Structured packings

Energy-efficient,
innovative & profitable
Sulzer Chemtech –
Heat and mass transfer technology
Your partner in separation and mixing technology

Comprehensive
The highest level of Fast and reliable engineering
application know-how turnaround services and technology services

Our team provides state-of-the-art We don’t shut down, when you We provide a full scope of associated
expert know-how for more than shut down. You can rely on Sulzer’s engineering and technology services
500 applications in 100 processes. professionals, expertise and to optimize or trouble-shoot your
This enables us to optimize the procedures to get you back up and installation.
performance of your installation. running in the shortest possible time.

A broad range of innovative and high-performing products

MellapakPlus™ VGPlus™ trays NeXRing™ SMV™ Dusec Plus™

packing static mixer coalescer
One of the best The next
Often copied, high performance trays big thing in High mixing efficiency High performance
never equaled ever tested at FRI random packing combined with large liquid/liquid
turn-down processing coalescer
capabilities

2
Sulzer structured packing portfolio
The complete range

Structured packing is one of our core abilities. Over

50 years of experience in development, design, 4 Metal sheet packings
and fabrication of this type of packing makes us
your best partner to find the optimum solution
8 Gauze packings
for your application. This brochure provides an
overview of all Sulzer structured packing types and
their applications. 11 Special packing types

Sulzer’s complete structured packing portfolio

16 Column internals
ranges from the conventional BX gauze packing,
developed by us 50 years ago, to the MellapakPlus
high capacity packing. We offer packing types for 18 Services
all kind of applications, made in almost all types of
metal and also other corrosion resistant materials.

MellapakPlus™ Mellapak™ BX™ and BXPlus™ CY™ and CYPlus™ AYPlus™ DC

for improved capacity the allrounder packing gauze packings gauze packings for aqueous solutions
for high separation for even higher and low liquid loads
efficiency efficiency

Mellacarbon™ Mellapak™ and Mellagrid™, F-Grid™ Katapak™-SP Laboratory

for demanding MellapakPlus™ and Nutter Grid™ for reactive distillation packings
corrosive applications in plastic for corrosive for fouling conditions for small columns
applications

3
For improved capacity
MellapakPlus Separation Efficiency

MellapakPlus is a capacity enhanced structured packing.

It combines all advantages of the metal sheet packing Mellapak
with new geometrical features.

Features and benefits

At the lower and upper end of each packing element, the orientation of
the corrugation gradually approaches the vertical axis. Advantages of this
geometrical modification:
• The vapor flow smoothly changes direction at the interface between two
packing elements
• At the interface vapor flow is nearly parallel to the vertical axis of the column.
The gas velocity is therefore reduced by about 25% compared to the velocity
inside the packing element

Both factors reduce the pressure drop and the shear forces, which are especially
critical at the inter-face due to the presence of thicker and less stable liquid films. As
a result, premature flooding at the interface is no longer of concern.

In the interior part of the packing element the geometrical features of MellapakPlus
and Mellapak are identical. Hence, separation efficiency is similar – but with a parameter = head pressure p /mbar
significant increase in capacity and a reduction in pressure drop.

All other MellapakPlus properties – including installation procedure, mechanical Pressure Drop
strength and corrosion resistance – are identical to Mellapak.

MellapakPlus performance has been confirmed in category 1 tests at F.R.I.

Internals
The close resemblance between MellapakPlus and Mellapak guarantees continued
use of the whole range of well known and reliable internals. Internals are now able to
handle the increased gas load typical for the high capacity of MellapakPlus. Sulzer
Chemtech is committed to the ongoing, focused development of novel designs.

MellapakPlus 252.Y vs.

Mellapak 250.Y

4
 Separation Efficiency Separation Efficiency Separation Efficiency

parameter = head pressure p /mbar parameter = head pressure p /mbar parameter = head pressure p /mbar

Pressure Drop Pressure Drop Pressure Drop

0.1

MellapakPlus 202.Y MellapakPlus 352.Y MellapakPlus 452.Y

MellapakPlus 602.Y MellapakPlus 752.Y

5
The allrounder packing
Mellapak Separation Efficiency

Mellapak is the most widely used structured

packing worldwide. It has proven excellent
performance in columns with diameters up to
15 m. It is supplied in sheet metal thicknesses
from 0.1 mm up.

Features and benefits

• Pressure drop per theoretical stage 0.3‑1.0 mbar
• Pressure drop at 70‑80% flooding about 2 mbar/m
• Minimum liquid load approx. 0.2 m³/m²h
• Maximum liquid load up to more than 200 m³/m²h
(typically in desorption columns)

Preferred applications
• Vacuum to moderate pressure
• High pressure in selected applications
• Increasing capacity of existing tray and packed
columns
parameter = head pressure p /mbar

Typical applications
Pressure Drop
Chemical industry: Ethylbenzene/styrene, tall oil,
cyclohexonone/‑ol, air separation

Petrochemical industry: Quench columns, C3‑ and C4‑

splitters, xylene splitters

Refineries: Vacuum and atmospheric columns

Absorption: Natural gas drying, CO2‑ and H2S‑absorbers

and strippers, ethyleneoxide absorbers and strippers,
acrylonitrile absorbers

Mellapak 250.Y
Mellapak 250.X

6
 Separation Efficiency Separation Efficiency Separation Efficiency

parameter = head pressure p /mbar

parameter = head pressure p /mbar parameter = head pressure p /mbar

Pressure Drop Pressure Drop Pressure Drop

Mellapak 125.Y Mellapak 170.Y Mellapak 2Y

Mellapak 125.X Mellapak 170.X Mellapak 2X

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For high separation efficiency
BX and BXPlus Gauze Packings
Separation Efficiency

This packing has been successfully

employed in the industry for over 40 years.
Largest diameter supplied to date: 6 m.

Features and benefits

• High number of theoretical stages per unit height
• Pressure drop per theoretical stage 0.1 – 0.5 mbar
• Most economical load range: F factor 1-2.5 √Pa
• Minimum liquid load approx. 0.05 m³/m²h
• Small hold‑up

Preferred applications
• Large number of theoretical stages
• Vacuum from 1 mbar to atmospheric pressure
• Where minimum pressure drop per theoretical
stage is important

Product applications
• Monomers from plastics (MDI, DMT, etc.)
parameter = head pressure p /mbar
• Fatty acids, fatty alcohols, fatty acid esters
• Mono‑, di‑, tri‑, and tetraethylene glycols
• Fine chemicals Pressure Drop

BXPlus
BXPlus is a further development of the well proven
gauze packing BX. Its geometry is similar to
MellapakPlus. BXPlus offers the same efficiency as BX
with a 20% lower pressure drop. It is recommended for
gentle distillation at higher capacity.

Gauze packing BX
Gauze packing BXPlus

8
For even higher separation efficiency
CY and CYPlus Gauze Packings
Separation Efficiency

This packing was developed for separations

that require a large number of theoretical
stages. Largest diameter supplied to date:
1.8 m.

Features and benefits

• Maximum number of theoretical stages per meter
• Most economical load range: F factor 1.5 – 2 √Pa
• Minimum liquid load approx. 0.05 m³/m²h

Preferred applications
• For a very large number of theoretical stages
• Vacuum from 1 mbar to atmospheric pressure
• Small overall height
• Batch and continuous columns
• Pilot and laboratory columns (reliable scale up)
Limited suitability for:
• Fouling substances
• Non‑wetting liquids parameter = head pressure p /mbar

Product applications
• Pharmaceutical products (vitamins, etc.) Pressure Drop
• Fragrances (menthol, geraniol, etc.)
• Separation of isomers

CYPlus
The traditional CY structure was modified using the
know-how from the MellapakPlus and BXPlus concept
for more capacity, resulting in the new CYPlus packing.
The Plus structure allows for 15% more capacity while
keeping the same efficiency as the traditional CY gauze
packing.

Gauze packing CY

9
For aqueous solutions and low liquid loads
AYPlus DC
Pressure Drop

AYPlus DC is based on a newly developed

hybrid gauze material combination and the
geometry of MellapakPlus 252.Y. AYPlus
DC has a distinctly increased separation
efficiency compared to MellapakPlus 252.Y,
in particular at low liquid loads and with
aqueous systems.

Features and benefits

• Excellent wettability for organic and aqueous
systems even at very low liquid loads such as
below 0.1 m³/(m²h) AYPlus DC MellapakPlus 252.Y
20 20
• Low HETP, depending on the system 10 10
• More than twice as efficient as comparable sheet Wet Wet
Parameter: Specific liquid load / m3 / (m2h)
metal or plastic packings in aqueous applications System: Air-water
with low liquid load Column Diameter: 1000mm

• Pressure drop comparable to MellapakPlus 252.Y

and for aqueous systems even lower
• Most economical liquid load range < 1 m³/(m²h) Efficiency for Absorption Systems Test: DMF absoprtion with water

• Maximum operating temperature about 300°C

Product applications
Aqueous systems
• Dimethyl acetamide / water
• Dimethyl formamide / water
• Gas sweetening wash sections
• Glycol dehydrations
• High-boiling alcohols / water
• Wash sections in CO2 absorbers
Separation Efficiency

AYPlus DC MellapakPlus 252.Y

100 100
10
Parameter: Head Pressure p / mbar
System: Trans-/cis-Decalin

10
For demanding corrosive applications
Mellacarbon
Separation Efficiency

Carbon does not react with most solvents,

acids or lyes. Sulzer Chemtech offers various
Mellacarbon types.

Features and benefits

• Corrosion‑proof against caustic solutions,
non‑oxidizing inorganic acids including hydrofluoric
acid and carboxylic acids
• Excellent wettability, also in aqueous systems
• Specific surface area of 125 – 1700 m²/m³
• High thermal stability (> 400˚C)

Product applications
• HCI separation for production and for HCI recovery
(typically in the production of polycarbonate)
• MCA / DCA distillation head pressure p /mbar
• Production of phosphoric acid
• Concentration of hydrofluoric acid
• Separation of chlorophenols

Pressure Drop

Mellacarbon

11
For corrosive applications
Mellapak and MellapakPlus
Separation Efficiency
from plastics

The MELLAPAK 125.X, 125.Y, 250.X and

250.Y and MellapakPlus 252.Y are also
available in different kinds of thermoplastics.
Packings made of polypropylene (PP),
postchlorated polyvinylchloride (PVC-C),
polyvinylide-nedifluoride (PVDF), Teflon® PFA
and polyether ether ketone (PEEK) can be
supplied. The plastic versions of MELLAPAK Acetone / H 2O
have proven operational record in various SO2 / H 2O
types of absorption and desorption columns.

Features and benefits

• Large number of transfer units per meter, low HTU,
depending on the system Separation efficiency of Mellapak 250.Y PP
• Small pressure drop per meter packed height
• Most economical load range up to F factor 4 √Pa
• Maximum operating temperatures: Pressure Drop
approx. 110 ˚C for polypropylene
approx. 150˚C for PVDF

Product applications
• HCI absorbers
• SO2 absorbers
• Flue gas cleaning columns 75 m3/(m2h)
• Sea water deaerators

MellapakPlus 252.Y has the same efficiency as

Mellapak 250.Y and same capacity as Mellapak
250.X

dry

Mellapak PP
atmospheric pressure

12
For fouling conditions
Mellagrid, Nutter Grid and F-Grid
Capacity

Grids are developed for severe services that are susceptible

to fouling, erosion, coking, and high solids content. Grids are
installed in rigid modules stacked in successive layers with a
fixed orientation, thus minimizing the overall pressure drop while
simultaneously increasing tower efficiency.

load factor cG /m/s

We offer three types of grids: Mellagrid, Nutter Grid and
F-Grid.

Features and benefits

• Not sensitive to coking and fouling due to its smooth surface and
geometrical structure
• Efficient dissipation of temperature
• Better de-entrainment and separation efficiency than a traditional grid
• The low element height and its structure allow for easy cleaning. It can be
removed, unscrewed and cleaned with a water jet
• Mechanically robust structure Flow parameter Ψ /-

Main applications
• Vacuum tower wash section
• Atmospheric column over flash section
• Fluid Catalytic Cracker (FCC) main fractionator slurry pump around section
Pressure Drop
• FCC flue gas scrubber
• Coker main fractionator quench section
• Viscosity breaker main fractionator wash section
• Ethylene primary fractionator
• Ethylene water quench tower
X
90.

Mellagrid
Various liquid loads, air / water, T=30˚C,
atmospheric pressure

13
For reactive distillation
Katapak-SP Separation Efficiency

This packing was developed to be applied

in reactive distillation processes. With the
modular concept separation efficiency and
catalyst volume fraction can be varied to
perfectly fit the requirements of each specific
process.

Other types are available on request. Largest

diameter supplied to date: 2 m.

Features and benefits

• Flexible design combining catalyst elements and
MellapakPlus layers
• High separation efficiency
• High reaction capacity

Product applications
• Synthesis of acetates (e.g. butyl acetate)
parameter = head pressure p /mbar
• Hydrolysis of methyl acetate
• Synthesis of fatty acid esters
• Synthesis of acetals Pressure Drop
• MTBE, ETBE, TAME

Katapak

14
For small laboratory columns
Laboratory packing
Separation Efficiency

Standard structured packings are hardly

suitable for use in laboratory columns of
less than 50 mm diameter. Sulzer laboratory
packings are especially designed for this
purpose.
Preferred applications:
• Laboratory columns from 20 to 80 mm
• Vacuum from 1 mbar
• Where a high number of theoretical stages is required
(DX™, EX™)
• Distillation of components prone to decomposition
• Preliminary assessement of a separaton task
• Deriving of reliable scale-up rules

Features and benefits

Type EX:
• Highest possible number of theoretical stages,
even with very low liquid loadings
• Same pressure drop per theoretical stage as Sulzer
BX packing
• Small hold‑up Pressure Drop
• Capacity nearly double that of wire mesh rings (3 x
3 mm)

Type DX: This packing has a coarser structure and

hence a lower number of theoretical stages.

Suitable for laboratory columns where a modest num-

ber of theoretical stages is required, together with low
pressure drop and high capacity.

Type DXM/DYM: These packing types, made of sheet

metal, have a lower number of theoretical stages
compared to DX. HETP or NTSM remain constant over
a wide range of F factors and liquid loads. This makes
scale-up significantly easier.

Laboratory packings
Head pressure = 50 mbar

15
 Column Internals
Liquid distributors
300
High-Liquid-Load Tube Distributors

100
Distributor / Collector

Trough-Distributor Element-Distributor

50
Specific liquid load l [m3/m2 h]

Standard-Load

10

1
Low Liquid-Load

0.05
0.25 0.8 3 20
Column-Diameter [m]
Collector support grids Collector-distributor systems /
Vapor distributor

SLRT/SLMT VSI

Collectors Support grids

SLR/SLM TEB/TSB

Chimney trays

SK TS/TE

17
Comprehensive engineering and
technology services

Customer hydraulic design software

SULCOL

SULCOL is the latest development step in our

endeavor to provide state-of-the-art tools to our
customers for the design of mass transfer columns.

Structured and random packing hydraulic design and rating

• Default packing efficiency based on standard organic test
mixtures
• Efficiency calculation may be suppressed
• Extractive distillation
• Graphical capacity diagram with operating points
You may download SULCOL from sulzer.com
Tray hydraulic design and rating
• Fixed and movable valves
• One pass and multipass tray design
• Conventional downcomer design
• Description of Sulzer tray portfolio including Shell tray
technology

Turn Around and Tower Field Services

Sulzer’s global manufacturing capabilities ensure fast
delivery of any tray hardware and replacement tray parts,
regardless of the original supplier.

Customer support services

We combine the array of our technologically advanced
products with a full scope of associated engineering and
technology services. Tell us your need and leave the rest to us!

Process studies
• Energy saving
• Moving columns
• Process optimization
• Troubleshooting

Laboratory and Pilot Tests

• CO2 absorption
• High pressure testing up to 50bara
• Gas / Liquid and Liquid / Liquid separation

18
Development and technology
Sulzer makes every effort to support our customers and
continuously improve our design tools. Engineers in the
R&D lab develop new and improved products, analyze and
optimize processes.

We maintain close relationships to universities

and independent research organizations to support these
efforts.

Engineering and manufacturing

Sulzer has a long-standing manufacturing tradition. Sulzer
owns dedicated factories in every region to produce mixers,
columns, reactors, and heat exchangers.

For certain sizes and certain countries, we work with well-

known and proven subcontractors who are bound by Sulzer
manufacturing policies and quality standards.

Capabilities
Manufacturing according to PED 97/23/EC, ASME VIII Div.1,
and ASME B31.3/U-Stamp, Gost (TR), China Stamp, Norsok,
or NACE

Design codes acc. to AD2000, EN 13445, ASME Broad

selection of material for construction available

Non-destructive testing (LPT, X-ray, pressure testing up to

500 bar, PMI, MT, UT etc. acc. EN and ASME)

Designing with SolidWorks

Strength calculations, FEM analysis, nozzle loads etc.

Certification for ISO 9001, ISO 14001 and ISO 18001

Experienced project management team

CFD Analysis
CFD calculations done in advance of fabrication can support
the decision to go for a particular technology, and can save
on the time required for commissioning and testing later.
Sulzer uses CFD technology both for the modeling of existing
and the development of new products.

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sulzer.com

The Chemtech division is the global market leader in innovative mass

transfer, static mixing and polymer solutions for petrochemicals,
refining and LNG.

Chemtech is also leading the way in ecological solutions such as bio-

polymers as well as textile and plastic recycling, contributing to a circular
economy. Our product offering ranges from technology licensing to
process components all the way to complete separation process plants.
Customer support ranges from engineering and field services to tray and
packing installation, tower maintenance, welding and plant turnaround
projects – ensuring minimal downtime.

E10686 en 9.2023, Copyright © Sulzer Ltd 2023

This brochure is a general presentation. It does not provide any warranty or guarantee of any kind. Please,
contact us for a description of the warranties and guarantees offered with our products. Directions for use and
safety will be given separately. All information herein is subject to change without notice.