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MellapakEvo and the evolution of structured packing

Shwu Tyng Goh Sulzer

MellapakCC TM was tailored to meet the specific demands of carbon capture appli- cations. The latest milestone in this evo- lutionary journey came with the launch of MellapakEvo TM in 2024. Advancing structured packing Sulzer’s new packing MellapakEvo repre- sents the culmination of extensive research and development efforts, leveraging dec- ades of expertise to push the boundaries of efficiency and performance in distilla- tion processes. It marks the beginning of a new generation of structured packing, dis- tinguished by its high effective interfacial or wetted area. It enhances mass transfer between the vapour and liquid phases for component separation in a distillation col- umn. Simultaneously, the pressure drop is minimised due to the packing’s low gas flow resistance, thereby increasing the pack- ing’s useful capacity. The efficiency is sig- nificantly influenced by the wettability of the packing surface. A superior surface texture ensures the creation, maintenance, and continuous renewal of the liquid film on the wetted surface, maximising the uti- lisation of the packing surface. The result is an enhanced performance of the dis- tillation column while the useful capacity is extended. These upgrades collectively result in up to 40% greater efficiency than the structured packing MellapakPlus 252.Y. Compared to MellapakPlus 452.Y, it offers similar sepa- ration efficiency with approximately 20% higher capacity. This makes it ideal for use in diverse applications in the chemical pro- cessing industry. A look to the future Sulzer remains dedicated to reducing the environmental impact of distillation col- umns. With our MellaTech TM column inter- nals technology and applications know-how, we continue to focus on bringing optimum solutions with greater efficiencies and lower energy consumption to our custom- ers. Sulzer is poised to lead these advance- ments and ensure Mellapak continues to set the standard for structured packing.

Distillation has been the most prevalent sep- aration technology in the chemical industry. Distillation mass transfer components are categorised into three primary groups: trays, rings (random packing), and structured pack- ing. Among the three groups of components, structured packing was the latest to be introduced and was initially applied mainly in vacuum and low liquid load applications. As the understanding of structured packing performance deepens, leading to advanced product innovations, structured packing is now used in both vacuum and pressure distillation columns, high liquid load absorption columns, and extraction columns. Despite being a well-established technology, there remains significant potential for fur- ther research and development in structured packing and the associated column internals. Every aspect of the packing, from the material to the geometric configuration and surface texture, must be carefully opti- mised to ensure uniform liquid distribu- tion, minimal pressure drop, and enhanced phase interaction. This intricate balance between simplicity and precision holds the potential for further improvements in struc- tured packings to achieve unprecedented efficiency in separation processes. Since the first introduction of its struc- tured packing, the Sulzer BX gauze packings, Sulzer has continued to drive excellence in this technology. The Sulzer Mellapak TM product family launched in 1976 has since become synonymous with structured packing. The latest iteration of the technology, MellapakEvo TM , relies on the same fundamental principles but takes advantage of high effective interfacial area and optimised geometry to deliver a signifi- cant boost in performance. anatomy of structured packing A structured packing solution consists of a carefully engineered arrangement of cor- rugated sheets, typically made from metal or other corrosion-resistant materials, stacked within a distillation column. These sheets are designed to maximise the sur- face area for contact between the liquid and vapour phases, which is crucial for effi- cient mass transfer.The key elements of a structured packing solution include:

220%

750.Y

Mellapak™ MellapakPlus™

752.Y

200%

180%

602.Y

160%

500.Y

MellapakEvo™

452.Y

140%

350.Y

352.Y

120%

100%

252.Y

250.Y

M2.Y

80%

202.Y

170.Y

60%

50% 60% 70% 80% 90% 100% 110% 120% 130% 140% 150% 160%

Capacity increase (%)

Efficiency increase vs capacity increase for Mellapak and MellapakPlus

• Material: Structured packing can be made from various materials, including stainless steel, alloys, and other corrosion- resistant materials. The choice of material depends on the specific application and the chemical compatibility requirements. • Geometry: The sheets are arranged in a way that creates a large interfacial area, promoting efficient interaction between the liquid and vapour phases. The geometric configuration is designed to minimise pres- sure drop while maximising surface area. • Surface texture: The texture of the cor- rugated sheets can be modified to enhance liquid spreading and improve wetting char- acteristics. This helps to ensure uniform distribution of the liquid phase across the packing surface. A legacy of success Sulzer Chemtech’s journey in structured packing technology began in 1964 with the introduction of Sulzer BX gauze packing.

Twelve years later, the Mellapak product family was introduced and became a bench- mark for distillation, absorption, and extrac- tion applications under different operating conditions. As industry demands for higher capac- ity and efficiency grew, Sulzer launched MellapakPlus TM in 1999. This second-gen- eration packing featured an enhanced cor- rugation profile that reduced liquid holdup and significantly boosted column perfor- mance, setting new efficiency standards. Building on this success, Sulzer intro- duced BXPlus TM in 2003, applying similar advancements to gauze packing to further improve efficiency at lowest pressure drop. In response to the increasingly specific needs of its expanding customer base, Sulzer developed diverse structured pack- ings tailored to specialised processes. For example, MellaCarbon TM was designed to operate in corrosive environments without suffering a reduction in performance, while Business Development Director Paul Mason tel: +44 7841 699431 sales@petroleumtechnology.com Managing Director Richard Watts PUBLISHED BY Publisher of PTQ/Digital Refining

Contact: chemtech@sulzer.com

PTQ is the leading industry magazine covering developments in the refining,

Managing Editor Rachel Storry rachel.storry@emap.com Editorial Assistant Lisa Harrison lisa.harrison@emap.com Graphics Peter Harper

gas and petrochemical processing industries.