Manufactured in corrosion-resistant ceramics, Ceramic Structured Packing is an economical alternative to exotic metals and engineered plastics, and provides excellent service life in most corrosive applications.

Sheets of our structured packing are arranged at a 45° angle with respect to the vertical column axis, forming mixing cells at every point where the corrugations intersect. This promotes intimate mixing and high mass transfer efficiency, as the corrugation directions of one element are opposed to the sheets of the elements above and below. In passing through each element, gas and liquid are thoroughly mixed in the direction parallel to the plane of the sheets. By rotating subsequent elements, excellent mixing and spreading — both side-to-side and front-to-back — are achieved over the entire cross-section of the tower. The flow characteristics developed by the structured geometrical arrangement create a high effective surface area, resulting in superior efficiency compared to other mass transfer devices. Improved hydraulic performance of our structured packing results from the corrugated sheets being vertically oriented, eliminating any horizontal surfaces that create resistance to fluid flow. As a result, towers packed with our structured packing have a very low pressure drop and a corresponding higher capacity.

Our structured packing system stands up to the toughest operating environments. Whether applying the technology to retrofits, upgrades or new construction, our professionals draw on an accumulated body of knowledge that nobody else can offer: more installations, more years of experience, more technical expertise than any other supplier.

Unique Features of Ceramic Structured Packing System Provide Significant Benefits Over Traditional Random Packing

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• Geometric Design — Effectively minimizes channeling and radically distributes gas and liquid uniformly over the tower cross-section.
• Rigid Construction — Significantly reduces breakage and fouling of downstream equipment normally associated with random ceramic packing.
• Natural Wettability — Improves film formation for high surface tension aqueous liquids and enhances mass transfer efficiency.
• Higher Capacity — Enables reduced diameters for new tower designs, lowering capital costs.
• Lower Pressure Drop — Cuts energy costs without sacrificing process capacity.

Specification

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Typical Application

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• Sulfuric Acid Plants
• Regenerative Thermal Oxidizers
• Chlorine Cooling and Drying Towers
• Bromine and Hydrochloric Acid Plants
• Liquid Organic Waste Disposal Coolers and Scrubbers
• Natural Gas Treating and Dehydration Units
• Purification of Aqueous Organic Acids

With our technical expertise in design, manufacturing, and installation, a well-designed valve tray generally provides the most economically viable solution for grassroots column construction projects. Valve trays combine high capacity and excellent efficiency with a wide operating range. Leveraging proprietary design techniques and a comprehensive range of valve types, Saiptech's design engineers can assist you in optimizing performance for your specific application.

Common Types

• Float Valves — Round & Rectangle
• Fixed Valves
• Caged Valves
• Mini Type
• Snap In

Material of Construction

Fractionation trays are fabricated from a wide variety of materials. When corrosion is expected to be extremely low and design temperatures are not excessive, carbon steel is a logical choice due to its favorable mechanical properties, malleability, and cost-effectiveness. However, since the material of construction is dictated by the process conditions of each particular system for which the trays will be used, many different types may be required — each with unique properties that allow the material to resist corrosion and maintain its strength at elevated temperatures.

The most common tray materials utilized by Saiptech are listed below (in order from least to most expensive):

• Carbon steel
• Stainless steel: 410s/304/316L/321/904L
• 2205/2507 Duplex Steel
• Titanium
• Zirconium
• Monel 400
• Hastelloy C276

Bubble cap trays are used primarily in applications with very low liquid loading and very high flexibility, where large turndown ratios are required. They typically have a 10%–20% lower capacity than properly designed valve or sieve trays; however, they deliver efficient performance over a wider operating range due to their superior leak-proof characteristics.

Saiptech designs and supplies a wide range of bubble cap trays, which are among the most leak-free trays on the market. Our most common bubble cap designs include conventional slotted caps — some feature slots for vapor passage, while others do not. Custom designs are also available to meet specific project needs, as the mechanical configurations for various riser and cap assemblies are highly versatile.

Typical manufacturing methods to secure the riser and cap assembly to the tray floor include seal welding, press fitting, and threaded connections.

Bubble Cap Types Available

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• Round type — Sizes 3", 4", 6", also tailor-made
• Tunnel type — Thormann Tray
• Plastic type — PP, PVDF
• Cast Iron
• Copper

SPT mesh pad type demister removes droplets by impingement on the wire surface. The liquid collected on the filaments is then able to drain from the pad under gravity. They have a limited range of useful operation in which they provide almost complete removal of droplets down to about 3–5 microns. Turndown range of the vapour rate is around 3:1. At excessively high vapour velocities, the liquid droplets that impinge on the wire surface are sheared off by the vapour and re-entrained before they are able to drain. At very low vapour velocities, all but the larger droplets are able to follow the vapour path through the mesh and thus avoid impingement; however, the inherent design of the separator vessel means that in most applications an effective turndown performance of 10:1 or better can be achieved.

Standard Mesh Pad Type

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At Saiptech, mist eliminators can be manufactured in virtually any size and are available in a wide range of materials, with over 14 distinct styles designed and fabricated to meet specific application needs.

* Other types are also available for custom manufacturing as per request.