Sulzer Chemtech

High Performance Trays

Enhanced Deck and Downcomer Technology
 Sulzer "Plus" Technology 6

Sulzer VG AFTM 9

Shell HiFiTM Trays 10

Shell ConSepTM Trays 12

Mechanical Features and Services 14

Sulzer Chemtech- Mass Transfer Technology
Your Partner in Separation and Mixing Technology High Performance Trays
We understand the ever increasing requirement for MVGTM decks and enhanced downcomer technology
both reliability and performance of your process as well as the newest trays, UFMPlusTM with UFM TM
A Broad Range of Innovative and High-performing Products equipment. To meet these challenges, you can valves. The UFM valve is an industrially proven,
rely on our innovative, industry-leading products advanced movable mini-valve providing the highest
Our more than 200 products cover a wide range of needs in the field of separation and mixing technology. They
and expertise. Our extensive tray portfolio ranges efficiency and capacity. For fouling applications that
have proven their performance in more than 100,000 columns, 40,000 gas/liquid separators and 100,000 mixers
from single pass to multi-downcomer as well as require high performance, our VG AF TM Anti-Fouling
in operation worldwide.
conventional to high-performance, including the trays provide a proven and robust solution. This
latest technology in ultra-system limit trays. All portfolio has been greatly enriched since 2000 by
designs are tailored to meet the exact requirements our technology alliance with Shell Global Solutions,
of your specific application. and also includes Shell high performance trays such
as the Shell HiFi TM trays, ideal for high liquid load
For your most demanding applications, our High applications, and Shell ConSepTM trays with proven
Performance Trays include VGPlusTM trays with ultra-system capabilities.

0602 2510 0605 2504 0603 2535-3 0694 2720

The Highest Level of Fast and Reliable Comprehensive Engineering Tray Portfolio
Application Know-how Turnaround Services and Technology Services
Sulzer Technology Sulzer-Shell Alliance
Our team provides state-of-the art You can rely on Sulzer professionals, We provide a full scope of associated
expert know-how for more than expertise and procedures to get you engineering and technology services Conventional Trays Chordal Downcomer High Multi Downcomer High
500 applications in 100 processes, back and running in the shortest to optimize or trouble-shoot your Performance Trays Performance Trays
this enables us to optimize the possible time. installation.
performance and your installation. Floating Valves Other Trays Enhanced Deck Enhanced Deck Shell HiFiTM
and Downcomer
Shell HiFiTM Plus

BDHTM / BDPTM Bubble Cap MVGTM VGPlusTM Shell Calming SectionTM (CS)
Naphtha

Round Valves Sieve MMVGTM UFMPlusTM Shell CSTM Plus

Fixed Valves Dual Flow UFMTM e-VGPlusTM Dual Flow High Performance Trays

Kero SVGTM / LVGTM Baffle e-UFMPlusTM Shell CS GridTM

SVG-HTM Shower Deck VG AFTM Ultra-System Limit High Performance Trays

XVGTM Disc and Donut Shell ConSepTM

Cartridge

Slit TraysTM
Diesel

High Performance Trays featured in this brochure

2 3
 Leading Tray Technology

In the 1820s, an early version of bubblecaps trays were In the 1950s, valve trays were developed, providing higher In 2000, Sulzer formed a technology alliance with Shell In 2012, Sulzer launched a new valve product UFM
introduced for continous distillation towers. capacity and better efficiency over a wider operating range. Global Solutions providing a full range tray product (Umbrella Floating Mini), a movable valve which
portfolio from one source. These include Shell Calming provides higher capacity and a wider operating range
The modern valve tray, a rectangular float valve tray, was SectionTM (Plus) Trays, Shell HiFi (Plus) Trays and ultra- than conventional valves.
first installed by I.E. Nutter in 1951. By 1956, different high capacity Shell ConSep Trays.
variations of round valves had surfaced. In 2014, Sulzer launched UFMPlus, a high performance
tray with a UFM deck and enhanced downcomers.

0605 2521 0605 2522 0605 2518 0605 2520

Bubblecaps in Sulzer's Tray Portfolio Round Valve Caged Valve Shell HiFiTM Tray Shell ConSepTM Tray

1800 1900 2000 2010

BDHTM Rectangular Float Valve

0610 2503-1

VGrid Fixed Valves

From Left to Right:
SVGTM, MVGTM and 0605 2505
MMVGTM Fixed Valves
Modern 1-pass Sieve Tray 0605 2529
In 2000, Sulzer introduced Sulzer has also introduced Sulzers 6-pass VGPlus High Performance Trays
high performance VGPlus high performance VG AF Anti were successfully installed in several C3 Splitters
trays which provide higher Fouling Trays featuring large and are performing beyond expectations.
In the 1830s, sieve trays were developed, In 1998, Sulzer acquired Nutter Engineering, incorporating the well- capacity with the combination fixed and push valves, and
offering higher capacity despite design acclaimed BDHTM rectangular float valve and V-Grid fixed valves of enhanced downcomers fouling resistant outlet weirs. 6-pass trays are a natural progression after
simplicity. into Sulzer's tray product portfolio. and optimized tray layout. 4-pass trays for large diameter columns (typically
> 6 m) with high liquid loads.

4 5
 Sulzer "Plus" Technology

VGPlus and UFMPlus Trays, are Sulzers high performance Plus technology chordal downcomer trays. They VGPlusTM Trays UFMPlusTM Trays
offer industry proven and validated advanced tray technology for todays market.
VGPlus Trays are enhanced downcomer trays with high UFMPlus Trays are enhanced downcomer trays with
capacity MVG or MMVG fixed valves. high capacity UFM float valves.
Enhanced Downcomers Enhanced Decks
A main feature of Sulzer "Plus" technology trays is the Sulzer "Plus" technology trays can be equipped with MVG valves provide higher capacity compared to UFM valves are an advanced type of movable mini-valve
use of high performance downcomers such as highly high capacity fixed valves or float valves. VGPlus trays standard sieve or conventional valves, while providing which maximize the hydraulic capacity, the separation
sloped, Truncated, StepArc (stepped) and ModArc are equipped with high capacity fixed valves such as higher efficiency and lower pressure drop per theoretical efficiency, and the operating range of fractionation trays.
(multi-chordal) downcomers. These downcomer designs MVG or MMVGTM while UFMPlus trays use high capacity stage. The MVG tray deck offers better turndown
capability than a sieve tray, i.e. up to 3:1. The "Umbrella" shape of UFM valves reduces the jetting
maximize the tray deck area by optimizing the downcomer UFM float valves.
momentum of the released vapor which maximizes the
bottom area, thereby increasing vapor handling capacity
Redirecting and froth promoting devices such as MMVG valves are used where extremely high vapor contact area of vapor and liquid on the tray deck and
and reducing pressure drop and backup.
push valves and baffle bars, enhance the vapor/ liquid capacity or a very low pressure drop is required. The promotes uniform mixing and minimizes entrainment.
interaction on the tray deck. smaller size opening compared to MVG results in up to
7% additional capacity. The UFM tray deck offers better turndown capability
than a fixed valve tray, i.e. up to 5:1.
Liquid Flow Study with Conventional Trays

FRI Validation Key Areas of Application

Sulzer VGPlus Trays have been tested at FRI, in Refinery: Main Fractionators and Gas Plants
the iso-butane/n-butane system at 7 and 11 bar.
"Plus" technology with baffle bars
Olefins: Deethanizers,Depropanizers,
4-pass VGPlusTM tray equipped with ModArc The VGPlus tray is one of the best performing
downcomers, MVGTM and push valves Debutanizers, Deisobutanizers,
trays ever tested, delivering up to 10% higher
SuperFractionators: C2 and C3 Splitters
capacity than some other tested competitor's
high performance trays. Aromatics: Xylene Splitters, Xylene Rerun,
Raffinate Columns

e-VGPlus and e-UFMPlus

Sulzer also offers e-VGPlus and e-UFMPlus, our new e-series enhanced high performance trays. These trays
are equipped with capacity enhancement features, which further optimize the utilization of the tray decks,
for maximum potential capacity of chordal downcomer trays. Depending on process conditions and tray
designs, these enhancement features can offer up to 12% higher capacity than our Sulzer Plus Technology
trays - VGPlus and UFMPlus. Kindly contact Sulzer Chemtech for a technical evaluation.

0614 2503-05 0614 2503-03 0614 2503-02

Truncated downcomer StepArcTM downcomer ModArcTM downcomer

6 7
 Sulzer "Plus" Technology VG AFTM AntiFouling Trays
Case Study - Revamp of Deisobutanizer with VGPlusTM Trays
VG AFTM Trays
A refinery deisobutanizer column, upstream of an HF
Alkylation Unit, was identified to be the bottleneck of Feed-3
PC Fuel Gas VG AF (AntiFouling) trays are part of the VGPlus tray
the capacity expansion. 1 LC family and especially designed for fouling services.
Feed-2 FC

This deisobutanizer column of ID 2.96m was originally Feed-1 10

TC
FC Iso-C4 Features of VG AF which increase tray fouling
equipped with 56 2-pass conventional round valve LC resistance and run length:
trays. A process study highlighted that the throughput
could be almost doubled by retrofitting the tower with
FC
28
New VGPlus
Large V-Grid: SVGTM or XVGTM
high performance trays.
29
HPTrays Modified outlet weirs: stepped or sloped weirs
Push valves
Revamp Objective: From

The VG AF provides superior anti-fouling performance

Iso-Stripper

Maximize the production of iC4 0605 2506

while delivering high capacity and efficiency, making
56

Minimize nC4 in top product: <3 wt%

Maximize iC4 recovery: >94 wt% Reboiling FC
LC FC
n-C4 this tray ideal for debottlenecking fouling services. 2-pass VG AFTM trays equipped with V-Grid, stepped outlet
Fluid
weir and push valves
Revamp Solution:
Sulzer VGPlus High Performance Trays with Key Areas of Application
Before Design Test Run
MVG Fixed Valves Revamp
ModArc Side Downcomers
Froth Enhancers: Push Valves Feed flow rate 100% 191% 143% Primary Fractionators in Ethylene Plant

Test run was performed at 143% of the pre-revamp

Top iC4 flow rate 100% 193% 157% Stripping Section of CDU and VDU
capacity due to shortage of feedstock. To further load Reflux ratio NA 12.7 17.5 Coker Main Fractionators
the tower, the reflux ratio was increased till maximum Tray efficiency NA 86% > 93% Heads and Dry Columns of Acrylonitrile Plant
reboiler duty: the production of iC4 increased by
nC4 impurity > 3 wt% 3 wt% < 0.9 wt%
57%, with a nC4 impurity as low as 0.9 wt% and iC4 PVC Slurry Strippers
recovery over 98 wt% leading to a tray efficiency over iC4 recovery < 94 wt% 94 wt% > 98 wt% 0608 2501
Beer Columns
93% even at flooding close to 90%. 2-pass VG AFTM with V-Grid, sloped outlet weir and push valves
Flooding NA 80% 89%

Sulzer's Experience - 6-Pass VGPlusTM Trays for new C3 Splitters Case Study - Revamp of Acrylonitrile Heads and Dry Column to VG AFTM

Three new C3 Splitters, each designed with 195 Acrylonitrile (ACN) Heads and Dry Column was
BRINE

6-pass VGPlus High Performance Trays. revamped from round valves trays to Sulzer From Dec.
HCN Tower

VG AF AntiFouling trays for higher performance and Recovery

For columns with large diameters, 6-pass trays Column

longer run length.

provide extensive weir length to handle the high
liquid loads. The multiple pass design also avoids This ACN Column was originally equipped with 62
excessively long flow path lengths to mitigate 1-pass conventional round valve trays.
undesirable liquid flow gradients on the tray decks.
CW

Revamp Objective:
Enhanced downcomers are utilized to maximize the
Increase capacity by 25% Quench
bubbling area for mass transfer. Tower
Maximize Acrylonitrile recovery: > 91 wt%
Sulzer Design: Maximize run length: > 6 months Product Tower
Sulzer VGPlus High Performance Trays with
Revamp Solution:
MVG Fixed Valves
Sulzer VG AF Antifouling Trays with Before After
ModArc Side Downcomers
SVG Fixed Valves Revamp Revamp
Froth Enhancers: Push Valves
Stepped Outlet Weirs
Feed 100% 125%
Froth Enhancers: Push Valves
ACN Production 100% 130%
As a result of the revamp with VG AF trays, the column
capacity increased by 25%. The ACN recovery ACN Recovery 91 wt% 95 wt%
improved to 95% and the run length increased to Tray Efficiency 70% 74%
more than 11 months.
Run Length [months] 4 >11
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 Shell High Performance Trays
Case Study - Revamp of C2 Splitter to Shell HiFiTM Plus Trays
Shell HiFiTM Plus Trays
A C2 Splitter (3.96m I.D.), was revamped from 153
Shell HiFi trays are fractionation trays equipped with competitor's Multi-Downcomer trays to 123 Sulzer
multiple envelope downcomers, oriented offset to the HiFi Trays for improved C2 Splitter performance
tray's center line. higher capacity and stringent product purity.

They are supported on a 360 support ring and central Revamp Objective:
major beams, without the need of the downcomer Increase capacity by 25%
bolting bars. Ethylene Purity : 99.96 wt%

For a given column diameter, they allow for: Revamp Solution:

Shell HiFi Plus Trays with
Highest number of passes MMVG Fixed Valves Full Assembly during Trial Layout at Workshop
Large downcomer area HiFi Downcomer Boxes
Long weir length Long Weir Length > 23m
High hydraulic capacity
Low tray spacing HiFiTM Plus tray with MVGTM valves During the Performance Test Run when the
Design Test Run
High NTS per column height column was artificially loaded up for the highest
throughput, steady operation was observed with
Ethylene Purity 99.96% 99.98%
The HiFi Plus trays are an enhanced version featuring a useful capacity around 95%, and a measured
advanced valves (i.e. MVG, MMVG, UFM) to further ethylene purity of 99.98%. A tray efficiency of 79% Tray Efficiency 80% 79%
boost the tray deck performance, and/or the Crown was achieved.
Inlet Device CIDTM to maximize the downcomer
capacity as well.

FRI Validation Key Areas of Application

Case Study - New Xylene Rerun Column with Shell HiFiTM Plus Trays
Shell HiFi Trays, with tray spacings of 305mm Refinery: Main Fractionators' PA and
and 610mm, have been tested at FRI, in the iso- Stripping Sections A new Xylene Rerun Column, of ID 8.3m, was Sulzer Design:
butane/n-butane system at 11, 21 and 28 bar. designed with 117 Shell HiFi Plus Trays. The design Shell HiFi Plus Trays with
Olefins: Deethanizers, Depropanizers, included 1 lattice beam for every 2 trays. MVG Fixed Valves
As compared to 1-pass round valve trays with
Debutanizers, Deisobutanizers, 10 HiFi Downcomer Boxes
truncated downcomers, Shell HiFi Trays of same
SuperFractionators: C2 and C3 Splitters Long Weir Length > 60m
tray spacing, exhibit up to 40% higher capacity.
Aromatics: Xylene Splitters, Xylene Rerun,
Although actual production was less than maximum
Raffinate Columns
loads, the reflux ratio was higher than design due to
Gas Sweetening: Absorbers, Regenerators higher amount of impurities in feed. The Shell HiFi
Plus Trays performed well, providing higher capacity
while meeting the process requirements.

Sulzer's Experience - New Shell HiFiTM Trays for Crude Distillation This column was compared with a similar column
in client's plant, equipped with competitor's multi-
downcomer trays, and proved to be better in terms
Revamp of top 3 rectifying trays of a Crude Distillation of relative energy consumption and product recovery.
Column from conventional trays to Shell HiFi trays
which offer longer weir length to handle the higher Design Actual
liquid loads. Due to large column diameter of 9.6m, Operation
two beams were required for each tray. Feed 125% 100%
Revamp Design: Process Requirements: Reflux / Feed Ratio [mass] 1.61 1.84
Shell HiFi Trays with 2 beams design C9+ impurity in Distillate: <300 ppmwt
Min. Recovery 99.0% 99.5%
21 HiFi Downcomer Boxes O-Xylene Recovery in Distillate: >99.0 wt%
Long Weir Length > 110m Tray Efficiency 73% 74%

10 11
 Shell Ultra-System Limit High Performance Trays
Case Study - Revamp of FCC Debutanizer to Shell HiFiTM Plus and ConSepTM Trays
Shell ConSepTM Trays
A debutanizer was revamped from 2-pass chordal
The Shell ConSep trays are one of the highest capacity downcomer trays to high performance Shell Trays.
fractionation trays available on the market, offering up to
Improved feed quality, increased throughput and
80% additional capacity over conventional trays without
conversion at FCC unit led to increased feed rate
any major impact on separation efficiency.
and more LPG content to the Debutanizer.
They utilize the principle of de-entrainment by centrifugal
Revamp Objective:
force to overcome the gravitational limitation of jet
Increase capacity by 15%
flooding, and the system limit of the vessel.
C5 content in Top Stream < 0.6 vol%
Every set of ConSep tray consists of a primary tray (with RVP of bottom LCN < 85 kPa
chordal or HiFi downcomer layout) and a secondary tray
Revamp Solution:
with Swirl tubes.
15 HiFi Plus Trays in Rectifying Section
15 ConSep Trays in Stripping Section
The column proven capacity after the revamp
0603 2508
increased by 21%, exceeding the objective by 6%,
Shell HiFiTM Sieve Trays with ConSepTM decks with lower C5 content in the top (0.3 vol %versus
0.6 vol%) and lower RVP in LCN (77 kPa vs 85 kPa).
Overall tray efficiency achieved was more than
FRI Validation 86%, well above the tray efficiency of the first
generation high performance trays used before
revamp which was 69%.
Shell ConSep Trays have been tested at FRI,
in the iso-butane/n-butane system at 11bar.
At least 50% higher capacity was observed
over some other high performance trays, with
a separation efficiency as high as 90% and
capacity substantially exceeding the system
limit of the column. Case Study - Debottlenecking of HGO Pumparound with Shell ConSepTM Trays

Shell ultra high capacity ConSep Trays were applied

in the capacity constrained HGO Pump-around
Experience List of Shell ConSep Trays: section of a Crude Distillation Unit in a refinery. This
Key Areas of Application
was the first application of ConSep Trays in a CDU.
Service Industry No. of Columns The post revamp test run established the realization
Refinery: Main Fractionators of the expected performance.
Debutanizer Refinery 8
Olefins: Deethanizers, Depropanizers, Revamp Objective:
Debutanizers, Superfractionators C2 and C3 Depropanizer Refinery 5
Increase capacity by 53%
Splitters Main Fractionator Refinery 2 Maintain product specifications for Naphtha,
Kero, LGO and HGO
Naphtha Splitter Refinery 1
Main Modifications:
Diesel HDT Stripper Refinery 2 3 Shell ConSep Trays in HGO PA section
H2S Stripper Refinery 1 7 Shell HiFi Trays in stripping section
1.3m Sulzer MelapakPlusTM 252.Y
C2 Splitter Olefins 1 in wash section
16 Shell CSTM trays in other sections
PO Drying Column Chemicals 1

C6 Dryer Chemicals 1

As of March 2014

12 13
 Mechanical Features Services

Non-Welded Tray Support System Trays for Heavy Duty Services Computer-Aided Engineering (CAE): Natural Frequency Analysis for Tray
In several revamp projects aimed to increase the In some applications, particularly those subjected to 3D Models Vibration Phenomena
separation stages of an existing column, the number operating upsets leading to panel dislodgment, the trays Upfront engineering and design play a crucial role in In some critical applications and under specific operating
of actual trays had to increase (e.g. 3-for-2, 4-for-3, or must withstand higher than normal mechanical loadings, cost optimization. Sulzer has integrated all major mass conditions, vibration phenomena may be induced to
5-for-4). i.e. 7000 N / m2 (1 psi) or even 14000 N / m2 (2 psi). transfer products into an in-house design tool, creating the trays. Based on plant feed-back data and in-house
To accomplish this, a mechanical design is required to In such cases, special features may be employed in the a global standard. know-how, Sulzer has developed a design tool to check
avoid impact on the schedule of the plant's turn-around, mechanical design: for the following two main parameters:
Customers profit directly from the use of our internal
and minimize cost as well. CAE tool. Layout drawings supplied in the course of Natural frequency of the tray panels, as a function
Through-bolting panel connection
Sulzer has developed a mechanical solution enabling Shear clips the engineering phase will show a 3D sketch of the of the geometry, the supports, and the material of
installation of the trays by reusing the existing tower Downcomer spreaders equipment being designed, for an easy and fast checking construction.
attachments, without any direct welding to the tower Explosion doors by the customer.
Vibration factor, as a function of the flow rates and
wall, thus avoiding any post-welding heat treatment physical properties of the streams being processed.
and/or hydraulic testing of the vessel. This technique
consistently reduce the turnaround time by using this
technique.

The following devices show in the illustration below are

used:

Expansion rings
Expansion joints
Vertical struts
Downcomer adaptors
Solid or lattice beams

The system can be also used for other purposes: modify 2 psi uplift BDHTM tray equipped with through-bolting
assembly, shear clips and explosion doors Natural frequency analysis of a full tray
the geometry of existing downcomers, modify the
number of passes; change the tray orientation; replace
packing beds with trays.

Expansion ring Vertical strut

Lip-SlotTM Panel Connection Finite Elements Method (FEM) and Turn Around and Tower Field Services
The Lip-Slot is an enhanced type of tray panel connection Computational Fluid Dynamics (CFD) Sulzers global manufacturing capabilities ensure fast
which allows for: Sulzer also employs other advanced design tools, delivery of any tray hardware and replacement tray
for example verification of mechanical integrity and parts, regardless of original supplier. These can be
safe and easy installation manufactured from existing drawings or damaged parts
up to 30% less installation time functionality using finite element and CFD analysis.
and supplied on site quickly to meet your turnaround
less maintenance costs as it does not use any schedules. Replacement hardware can be supplied on
bolted connection consignment in lockers or trailers for convenience.
same mechanical reliability as conventional connections

The Lip-Slot is combined with universal clamps for the

fixation around the tray periphery.

Existing Lattice Expansion

support ring beam joint
14 0605 2524 15
 www.sulzer.com
Please check for your local contact

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with The activity program comprises:
headquarters in Winterthur, Switzerland, is active in the field of process Process components such as fractionation trays, structured and
engineering and employs some 4500 persons worldwide. random packings, liquid and gas distributors, gas-liquid separators,
and internals for separation columns
Sulzer Chemtech is represented in all important industrial countries and
Engineering services for separation and reaction technology such as
sets standards in the field of mass transfer and static mixing with its
conceptual process design, feasibilities studies, plant optimizations
advanced and economical solutions.
including process validation in the test center
Recovery of virtually any solvents used by the pharmaceutical and
chemical industry, or difficult separations requiring the combination
of special technologies, such as thin film/short-path evaporation,
distillation under high vacuum, liquid-liquid extraction, membrane
technology or crystallization.
Complete separation process plants, in particular modular plants
(skids)
Advanced polymerization technology for the production of PLA and
EPS
Tower field services performing tray and packing installation, tower
maintenance, welding, and plant turnaround projects
Mixing and reaction technology with static mixers
Cartridge-based metering, mixing and dispensing systems, and
disposable mixers for reactive multi-component material

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Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to
be construed as implying any warranty or guarantee of performance. Sulzer Chemtech waives any liability and
22.88.06.40 - X.14 - 10 indemnity for effects resulting from its application.