ERTC 2024
MellapakEvo and the evolution of structured packing
Shwu Tyng Goh SULZER
Distillation has been the most prevalent separation technology in the chemical industry. Distillation mass transfer compo- nents are categorised into three primary groups: trays, rings (random packing), and structured packing. 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 further research and develop- ment in structured packing and the associ- ated column internals. Every aspect of the packing, from the material to the geometric configuration and surface texture, must be carefully optimised 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 structured packings to achieve unprece- dented 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 significant 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 efficient mass transfer.The key elements of a structured packing solution include: • 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.
did you know? MellapakEvo is distinguished by its high effective interfacial or wetted area
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 packing’s useful capacity. The efficiency is significantly influenced by the wettability of the packing surface. A superior surface texture ensures the creation, mainte- nance, and continuous renewal of the liq- uid film on the wetted surface, maximising the utilisation of the packing surface. The result is an enhanced performance of the distillation column while the useful capac- ity 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 separation efficiency with approxi- mately 20% higher capacity. This makes it ideal for use in diverse applications in the chemical processing industry. A look to the future Sulzer remains dedicated to reducing the environmental impact of distillation columns. With our MellaTech TM column internals technology and applications know-how, we continue to focus on bring- ing optimum solutions with greater effi- ciencies and lower energy consumption to our customers. Sulzer is poised to lead these advancements and ensure Mellapak continues to set the standard for struc- tured packing.
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
• 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 pack- ing. Twelve years later, the Mellapak prod- uct family was introduced and became a benchmark for distillation, absorption, and extraction 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 fur- ther 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 with- out suffering a reduction in performance, while MellapakCC TM was tailored to meet the specific demands of carbon capture applications. The latest milestone in this evolutionary journey came with the launch of MellapakEvo TM in 2024.
Contact: chemtech@sulzer.com
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