Sulzer India Limited

Structured Packings for

Distillation & Absorption
 Sulzer India, an ISO-9001:2000 company, began
its full fledged manufacturing operations in 1989,
building upon Sulzer's inherent strength in process
engineering which dates back to the end of the
19th century. At the very onset, there was a
necessity to deliver quality products as a means to
stay ahead of the competition. Guided by the same
philosophy as it's parent company; Sulzer India has
been delivering total turnkey solutions from
conceptualizing to designing, installation and
commissioning to customer support service.
Thousands of customers have benefited from the
breakthrough made at Sulzer in various fields.
Sulzer India's role goes beyond being simply an
equipment supplier. At Sulzer, the accent is on
nurturing relationships that lasts beyond the
lifetime of a Sulzer equipment.

Sulzer Columns The Configuration:

The Columns can be configured as monoblock or flanged construction

Sulzer columns of Welded column,

sectional design. monoblock type.
All internals can be installed All internals in segments for installation
through the column flange openings and removal through manhole, nominal
diameter 500-1000mm.

Sulzer Packings 1
In various types and different materials

Support grid 2
For the packing

Liquid collectors 3
5
Feed pipe 4 6

To distributor
1
Liquid distributors 5
1 Mounted on locating grid
3
Locating grid 6 4

Steam inlet pipe 7

Column sump 8 5

3 Circulation pipe
to reboiler 9
4
Skirt 10
Anchorage 11

7
8

Variations on the above design

Feed:
-gas
-two phases with flash box 9
2 Side stream:
-liquid from collector 10
-gas below collector
11

2
The notable designing edge

At Sulzer, each column internal is custom-designed to
suit the specific need of the customer's process. This calls
for thorough understanding of the customer's exact
requirements and providing a creative engineering
solution. In the case of revamps where the new internals
are to be fitted in the existing column shell, the design
and engineering needs to be done with utmost care and
precision.
At Sulzer India, this is achieved with the aid of state-of-
the-art software for simulation of the column operation,
added to the exhaustive database of over 8000 columns
designed by Sulzer. Data can also be tapped from the
extensive field data that Sulzer has developed in
collaboration with renowned Process Licensors.
Our full fledged Design and Engineering office can
independently design and engineer the most optimum
design solutions for the customer's column internals
problems, be it a grass-root plant or a revamp.

Installation of packing Easy Installation

Fitting the packing in the column

®
Mellapak can be installed in the column either
through the shell flange for smaller diameter or
through the man-ways for large diameter monoblock
columns.
A fully trained and well experienced Engineer from
Sulzer India is available for supervision of installation.

7
 ®
MellapakPlus
A new Generation of Structured Packings

MellapakPlus is a capacity enhanced structured packing.

It combines all advantages of the metal sheet packing
Mellapak with new geometrical features.

Features of MellapakPlus
At the lower and upper end of each packing element,
the orientation of the corrugation gradually approaches
the vertical axis. Advantages of this geometrical
modification:

• The vapour flow smoothly changes direction at the

interface between two packing elements.

• At the interface vapour flow is nearly parallel to the

vertical axis of the column. The gas velocity is
therefore reduced by about 25% compared to the
velocity inside the packing element.

Both factors reduce the pressure drop and the shear

forces, which are especially critical at the interface due
separation efficiency to the presence of thicker and less stable liquid films. As
0.4 a result, premature flooding at the interface is no longer
of concern.
0.3
In the interior part of the packing element the
geometrical features of MellapakPlus and Mellapak are
HETP [m]

0.2
identical. Hence, separation efficiency is similar, but with
a significant increase in capacity and a reduction in
0.1 pressure drop. All other Mellapak properties, including
installation procedure, mechanical strength and
0 corrosion resistance are identical to Mellapak.
0 1 2 3 4 5

FV [ Pa[
350Y 500Y 452Y

For Guaranteed results...

Uniform liquid distribution is a vital prerequisite in the
separation performance of large diameter Separation
Columns. To ensure optimum distribution, Mellapak
uses an entire series of liquid distributors. These
distributors not only meet your exact individual
requirements, but their range too encompasses the
entire gamut of needs. During the designing of these
distributors sophisticated software techniques are used
to ensure that the distributors match optimally to the
column diameter, packing type and operating
conditions.
Manufactured on state-of-the-art CNC machines,
these distributors undergo stringent quality tests that
guarantee optimum performance. Our Modern
Distributor Test facility subjects all critical components
6 of the liquid distributor to thorough testing.
 ®
Mellagrid
Sulzer structured grid packings

With the development of Mellagrid, Sulzer

Chemtech combined the efficiency of
structured packings with mechanical
resistance of grid.
Mellagrid is used in every area where the
mechanical strength of structured packings
could result in some concern or where coking
is likely to occur.
Special features
• Not sensitive to coking and fouling due to
its smooth surface and geometrical
structure that secures efficient dissipation of
temperature and concentration gradients
• Much better de-entrainment and
separation efficiency than traditional grid
• The low element height and its structure
allow for easy cleaning. It can be removed,
unscrewed and cleaned with a water jet
• Mechanically robust structure

Gauze Packings
Sulzer metal gauze packing, Type BX & CY

Curve parameter = head pressure (mbar)

10

BX
stages per meter (1/m)
Number of theoretical

6
7
96
0
4 25

70-400
0.6 0.8 1 2 3 4 5

F factor (m/s Kg/m3)

This packing was developed for separations, which

Curve parameter = head pressure (mbar)
require a large number of theoretical stages. Largest
14
diameter supplied to date : 1.8 m. 400 100
CY
stages per meter (1/m)
Number of theoretical

Special features 12
950 25
• Maximum number of theoretical stages per meter.
• Pressure drop per theoretical stages 0.1 - 0.5 mbar 10

• Most economical load range: F factor 2-2.5

for BX, 1.5 -2 for CY. 8

• Minimum liquid load approx.0.05 m 3 / m 2 h

• Small hold -up 0.1 0.2 0.4 0.6 0.8 1 2 3 5
3
F factor (m/s Kg/m )
5
 ®
Mellapak
The Ultimate in Structured Packings

The characteristic surface structure of Mellapak results

in a high separation performance for a range of liquid
loads. The packing elements consist of thin, corrugated
sheets (metal or plastic) stacked to form open,
intersecting channels at an angle to the column axis.
This results in mixing of the gas flowing through the
packing in the direction of the parallel layers. The
rotated placement of successive elements induces
radial mixing over the entire column cross section.
Moreover, the packings are fabricated in the form of
cylinders of standard height to fill the entire cross
section of the column. For larger diameter columns, the
packing elements are assembled from segments which
can be introduced through column manholes.
Depending on the chosen flow channel hydraulic
diameter, different specific surface areas (125 to 750
m2 / m3) can be obtained. The angle of inclination of the
0 0 10
channel is 30 for the X series and 45 for the Y series.

500Y
350Y
250Y

125Y
By selecting appropriate combinations of the two 7
parameters, Mellapak ® provides optimum
configuration for any application. 5
Pressure drop per meter (mbar/m)

Special features
• Pressure drop per theoretical stage 0.3-1.0 mbar 3
• Pressure drop at 70-80% flooding about 2 mbar/m
2
• Minimum liquid load approx. 0.2 m3 /m2h
• Maximum liquid load up to more than 200 m3 /m2h
( typically in desorption columns) 1.0

Preferred applications
• Vacuum to moderate pressure 0.7
0.5
• High pressure in selected applications
• Increasing capacity of existing tray and packed
columns 0.3
0.5 0.7 1 2 3 4 6 8

F factor (m/s Kg/m3)

X series Y series
Number of theoretical stages per meter ( 1/ m)

6 6
Number of theoretical stages per meter (1/m)

750.Y
5 5

500.Y
4 4
350.Y
500.X
3 3 250.Y

250.X 2Y
2 2 170.Y
2X
125.Y
170.X
1 1
125.X

0.5 0.7 1 2 3 4 5 6 7 0.4 0.5 0.7 1 2 3 4 5 6

F factor (m/s Kg/m3) F factor (m/s Kg/m3)

4
 Structured Packings from Sulzer Chemtech
Type of Packing Mellapak 125.X / 125.Y
Mellapak 170.X / 125.Y
Mellapak 2X / 2Y
Mellapak 250.X / 250.Y
Mellapak 350. Y
Mellapak 500.X / 500.Y
Mellapak 750.Y
Further on request
Material Stainless Steel
Carbon Steel
Hastelloy, Monel,
Aluminium, Copper-Bronze, PP,
PVDF, Teflon PFA, CFC (carbon)
Other materials on request
Applications Basic chemicals &
petrochemicals, ethyl-benzene/
styrene, fatty acids, tall oil,
cyclohexanone/-ol, caprolactam,
refinery operation, absorption/
desorption columns, drying of
natural gas
Characteristics • Universal packing type,
Suitable for a wide
range of applications
• Usable for liquid loads
ranging from low to very
high (0.2 to over 200 m3/m2 h)
3
Mellagrid MG 40.Y
Mellagrid MG 64.X
Mellagrid MG 64.Y
Stainless Steel,
Carbon Steel,
Other materials on request
Crude oil distillation,
quench columns,
refineries and petrochemical
industry
• Smooth surface
• Mechanically robust
• Not prone to blockage
• Excellent flow
stabilizer
BX gauze packing
CY gauze packing
Stainless Steel, Copper-
Bronze, Monel, Hastelloy,
Nickel, Titanium Gauze-made
from Polypropylene/
Polyacrylonitrile mixture
(PP/PAN)
Other materials available on
request
Fine chemicals,
isomers,
perfumes,
flavours
• High separations
efficiency, even at
small liquid loads
• Minimum pressure drop
• Small hold-up
MellapakPlus 252.Y DX laboratory packing
MellapakPlus 452.Y EX laboratory packing
MellapakPlus 752.Y
Stainless Steel, Carbon Steel CrNiMo Steel,
Hastelloy, Monel, Alloy C22,
Aluminium, Copper-Bronze, Carbon (CFC)
Brass, Titanium, Nickel.
Other materials available on
request.
Basic chemicals and Laboratory columns
petrochemicals, ethyl- and pilot columns
benzene/styrene, fatty acids,
tall oil, cyclohexanone/-ol,
caprolactam, refinery
operation columns, natural
gas drying
•Universal packing type • Fine structured packings
•Boosts useful capacity • Very high number of
theoretical stages
per meter, with low
pressure drop
 Our Other Mass Transfer Devices…

Trays
Sulzer India can also design, engineer and fabricate all types
of trays, these include:

• Float valve trays

• Round valve trays
• Snap in valve
• Caged valve
• Mini V-Grid
• Vortex tray
• Bubble cap trays
• Shell trays

Random packing & Internals

Sulzer India has always endeavoured to offer
technology that is second to none and a range that is as
exhaustive. Our Random Packing & internals includes:

TM
• Nutter Ring
• Support Grid
• Hold- down Grid
• Liquid
Distributors
• Gas Distributors
• Chimney Tray
& others.

Sulzer India Limited
Regd. Office & Head Office: Sulzer House, Baner Road, Aundh, Pune, Maharashtra, India 411 007
Tel.: +91-20- 5888991 Fax: +91-20- 5886393, E-mail sind-chemtech@sulzerind.com
Works: Kondhapuri, Pune Nagar Road, Taluka Shirur, Dist. Pune 412 209
Maharashtra, India Tel.: +91-2137-270212 / 13 / 14 Fax:+91-2137-270196
Outline/07/03

AN ISO 9001: 2000 COMPANY

Baroda Kolkata Delhi Chennai

Tel. : (0265) 2342194 / 294 Tel. : (033) 22821325 / 3889 Tel : (011) 26294771 / 2 Tel. : (044) 24992436 / 448
Fax : (0265) 2342394 Fax : (033) 22821439 Fax : (011) 26294226 / 7 Fax : (044) 24997276
Email : sindwr@satyam.net.in Email : sindcal@satyam.net.in Email : sulzdel@ndb.vsnl.net.in Email : sindmds@eth.net

8 www.sulzerindia.com
CT/MKTG/C-001/02