Chapter 14

14
Packed Towers

Packed towers are used increasingly in a variety of ap-
plications in the chemical process industries. The reasons
for this are an increase in the availability of design in-
formation, the evolution of higher-capacity and higher-
efficiency mass transfer packings, and improvements in
distributors and support plates. Today, packings can be
considered for most services where high numbers of
theoretical stages are required for mass transfer.
Most of the fractionating columns in gas-processing
plants that were previously equipped with trays can now
be filled with packings. Packings, such as slotted rings in
metal and plastic saddles, offer large improvements in
capacity for absorption and heat transfer applications. An
example of this is the use of slotted rings in a gas-plant
demethanizer, which has resulted in a significant capacity
improvement over trays.
Packed towers are used increasingly in small frac-
tionating towers and absorbers where access is re-
stricted. Their use is also advantageous where corrosion
control is essential. Because of liquid-distribution con-
cerns, packing still is usually not recommended for large-
diameter columns, or where a high turndown ratio is
required. All packings tend to spread liquid as it flows
downwards. This characteristic is adequate for dispers-
ing the liquid between distribution points, but not to
correct poor distribution across a tower without consid-
erable loss of efficiency. Studies of liquid spread in tower
packing have been reported by Hoek [158]. Figure 14-1A
shows a cross-section of a typical packed tower,
Figure 14-1B illustrates a typical packed tower with
internals for improved distillation. Figures 14-1C and 14-
1D show a photograph of a packed column, and a sche-
matic of the pilot plant packed column respectively. The
shell is usually cylindrical, although square wooden, light
Ludwig’s Applied Process Design for Chemical and Petrochemical Plants; ISBN: 9780750683661
Copyright Ó 2010 Elsevier Inc. All rights of reproduction, in any form, reserved.
metal, or reinforced plastic towers are used. The basic
unit consists of:
1. shell
2. packing (one or more sections)
3. packing support(s)
4. liquid distributor(s)
5. intermediate supports and redistributors
6. gas and liquid entrance and exit nozzles.
Many of the mechanical aspects of tower construction
and assembly have an influence on the design and in-
terpretation of tower performance. Every effort should
be made to increase the effectiveness of contact be-
tween the process streams, and to reduce losses by
entrainment or wall effects whilst minimizing pressure
drop. At the same time the design must be consistent
with the economics dictated by the process and type of
construction.
14.1 Shell
The shell may be of metal (steel, alloy or non-ferrous),
plastic, wood or some combination, which may require
the addition of liners or inner layers of rubber, plastic or
brick. The mechanical problems of attaching inner noz-
zles, supports and brick require considerable attention
indesign that is not an integral part of sizing the equip-
ment. Figures 14-2A–C show a typical large, steel
brick-membrane lined tower with corbeled brick support
locations. In these towers, temperature and/or corrosive
conditions usually dictate the composition of internal
 CHAPTER 14 Packed Towers
Figure 14-1A Cross-section of typical packed tower.
lining, and the requirements for the proper acid-(or
alkali-) proof cements.
Ceramic, plastic and other non-metal tower shells
are used quite often (Figures 14-3, 14-4, and 14-5). It
is important in ceramic construction to consider that
the main inlet or outlet nozzles, or any other large
connections, should be oriented 90 to each other in
order to reduce the possibility of cracking the walls,
as most cracks go one-half diameter. Preferably there
should only be one nozzle in any one horizontal plane.
The nozzles should never carry any piping or other
stress load.
The bell and spigot type tower, shown in Figures 14-3
and 14-4, is satisfactory for 2 to 2.5 psi in 12-in. dia. to
30-in. dia. towers when the joints are packed with
chevron-type caulking compound. For an operating
pressure of 5 psi in 18-in. through 48-in. dia., use of non-
asbestos and silicate cement. Special hold-down packing
gland-type rings will allow this pressure to be raised
484
slightly. Porcelain towers should be used for higher
pressures rather than the weaker stoneware.
The rate of heating or cooling a stoneware or porcelain
tower should not exceed 15 F/min.
14.2 Random Packing
The distributor and packing define the performance of
this equipment. Their proper selection entails an un-
derstanding of packing operational characteristics, and
the effect on performance of the points of significant
physical difference between the various types.
Good progress has been made in the past decade in
the development of packing types for difficult and wide
ranging process applications (see: Websites in bibliogra-
phy). These types include:
1. Random particle packings are discrete, individually
shaped particles designed to provide contacting
 Packed Towers CHAPTER 14

Figure 14-1B Typical packed tower with internals for improved distillation. Used by permission of Jaeger Products Inc., Bull. 1100.

485
 CHAPTER 14 Packed Towers

surfaces between (normally) down-flowing liquid

and up-flowing vapor/gas. The degree of effective-
ness of the various shapes varies along with the mass
pressure drop through the packed bed. Usually these
particles are ‘‘dumped’’ into the column (tower) and
allowed to float gently to their free-fall resting posi-
tion in a column full of water. Some shapes and sizes
are not installed using water, but dumped in using
a special ‘‘sock’’ that allows the particles to be
lowered without a damaging free fall. Sometimes
large particles are hand set ‘‘dry’’ into position to fill
the tower tightly, See Figure 14-1A. The vapor-liquid
performance is different for each method of loading,
and appropriate data must be available to properly
size the tower. The random ‘‘dumped’’ (wet or dry)
method is the technique usually used in most
published data (see Figures 14-6A–X).
2. Structured packing, which is offered by several
manufacturers, is usually composed of pack ‘‘pads’’
fabricated by shaping/crimping, bending, rolling, etc.
sheets of thin gauge metal or wire, (see Figures
14-6Y to 14-6OO). Some ‘‘pads’’ or packs are
formed using various plastics material, selected to be
resistant to the fluid services involved.
3. Grid packing is probably the newest packing type. It
is lower in pressure drop, and has higher capacity, but
lower efficiency than the other types. (See Figures
Figure 14-1C Photograph of a pilot plant absorption column 14-6PP–UU).
(courtesy of Armfield, U.K.).
The types and corresponding physical data for packing
are given in Figures 14-6, and Tables 14-1 through 14-15.
Evaluation of these materials in various conditions of
service is provided later. However, Table 14-16 outlines
packing service applications and Table 14-17 summarizes
the usual applications of each packing type.

14.2.1 Packing Supports

Figure 14-1D Schematics of a pilot plant absorption column
(courtesy of Armfield, U.K.).
The packing support may be anything from cross-grid
bars spaced so as to prevent fall-through of packing, to
more refined, speciality units designed to direct the flow
of gas and liquid. (See Figures 14-7A–F.) Good tower
performance is definitely linked to proper packing sup-
port. The net free flow cross-sectional area of the support
should be 65% (or larger) of the tower area, and greater
than the free area of the packing itself. In addition, the
effect of any free area ‘‘blocking’’ by the positioning of
the packing on the support must be considered. To allow
for this, every effort should be made to obtain as large
a support-free area as possible, and yet remain consistent
with the structural strength of the material being used. If
this area is too restricted, liquid build-up will occur at the
plate, reducing efficiency and increasing the pressure
drop of the tower, which could lead to a flooding

486