Ceramic Packing

and Internals
for Acidic
Applications
Saint-Gobain NorPro is a global
leader in the production of
ceramic products for mass
transfer and heat transfer
applications. Our technical
accomplishments in developing
materials and products for
improved performance have
mirrored the industrys most
important advances for more
than 40 years. Saint-Gobain
NorPro continues to lead the
industry in delivering standard
and custom materials and
shapes for acidic applications.
WavePak ceramic packing is an example of Saint-Gobain NorPros ability
to engineer new products for specific acidic processing applications.
WavePak packing was developed and patented by Saint-Gobain NorPro
and is marketed exclusively by Monsanto Enviro-Chem Systems.
Saint-Gobain NorPros advanced ceramic technology is the result of
decades of experience developing products and materials, combined with
our access to the vast resources of our parent company, Compagnie de
Saint-Gobain. This level of expertise makes us uniquely qualified to pro-
vide quality standard products as well as custom products for particularly
difficult or unusual applications. Ask us about product development part-
nerships and custom-engineered solutions. No matter what your applica-
tion or where you are located, you will find us an exceptional resource.
Advanced Ceramic Technology
Proware Chemical Ceramic
Saint-Gobain NorPros Proware
chemical ceramic material is
mechanically stronger, less porous
and considerably more chemical
resistant than the typical chemical
stoneware on the market. A silica-
alumina body derived from refined
clays and other minerals, this tight-
ly controlled material is much
smoother, more finely-grained
and vitreous than typical
stoneware and is virtually iron-free.
Proware chemical ceramic resists
all alkalis, solvents and acids, with
the exception of hydrofluoric acid.
It maintains its integrity in solu-
tions of 10% sodium hydroxide up
to (50c) and 1% sodium hydroxide
up to (93c). Proware chemical
ceramic is the standard material
for all of NorPro packing products
for acidic applications.
Aludur 11 Ceramic
Saint-Gobain NorPro developed its
Aludur 11 ceramic material to pro-
vide the added strength necessary
for large shapes, such as grid bars
and support plates. This material is
approximately three times
stronger than Proware chemical
ceramic, and it provides equal or
better corrosion resistance. Like our
Proware material, Aludur 11
ceramic resists all alkalis, solvents
and acids, except hydrofluoric acid.
It maintains its integrity in solu-
tions of 10% sodium hydroxide up
to (50c) and 1% sodium hydroxide
up to (93c). Aludur 11 ceramic is
highly resistant to thermal shock,
which is an important characteris-
tic of large, monouthic ceramic
parts, such as support plates.
Other Available Materials
Carbon
For processes where ceramic pack-
ing is not viable, Saint-Gobain
NorPro offers carbon Raschig rings.
C
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PHYSICAL DATA
Typical Materials Comparison
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7

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N
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8
7

8
3
Proware
Chemical
Ceramic
<4.0%
<0.4%
<0.01%
Aludur

11
Ceramic
<3.0%
<0.4%
<0.005%
Two Basic Formulations
In addition to custom-formulating
material compositions to meet
specific process requirements,
Saint-Gobain NorPro offers two
standard materials for optimum
durability and chemical resistance
in most corrosive applications.
The beam construction of the
Model 4808 and Model 4908
gas-injection support plates
delivers the ultimate ceramic
plate performance. The continu-
ous beam-type risers increase
gas and liquid handling capaci-
ty while providing more than
four times greater load-bearing
capacity than ceramic plates
with cylindrical gas risers. In
addition, the uniform wall thick-
ness and sectional design pro-
vide exceptional thermal shock
resistance. Standard support
plates can be used with liquid
rates up to 50 gpm/ft
2
.
Saint-Gobain NorPro supplies
the Model 4808 support plate
for towers up to 48 inches
(1219mm) in diameter. For
greater tower diameters, Saint-
Gobain NorPro offers the Model
4908 support plate with beams
up to 72 inches (1829mm). The
modular design of the Model
4908 is ideal for towers with
cross sections greater than
72 in. (1829 mm), which require
the use of mid-span supports.
Model 4808 Aludur 11 Multi-beam Support Plate
For towers 6 in. 48 in. ID (152mm - 1219mm)
Model 4908 Aludur 11 Multi-beam Support Plate
For towers 48 in. ID and greater (1219mm and greater)
Support Plates
NorPro Aludur 11 grid bars are
ideal for use as primary supports
in sulfuric acid absorbers, driers,
coolers and other highly corrosive
applications in large-diameter
towers. The Aludur 11 ceramic
offers excellent chemical resistance
at temperatures well beyond the
limits of high-quality Proware
chemical ceramic. However, Aludur
11 grid bars should not be used
in systems where they will be
exposed to superheated steam
for an extended period of time.
Saint-Gobain NorPro generally
designs its grid bar supports for
installation on 6 in. (150mm)
centers for use with 6 in. rings or
on 8 in. (200mm) centers for use
with 8 in. grid block. Saint-Gobain
NorPro also custom-designs
systems to meet specific center-
to-center spacing requirements.
Individual grid bars are provided up
to 84 in. (2134mm) in length.
Towers with diameters greater
than 84 in. (2134mm) are accom-
modated through the use of
midspan supports.
Grid bars work equally well with
stacked or dumped packing. When
used with dumped packing, Saint-
Gobain NorPro recommends a
secondary layer of grid blocks or
cross partition rings on top of
the primary grid bar supports.
NorPro Aludur 11 grid bar supports have three to four times greater
mechanical strength than the best chemical porcelain, stoneware, or
refractory material. The exceptional strength of Aludur 11 ceramic
makes possible designs with greater center-to-center spacing.
Open Area Comparison
Higher open area means lower pressure drop or greater hydraulic capacity.
The square stacking pattern provides 62% open area. Secondary support ele-
ments that are not stacked in a square pattern have less than 62% open area.
Model 4817 Grid Bar Supports
for Stacked and Dumped
Packings
Model 4817 grid bars Model 4817 grid bars
on 8-in.(200mm) on 6-in.(150mm) Competitor Dome
spacing spacing
% open area of support 83% 77% 58-62%
Type of stacked 8 in. Saint-Gobain
6 in. cross partition rings 6 in. cross partition rings
elements on support NorPro grid block
% open at support/stack
59% 48% <37%
(1)
element interface
% open area at element
that supports random 72% 62% <62%
(1)
packing
Minimum size packing
2 in.(50mm) saddles 3 in.(75mm) saddles 3 in.(75mm) saddles
retained
Potential capacity
60% 30%
increase vs. dome
8 in. high bars at 6 in. centers 26.6 lbs/ft
2
130 kg/m
2
8 in. high bars at 8 in. centers 20.0 lbs/ft
2
98 kg/m
2
10 in. high bars at 6 in. centers 33.2 lbs/ft
2
162 kg/m
2
10 in. high bars at 8 in. centers 25.0 lbs/ft
2
122 kg/m
2
Grid Blocks
A secondary support system using
NorPro grid blocks provides greater
free space than a system using
cross partition rings: Grid bars
placed on 8 in. (200 mm) centers
with NorPro grid blocks on top
have 15 percent more free space
than the conventional system of
bars on 6 in. (150 mm) centers with
cross partition rings. Such a system
also requires 33 percent fewer grid
bars and 25 percent less secondary
support media. Thus, grid blocks
save material and shipping costs as
well as installation time.
Saint-Gobain NorPro manufactures
its grid blocks in high-grade
Proware chemical ceramic materi-
al. Each block weighs 6.1 pounds
(2.77kg) and is 3-1/2 in.(89mm)
high. When installed atop a grid
bar support system with 8 in. cen-
ters, the blocks occupy an area of
approximately 8 in. by 5-3/4
in.(203mm by 146mm). To deter-
mine the quantity of grid blocks
required, multiply the tower cross-
sectional area by 3.13. Generally,
Saint-Gobain NorPro specifies
a 5 8% overage for cutting at the
tower wall.
Cross Partition Rings
Saint-Gobain NorPro cross parti-
tion rings are available in Proware
material. When using 6 in.(150mm)
rings as a secondary support, a sec-
ond layer of 4-in.(100mm) rings is
necessary to retain 2-in.(50mm)
saddles.
Secondary Supports Systems
Brick Lining Steel Shell
8 in. (200 mm) Grid Block
Bar Length V in. TYP
Grid Bar
Support Plate
Midspan
Support
If Required
Brick
Support
Ledge
Installation and Design
Information
During installation, blocks should
be placed between adjacent grid
bars where they rest on the sup-
port ledge and midspan supports.
The blocks provide stability for the
bars and will prevent the bars from
tipping over when installing
secondary support systems.
A minimum 1/2 in. (13mm) clear-
ance between abutting bars and
between the bars and tower wall is
imperative to allow for unrestricted
thermal expansion. The tables
(right) list the load limits for grid
bars on 8-in. (200mm) centers.
Model 4817 Grid Bar Supports
Allowable Load with 8 in. Centers
Model 4817 Grid Bar Supports
Allowable Load with 200mm Centers
lb/ft
2
at < 300 F lb/ft
2
at > 300 F
Bar Height Bar Height Bar Height Bar Height
Bar Length (in.) 8 in. 10 in. 8 in. 10 in.
30 1500 1500 1000 1000
36 1500 1500 1000 1000
42 1500 1500 1000 1000
48 1310 1500 875 1000
54 1035 1500 690 1000
60 838 1297 560 865
66 693 1072 460 715
72 582 900 390 600
78 496 767 330 510
84 428 662 285 440
Kg/m
2
at < 150 C Kg/m
2
at > 150 C
Bar Height Bar Height Bar Height Bar Height
Bar Length (mm) 200mm 254mm 200mm 254mm
762 7324 7324 4882 4882
914 7324 7324 4882 4882
1067 7324 7324 4882 4882
1219 6396 7324 4272 4882
1372 5053 7324 3369 4882
1524 4091 6338 2734 4223
1676 3384 5234 2246 3491
1829 2842 43940 1904 2929
1981 2422 3745 1611 2490
2134 2090 3232 1391 2148
Saint-Gobain NorPro provides
a complete range of random
packings, available in highly
acid-resistant Proware chemical
ceramic.
Norton Saddles
Norton saddles are the mass trans-
fer industrys packing of choice for
reliable, corrosion-resistant per-
formance. Available in sizes from W
in. (6mm) to 3 in. (75mm), NorPros
Norton saddles provide approxi-
mately 56% greater capacity than
Raschig rings.
Norton Super Saddles
For optimal performance, the
Norton Super saddle provides
better liquid/gas contact and lower
pressure drop than comparably
sized standard saddle. The
product features a unique scal-
loped edge that permits maximum
usable area for liquid/gas contact
and minimal resistance to flow
through the column. The NorPro
No. 2 Super saddle provides from
5% to 30% greater mass transfer
efficiency than the corresponding
size of standard saddles, along
with approximately 25% lower
pressure drop.
Carbon Raschig Rings
Saint-Gobain NorPro offers carbon
Raschig rings for processes where
ceramic packing is not viable.
Packings for
Acidic Applications
Snowflake heat transfer media
For reliable low pressure drop
performance, Snowflake media
are available in a range of sizes
and materials for use in RTOs and
other high-temperature heat trans-
fer applications.
Denstone catalyst
bed support media
The NorPro Denstone line offers
the industrys broadest selection of
standard and specially-formulated
catalyst bed support media for
refining and petrochemical appli-
cations. Request brochure DEN-3.
MacroTrap guard bed media
This innovative product effectively
filters particulates from refinery
feed stock, protecting the catalyst
bed from fouling and subsequent
pressure drop build-up. Request
brochure GB-1.
Catalyst carriers
Saint-Gobain NorPro custom-
tailors the size, shape, porosity and
surface area of catalyst carriers to
meet your specific process require-
ments. Request brochure CAT-3.
Installation Services
Saint-Gobain NorPro has partnered
with VIP International, a leading
North American company in the
removal and installation of ceramic
media in regenerative thermal oxi-
dizers. With knowledge, expertise
and equipment second to none in
the industry, VIP Internationals
highly-specialized crews execute
repairs in a fraction of the time of
general maintenance groups,
resulting in reduced downtime,
faster return to production, and
thus improved profitability.
Additional Ceramic Products
Pre-Qualification
Saint-Gobain NorPro qualifies raw
materials well in advance of manu-
facturing. Extensive testing of core
samples from the mine site identi-
fies specific areas of prime reserves
to ensure a consistent supply far
into the future. Standard raw
material tests are conducted by the
supplier and in our laboratories as
well to confirm data accuracy.
Lot Qualification
Our pre-qualification procedures
ensure that only prime mining
sites are tapped; but we dont
stop there. Each shipment of raw
material must pass additional tests
prior to acceptance at our manu-
facturing facilities.
Blend Qualification
Saint-Gobain NorPro assures a con-
sistently high-quality product, even
when our testing reveals subtle
changes in raw material composi-
tion. Saint-Gobain NorPros experi-
ence in linking material character-
istics to the final product enables
us to fine-tune the blend at the
front end to ensure a consistently
high-quality ceramic product.
Size and material uniformity characterize the NorPro saddles (left),
which are compared to competitors product.
Process Control: Saint-Gobain NorPros
Assurance of Quality
Saint-Gobain NorPros adherence to strict process and material
control is evident in the uniform size and shape of NorPro saddles
and NorPro Super saddles. Our product consistency ensures that
NorPro packings maintain the free space necessary for reliable,
low-pressure drop performance and strength for long service life.
Process Checks
Saint-Gobain NorPros ISO certifica-
tion assures that documented pro-
cedures are followed at every stage
of the manufacturing cycle to
guarantee consistent quality.
Mixing
Forming
Drying
Firing
Screening
Packaging
Shipping
Finished Product Tests
Saint-Gobain NorPro inspects
the following characteristics of
all finished products to further
guarantee optimal quality:
Strength
Size
Shape
Chemical composition
Porosity
Chemical resistance
A copy of Saint-Gobain NorPros
documented test methods can be
provided upon request.
Saint-Gobain NorPro worldwide
headquarters, sales offices and
manufacturing facilities are
certified for ISO 9001:1994 and
DIN EN ISO 9002,8.94.
Certifications are available upon
request with any shipment.
Saint-Gobain NorPro Corporation
P. O. Box 350
Akron, OH 44309-0350
Tel: (330) 673-5860
Fax: (330) 677-7245
www.norpro.saint-gobain.com
The information herein does not constitute a guarantee or warranty.
The Saint-Gobain NorPro Corporation warranty is set forth in its stan-
dard terms and conditions, which govern sales of Saint-Gobain NorPro
products. The standard terms are set forth on Saint-Gobain NorPro quo-
tations and acknowledgements and are also available on request.
2002 Saint-Gobain NorPro Corporation 01/02 CPIAA-1
Saint-Gobain NorPro GmbH
Am Bahnhof
D-56414 Steinefrenz
Germany
Tel: +49 6435 9657 0
Fax: +49 6435 9657 19