What are the efficient fillers currently suitable for pilot-scale production?
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Recently, while looking for suitable distillation column packing, I found that some bulk-packed packings are very efficient; in laboratory setups, one meter of such packing is equivalent to ten or even dozens of plates. Would this efficiency decrease if it were used in pilot-scale plants? Currently, although Sulzer’s structured packing is efficient, it is also expensive. Are there any suitable alternative packings?
There is a discrepancy between the results obtained from scale-up experiments and those from laboratory tests! Tianjin University has conducted extensive research on fillers; nowadays, many filler manufacturers collaborate with university professors to obtain support for their work, and other universities can also be approached for such assistance.
Currently, for laboratory-scale pilot tests, Dixon ring packing (θ-ring packing) is generally used; this type of packing has a high theoretical number of plates, with a theoretical value of 40–70 plates. The number of theoretical plates varies depending on the specific substance being processed. For pilot-scale experiments, this type of packing is not very suitable. Currently, packing materials with higher efficiency include CY700, which should be sufficient for pilot tests.
The Petrochemical Center at Tianjin University – (not an advertisement) – emphasizes the integration of theory and practice. We have used the tower units designed by them, and their separation efficiency is higher than that of plate towers. They share resources with Sulzer, and the installation is even more rigorous. Each layer of filler is inspected one by one, photographed, and archived.
Bulk packing – the rectangular saddle ring packing designed by Tianjin University belongs to the category of bulk packing. Their regularly shaped packings, including liquid distributors, are of high quality.
Do you mean Tianjin University Petrochemical Center as referring to Tianda Kaitai Chemical Technology Co., Ltd.?
No, it’s the Petrochemical Center, located at the old campus of Tianjin University
It should be the Petrochemical Technology Development Center of Tianjin University, which is mainly engaged in engineering technology development
High-efficiency laboratory random packing is used, which imposes limitations on the tower diameter. The θ-ring packing is highly affected by the tower diameter; when used in a 100mm tower, its efficiency may still be acceptable. It seems that there is a value of 10–15 theoretical plates.
If there is no limit on tower height, can small, regular packing be used as well? The tower diameter can be made a bit larger; is 7–8 theoretical plates sufficient?
Small, regular-packed columns are generally better; industrial plants also use many small packed columns, which are mostly equipped with regular packing