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FLEXERAMIC

CERAMIC

STRUCTURED

PACKING SYSTEM

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The high performance FLEXERAMIC structured packingsystem, is a carefully engineered design comprising theproper size selection of FLEXERAMIC structured packingand critical column internals. Our Koch Knight LLCengineers, working with customers unique requirements,optimize the system design by selecting or designing keycomponents, to provide a total solution.

The key to system performance is the FLEXERAMICstructured packing. The geometrical arrangement providesfor maximum liquid-vapor mixing and improved hydraulics.

FLEXERAMIC proprietary structured packing is constructedof corrugated sheets of ceramic. The angle of inclination ofthe corrugations of adjacent sheets is reversed with respectto the vertical column axis, forming mixing cells at everypoint where the corrugation intersect. This promotesintimate mixing and radial distribution of the liquid and gasstreams. Each subsequent element is rotated about thecolumn axis so that the sheets of one element are opposedto the sheets of the elements above and below. In passingthrough each element, gas and liquid are thoroughly mixed inthe direction parallel to the plane of the sheets. By rotatingsubsequent elements, excellent mixing and spreading, bothside to side and front to back are obtained over the entirecross section of the tower. The flow characteristics

developed by the structured geometrical arrangementcreates high effective surface area resulting in good efficiencyas compared to other mass transfer devices.

Improved hydraulic performance of the FLEXERAMICstructured packing result from the corrugated sheets beingvertically oriented,eliminating any horizontal surfaces whichcreate resistance to fluid flow. As a result, towers packedwith FLEXERAMIC structured packing have a very lowpressure drop and a corresponding higher capacity.

A critical component to any packed tower system is the

liquid distributor. Working with our customers, ourapplication engineers select the optimal distributordesign for the specific application to maximize towerperformance.The high performance distributors used inthe FLEXERAMIC structured packing systems utilize theknowledge developed by Koch Knight LLC over theirdecades of involvement in heat and mass transferoperations. For more information on our high performancedistributors and other internals, contact Koch Knight LLCrepresentative.

FLEXERAMIC structured packing system stands up to thetoughest operating environments. Manufactured incorrosion resistant ceramics, FLEXERAMIC is an economicalalternative to exotic metals and engineered plastics, andprovides excellent service life in most corrosive applications.

Whether applying FLEXERAMIC technology to retrofits,upgrades or new construction,Koch Knight LLC profession-als draw on an accumulated body of knowledge that nobodyelse can offer:more installationsmore years ofexperiencemore technical expertisethan anyother supplier.

FLEXERAMIC Structured Packing Systems

For Heat and Mass TransferApplications - Distillation,Absorption, Stripping, HeatExchange, Gas Mixing,

Extraction

Features & BenefitsThe unique features of a FLEXERAMIC structured packing system provide significant benefits over traditional

random packing:

Geometric Design - Effectively minimizes channeling and radially distributes gas and liquid uniformly over the towercross section.

Rigid Construction - Significantly less breakage and fouling of down stream equipment normally associated with

random ceramic packing.

Greater Surface Area per Unit Volume - More efficient per unit height than random packing of equal capacity.

Natural Wettability - Improve film formation for high surface tension aqueous liquids enhances efficiency.

Higher Capacity - Increase flow to existing towers or reduce diameters of new tower designs.

Lower Pressure Drop - Lower energy costs without sacrificing capacity.

Better Efficiency - Increase product recovery and improve product quality.

Economical - Cost effective alternative to exotic alloy and engineered plastic tower packings.

Corrosion Resistance - Corrosion resistance benefits found in ceramics applied to a high performance mass

transfer device.

FLEXERAMIC systems canbe installed in: Carbon Steel Vessels

Glass Lined Columns

Acid Brick Columns

FRP Columns

RegenerativeThermal Oxidizers

Alloy and Alloy CladColumns

Refractory LinedChambers

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Properties of FLEXERAMIC Structured Packing

FLEXERAMIC Density Density Specific Surface Specific Surface Compressive Strength Compressive Strength % Void SpaceStructured Tower Packing lb/ft3 kg/m3 Area ft2/ft3 Area M2/M3 lb/in2 kg/cm2

Type 28 48 769 86 282 270 19 72Type 48 32 513 48 157 140 10 77Type 88 21 336 31 102 95 7 85

Linear Thermal Expansion % ExpansionTemperature F C

0 0 0400 204 0.07800 427 0.21

1200 649 0.381600 871 0.48

High Performance CeramicStructured Packings

Before the availability of FLEXERAMICStructured Tower Packing, if more capacitywas desired, the choices were limited and

costly construct a new, larger diametercolumn, or retrofit with expensive exoticmetal or engineered plastic packing andinternals.

FLEXERAMIC Structured Tower Packingoffers a more economical alternative. Anadvanced development in ceramic materials,FLEXERAMIC Tower Packing provides plant

operators increased separation efficiency,increased capacity, lower pressure drop andoften significantly lower energy costs ofoperation. This means retrofitting existingpacked units with FLEXERAMIC towerpacking will improve profitability.

FLEXERAMIC TYPE 28Higher efficiency (lower

HTU) than 1-inch saddles,with capacity equivalent to

1.5-inch saddles. Excellent inRegenerative Thermal

Oxidizers.

FLEXERAMIC TYPE 88Efficiency equivalent, or

better than 3-inch saddle,with much greater capacity.

FLEXERAMIC TYPE 48Better efficiency than

1.5-inch saddles, with morecapacity than 2-inch saddles.

Typical Physical Properties

Specific Gravity 2.6

Water Absorption, %

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Pressure Drop-Capacity Curves

FLEXERAMIC

Structured PackingMore Efficient ThanRandom Packings

Definition of Terms

Fs= VvvWhere Vv=Superficial vapor velocity, ft/sec or m/s

v= Vapor density, lb/ft3 or Kg/m3

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FLEXERAMIC Structured Tower Packings geometric design

effectively minimize channeling and radially distributes the gas and

liquid. Wall wipers around each element prevent by-passing

of fluid at the vessel wall. Virtually even distribution is quickly

established in the packed bed and homogeneous gas/liquid

concentrations are maintained at any given tower elevation.

The geometric design allows for FLEXERAMIC Structured Packing

to have a much higher effective surface area per unit volume than

any ceramic random packing of equal capacity.

The natural wettability of ceramic in aqueous systems further

improves the separation or absorption efficiency of FLEXERAMIC

Structured Tower Packing over metal and plastic packings where

high surface tension hinders thin film formation.

TypicalApplications

Sulfuric Acid Plants

Regenerative ThermalOxidizers

Chlorine Cooling and DryingTowers

Bromine and HydrochloricAcid Plants

Liquid Organic WasteDisposal Coolers andScrubbers

Natural Gas Treating andDehydration Units

Purification of AqueousOrganic Acids

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TechnicalEngineeringCurves

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Sulfuric acid is the worlds mostwidely produced chemical. Efficientoperation is dependent on good tower

performance.The tower mass transferefficiency and pressure drop have

major impact on the plants processeconomics.

With its excellent, radial distributionand wettability, FLEXERAMIC

Structured Tower Packing provides plantoperators operational benefits;with

higher capacity, lower pressure drop andbetter efficiency.

What do applying these benefits meanto the acid plant operation? The

following table summarizes theoperational improvements available by

applying FLEXERAMIC Tower PackingTechnology to a typical sulfuric acid

intermediate absorber in a 1000 ton/day plant.The base unit is a 20 ft ID final absorber packed with a 12 ft bed of3" FLEXISADDLE Tower Packing.

Convertor

Sulfur Burner

AirBlower

Drying Tower & Pump Tank

Intermediate Absorber Tower& Pump Tank

Final Absorber Tower& Pump Tank

Knight Linings & Tower Application

Knight Linings Application

Application File - Sulfuric Acid Production

Packing

Diameter

Packed Height

Gas Flow (lb/hour)

Acid (gpm)

Pressure Drop (w.c.)

% Flood at Bottom (Max.)

SO

3

Removal

3 CeramicFLEXISADDLERandom Packing

200

12

500,000

4,700

8

73%

99.98%

FLEXERAMICStructuredPacking 88

200

9

500,000

4,700

3

54%

99.98%

FLEXERAMICStructuredPacking 88

200

12

500,000

4,700

4

54%

99.99+%

PARAMETER62% P

REDUCTION

30%INCREASE INCAPACITY

BASECASE

25% SMALLERTOWER CROSS

SECTIONALAREA 25%

SHORTER BED

30% INCREASECAPACITY

AND INCREASEEFFICIENCY

INCREASEDEFFICIENCYAND 50% PREDUCTION

DATA COMMON TO ALL CASES

Inlet Gas Temp. (F) 450

Inlet gas Gauge Press. (w.c.) 40

Inlet Gas Comp. (wt%)

SO2 3

SO3 8

N2 83

O2 6

Inlet Acid Temp. ( F) 180

Inlet Acid Strength 98.0%

This proven tower packing technology is successfully

being applied in drying towers, intermediate and finalabsorbers, cross flow strippers,oleum towers,and

other process towers with diameters over 20 ft.

FLEXERAMICStructuredPacking 88

200

9

650,000

6,100

7

77%

99.98%

FLEXERAMICStructuredPacking 88

200

12

650,000

6,100

7

77%

99.99+%

FLEXERAMICStructuredPacking 88

173

9

500,000

4,700

8

80%

99.98%

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NOTE:The informationcontained in this bulletin is believed to be accurate and reliable but is not to be

construed as implying any warranty or guarantee of performance

Your Single Source for Tower Optimization

Koch Knight LLC can put it all together for youfrom process design and mechanical layout to fieldconstruction and installation.

Our design capability does not stop at the processapplication. We can design and build the vessel withstate of the art lining systems using custom engineeredplastics, PYROFLEX membrane, KNIGHT-WARE acidproof brick and our proprietary corrosion resistant

mortars.

Our world class field crews and top flight projectmanagement teams insure Knight quality is maintainedthroughout the installation.

Let our over 90 years of field experience and over$100 hundred million in recent successful constructionprojects go to work for you.

KOCH KNIGHT LLCA member of Koch Chemical Technology Group LLC

Bulletin KCP-7 2M0303E Printed in U.S.A. Copyright 2003 Koch Knight LLC

Koch-Knight LLCHeadquartersP.O. Box 30070East Canton, OH 44730Phone: 330/488-1651Fax: 330/488-1656

Koch-Knight LLCSales Office10455 Jefferson Hwy. Suite 120Baton Rouge, LA 70809 2732Phone: 225/292-9899Fax: 225/292-0033

Koch-Knight LLCCanadian Operations2446 Bank StreetSuite 717Ottawa, Ontario, Canada K1v 1A8Phone: 613/731-2001Fax: 613/731-2218

Koch-Glitsch Italia S.r.l.Via Tonale 50, Casella Postale 1324061 Albano S AlessandroBergamo, ItalyPhone: +39-035-328-611Fax: +39-035-328-600

Koch-Glitsch LPBijkhoevelaan 12B-2110 Wijnegem, BelgiumPhone: +32-3-647-2847Fax: +32-3-647-2879

Visit us on the internet:www.kochknight.com