concentration: 400ppm CO2
Temperature: 25 oC
F = 1.5 Pa
Bracket indicates extrapolated data
Pressure drop performance curves
The NeXRing has:
The NeXRing enables you to:
Reduced costs
Reduce capital investment
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
NXR#1
NXR#1.5
NXR#2
Liquid Load i, m3/m2 h
0 20
60
100
Air-water system, ambient conditions
5
NeXRing
The NeXt generation random packing
Notable advantages compared to P-Ring (the 2nd generation random packing)
For nearly 60 years the P-Ring has been the standard
random packing for distillation and absorption.
P-Ring#1.5
NeXRing#1
NeXRing#1.5
Efficiency
100%
105%
95%
Capacity
100%
145%
160%
Replacing P-Ring#1.5 to NeXRing#1, up to a 45%
increase in capacity can be obtained with a 5%
increase in efficiency.
Pressure Drop
100%
50%
30%
P-Ring#2
NeXRing#1.5
NeXRing#2
Replacing P-Ring#2 with NeXRing#1.5 will give up
to 10% increase in efficiency and a 20% increase in
capacity. If NeXRing#2 is used up to a 40% increase
capacity is obtained with the same efficiency
Efficiency
100%
110%
100%
Capacity
100%
120%
140%
Pressure Drop
100%
50%
30%
P-Ring#3.5
NeXRing#2
Efficiency
100%
120%
Capacity
100%
115%
Pressure Drop
100%
60%
I-Ring#40
NeXRing#1
NeXRing#1.5
Efficiency
100%
105%
95%
Capacity
100%
110%
130%
Pressure Drop
100%
70%
50%
I-Ring#50
NeXRing#1.5
NeXRing#2
Efficiency
100%
110%
100%
Capacity
100%
100%
110%
Pressure Drop
100%
90%
75%
Sulzers NeXRing demonstrates a significant improvement
in performance in comparison to the P-Ring.
Replacing P-Ring#3.5 with NeXRing#2 can
achieve a 20% increase in efficiency with a 15%
increase in capacity.
Higher performance compared to I-Ring
(the 3rd generation random packing)
I-Ring generation random packing is one of the most
widely used in mass transfer applications worldwide
recognized as giving high efficiency and capacity.
With development of the 4th generation of random
packing the Sulzer NeXRing can provide an increase
in column capacity by up to 10% compared to 3rd
generation random packing with no reduction in
efficiency and a lower investment cost.
By replacing I-Ring #40 with NeXRing#1, a 10%
increase in capacity can be achieved with a 5%
increase in efficiency. For some applications, e.g.
for further increase in capacity, increase in fouling
resistance or decrease in pressure drop is needed
NeXRing #1.5 can be used.
These comparisons are based on trials in a Sulzer column of
1m diameter and 3.5 m packing height, with the chlorobenzen/
ethylenebenzen test mixture at total reflux.
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.
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.
Applications
Fertilizer, Acid
Gas Removal, Gas
Sweetening
Random packing is widely
used in the removal of
CO2 and H2S from natural
or bio-gas by contacting
with amine based solvents
such as MEA, DEA, MDEA
and Activated MDEA. A
common characteristic
of these solvents is the
strong tendency to foam.
The Sulzer NeXRing
can provide capital
and operational cost
reductions in these
applications by giving
a much lower pressure
drop compared to
older random packing
types minimizing the
hydraulic impact of foam.
Sulzers NeXRing can
directly replace existing
previous generations of
random packing either to
hydraulically debottleneck
the column or to increase
the column efficiency by
using a smaller ring size
while keeping the same
pressure drop.
NGL (Natural Gas
Liquids) Treatment
NGL produced from
liquids recovery plants
contain H2S, CO2 and
Mercaptans which need
to be removed to satisfy
gas purity requirements.
Random packing is the
industry standard for
this application and the
Sulzer NeXRing with its
uniform surface area
distribution and high
open area helps to create
a more uniform droplet
dispersal compared
to previous generation
random packing while also
minimizing the potential
for back-mixing.
Replacing existing older
types of random packing
with Sulzer NeXRings
combined with Sulzers
high performance VSX
continuous and dispersed
phase distributors
provides either an
increased efficiency or
increased capacity.
Butadiene
Demethanizers
In butadiene production
random packing is
typically used in the
main wash, rectifier and
degasser columns due to
their characteristically high
specific liquid load.
Separation of methane
from heavy hydrocarbons
is done at high operating
pressure and low
temperature. Due to the
low surface tensions and
small density differences
leading to unstable liquid
films ensuring good
contact between the liquid
and gas phase is critical.
Replacing previous
generation of random
packing with the
equivalent Sulzer NeXRing
can lead to higher
capacities without loss
of efficiency. In these
unit operations it is fairly
common to use divided
wall columns. To prevent
loss of efficiency or
hydraulic performance
a good understanding
a of liquid distribution is
critical. With many divided
wall columns in successful
operation and a track
record of performance
since the 1960s Sulzer
can provide this critical
and often missed design
know-how to get the most
out of your column.
Due to these
characteristics random
packing has been
historically preferred for
on-shore applications
in comparison to trays
or structured packing.
The Sulzer NeXRing
with its higher capacity
and lower pressure drop
enables a further increase
in capacity for existing
columns or decreased
diameters and bed heights
for new columns.
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
Specific Surface
NR #0.7
NR #1
NR #1.5
NR #2
NR #2.5
NR #3
m /m
226
170
124
96
85
66
ft /ft
68.9
51.8
37.8
29.3
25.9
20.1
98
98
98
98
98
98
Void Fraction
Material thickness can be adjusted to clients needs. Other sizes are available on request.
KGa of Nutter Ring
HETP of Nutter Ring
F, ft/s lb/ft3
Liquid Load, gpm/ft2
8
10
20
30
40 50 60
100
80
70
NR #1
60
.5)
(NR #1
40
(NR
35
#3)
30
25
10
15
20 25 30
40 50 60
Liquid Load l, m3/m2 h
80 100
Conditions
Diameter: 0.3 m, Bed height: 2.25 m
Liquid concentration: 4% NaOH
Conversion to carbonate (Na 2CO3): < 1%
Inlet gas concentration: 400ppm CO2
Temperature: 25 oC
F = 1.0 Pa
Bracket indicates extrapolated data
150
0.5
1.0
1.5
2.0
2.5
1100
1000
2
NR #
2.5
#
R
N
50
1200
)
(NR #0.7
KGa, lb-mol/(h ft3 atm)
KGa, kg-mol / (h m3 atm)
90
40
NR #3
900
NR #2.5
800
700
NR #1.5
600
30
NR #2
NR #1
500
20
NR #0.7
400
300
10
200
100
0
0.5
1.0
1.5
F, Pa
2.0
2.5
3.0
Conditions
Valid for atmospheric distillation with standard organic test mixture
at total reflux
3.5
HETP, inches
HETP, mm
110
1.22
1.0
0.12
0.1
0.5
1.0
3.0 4.0
2.45
10
1.22
1.0
0.12
0.1
5.0
0.5
1.0
NR #2
10
1.22
1.0
0.12
0.1
0.5
1.0
F, ft / s lb / ft3
1.0
2.0
Liquid
Load l, m3/m2 h
0
20
40
60
80
100
120
150
p /z, mbar / m
20
3.0 4.0
2.45
p /z, in H2O / ft
p /z, mbar / m
F, ft / s lb / ft3
1.0
2.0
Air-water system,
ambient conditions
5.0
20
3.0 4.0
2.45
10
1.22
1.0
0.12
0.1
0.5
1.0
10
1.22
1.0
0.12
0.1
0.5
1.0
5.0
F, Pa
NR #3
F, ft / s lb / ft3
1.0
2.0
p /z, mbar / m
20
3.0 4.0
2.45
p /z, in H2O / ft
p /z, mbar / m
F, ft / s lb / ft3
1.0
2.0
5.0
F, Pa
F, Pa
NR #2.5
5.0
F, Pa
F, Pa
NR #1.5
p /z, in H2O / ft
10
20
p /z, in H2O / ft
3.0 4.0
2.45
F, ft / s lb / ft3
1.0
2.0
20
3.0 4.0
2.45
10
1.22
1.0
0.12
0.1
0.5
1.0
p /z, in H2O / ft
20
NR #1
p /z, mbar / m
F, ft / s lb / ft3
1.0
2.0
p /z, in H2O / ft
p /z, mbar / m
NR #0.7
5.0
F, Pa
I-Ring
Equivalent to IMTP Rings - industrys 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
Specific Surface
IR #15
IR #25
IR #40
IR #50
IR #60
NIR #70
m2/m3
305
226
151
100
80
60
ft2/ft3
93.0
68.9
46.0
30.5
24.4
18.3
97
97
98
98
98
98
Void Fraction
Material thickness can be adjusted to clients' needs. Other sizes are available on request.
100
KGa, kg-mol / (h m3 atm)
90
10
20
30
40 50 60
(IR #15)
IR #25
6
5
80
IR #40
70
60
50
IR #
60)
(IR #
50
40
35
(IR
#70
30
25
0.5
1.0
F, ft/s lb/ft3
1.5
2.0
2.5
1200
1100
1000
40
IR #70
900
800
30
IR #60
IR #50
700
600
IR #40
500
20
IR #25
400
IR #15
300
10
200
100
10
15
20 25 30
40 50 60
Liquid Load l, m3/m2 h
80 100
Conditions
Diameter: 0.3 m, Bed height: 2.25 m
Liquid concentration: 4% NaOH
Conversion to carbonate (Na 2CO3): < 1%
Inlet gas concentration: 400ppm CO2
Temperature: 25 oC
F = 1.5 Pa
Bracket indicates extrapolated data
10
150
0.5
1.0
1.5
F, Pa
2.0
2.5
3.0
Conditions
Valid for atmospheric distillation with standard organic test mixture
at total reflux
3.5
HETP, inches
HETP, mm
110
HETP of I-Ring
Liquid Load, gpm/ft2
KGa, lb-mol/(h ft3 atm)
KGa of I-Ring
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
Specific Surface
CR #1
CR #1.5
CR #2
CR #2.5
CR #3
CR #4
CR #5
m2/m3
244
187
142
126
101
70
62
ft /ft
74.4
57.0
43.3
38.4
30.8
21.3
18.9
97
97
98
98
98
98
99
Void Fraction
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
Worlds largest collection of performance data is
available for the Pall Ring
P-Ring Types
Specific Surface
PR #5/8
PR #1
PR #1.5
PR #2
PR #3.5
m /m
350
222
144
112
64
ft /ft
106.7
67.7
43.9
34.1
19.5
95
95
97
97
98
2
2
Void Fraction
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
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
Specific liquid load l [m3/m2 h]
0600 2507-6
0609 2500-5
0609 2500-1
Standard-Load
VKGF
10
VKR2
0609 2500-4
0610 2501-4
VKR2F
0609 2500-6
VER2
VEP/VEPW
0609 2500-7
0609 2500-2
Low Liquid-Load
VEPK
VKPK
0.05
0.25
12
0610 2501-5
0609 2500-3
0.8
3
Column-Diameter [m]
20
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/[Link])
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/[Link]
Equivalent Drip Point Density 60 to 200 drip point per m2
Turn Down Ratio
2.5 to 1 (max 10 to 1)
Support grids
0600 2509-4
Collectors
GIS/SLMT
Collector-distributor systems / Vapor distributor
0602 2511-2
VSI
0600 2509-2
SLR/SLM
Chimney trays
0600 2506-1
SK
13
Internals for Random Packing Columns
Column Internal for NeXRing
Liquid Feed Pipe
Liquid Distributor
Distribution liquid to the
packing below, a proper
selection and design
of liquid distributor is
important to overall
efficiency
Mist Eliminator
Remove liquid droplet
from vapor entrainment
Bed Limiter
Required above random
packing bed to stop
random packing being
blow away
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,
side draw off can also
be realized with the
collector
Random Packing
(Bed#2)
14
Liquid Redistributor
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
Global Headquarter: Singapore
Manufacturing/Service Centre
Sales offices
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)
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
[Link]
Please check for your local contact
Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with
headquarters in Winterthur, Switzerland, is active in the field of process
engineering and employs some 4000 persons worldwide.
Sulzer Chemtech is represented in all important industrial countries
and sets standards in the field of mass transfer and static mixing with
its advanced and economical solutions.
The activity program comprises:
Process components such as fractionation trays, structured and
random packings, liquid and gas distributors, gas-liquid separators,
and internals for separation columns
Engineering services for separation and reaction technology such as
conceptual process design, feasibilities studies, plant optimizations
including 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,
distillation under high vacuum, liquid-liquid extraction, membrane
technology or crystallization.
Complete separation process 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
disposable mixers for reactive multi-component material
Distributed by:
[Link] V.15
Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to
be construed as implying any warranty or guarantee of performance. Sulzer Chemtech waives any liability and
indemnity for effects resulting from its application.
