Structured Packing

®
Introduction
Commercialized in the 1970’s, structured packings of corru-
gated sheet metal were developed and introduced to the
market by Koch-Glitsch. FLEXIPAC® Structured Packing
has been the industry standard since that time.
INTALOX® Structured Packing, introduced in 1986,
demonstrated an increased capacity over other available
structured packings. The most recent development,
FLEXIPAC® HC® Structured Packing, was introduced in
1997. In addition to its high capacity, FLEXIPAC HC packing
offers a lower pressure drop when operating near its maxi-
mum capacity. Each type of structured packing has a
specific surface texture that contributes to its performance
characteristics.

INTALOX® Structured Packing

FLEXIPAC® HC® Structured Packing

Koch-Glitsch structured packings offer excellent capacity

and low pressure drop per theoretical stage. In order
to best predict the benefits that can be realized with
structured packing, it is recommended to use a rating
software that has been developed based on extensive
test data specific to each packing. KG-TOWER™
Software is available for download from the Koch-Glitsch
website: [Link] to aid in the hydraulic
rating of Koch-Glitsch structured packings.

Materials of Construction
Stack of six layers of FLEXIPAC® Structured Packing

Koch-Glitsch structured packings are available in a variety

Structured packings are made out of corrugated sheets of materials of construction including:
arranged in a crisscrossing relationship to create flow chan-
nels for the vapor phase. The intersections of the corrugat- • Carbon steel (Koch-Glitsch does not recommend the
ed sheets create mixing points for the liquid and vapor use of carbon steel structured packing)
phases. Wall wipers are utilized to prevent liquid and/or • Stainless steel alloys
vapor bypassing along the column wall. Rotating each struc- • Aluminum
tured packing layer about the column axis provides cross • Titanium
mixing and spreading of the vapor and liquid streams in all • Nickel alloys
directions. All types of Koch-Glitsch structured packings • Copper alloys
are available in a variety of corrugation sizes, providing the • Zirconium
versatility to optimize the packing configuration to best
meet the efficiency, capacity and pressure drop require- FLEXIPAC structured packing is also available in a variety of
ments for any particular application. thermoplastic materials. For more information, please ask for
brochure KGPP-1.
1
 FLEXIPAC® Structured Packing
As the industry standard, FLEXIPAC structured packing has The plot below provides approximate efficiency information
been used in thousands of columns worldwide. FLEXIPAC for FLEXIPAC structured packing as typically seen in distilla-
packing provides a lower pressure drop per theoretical tion service of hydrocarbons operating under atmospheric
stage and increased capacity compared to trays and conven- to moderate vacuum conditions. From years of applications
tional random packings. Columns packed with FLEXIPAC experience, Koch-Glitsch has an extensive collection of effi-
packing have resulted in: ciency information for a wide variety of processes and
• Improved product yields operating conditions. Consult Koch-Glitsch for further
• Improved product purities information.
• Reduced reflux ratios
• Increased throughput
• Lower pressure drop FLEXIPAC® Structured Packing
• Reduced liquid holdup Approximate Efficiency in Atmospheric Distillation.
• Increased heat transfer
Specific Surface Area, ft2/ft3
FLEXIPAC structured packing is available in a variety of cor-
rugation crimp sizes, each at two inclination angles. The "Y"
designated packings have a nominal inclination angle of 45º
from the horizontal, and are the most widely used. The "X"
packings have a nominal inclination angle of 60° from hori-
zontal and are used where high capacity and low pressure
drop are the overwhelming requirements for a specific

HE
application. The benefit of the "X" packings is that they pro-

TP
vide a lower pressure drop per theoretical stage for the

TY
same surface area.

PE
HE
TP

X
TY
PE
Y
HETP, inches

NTSM, mm
Note: HETP values are typical for total reflux distillation of
low-alpha systems with good liquid and vapor distribution at
moderate vacuum to moderate pressure in the typical design
range of 50% to 80% of flood

FLEXIPAC® Structured Packing with perforated and textured sur-

face shown with attached wall wiper band Specific Surface Area, m2/m3

Increasing Capacity Increasing Efficiency

FLEXIPAC® Structured Packing

Surface Area
ft2/ft3 17 25 34 47 68 77 90 106 129 152 220
m2/m3 55 80 110 155 225 250 295 350 420 500 725

Inclination Angle
45° 4Y 3.5Y 3Y 2.5Y 2Y 250Y 1.6Y 1.4Y/350Y 1Y 500Y 700Y
60° 4X 3.5X 3X 2.5X 2X 250X 1.6X 1.4X/350X 1X 500X 700X

2
INTALOX High Capacity Structured Packing
®

Introduced in 1986, INTALOX structured packing was

shown to have greater "efficient capacity" than other struc-
tured packings. A patented, aggressively textured surface,
combined with patented corrugation reversals in each packing
layer, along with other subtle proprietary geometric features,
give INTALOX structured packing a higher capacity.

Combining excellent performance characteristics with a

unique "efficient capacity" rating correlation, INTALOX
structured packing has been successfully utilized in a variety
of high liquid rate, high pressure systems besides the usual
applications in vacuum and atmospheric processes normally
reserved for structured packing. The aggressive surface
texture of INTALOX structured packing provides excellent
surface wetting, making this the preferred packing in aqueous
distillation applications.

The advantages of INTALOX structured packing are particu-

larly noticeable in the larger corrugation crimp sizes. Here,
the physical uniqueness of the INTALOX packing provides
superior efficiency compared to other structured packings
of similar surface area, while maintaining excellent capacity
and pressure drop characteristics.

Please refer to page 5 for recommended application INTALOX® Structured Packing – corrugation reversals and
guidelines and efficiency values. surface texture

INTALOX® Structured Packing

INTALOX® Structured Packing 5T 4T 3T 2T 1.5T 1T

Surface Area
ft2/ft3 27 41 52 65 77 95
m2/m3 90 135 170 215 250 310

3
FLEXIPAC® HC® High Capacity Structured Packing
Since its introduction in 1997, FLEXIPAC HC structured range of the packing. The advantages of FLEXIPAC HC
packing has been used in hundreds of columns to packing are particularly strong for smaller corrugation
increase capacity and reduce pressure drop both in new crimp size, higher surface area packings.
construction and for replacing standard sheet metal
structured packings, conventional random packings and
trays. Combining excellent capacity and efficiency char-
acteristics along with a lower pressure drop per theo-
retical stage, it is the preferred packing for use in vacu-
um distillation applications.

FLEXIPAC HC is similar in construction to standard

FLEXIPAC packing, except for a subtle modification in
the geometry of the corrugation at the top and bottom
of each packing layer. This relatively small change in
geometry eliminates the abrupt change in flow direction
of the liquid and vapor phases at the packing layer inter-
face.

Conventional structured packing capacity is limited by

flow interaction at the layer interface where the abrupt
directional change limits the amount of counter-flowing
liquid and vapor. As the liquid flow becomes restricted
by the upward-flowing vapor, the liquid begins to build
up at the layer interface which increases the pressure
drop and may ultimately lead to flooding. The geometry
of FLEXIPAC HC packing relieves this restriction. Since FLEXIPAC® HC® Structured Packing with a perforated
the premature build-up of liquid is eliminated, the low and textured surface showing corrugation configuration
pressure drop characteristics of structured packing are at layer interface
better maintained throughout the efficient operating
Please refer to page 5 for recommended application
guidelines and efficiency values.

LIQUID Flexipac® HC® structured

STREAM packing enhances the
liquid drainage from one
element to the next,
resulting in reduction
of liquid holdup at the
interface.
TOWER
SHELL

The transition
between the packing
elements is improved
due to the enlarged
turning radius for
the vapor flow that
reduces the pressure
drop and increases VAPOR
capacity. STREAM

FLEXIPAC® HC® Structured Packing 2Y 250Y 1.6Y 1.4Y/350Y 1Y 500Y 700

Surface Area
ft2/ft3 68 77 90 106 129 152 220
m2/m3 225 250 295 350 420 500 725

4
Choice and Application of Koch-Glitsch High Capacity Structured Packings
Each type of Koch-Glitsch structured packing has strong per- When choosing a high capacity structured packing, FLEXIPAC
formance characteristics. Under certain conditions or in spe- HC and INTALOX structured packings each offer distinct
cific applications, each has a particular strength which may advantages, depending upon the application. Through its wet-
make one style more desirable. Considerations in choosing a ting and liquid handling characteristics, the patented, aggres-
specific structured packing type are: sive surface texture of the INTALOX structured packing
offers extremely efficient use of the available packing surface.
• To meet specific process requirements For the larger corrugation size packings, INTALOX structured
• As a direct replacement of an existing packing packing provides a better efficiency than other structured
• Familiarity with the packing type and its performance packings with similar surface area.
• Past experience of using a specific packing type in a
particular application FLEXIPAC HC structured packing uses a less aggressive, per-
forated and textured surface style to provide excellent sur-
• Specified for use in a licensed process
face area utilization. This surface, along with the smooth
channel transition at the layer interface, provides a less
With more than thirty years of history, FLEXIPAC structured
restricted flow channel and results in lower pressure drop as
packing continues to be a strong performer in applications
the packing reaches the loading region. This is particularly
where the incremental capacity increase of high performance
true for the smaller corrugation packing sizes. The table
structured packing is not required.
below provides guidance in choosing the recommended high
capacity packing.

Increasing Capacity Increasing Efficiency

INTALOX® Structured Packing 5T 4T 3T 2T 1.5T 1T

FLEXIPAC® HC® Structured Packing 2Y 250Y 1.6Y 1.4Y 1Y 500Y 700Y

Approximate HETP*
inches 30 24 18 16 14 12.5 11 10 9 7.5
mm 762 610 457 406 356 318 279 254 229 191
* HETP values are typical for total reflux distillation of low-alpha systems with good liquid and vapor distribution at moderate vacuum to moderate
pressure in the typical design range of 50% to 80% of flood

All Applications
Aqueous Service, High Pressure or High Liquid Rate
Low Pressure Drop Requirement

Special Purpose Structured Packings

INTALOX® Structured Packing 5TX corrugation configurations. Applications include top
pumparound zones of Refinery Fractionators as well as
As the only high capacity, high efficiency packing available in Ethylene Water Quench Columns.
the "X" (60°) corrugation configuration, INTALOX structured
packing 5TX offers grid type packing capacity with good FLEXIGRID® and GLITSCH-GRID® structured packings
efficiency. INTALOX 5TX structured packing should be con- are the packings of choice for applications in severe services
sidered whenever fractionation or excellent heat transfer is subject to fouling, coking, erosion and high solids content,
required at the absolute maximum throughput. while providing a robust mechanical structure to resist damage
during upsets. FLEXIGRID and GLITSCH-GRID structured
FLEXIPAC® S, FLEXIGRID® and GLITSCH-GRID® packings are available in a wide variety of materials.
Structured Packings Applications for these packings include Crude Atmospheric
and Crude Vacuum Towers, FCC Main Fractionators, Coker
FLEXIPAC® S packing is similar in construction to FLEXIPAC Fractionators as well as Ethylene Plant Oil and Water Quench
packing but has a smooth surface and can be manufactured Columns. For further information on FLEXIGRID, GLITSCH-
using thicker material. The smooth surface enables the pack- GRID and FLEXIPAC S packings for use in severe service,
ing to be used in moderately fouling systems while the thicker please ask for brochure KGSS-1.
material gauge gives it greater mechanical strength and pro-
vides increased corrosion resistance. FLEXIPAC S packing is
available in various sizes and in both the X (45°) and Y (60°)

5
Wire Gauze Structured Packing
Koch-Glitsch wire gauze packing is the recognized leader in Fs, m/s • (kg/m3)1/2
distillation service for deep vacuum and low liquid rate appli- 1 2 3
12
cations. For processing specialty chemicals, pharmaceuticals 300
and temperature sensitive materials, the very high efficiency HETP BX
and low pressure drop characteristics of this packing are System: o-/p-Xylenes
unsurpassed. Used in thousands of diverse applications Diameter: 8 in [203 mm]
around the world, BX wire gauze structured packing is the 10 Packing Depth:10 ft [3.05 m] 250
Total Reflux Operation
most widely used. For even greater efficiency requirements, Hg
CY wire gauze structured packing is also available. DX and mm

HETP, inches
720

HETP, mm
EX wire gauze structured packings are available for laboratory Hg
8 m m
and pilot testing applications. 20 200
Hg
mm
300 Hg
5 mm
6 150

4
0.5 1.0 1.5 2.0 2.5
Fs, ft/s • (lb/ft3)1/2

Fs, m/s • (kg/m3)1/2

1 2 3
8 200
HETP CY
7 System: o-/p-Xylenes
Diameter: 8 in [203 mm]
Packing Depth: 6 ft [1.83 m]
Total Reflux Operation
6
inches

HETP, mm
HETP, mm
inches

5 Hg Hg
mm m
HETP,

720 mm Hg m
20 Hg
300
HETP,

m
5m
4 100
Koch-Glitsch Wire Gauze Packing with attached wall wiper bands
3
Wire gauze structured packing is generally used in medium to
small diameter columns for separations where the require-
ment is to achieve the maximum number of theoretical stages 2
in the minimum column height. Because of the capillary effect, 0.5 1.0 1.5 2.0 2.5
the wire gauze material provides an extremely wettable sur- Fs, ft/s • (lb/ft3)1/2
face, resulting in excellent mass transfer efficiency, particularly
at very low liquid rates.
Fs, m/s • (kg/m3)1/2
1 1 2

Random Packings and Tower Internals 4

HETP DX and EX
100

System: CB/EB 80
3
Koch-Glitsch is the world leader in the supply of mass transfer Total Reflux Operation
Pressure: 40 mmHg
equipment, offering a wide range of random packings in metal DX
HETP, inches

60
HETP, mm

and plastic including IMTP®, CASCADE MINI-RINGS®,

β−ETA RING® and SNOWFLAKE® High Performance Ran- 2
dom Packings. Please ask for brochures KGIMTP-1, KGRP-1, 40
and KGPP-1. EX
1
Koch-Glitsch offers a wide range of INTALOX High Performance 20
Distributors as well as traditional tower internals to ensure
optimal and predictable tower performance. Internals are avail-
0 0
able in various metals and plastic materials. Please ask for 0.0 0.5 1.0 1.5 2.0
brochures KGMTIG-1 and KGPTIG-1.
Fs, ft/s • (lb/ft3)1/2

6
Koch-Glitsch Corporate Offices
Worldwide Headquarters
Koch-Glitsch, LP
4111 East 37th Street North Wichita, KS 67220 – United States tel: (316) 828-5110 fax: (316) 828-7985

Europe
Koch-Glitsch Italia S.r.l.
Viale Giulio Cesare 29 24124 Bergamo – Italy tel: +39 035 2273.411 fax: +39 035 2273.400

Asia
Koch-Glitsch Korea, Ltd.
17-8, 8F, Dongsung Bldg. Seoul 150-874 – Korea tel: +82-2-3276-7500 fax: +82-2-3276-7590
Yoido-dong, Youngdeungpo-ku

Koch-Glitsch (A division of Koch Chemical Technology Group India Pvt. Ltd).

Corporate Park II, 10th Floor
Chembur, Mumbai 400 071 – India tel: +91 22 6771 7171 fax: +91 22 6771 7161
Sion-Trombay Road

For a complete list of our offices and facilities, visit us on the Web at [Link].

Emergency Numbers
US: 1-888-KOCH-911.
Europe: +39-06-928-911, +44-1782-744561, or your local Koch-Glitsch office.
Asia Pacific: Contact your local Koch-Glitsch office.

Trademarks Patents
CASCADE MINI-RINGS, FLEXIGRID, FLEXIPAC, GLITSCH GRID, IMTP, Available exclusively from Koch-Glitsch, FLEXIPAC® HC® structured packing is
INTALOX, INTALOX PACKED TOWER SYSTEMS with process tower “L”, protected by US Patent 5,632,934 and other patents worldwide assigned to Praxair
KOCH-GLITSCH, “K” KOCH-GLITSCH, and SNOWFLAKE are registered Technology, Inc. Koch-Glitsch, LP is the exclusive worldwide licensee of Praxair
trademarks of Koch-Glitsch, LP and are registered in the US and various Technology, Inc. for the manufacture and sale of this packing in all markets except
other countries worldwide. HC and KG-TOWER are registered trademarks of for industrial gas separation.
Koch-Glitsch, LP and are registered in the US. BETA RING is a trademark of
Koch-Glitsch, LP and is registered in the CTM. INTALOX PACKED TOWER BETA RING and IMTP random packing and INTALOX structured packing
SYSTEMS is a trademark of Koch-Glitsch, LP. All other trademarks, service technologies are protected by various patents worldwide.
marks, or registered trademarks that appear in this document are the
trademarks or service marks of their respective owners.
Legal Notice
The information contained in this bulletin is believed to be accurate and reliable,
but is not to be construed as implying any warranty or guarantee of performance.

Bulletin KGSP-2. Rev. 6-2010. Printed in U.S.A.

© 2003-2010. Koch-Glitsch, LP. All rights reserved.