Introduction

Pentane Chemistry Industry (PENTANE) is a

well-established leading designer and manufacturer
of a complete range of Mass Transfer Equipment in
Oil, Gas and Petrochemical Industries over a decade.
Fractionation Trays
Packed Tower Internals
Separator Internals
Reactor Internals
Services
Also recently PENT AE has developed his field of
activity to specific Separation Process Packages like
Sulfur Removal packages, Vapor Recovery Unit,
Flare Gas Recovery etc.
PENTANE is proud to provide customers with reliable
solutions as right, every time and on time services.

Distillation tray columns always play a key role in

oil,gas and petrochemical industries processes.
Some specifications which make tray outstanding
from other similar internal equipment are:
Operation flexibility
High liquid load traffic handling
Suitable for dirty system
More withstanding against corrosion/erosion
This section provides customers with information of design
and specification ofValve, Sieve and Bubble Cap Trays.

TRAY FUNDAMENTALS

In classical hydraulic model liquid and vapor flow counter

currently. Liquid phase horizontally flows over the tray
deck and vapor phase vertically goes upward from
bottom tray to the upper tray and disperses through
continuous liquid phase, result of this contact is a froth
which flows over the deck during the traveling along tray.
Some vapor separate from mixed phase and go upward
and remaining froth releases over weir to the downcomer.
In downcomer vapor phase disengages from mixture
extensively and goes toward upper tray.
In this normal flow regime most contacting surface area
between phases will be provided but different direction
of phases causes noticeable pressure drop.

LIMITATIONS OF TRAY DESIGN

AND OPERATION

Typical tray stability diagram shows area of satisfactory

operation (shaded area) is bound by tray stability limits.
Upper capacity limit is the onset of flooding; at moderate
and high liquid flow rates, the entrainment or jet flooding
is normally reached when vapor flow is raised, while the
downcomer flooding normally happens when liquid flow is
raised, whilst vapor rate is lowered, either at constant liquid
rate or at constant L/V ratio, the limit of excessive entrainment
is often occurred.

Liquid Flow rate ---+

II

Jet Flood

Definition: Flooding is excessive accumulation of liquid

inside the column
Cause : High vapor superficial velocity over the tray active area
Effect: Excessive froth/spray height over the tray (equal
to tray spacing)
Solution: Increase tray active area or tray spacing

Definition: Entrainment is liquid transported by

the gas to the tray above
Cause : High vapor velocity through tray open area
Effect: counteracts the mass transfer process and
reduces tray efficiency, carryover of nonvolatile
impurities upward
Solution: Increase open area (more perforations,
valves, caps) to eliminate entrainment.

t - - - - Weeping

Liquid
Moderate
Weeping

Heavy
Weeping

Downcomer Backup Flood

Definition: Downcomer backup flooding occurs

when the backup of aerated liquid in the downcomer
exceeds the tray spacing
Cause: High tray pressure drop, liquid height on
the tray , frictional losses in the downcomer apron
Effect: Froth height exceeds tray spacing, liquid
accumulates on the tray above
Solution: Increase tray opening area
(more perforations, valves, caps) or tray spacing

Chock
Flood

Weeping

Definition: Weeping is liquid descending through

the tray perforations. Under weeping conditions,
part of the liquid flows over the outlet weir while
the rest descends through the perforations
Cause : vapor velocity through the holes isn't
high enough to overcome static head of fluid over
the deck
Effect: Significant leakage from upper tray to the
below tray
Solution: Decrease open area(less perforation,
valve, cap) or change type of tray (from sieve to
valve or bubble cap)

Backup
Flood

Entrainment

Downcomer Chock Flood

Definition: If the friction losses in the downcomer

and/or downcomer entrance are excessive, liquid
will back up onto the tray and eventually flood the
column
Cause : High superficial liquid velocity at downcomer
mouth
Effect: Inadequate disengagement of vapor-liquid
phases and liquid back mix ing, frothy mixture
cannot be transpo rted to the tray below, liquid
accumulates on the tray above
Solution: Increase downcome r mouth area

II

TRAY ARRANGEMENT

Tray style and parts are designed in accordance with accepted industry standards to cover all necessities
of various processes .

1- Tray Floor
2- Seal Pan
3- Manway
4- Outlet Weir
5- Downcomer Upper Section
6- Downcomer Lower Section
7- Support Ring
8- Support Bar

Flow Path Len h

Downcomer
Width

Tray spacing

Downcomer
Area
Elevation View

Top View

Tray Parts Description and Geometrical Parameters

Graphical configurations of conventional I, 2
and 4 pass trays are shown below with various
styles of liquid and vapor traffic.

When high liquid rates are encountered, 2 pass

and 4 pass trays are preferred because they
provide lower weir load.

Sloped
Downcomer
Inlet Weir

1-Pass Factionating Tray

~

,.
TAN E
MIST RY
INDUSTRI ES Co.

II

2-Pass Factionating Tray

Depending on tray hydraulic,downcomer also

can be designed straight and sloped in order to
increase more tray active area.

Inlet weir and recessed seal pan are applied

for achieving downcomer seal and where
downcomer clearance is limited.

PRODUCTS INTRODUCTION

Bubble Cap Tray

Bubble cap tray is the oldest liquid-vapor contacting device
in distillation columns. In occasions when low liquid loads
and very high turndown ratios are required, bubble cap
trays are commonly used.
This tray is the most expensive option and it has lower
capacity compared to sieve and valve trays.
Features
High Operation Turndown
Low-Liquid Vapor Flow Rate

Sieve Tray
Consists of tray panels area uniformly punched with holes
hence is the cheapest mass transfer device because of
simplicity and cost-effectiveness.
Sieve tray usually provides about I 0% open area with 13 mm
holes diameter and when low turndown is required. This tray
is the most economical choice.
Features
Simple and low cost
Narrow operation flexibility over a range of 2: I turndown ratio
Tried and tested performance

Float Valve Tray

Float Valve Trays are composed of punched tray decks fitted
with movable valves to vary the tray open area with changing
vapor load. In cases where high turndown ratios are
considered, floating valve trays are an option.
There are various valve types which may either have legs
integrated to the valve disc to limit upwards movement or
alternatively the valve disc movement is restricted by a
cage fitted to the tray panel.
Valve discs/caps are available in both round and rectangular
shapes.The capability of floating valves makes these valves can
control vaporflow so as a result, they provide better sustained
efficiency over a wider operating range than sieve trays.
Features
Medium operating flexibility up to 5: I turndown ratio
Enhanced liquid-vapor contact
Steady liquid movement across the tray deck
Less froth height and weeping
Turndown parameters adjustment by selecting suitable
range of valve lift and weight
More resistance against fouling or corrosive fluids
Extra fatigue causes the legs to be damaged; cage valves
solve this problem easily

Fixed Valve Tray

This type of valve tray has been developed to achieve
both sieve and floating valve tray specifications as
moderate pressure drop, turndown ratio and cost.
Fixed Valve Tray is the preferred tray when fouling
conditions are possible. However, it provides lower
turndown and less efficiency than floating valve.
Smaller fixed valves provide more capacity than larger
valves owing to the fact that press ure drop and
entrainment decrease.

Features
More resistance against fouling services
Moderate operation flexibility about 3 : I
turndown ratio
Lower entrainment and pressure drop
Higher Capacity as tray spacing can be reduced
especially in existing columns it allows to
increase the number of trays
High efficiency is attainable over wide range
of operational conditions
excellent mechanical strength
leakage is low

lsi

II

 Penta Valve TM

RE
(Std BDH Valve)

CG
(Std Cage Valve)

R0-2
(Std 31eg Valve)

R0-3
(High efficiency 31eg Valve)

CARTRIDGE TRAYS

Cartridge trays are typically used in flanged columns where

the tower diameter is so low and no manhole is used.
Generally, for columns with diameters less than 900 mm,any
of tray products can be manufactured in cartridge -style
construction.
This scheme can only provide up to 5 trays per cartridge, they
are joined together in bundles for easy installation.

HIGH PERFORMANCE TRAYS

In order to provide higher capacity and to reduce Jet Flood,

PENTANE offer complete range of high performance trays
based on optimum tray geometry, such as high performance
chordal downcomers, Swept-back Downcomers, Sloped
downcomers and Multi-downcomer trays, Special tray decks
for enhancing vapor capacity with state-of-the-art downcomer
technology.
These kinds of trays are suitable for column revamping and
for reducing the size of new towers.

Features:
Maximized active area
Swept-back Downcomers
Sloped Downcomers
Micro Valves
Jet Tabs
Clear Liquid Separators

Results:
Increased Tray Efficiency
Increased Capacity

Advantages:
More trays in t he same space
reflux ratio
Lower pressure drop

Ill. Lo w e r
'

TAN E
MIST RY
INDUSTRI ES Co.

161

II

R0-1
(Std 31eg Valve)

DESIGN TOOLS

PENTANE has developed home based Tray design codes

compatible with comprehensive Tray types which give
efficient and accurate output with minimized cost.
Depend on costumer necessities, all hydraulic/rating
and mechanical parameters such as jet flood, downcomer
flood, pressure drops, stresses, deflections and etc will
be fitted in the acceptable range.
The results will be provided to costumer in a standard
output format. Based on rating and strength outputs, internal
parts are designed by use of standard 3D or 2D drafting
software then assembly and shop drawings are generated
in CAD format.

MECHANICAL CONCEPTS
& FABRICATION TECHNIQUES

By use of 3D model with real world scale in tray part

design, any probable mistakes would be omitted.
Then the CAD model of trays is produced from 3D model
and the program of CNC machines is generated from
CAD file for accurate fabrication of tray panels.
By using the CAD/CAM system for tray design and
manufacturing,we assure the good fit up of all tray parts.

Beside of tray shape design, the strength and

deflection of tray parts, support beams and
attachments are calculated with home based software
and if needed will be checked with FEM analysis
software. In most cases to achieve the required
strength, tray panels are folded to form integral
truss; this truss reduces overall cost and permits
faster installation respect to major beam.

=--=
._,
,_,

~-

~
~

.......
~

In case of using major beam in large column, to

prevent poor distribution of liquid and vapor on tray
deck, beam must be parallel to the direction of
liquid flow. All major beams are through bolted
to welded support brackets.
Generally, the upper section of downcomer
functions as support beam for tray deck panels
and is through bolted to welded support bars,
lower section of downcomer may be clamped
or bolted to welded support bars.

All parts shall be made as large as possible in

order to reduce the number of joints and designed
to pass through Vessel Manhole.
One tray pane l should be furnished in each flow
path as tray manway, this ma nway should be
siz ed so t hat a man can pass thro ugh it for
installation and mainte nance purposes and sho uld
be removable from top and botto m.

II

INSTALLATION LAYOUT

Tray panels join together and to the supports with a suitable quick fastening method which should
not be loosened by vibration.
Selecting the assembly method depends on tray operation conditions and clients standard mandate.
Normally tray panels are assembled through following methods:

Clamping

This method is used for jointing tray panels together

with friction washers and also connecting tray panels
to support ring or bars with universal/ lever clamp.

Through bolted
Through bolted tray panel connection results in more
rigid structure and ensures mechanical integrity,
especially in case of considerable vibration.
The parts which are designed for load bearing such
as upper section of downcomer or major beam need
to be through bolted to supports.

Lip joint

Lip joint eliminates connecting accessories between

adjacent tray panels, cancels vibration caused by panels
shift and reduces installation time.

II

STANDARD TRAY ASSEMBLY

Accessories

Replacement hardware to match trays is supplied by PENTANE as well as other major manufacturers.
PENTANE maintain a large inventory of standard tray hardware such as Valves, Clamps and Fasteners
in common materials grades of stainless steel for emergency supply.
For maintenance purposes, comprehensive services are provided to help clients to decrease costs and
shutdowns/overhaul schedule.

II

PACKED TOWER INTERNALS

Packed Columns play an important role in distillation,

absorption and stripping processes.This section provides
the information of the key design and specification of
column packings and packed column internals including :

Random Packing
Structured Packing
Liquid Distributor
Collector/Chimney Tray
Support Grid
Hold down Grid I Bed Limiter

Column Packing

A packed bed provides a mechanism for mass or heat transfer

through which the gas and liquid phases usually flow counter
currently in the column. The presence of tower packing
elements provides a resistance to the flow of these fluids
that is greater than it would be in an empty column shell.
The modification of existing mass transfer columns with
modern column packings can increase the number of available
mass transfer stages.These additional stages permit greater
product recovery through a reduction in losses of product
in recycled or waste streams.
Packings are divided into two main categories;

Random or Dumped packing: These are discrete pieces

of packing with a specific geometrical shape which are randomly
packed into the column.
Structured packing: These are corrugated sheets of thin
gauge metal or wire gauze which are supplied in segments to
form the packed bed.

Features
Low pressure drop
Operation flexibility
Capacity enhancement
Availability of materials with high resistance against
corrosive services

Because of these outstanding advantages, substitution

of exis ting trays by new packings can be the first
approach for revamping of mass transfer processes to
gain additional capacity or efficiency requirement.

II

HYDRAULIC DESIGN

The optimum efficiency and loading point are evaluated by using reliable design models, for selected
random or structured packing the bed heights are determined from HETP (height equivalent theoretical
plate) and the column diameter is determined from capacity and pressure drop.
PENTANE packed bed hydraulic design software not only consists of tried and tested correlations for
HETP, pressure drop, Flooding, liquid hold up and etc but also contains a sufficient data bank of various
experienced cases to check the design output.

PACKING EFFICIENCY

HETP as Packing Efficiency is determined to

evaluate required height of packing to achieve
specified number of theoretical equilibrium stages.
Basic data such as number of theoretical stages,
liquid-vapor loads and physical properties are
derived from standard process simulation software.
There are some direct parameters for HETP
calculation such as liquid-vapor loads, physical
and transport properties, packing type-size as
well as indirect factors like liquid-vapor distributor
quality.
Proper liquid distribution is the key parameter in
order to achieve optimum performance with any
high efficiency random or structured packing.
Below curve shows a typical HETP versus vapor
rates of typical packing.

System Base

~----------------~--------~HE~
Vapor Rate

PACKING PRESSURE DROP

Generalized pressure drop correlation (GPDC) is a common method for estimating pressure drop
and maximum capacity of most generic random packings.
Pressure drop estimated by using this model are accurate to within 20% for most random packing styles.
Pressure drop for structured packing is calculated by related GPDC for rough estimation or by correlations
and experimental data for more accurate evaluation.

Generalized Pressure Drop Correlation for Random Packing

0.40
0.35

dp=l POO Pafm

............

0.30

'

..........

0.25
.., 0.20
"l

....u

500 Pa/m

!'-..r-....

r--~

--

........ ~

0.15

300 Pa/m 1----

1--

0.10

200 Pafm
101) Pa lm

0.05

1-

""'
~

1121

II

0.01

""- --

...........
............
...............
t:---t:::::::r-.. 1'---

::::--

50 Pafm

0.00

.........
1--..

0.1

r- ' r--- . . .
1

Flow Parame"-'-te"-!r,-.:.X:.:......--=========================~

RANDOM PACKING

This type of packing includes discrete pieces of specific geometrical shapes which are dumped into the tower and
permitted to fill in a random manner; design of packed bed w ith random packings is performed based on desired
separation efficiency and capacity margins. As a general rule, the higher capacity is achievable with larger packing
size although provides lower separation efficiency. Thus an engineering judgment for optimum capacity, efficiency
and cost should be done.
PENTANE manufacture a comprehensive range of traditional generation ("Generic") random packings compatible
with accepted industry standards for which considerable performance data is readily available.
Also PENTANE supply unique third generation ("Proprietary") random packings which are developed to meet the
current performance demands

GENERI C RANDOM PACKING

RR-PentaRing (Equivalent with Raschig Ring)

RR-PentaRing has cylindrical design and is the first

generation of random packings.

Metal Raschig Ring

Nominal Size

Equivalent Size

Thickness

Bulk Density

Quantity

Surface Area

[mm]

[ inch]

[mm]

[kgJml ]

# 25

I"

0.5

400

50000

220

# 40

I y, "

0.5

246

14500

130

# 50

2"

0.8

320

6500

11 0

[pieces/m

[m 2 /m3 ]

Carbon Raschig Ring

Carbon Raschig Rings as one of the most common and
generic type of packings provides a corrosion resistance ,
thermal shock resistance, and high temperature stability
conditions.

Nominal Size

Equivalent Size

Bulk Density
[kg/m

Quantity

Surface Area

[mm]

[inch]

# 25

I"

570

42000

186

# 40

I y, "

520

11900

126

[pieces/m

[m 2 /m 3 ]

II

PR-PentaRing (Equivalent with Pall Ring)

The second generation of random packings
includes the Pall Ring which is one of the most
common type of packings, it is already an industry
standard design media developed from the Raschig
Ring and is used widely in all variety of applications
and modern distillation practice.
Features
Most experienced random packing in industries
and research institutes
Improved strength by proper material thickness
Lower pressure drop rather than Raschig Rings

Nominal Size

Equivalent Size

Thickness

Bulk Density

Q uantity

Surface Area

[mm]

[i nch]

[mm]

[kgfml]

[pieces/ m1 ]

[m1Jml]

# 16

5/8"

0.3

560

196000

360

#25

I"

0.6

438

45000

215

#40

I '/2"

0.6

208

15000

135

#50

2"

0.8

213

6600

105

PROPRIETARY RANDOM PACKING

IR -PentaRing (Equivalent with IMTP)

This generation of random packing media designed

to give enhanced capacity and increased efficiency
over the older style Pall Ring packing.
This type of packing combines the high void fraction
and the well-distributed surface area of the Pall Ring
with the low aerodynamic drag of the saddle shape.
This kind of random packing is used widely in separation
columns. By comparison to the PR Series, PentaRing TM
IR series provides a more open shape and improved
liquid spread, also produce adequate mechanical
strength resistance
Features
30% lower pressure drop rather than Pall Rings
More efficiency and capacity rather than other
random packings
Minimum liquid hold up
Equivalent Size
[ inch]

Thickness

Bulk Density

Quantity

Surface Area

[mm]

[mm]

[kg/m1 ]

[pieces/m1 ]

[m1 /m1 ]

# 25

I"

0.3

252

170000

226

#40

I !12"

0.35

180

34500

145

#50

2"

0.35

136

13500

100

Nominal Size

I
1141 '

TANE
MISTRY
INDUSTRI ES Co.

Well surface utilization in transfer phenomena

Shorter packed bed height.
Outstanding mechanical strength

STRUCTURED PACKING

Penta-Pack structured packing is formed from corrugated

thin sheet metal as the angle of the corrugations reversed in
adjacent sheets in order to create a very open honeycomb
structure media.
Structured packing is ideal for difficult separations requiring
a large number of theoretical stages, in low liquid rate
absorption/stripping systems or applications that require
a wide operating range such as vacuum and atmospheric
crude oil fractionators, FCC main fractionators and TEG
contactors meanwhile it causes lower pressure drop than
random packing.
Penta-Pak is a typical structured packing formed from
corrugated sheets of perforated embossed metal [PS series]
or wire gauze [PG series].

PENTA-PAK"PS" SERIES

An industry standard sheet metal which is available with

specific surface ranging from below 125 m2/m3 for high capacity
to more than 750 m 2/m 3 for high efficiency applications.
The standard angle of the corrugations is 45 [referred M1]
and 60 [referred M2], also high capacity structured packing
[referred MH] are also fabricated in PENTANE.
Metal Structured Packing provides high capacity, low pressure
drop and good wettability in many process columns.
Features
Ideal for vacuum services
Very low liquid loads(< I 00 L/m 2 h) are possible
Low pressure drop per theoretical stage
High separation efficiency owing to larger mass transfer area
Good wettability of the packing surfaces
Superior compressive strength

Penta-Pak "PG" Series

This type of Structured Packing is made of mesh type

gauze woven by metal wire and is mainly used to
enhanced separation characteristics for fine chemicals,
perfumery, and pharmacy.
It is normally manufactured with very high surface area
[500 m 2/m 3 and 750 m 2/m 3]
Features

Superior wetting ability owing to capillarity

High separation efficiency/High number of theoretical stages
Lower specific pressure drop
Small liquid hold-up

II

1
-

PS-SOOM l
PS-250M l
PS-1 25M l

Q)

~ 0.1
....

0
0..

0.01
0

0 .02

0.04

0.08

0.06

0. 1

Flow Pa ram eter

Flooding Curves for Penta-Pak Structured Packing

4.5~------------------------------------------------------~

4 -+-- - - - - - -

3 .5 -+------------

Relative Capacity
Relative HETP

3 -t--- - - - - - - - - - 2 .5-+-----------2 -t-- -

Relative Capacity & HETP for Penta-Pak Structured Packing

Note: Relative capacity and HETP are for estimation purposes only and may vary according to actual
column loads and duty .

...

'

TAN E
MIST RY
INDUSTRI ES Co.

1161

II

Penta-Pak

Surface area [m2 /m 3 ]

Corrugation Angle

Relative HETP

PS-12SMI

li S

4S'

2.0S

PS-12SM2

li S

60'

4.0S

PS-16SMI

16S

4S'

I.S

PS- 16SM2

16S

60'

2.3S

PS- 175M I

17S

4S'

1.2S

PS-I 75M2

175

60'

1.8S

PS-22SM I

22S

4S'

1.1

PS-22SM2

22S

60'

1.6S

PS-2SOM I

2SO

45'

PS-2SOM2

250

60'

PS-2SOMH

2SO

45'

PS-300M I

300

4S'

0.9

PS-300M2

300

60'

1.2

PS-SOOM I

500

45'

0.7

PS-SOOM2

60'

0.9

PG-500M2

soo
soo

60'

0.8

PS-7SOM I

750

45'

0.6

PG-7SOMI

750

4S'

0.33

1.55

Typical Features o Corrugation Angles

~ Pressure

Capacity Efficiency

Drop

M1

High

Low

High

MH

Moderate

Moderate

Moderate

M2

Low

High

Low

Penta-Pak '1M PS-250 M2 Structured Packing

Pressure Drop Data

8oo r--,---r--;--.,_. ,_ , ,

Penta-Pak '1M PS-250 M1 Structured Packing

Pressure Drop Data
800

700

600

ii:'

~ 500 1---l---+---+-+---lf-~--f-1

~ 500

<l

<l

0.,

~.,

"'
~

"'

~ 400 t---;---+---+-1--l't--+-i-+--;

~ 300 1---l---+---+-+--tf-----.ll----1

~400

1/ /

100

0.02 0.04 0.06 0.08 0.10

Vapor Rate , C5 (m/s)

Liquid Rate

~ 300
200

0.12

Penta-Pak '1M PS-250 MH Structured Packing

Pressure Drop Data
rr-.,, - --,
800

1/!I

~ 500 1---lf----+---+---11-+-I,...--JH

<l

i 'v
(/

I v~ /

~400 1---;r--+---r-+~-;~~

~.,

~ 300 f-----t---t-----t-;,___,'1-----fti ---j

"'
~

~~

0
0.00 0.02

0.04 0.06 0.08 0.10

Vapor Rate , C5 (m/s)

0.12

0.02 0.04 0.06 0.08 0.10

0.12

Vapor Rate, C5 (m/s)

117(

II

PACKED TOWER INTERNALS

Packed columns including both random and structured packing must have several compatible internal
components to function properly. Reliable design and selection of internals including liquid distributors,
collectors/chimney tray, support grid and hold down grid/bed limiter is essential for gaining the specific
service requirements. PENTANE has valued experiences in design, selection and manufacturing the packed
column internals.

Liquid Feed Pipe

Liquid Distributor
Bed Limiter

Packing

Feed

Support Grid

Liquid Re-distributor
Bed Limiter

Packing

Support Grid

Reboiler
Vapor

Vap or Distributor

Packed Column Internals Layout

1181

II

LIQUID DISTRIBUTOR

To acquire the maximum efficiency in packed column, liquid should be distributed uniformly over the packed
bed. Therefore, Liquid Distributors are used above each bed of packing.
Good practice designed distributors have following specifications:
Uniform liquid distribution

Operation flexibility through the turn down range

Low vapor pressure drop

Low liquid residence time

Capability to be used as combined with collector

for re-distribution
Minimum distributor height
Fouling resistance
Cross mixing capability

Model TD-111

IType
l D iameter

> 1000 mm

j lrrigation Rate

0.8 - 30 m3/ h /m 2

Drip Tube Trough Distributor

IResistance to Fouling I Medium

ITurndown Ratio j 2: I (maximum I 0: I in multiple level holes)

--------------------------------~

Holes Position

l Drip Points Density

Square pattern punched in the trough's side which is

covered with drip tubes (Multiple levels & series of
holes can be punched to achieve high turndown ratio)
80 - 200 drip points /m 2

Model TD-112

IType
IDiameter

Drip Panel Trough Distributor

> 1000 mm

!Irrigation Rate
0.8 - 30 m
IResistance to Fo uling I Medium
ITurndown

3
/

h /m2

--------------------------------~

Ratio

Holes Position

Drip Points De nsity

2: I (maximum I0: I in multiple level holes)

Square pattern punched in the trough's side which is
covered with drip tubes (Multiple levels & series of
holes can be punched to achieve high turndown ratio)
80 - 200 drip points /m 2

II

Model PD-121/ PD-122

PD-122

PD-121

Type

Orifice Pan Distributor

Diameter

300 - 1000 mm

Liquid Range

2.5 - 75 m 3/ h /m 2

Resistance to Fouling _ L_o_w_ __ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _- l

1
Turndown Ratio
2: I
Holes Position

Square or triangular pattern punched in the pan floor

Drip Points Density

60 - I 00 drip points I m2

Optional Features

Combined with hat to operate as re-distributor

Model DD-13 I

Type

Bottom Orifice Deck Distributor

Diameter

> 300 mm

Liquid Range
Resistance to Fouling Low
Turndown Ratio

I'

TANE
MISTRY
INDUSTRI ES Co,

1201

--------------------------~

2:1

Holes Position

Square patte rn punched in the deck

Drip Points Density

70- 100 Drip points /m 2

Optional Feature s

Combined with Hat to Operate as Re-distributor

Model DD-132

Type

Drip Tube Deck Distributor

Diameter

>1000 mm

Irrigation Rate

0.8 - 30 m3/ h /m 2

Resistance to Fouling j_ M_e_d_iu_m_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _____.J

Turndown Ratio

2 :I (I 0: I max in multiple levels holes)

Holes Position

Square pattern punched in the trough si de which is covered with drip tubes
(Multiple levels & series of holes can be punched to achieve high turndown ratio)

Drip Points Density

80-200 Drip points /m 2

Optional Features

Combined with Hat to Operate as Re-distributor

Model AD-141

Type

Pipe Arm Distributor

Diameter

> 400 mm

Liquid Range
Resistance to Fouling Low (can be used only for clean services)
1
Turndown Ratio

2: I

Holes Position

Orifices furnished in pipe below

Feature

Suitable for Low irrigation rate and limited height space services

LIQUID COLLECTOR/CHIMNEY TRAY

Liquid Collector/Chimney tray is used in the columns to achieve one or more of following purposes:
Vapor distribution
Liquid collection from above bed and conduction to below distributor
Total or partial liquid draw-off
Open area, allowable pressure drop, height of collector, liquid & vapor loads, column diameter and quantity
of Liquid draw-off are the main parameters in collector design.

Model VC-21 I

I
1221 '

TANE
MISTRY
INDUSTRI ES Co.

Type

Vane C o llector

Diameter

> 800 mm

Service

Suitable for vacuum services because of low pressure drop (high vapo r & low liquid loads)

Open Area

50-80%

Features

can be used as a part of combined distributor/collector for re-distributing liquid

between packed beds

Model CC-221/ CC-222/ CC-223

Model CC-221

Model DD-132

Model CC-222

Model CC-223
Type

Rectangular Chimney Tray (C-221)

Diameter

All diameters

Service

Suitable for large columns total or partial liquid draw-off as seal welded

Open Area

25-40%

Type

Rectangular Chimney Tray (C-222)

Diameter

All diameters

Service

Suitable for large columns total or partial liquid draw-off as seal welded- Usable for vapor distribution I

Open Area

25-40%

Type

Rectangular Chimney Tray (C-223)

Diameter

> 1000 mm

Service

Suitable for large columns total or partial liquid draw-off specially where thermo expansion is a concern

Open Area

25-40%

l23l

II

SUPPORT GRID

Packings are installed on support grids which are designed to provide sufficient strength to support
packed beds under normal operating conditions without creating any capacity restriction in the column.
Criteria for selecting a support grid include :
Type of packing (random or structured)
Maximum design load

Model SG-31 I

IType

Structure Packing Support Grid

IDiameter

All diameters

Service

Support sheet metal or wire gauze structured packing

Model SG-321

1241

II

IType

Ra ndom Packing Support Grid

! Diameter

All diame t e rs

! service

Support Random packing media

HOLD DOWN GRID/BED LIMITER

Hold down grid for random packing is used because vapor load has potential for moving the top packing media.
When top packing layers have potential of upward displacement in the structured packing, Hold Down Grid/
Bed Limiter is recommended.
Where the upward displacement of structured packing is not a concern, the distributor over the packed bed can
also be used as bed limiter.

Model HG-41 I

! Type

Structured Packing Hold Down Grid

! Diameter

All dia meters

! Service

Retain the sheet metal or wire gauze structured packing

Features

Integrating with liquid distributor

Model HG-421

IType

Ra ndom Packing Ho ld Down Grid

! Diameter

All diamete rs

Service

Retain the Random packing media

Features

Integrating with liquid distributo r

II

In any processes where gas and liquid come into contact, the gas will entrain some tiny liquid droplets.
These mists can result in process inefficiency, product loss, and serious equipment damage.
To solve the problem, vapor-liquid separator devices are used in Oil & Gas industries either to protect
downstream equipment which is sensitive to liquid droplets (compressor, etc) or to lower product loss and
pollution emission .
Mist Eliminators provide huge surface area per little volume to separate liquid mist without creating
limitation against vapor flow.
Two main categories of separator drum internals which are provided in PENTANE are as below:
Penta-Mesh Mist Eliminator (PM series)
Penta-Vane Mist Eliminator (PV series)

Penta-Vane Mist Eliminator (PV series)

Penta-Mesh Mist Eliminator (PM series)

Design of each separator drum internals has its own complexity and specifications which requires
ex tensive knowledge of vapor-liquid physical properties, separation efficiency, eliminated droplets size,
capacity, etc. To have a comprehensive understanding of separation process, each separator has to be
considered as a new design case with unique requirement.

LAYOUT AND ARRANGEMENT

Typical arrangements of drum internals are as below:

Gas Outlet

Gas Outlet

t
I

I II

Gas
Outlet

tt
Feed
Inlet

Feed
Inlet

J!!+

'
-

Type I

Liquid Outlet

Type 2

Feed Inlet

Type 3

Gas Outlet

,._
Liquid Outlet

Liquid Outlet

Type 4

Type 5

Table of Typical Application

r Type

1r

Device

Application

Penta- Mesh

Separation columns, KO drums

Penta-Mesh

Separation columns, KO drums

Penta-Vane

KO drums, Suction scrubbers

Penta-Mesh

Knock out drums, Product separator

Penta-Vane

Slug catcher, Product separator

It is worth to mention that the application range of Mesh pad and Vane pack are different; Mesh pad is
suitable where higher removal efficiency in low/moderate gas flow is needed, while vane pack is more
suitable where moderate removal efficiency in high gas flow is required. Two stage mist eliminator (mesh
pad and vane pack) is an advanced solution to achieve higher efficiency in high capacity loads.

1281

II

SEPARATION MECHANISM
Submicron droplrts
flow uou.nd wire.
Sn>eral c.llptw'N droplets
/
Droplttssbikt wire
tt
and adhrro.
lng" drops...

c~esceforming

..:.

'

0
Droplet Elimination by Vane Pack

Mechanism of droplet removal is based on liquid droplets

inertia. Larger droplets (>51Jm) have greater inertia rather
than smaller ones (3 to 5 1Jm), so droplets don't intend to
change movement direction near the wire of mesh.
As a result, their collision with the mesh is more likely
to happen. Afterward, collided droplets coalesce and form
larger droplets which can trickle downward to the liquid
in the bottom of separator drum.

Droplet Elimination by Mesh Pad

This mechanism is also valid for vane pack mist

eliminator. Gas is forced to move between corrugated
plates.
Successively changes of direction in gas flow pass make
large droplets (with greater inertia) collide with the
plates and form larger drop lets which move downward
to the bulk of liquid in the bottom of drum.

Penta-Mesh

Penta-MeshTM mist eliminator comprises a pad of knitted

wire mesh sandwiched between two rigid grids to provide
support. Liquid mists collect on the wires as the bulk vapor
travels through the pad. The collected liquid droplets coalesce
in to a continuous film on the wires and drain from the
mesh under gravity. Typical removal efficiency for common
mesh type mist eliminators is 99% of I0 micron droplets.
Efficiency of droplet removal might be affected by some
parameters; such as quantity of wire in the unit of volume
which is related to mesh density that provides number of
restrictions against upward gas and liquid droplets flow.

Denser wire mesh causes greater removal efficiency

and of course higher pressure drop .
Higher gas velocity increases inertia of droplets which
increases possibility of collisions.
Of course very high gas velocity causes re-entrainment
and flooding in wire mesh, thus gas velocity shouldn't
be increased (drum diameter decreases) as the
critical velocity (usually a 20% margin is reasonable) .

Thickness of wire mesh has the same effect as mesh

pad density on efficiency. Liquid and gas transfer
properties also affect removal efficiency and their
influences are experimentally evaluated and exerted
in design models.
Design parameters are as follow :
Mesh density
Uniformity of gas velocity profile
Gas velocity (drum diameter)
Wire mesh thickness
Gas liquid transfer properties
Internal device layout in drum

Penta-Mesh TM Type

Material

Uniformity of gas velocity profile across mesh pad

entrance is also a very important parameter in
wire mesh performance.
PENTANE design software considers all the
design parameters to provide a quick and reliable
design to our customers.
Specifications of two more popular types of
mesh pads which are used in most processes
are stated in the below table:

Wire Diameter

Mesh Density

[mm]

[kg!m3]

[m2/m3]

Efficiency

Surface Area

Void Fraction I

PM-145

Metal

Moderate

0.28

144

255

0.98

PM-195

Metal

High

0.28

192

360

0.97

Penta-MeshPressure Drop Curve

2250
2000

PM-145

___,_

PM-195

-'/

1750

//

1500
~

...""
"'...::!

750

"'...

500

"'"'

ll..

1250

'/

1000

..v:,-'

250

r-

..,'/"'

10

11

12

Superficial Gas Rate [ Pa AO.S ]

Penta-Mesh TM Capacity

For most application, K=O. I07 mls, may however

The liquids collected by the Penta-MeshT M Pad will

be used for estimation purposes.

re-entrain if the gas load on the Pad face exceeds :

To account for the effect of induced maldistribution

Cs (max) =K x ((d 1 -d)

I d)
g
g

Penta-Meshshould be sized with:

05

Where: dg =Gas density (kg I m 3)

Cs (actual) =0.8 x Cs (max)

05

d =Liquid density (kg 1m

Where: Cs (actual) =Vx ((d1 -d)

I d)
g
g

K =Mesh capacity factor (mls)

Vs= Q I Af (mls)

K dependents on mesh style, liquid surface Cs tension

Q =Gas rate (mls)

and viscosity and also liquid loading.

AF=Net face area of Penta-MeshTM pad m2)

3
)

TANE
MIST RY
INDUSTRI ES Co.

301

~------------------------------------------------------------------------------------------

PENTANE Mist Eliminator home based software not only calculates hydraulic and efficiency but also designs
mechanical aspects and generates detail drawings automatically which reduce the human errors and increase
the speed of design considerably.
The characteristics of Penta MeshT M are as follow:
Straightforward installation in vessels
Flexibility in size especially when equipment sizes are set before
Superior performance with low pressure drop

PENTA-VANE

Vane pack mist eliminator consists of a series of specially

profile baffle that removes liquid droplets from vapor stream
by the inertial impaction of the droplets on the baffle
while the gas negotiates the zigzag flow path between
the baffles.
Design Parameters of Penta Vane are as follow:
Plate pitch
Gas velocity (drum diameter)
Vane angle
Uniformity of gas velocity profile
Specifications of two types of horizontal flow Penta-Vane
are as below:

.------Vane Pitch
Penta -Vane Type

----.II

[mm]
PY-020

PY-025

20

Maximum Capacity

-,I

Factor [m/s]

25

0.27
0.27

Removal
Range [ ... m]

IS

20

Proper sizing of a vane pack mist eliminator includes the best vane face area layout which results in maximum
safe gas velocity through narrow passages that is followed by the best efficiency of droplet removal.
Typical removal efficiency for common vane mist eliminators is 99% of 30 micron droplets.

FEED INLET DEVICE

Feed inlet devices including half open pipe/ baffle and vane
distributor would be added to the separator drum inlet
nozzle, depending on configurations and process specifications
to gain one or more of following advantages:
Minimum liquid droplet entrance to the mist eliminator
Lower vapor velocity
Lower re-entrainment
Smaller nozzle size
Based on the magnitude of gas momentum, 3 options are
available:
In high pv2, vane inlet device is mandatory
In moderate pv2 , inlet baffle or half open pipe is used
In low pv2, no inlet device is r ecommended

II

COMPUTATIONAL FLUID DYNAMICS (CFD) ANALYSIS

One of the key parameters previously mentioned for both mesh pad and vane pack efficiency is uniformity
of gas velocity profile in both inlet/outlet nozzles and through the vessel. CFD analysis enables us to judge
about flow distribution quality to prevent unexpected high liquid carry over.
Effects of vane inlet devices on uniformity of fluid velocity, are shown in graphical models:

a=::

~=

i;
--1

15
1::::::

t:Jt

lii
iS

~-

i~

!
u::: L

~~

i$!

n~::::

ne

~~

l5
L

a) Without Inlet Vane

b) With Inlet Vane

Contours of Velocity Magnitude

!~~1
,,,..0'

ue
l~

-~
-~
tt=
.,.,..01
Ul..-0'1

-~
:~:::5
.....

~~
:=:

-~
!!:::~
1,~01

~~
-~

~=5
......00

. ,,...Of

l.

,.....,
,.....,
,.,...,

-.......
,i::::::......--

~=

I
1321 '

TANE
MISTRY
INDUSTRI ES Co.

J_,

~~~

l SI....

~=

::::::~

:t=:
f ....
::::!'
..,..,,:
.......

111. . .1

u ....,
,,...,

!.I

jfi
-

l5

ie
..oo
,.....,

j=

L;:

~el
:1::1

Contours ofY Axis Velocity

.
.
.

--.
I

I
i
L_
_
,

~\
--------------~----I

'

-----------~----------~---

INTRODUCTION

PENTANE design and manufacture a wide range of reactor internals for media retention. Amongst these
innovative products, there is a line of internals used in down-flow or up-flow reactors to retain the often-costly
media and to provide a collection area for the process flow across the entire vessel diameter or length.
This section provides the information of the key design and specification of PENTANE reactor Internals
including:
Liquid-Vapor Distributor
Quench Mixer
Screen Support Grid
Inlet Diffusers & Outlet Collector/Basket
Transfer/Quench Pipes
Because of their strength, durability and flow characteristics, support grid and distributor of tray systems are
widely used in hydrotreaters, desulfurisers, hydrocrackers, molecular sieves, sand filters, gas sweeteners
and other absorption systems.

\ ! I
\ I/

/~

. I \

I i \
'

\ II

/'\
I . I. .\

/ ! .

I
1341 '

TANE
MISTRY
INDUSTRI ES Co.

LIQUID-VAPOR DISTRIBUTOR

To acquire maximum efficiency of column beds, liquid should

be distributed uniformly. Suitable distributor should meet
the following criteria :
Uniform Distribution
Low Pressure Drop
Low Residence Time
Fouling Resistance
Cross Mixing Capability
Minimal use of height

Effective distribution is a key parameter to optimal

performance of chemical beds. Possibility of poor
performance decreases by optimum liquid vapor contact.
Suitable gas passage area must be provided by liquid
distributor to prevent high pressure drop or liquid
entrainment. It should be mentioned that deep catalytic
bed is sensitive to liquid distribution quality.

QUENCH MIXER

In order to make good contact between phases in hydroprocessing reactors, quench mixer is required.
This device ensures applicable contact between quench vapor and liquid in catalytic beds.
The result of using this device is efficient transfer phenomena with uniform composition profiles in the bed
below.

SCREEN SUPPORT GRID

Support grids are designed to provide sufficient strength to support catalytic beds under normal operating
conditions while at the same time without creating any capacity restriction in the column.
A suitable support grid selection depends on the type of catalyst as well as maximum design load.
Our Screen Support Grids are designed as very tiny catalysts can retain on the Screen and do not drop from the
slots. This equipment has better open area as can translate fluid directly into superior process efficiency.

INLET DIFFUSERS & OUTLET COLLECTOR/BASKET

In order to valid distribution of the incoming vapor

and liquid, inlet diffuser is used in chemical reactors.
PENTANE Inlet and Outlet baskets are designed
to meet open area, design temperature, catalyst load
and differential pressure specifications.
Moreover, optimum fluid flow distribution in the bottom
of the catalyst beds is attainable by outlet collector.
In order to achieve optimum catalyst utilization and
prevent escape of the catalyst this device is an option
also has exceptional resistance to collapsing or buckling
even under extreme loads and high temperatures.

TRANSFER/ QUENCH PIPES

This device cools gas flow in order to produce

optimum conversion .

...

'

TAN E
MIST RY
INDUSTRI ES Co.

1361

II

PENTANE ADVANTAGE

In addition to our high-quality products, PENTANE offer a range of services and technical expertise
to his customer

Engineering Services

Effective design and responsive services are the main duties of PENTANE. It is not the case whether small
diameter or large, new construction, revamp or replacement, we will provide reliable solutions to our customer's
requirements at an economical condition.

CFD Simulation

Based on the customer request, we provide CFD consultation for some industrial processes in order
to design equipment based on CFD simulation instead of built and test approach.
Moreover, we use CFD modeling for de-bottlenecking and process optimization purposes.

II

 Spare Part Support

PENTANE has developed procedures and resources
to provide replacement column internals such as tray,
tray parts and packings on a like for like basis in either
planned or emergency shutdown. This service is available
to users of Distillation Internals supplied by almost any
manufacturer.

Installation Supervision
Specialist Site Supervision is the commonly requested
support service. Generally the installation or modification
of vessel internals is carried out as part of an overall
shutdown program and it is normally convenient to
appoint a single contractor to carry out all site work.
In the such situations, the Installation Supervisor provided
by us would typically function as follows:
To verify that installation procedure is compatible with
the design and proper functioning of vessel internals
Planning to ensure that adequate preparation is made
for smooth installation compatible with the shutdown
schedule
Generally support the installation contractor with
techniques and procedures to suit site conditions
Assistance in overcoming any installation problems
Final inspection of installed equipment

EPC Process Packages

PENTANE developed some specific process package systems which are separation based and environmental protect
oriented such as:
Vapor Recovery Unit
Flare Gas Recovery
H2S Removal from crude Oil
Sulfur Removal from gas stream in low capacity
More information is available on EPC Package brochure.

Headquarter Office: Slh floor,No.192, Darya and

Paknejad blv.cross section, Shahrak Gharb, Tehran, Iran
Tel : +98 21 88370637-8 , Fax :+98 21 88373414
Manufacturing Headquarter: Safadasht Industrial
Zone,Tehran, Iran, Tel: +98 21 65439160-3