Decarbonisation Technology February 2026 Issue

Conclusion The advancement of structured packing

placement can lead to significant maldistribution, undermining the effectiveness of even the most advanced distributor systems. Levelling ensures that liquid and gas are distributed evenly across the entire column cross-section, supporting optimal hydraulic performance and maintaining mechanical integrity in large-scale applications. By integrating meticulous distributor design with comprehensive flow testing, operators can achieve optimal hydraulic performance, safeguard mechanical integrity, and ensure consistent results in large-scale column applications. Mechanical support and structural integrity are essential considerations in the design and operation of large absorber and cooler columns utilising advanced structured packing. These massive vessels must withstand substantial static and dynamic loads arising from process fluids, packing weight, and operational pressures. Robust mechanical supports, such as carefully engineered support beams and trusses, ensure that the packing remains securely in place under all process conditions, preventing deformation or collapse. Additionally, proper alignment and reinforcement of column shells and internals safeguard against vibration, thermal expansion, and mechanical stresses, thereby prolonging equipment life and maintaining reliable separation performance over extended operating periods. Comprehensive CFD analysis further supports these operational improvements by providing detailed visualisation of flow patterns within the absorber and cooler columns. By integrating CFD insights with pilot-scale data, engineers can refine internal configurations, validate design assumptions, and anticipate operational challenges. These analyses would ensure that mega-column deployments maintain optimal liquid and gas distribution while maximising CO2 absorption efficiency. This approach enhances the accuracy of scale-up calculations, strengthens process reliability, and builds confidence in the successful implementation of Flexipac CP structured packing across large industrial projects. Effective post-combustion carbon capture mega-column projects require an integrated approach, addressing hydraulics, mass transfer, mechanical integrity, construction, logistics, and operations. Success depends on disciplined scale- up, proven design practices, and coordinated execution from fabrication to site.

technology marks a significant step forward in addressing the economic and operational challenges of industrial decarbonisation. By optimising the internal design of absorber columns, Flexipac CP structured packing enhances gas-liquid contact, which directly improves CO2 capture efficiency. This heightened efficiency may lead to lower residual CO2 emissions in treated gas streams, which can support compliance with stringent environmental regulations and advancing sustainability objectives. Optimal packing not only reduces pressure drop but also enables more effective mass transfer. The enhanced mass transfer characteristics allow for a lower solvent circulation rate, which in turn decreases the thermal energy required for solvent regeneration. These reductions in regeneration duties contribute to significant energy savings and operational efficiency, making large-scale carbon capture projects more economically viable. Through rigorous pilot-scale testing and real-world case studies, Flexipac CP packing has demonstrated substantial improvements, including up to a 25% increase in efficiency over conventional packing. These benefits translate directly into measurable cost savings, reduced emissions, and improved process reliability for large-scale carbon capture applications. By integrating advanced mass transfer equipment, operators can optimise column designs, minimise spatial requirements, and confidently adapt to evolving environmental standards. As industries aim for decarbonisation, innovations like Flexipac CP structured packing can help reduce emissions, solvent use, and energy needs for regeneration. FLEXIPAC ® CP™ Structured Packing, FLEXIPAC ® HC ® Structured Packing, and FLEXIPAC ® Structured Packing are trademarks of Koch-Glitsch.

Taylor Topham taylor.topham@kes.global VIEW REFERENCES Anand Vennavelli anand.vennavelli@kes.global Zack Bondley zack.bondley@kes.global