Sulzer Chemtech

High Performance Trays

Enhanced Deck and Downcomer Technology

Sulzer Chemtech- Mass Transfer Technology

Your Partner in Separation and Mixing Technology
A Broad Range of Innovative and High-performing Products
Our more than 200 products cover a wide range of needs in the field of separation and mixing technology. They
have proven their performance in more than 100,000 columns, 40,000 gas/liquid separators and 100,000 mixers
in operation worldwide.

0605 2504

0603 2535-3

Fast and Reliable

Turnaround Services

Comprehensive Engineering
and Technology Services

Our team provides state-of-the art

expert know-how for more than
500 applications in 100 processes,
this enables us to optimize the
performance and your installation.

You can rely on Sulzer professionals,

expertise and procedures to get you
back and running in the shortest
possible time.

We provide a full scope of associated

engineering and technology services
to optimize or trouble-shoot your
installation.

Kero

Sulzer VG AFTM

Shell HiFiTM Trays

10

Shell ConSepTM Trays

12

Mechanical Features and Services

14

We understand the ever increasing requirement for

both reliability and performance of your process
equipment. To meet these challenges, you can
rely on our innovative, industry-leading products
and expertise. Our extensive tray portfolio ranges
from single pass to multi-downcomer as well as
conventional to high-performance, including the
latest technology in ultra-system limit trays. All
designs are tailored to meet the exact requirements
of your specific application.

MVGTM decks and enhanced downcomer technology

as well as the newest trays, UFMPlusTM with UFM TM
valves. The UFM valve is an industrially proven,
advanced movable mini-valve providing the highest
efficiency and capacity. For fouling applications that
require high performance, our VG AF TM Anti-Fouling
trays provide a proven and robust solution. This
portfolio has been greatly enriched since 2000 by
our technology alliance with Shell Global Solutions,
and also includes Shell high performance trays such
as the Shell HiFi TM trays, ideal for high liquid load
applications, and Shell ConSepTM trays with proven
ultra-system capabilities.

0694 2720

The Highest Level of

Application Know-how

Naphtha

High Performance Trays

For your most demanding applications, our High

Performance Trays include VGPlusTM trays with
0602 2510

Sulzer "Plus" Technology

Tray Portfolio
Sulzer Technology

Sulzer-Shell Alliance

Conventional Trays

Chordal Downcomer High

Performance Trays

Multi Downcomer High

Performance Trays

Floating Valves

Enhanced Deck

Enhanced Deck
and Downcomer

Shell HiFiTM

Other Trays

Shell HiFiTM Plus

BDHTM / BDPTM

Bubble Cap

MVGTM

VGPlusTM

Shell Calming SectionTM (CS)

Round Valves

Sieve

MMVGTM

UFMPlusTM

Shell CSTM Plus

Fixed Valves

Dual Flow

UFMTM

e-VGPlusTM

Dual Flow High Performance Trays

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
Diesel

Slit TraysTM
High Performance Trays featured in this brochure

Leading Tray Technology

In the 1820s, an early version of bubblecaps trays were
introduced for continous distillation towers.

In the 1950s, valve trays were developed, providing higher

capacity and better efficiency over a wider operating range.
The modern valve tray, a rectangular float valve tray, was
first installed by I.E. Nutter in 1951. By 1956, different
variations of round valves had surfaced.

0605 2521

0605 2522

Bubblecaps in Sulzer's Tray Portfolio

1800

0605 2518

0605 2520

Round Valve

Caged Valve

1900

In 2000, Sulzer formed a technology alliance with Shell

Global Solutions providing a full range tray product
portfolio from one source. These include Shell Calming
SectionTM (Plus) Trays, Shell HiFi (Plus) Trays and ultrahigh capacity Shell ConSep Trays.

Shell HiFiTM Tray

In 2012, Sulzer launched a new valve product UFM

(Umbrella Floating Mini), a movable valve which
provides higher capacity and a wider operating range
than conventional valves.
In 2014, Sulzer launched UFMPlus, a high performance
tray with a UFM deck and enhanced downcomers.

Shell ConSepTM Tray

2000

2010

BDHTM Rectangular Float Valve

0610 2503-1

Modern 1-pass Sieve Tray

In the 1830s, sieve trays were developed,

offering higher capacity despite design
simplicity.
4

0605 2529

VGrid Fixed Valves

From Left to Right:
SVGTM, MVGTM and
MMVGTM Fixed Valves

In 1998, Sulzer acquired Nutter Engineering, incorporating the wellacclaimed BDHTM rectangular float valve and V-Grid fixed valves
into Sulzer's tray product portfolio.

0605 2505

In 2000, Sulzer introduced

high performance VGPlus
trays which provide higher
capacity with the combination
of enhanced downcomers
and optimized tray layout.

Sulzer has also introduced

high performance VG AF Anti
Fouling Trays featuring large
fixed and push valves, and
fouling resistant outlet weirs.

Sulzers 6-pass VGPlus High Performance Trays

were successfully installed in several C3 Splitters
and are performing beyond expectations.
6-pass trays are a natural progression after
4-pass trays for large diameter columns (typically
> 6 m) with high liquid loads.
5

Sulzer "Plus" Technology

VGPlus and UFMPlus Trays, are Sulzers high performance Plus technology chordal downcomer trays. They
offer industry proven and validated advanced tray technology for todays market.

VGPlusTM Trays

UFMPlusTM Trays
UFMPlus Trays are enhanced downcomer trays with
high capacity UFM float valves.
UFM valves are an advanced type of movable mini-valve
which maximize the hydraulic capacity, the separation
efficiency, and the operating range of fractionation trays.

Enhanced Downcomers

Enhanced Decks

VGPlus Trays are enhanced downcomer trays with high

capacity MVG or MMVG fixed valves.

A main feature of Sulzer "Plus" technology trays is the

use of high performance downcomers such as highly
sloped, Truncated, StepArc (stepped) and ModArc
(multi-chordal) downcomers. These downcomer designs
maximize the tray deck area by optimizing the downcomer
bottom area, thereby increasing vapor handling capacity
and reducing pressure drop and backup.

Sulzer "Plus" technology trays can be equipped with

high capacity fixed valves or float valves. VGPlus trays
are equipped with high capacity fixed valves such as
MVG or MMVGTM while UFMPlus trays use high capacity
UFM float valves.

MVG valves provide higher capacity compared to

standard sieve or conventional valves, while providing
higher efficiency and lower pressure drop per theoretical
stage. The MVG tray deck offers better turndown
capability than a sieve tray, i.e. up to 3:1.

Redirecting and froth promoting devices such as

push valves and baffle bars, enhance the vapor/ liquid
interaction on the tray deck.

MMVG valves are used where extremely high vapor

capacity or a very low pressure drop is required. The
smaller size opening compared to MVG results in up to
7% additional capacity.

Liquid Flow Study with Conventional Trays

4-pass VGPlusTM tray equipped with ModArc

downcomers, MVGTM and push valves

"Plus" technology with baffle bars

The "Umbrella" shape of UFM valves reduces the jetting

momentum of the released vapor which maximizes the
contact area of vapor and liquid on the tray deck and
promotes uniform mixing and minimizes entrainment.
The UFM tray deck offers better turndown capability
than a fixed valve tray, i.e. up to 5:1.

FRI Validation

Key Areas of Application

Sulzer VGPlus Trays have been tested at FRI, in

the iso-butane/n-butane system at 7 and 11 bar.
The VGPlus tray is one of the best performing
trays ever tested, delivering up to 10% higher
capacity than some other tested competitor's
high performance trays.

Refinery: Main Fractionators and Gas Plants

Olefins: Deethanizers,Depropanizers,

Debutanizers, Deisobutanizers,
SuperFractionators: C2 and C3 Splitters
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

Sulzer "Plus" Technology

VG AFTM AntiFouling Trays

Case Study - Revamp of Deisobutanizer with VGPlusTM Trays

A refinery deisobutanizer column, upstream of an HF
Alkylation Unit, was identified to be the bottleneck of
the capacity expansion.
This deisobutanizer column of ID 2.96m was originally
equipped with 56 2-pass conventional round valve
trays. A process study highlighted that the throughput
could be almost doubled by retrofitting the tower with
high performance trays.
Revamp Objective:
Maximize the production of iC4
Minimize nC4 in top product: <3 wt%
Maximize iC4 recovery: >94 wt%
Revamp Solution:
Sulzer VGPlus High Performance Trays with
MVG Fixed Valves
ModArc Side Downcomers
Froth Enhancers: Push Valves
Test run was performed at 143% of the pre-revamp
capacity due to shortage of feedstock. To further load
the tower, the reflux ratio was increased till maximum
reboiler duty: the production of iC4 increased by
57%, with a nC4 impurity as low as 0.9 wt% and iC4
recovery over 98 wt% leading to a tray efficiency over
93% even at flooding close to 90%.

VG AFTM Trays
PC

Feed-3
1

Feed-2

For columns with large diameters, 6-pass trays

provide extensive weir length to handle the high
liquid loads. The multiple pass design also avoids
excessively long flow path lengths to mitigate
undesirable liquid flow gradients on the tray decks.
Enhanced downcomers are utilized to maximize the
bubbling area for mass transfer.
Sulzer Design:
Sulzer VGPlus High Performance Trays with
MVG Fixed Valves
ModArc Side Downcomers
Froth Enhancers: Push Valves

FC

TC

Iso-C4

LC

FC

28

From
Iso-Stripper
56

LC
Reboiling
Fluid

VG AF (AntiFouling) trays are part of the VGPlus tray

family and especially designed for fouling services.
Features of VG AF which increase tray fouling
resistance and run length:
Large V-Grid: SVGTM or XVGTM
Modified outlet weirs: stepped or sloped weirs
Push valves

New VGPlus
HPTrays

29

FC
n-C4

FC

The VG AF provides superior anti-fouling performance

while delivering high capacity and efficiency, making
this tray ideal for debottlenecking fouling services.

Design

Test Run

Feed flow rate

100%

191%

143%

Primary Fractionators in Ethylene Plant

Top iC4 flow rate

100%

193%

157%

Stripping Section of CDU and VDU

Reflux ratio

NA

12.7

17.5

Tray efficiency

NA

86%

> 93%

nC4 impurity

> 3 wt%

3 wt%

< 0.9 wt%

iC4 recovery

< 94 wt%

94 wt%

> 98 wt%

NA

80%

89%

Flooding

2-pass VG AFTM trays equipped with V-Grid, stepped outlet

weir and push valves

Coker Main Fractionators

Heads and Dry Columns of Acrylonitrile Plant
PVC Slurry Strippers
Beer Columns

0608 2501

2-pass VG AFTM with V-Grid, sloped outlet weir and push valves

Case Study - Revamp of Acrylonitrile Heads and Dry Column to VG AFTM

Acrylonitrile (ACN) Heads and Dry Column was
revamped from round valves trays to Sulzer
VG AF AntiFouling trays for higher performance and
longer run length.

BRINE

From Dec.
Recovery
Column

This ACN Column was originally equipped with 62

1-pass conventional round valve trays.

Revamp Solution:
Sulzer VG AF Antifouling Trays with
SVG Fixed Valves
Stepped Outlet Weirs
Froth Enhancers: Push Valves

HCN Tower

CW

Revamp Objective:
Increase capacity by 25%
Maximize Acrylonitrile recovery: > 91 wt%
Maximize run length: > 6 months

As a result of the revamp with VG AF trays, the column

capacity increased by 25%. The ACN recovery
improved to 95% and the run length increased to
more than 11 months.
8

0605 2506

Key Areas of Application

Before
Revamp

Sulzer's Experience - 6-Pass VGPlusTM Trays for new C3 Splitters

Three new C3 Splitters, each designed with 195
6-pass VGPlus High Performance Trays.

LC

FC

10

Feed-1

Fuel Gas

Quench
Tower

Product Tower

Before
Revamp

After
Revamp

Feed

100%

125%

ACN Production

100%

130%

ACN Recovery

91 wt%

95 wt%

Tray Efficiency

70%

74%

>11

Run Length [months]

Shell High Performance Trays

Case Study - Revamp of C2 Splitter to Shell HiFiTM Plus Trays

Shell HiFiTM Plus Trays

Shell HiFi trays are fractionation trays equipped with
multiple envelope downcomers, oriented offset to the
tray's center line.

A C2 Splitter (3.96m I.D.), was revamped from 153

competitor's Multi-Downcomer trays to 123 Sulzer
HiFi Trays for improved C2 Splitter performance
higher capacity and stringent product purity.

They are supported on a 360 support ring and central

major beams, without the need of the downcomer
bolting bars.

Revamp Objective:
Increase capacity by 25%
Ethylene Purity : 99.96 wt%

For a given column diameter, they allow for:

Revamp Solution:
Shell HiFi Plus Trays with
MMVG Fixed Valves
HiFi Downcomer Boxes
Long Weir Length > 23m

Highest number of passes

Large downcomer area
Long weir length
High hydraulic capacity
Low tray spacing
High NTS per column height

HiFiTM Plus tray with MVGTM valves

The HiFi Plus trays are an enhanced version featuring

advanced valves (i.e. MVG, MMVG, UFM) to further
boost the tray deck performance, and/or the Crown
Inlet Device CIDTM to maximize the downcomer
capacity as well.
FRI Validation

Key Areas of Application

Shell HiFi Trays, with tray spacings of 305mm

and 610mm, have been tested at FRI, in the isobutane/n-butane system at 11, 21 and 28 bar.
As compared to 1-pass round valve trays with
truncated downcomers, Shell HiFi Trays of same
tray spacing, exhibit up to 40% higher capacity.

Refinery: Main Fractionators' PA and

Stripping Sections
Olefins: Deethanizers, Depropanizers,
Debutanizers, Deisobutanizers,
SuperFractionators: C2 and C3 Splitters

During the Performance Test Run when the

column was artificially loaded up for the highest
throughput, steady operation was observed with
a useful capacity around 95%, and a measured
ethylene purity of 99.98%. A tray efficiency of 79%
was achieved.

A new Xylene Rerun Column, of ID 8.3m, was

designed with 117 Shell HiFi Plus Trays. The design
included 1 lattice beam for every 2 trays.

Aromatics: Xylene Splitters, Xylene Rerun,

Raffinate Columns

Test Run

Ethylene Purity

99.96%

99.98%

Tray Efficiency

80%

79%

Sulzer Design:
Shell HiFi Plus Trays with
MVG Fixed Valves
10 HiFi Downcomer Boxes
Long Weir Length > 60m
Although actual production was less than maximum
loads, the reflux ratio was higher than design due to
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 multidowncomer trays, and proved to be better in terms
of relative energy consumption and product recovery.

Revamp of top 3 rectifying trays of a Crude Distillation

Column from conventional trays to Shell HiFi trays
which offer longer weir length to handle the higher
liquid loads. Due to large column diameter of 9.6m,
two beams were required for each tray.

10

Design

Case Study - New Xylene Rerun Column with Shell HiFiTM Plus Trays

Gas Sweetening: Absorbers, Regenerators

Revamp Design:
Shell HiFi Trays with 2 beams design
21 HiFi Downcomer Boxes
Long Weir Length > 110m

Full Assembly during Trial Layout at Workshop

Design

Actual
Operation

125%

100%

1.61

1.84

Min. Recovery

99.0%

99.5%

Tray Efficiency

73%

74%

Feed

Process Requirements:
C9+ impurity in Distillate: <300 ppmwt
O-Xylene Recovery in Distillate: >99.0 wt%

Reflux / Feed Ratio [mass]

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

downcomer trays to high performance Shell Trays.

The Shell ConSep trays are one of the highest capacity

fractionation trays available on the market, offering up to
80% additional capacity over conventional trays without
any major impact on separation efficiency.

Improved feed quality, increased throughput and

conversion at FCC unit led to increased feed rate
and more LPG content to the Debutanizer.

They utilize the principle of de-entrainment by centrifugal

force to overcome the gravitational limitation of jet
flooding, and the system limit of the vessel.

Revamp Objective:
Increase capacity by 15%
C5 content in Top Stream < 0.6 vol%
RVP of bottom LCN < 85 kPa

Every set of ConSep tray consists of a primary tray (with

chordal or HiFi downcomer layout) and a secondary tray
with Swirl tubes.

Revamp Solution:
15 HiFi Plus Trays in Rectifying Section
15 ConSep Trays in Stripping Section
0603 2508

Shell HiFiTM Sieve Trays with ConSepTM decks

Overall tray efficiency achieved was more than

86%, well above the tray efficiency of the first
generation high performance trays used before
revamp which was 69%.

FRI Validation
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.

Key Areas of Application

Refinery: Main Fractionators
Olefins: Deethanizers, Depropanizers,

Debutanizers, Superfractionators C2 and C3
Splitters

The column proven capacity after the revamp

increased by 21%, exceeding the objective by 6%,
with lower C5 content in the top (0.3 vol %versus
0.6 vol%) and lower RVP in LCN (77 kPa vs 85 kPa).

Case Study - Debottlenecking of HGO Pumparound with Shell ConSepTM Trays

Experience List of Shell ConSep Trays:

Service

Industry

No. of Columns

Debutanizer

Refinery

Depropanizer

Refinery

Main Fractionator

Refinery

Naphtha Splitter

Refinery

Diesel HDT Stripper

Refinery

H2S Stripper

Refinery

C2 Splitter

Olefins

PO Drying Column

Chemicals

C6 Dryer

Chemicals

Shell ultra high capacity ConSep Trays were applied

in the capacity constrained HGO Pump-around
section of a Crude Distillation Unit in a refinery. This
was the first application of ConSep Trays in a CDU.
The post revamp test run established the realization
of the expected performance.
Revamp Objective:
Increase capacity by 53%
Maintain product specifications for Naphtha,
Kero, LGO and HGO

Main Modifications:
3 Shell ConSep Trays in HGO PA section
7 Shell HiFi Trays in stripping section
1.3m Sulzer MelapakPlusTM 252.Y
in wash section
16 Shell CSTM trays in other sections

As of March 2014

12

13

Mechanical Features

Services

Non-Welded Tray Support System

Trays for Heavy Duty Services

In several revamp projects aimed to increase the

separation stages of an existing column, the number
of actual trays had to increase (e.g. 3-for-2, 4-for-3, or
5-for-4).

In some applications, particularly those subjected to

operating upsets leading to panel dislodgment, the trays
must withstand higher than normal mechanical loadings,
i.e. 7000 N / m2 (1 psi) or even 14000 N / m2 (2 psi).

To accomplish this, a mechanical design is required to

avoid impact on the schedule of the plant's turn-around,
and minimize cost as well.

In such cases, special features may be employed in the

mechanical design:

Sulzer has developed a mechanical solution enabling

installation of the trays by reusing the existing tower
attachments, without any direct welding to the tower
wall, thus avoiding any post-welding heat treatment
and/or hydraulic testing of the vessel. This technique
consistently reduce the turnaround time by using this
technique.

Through-bolting panel connection

Shear clips
Downcomer spreaders
Explosion doors

Computer-Aided Engineering (CAE):

3D Models

Natural Frequency Analysis for Tray

Vibration Phenomena

Upfront engineering and design play a crucial role in

cost optimization. Sulzer has integrated all major mass
transfer products into an in-house design tool, creating
a global standard.

In some critical applications and under specific operating

conditions, vibration phenomena may be induced to
the trays. Based on plant feed-back data and in-house
know-how, Sulzer has developed a design tool to check
for the following two main parameters:

Customers profit directly from the use of our internal

CAE tool. Layout drawings supplied in the course of
the engineering phase will show a 3D sketch of the
equipment being designed, for an easy and fast checking
by the customer.

Natural frequency of the tray panels, as a function

of the geometry, the supports, and the material of
construction.
Vibration factor, as a function of the flow rates and
physical properties of the streams being processed.

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

the geometry of existing downcomers, modify the
number of passes; change the tray orientation; replace
packing beds with trays.
Expansion ring

Vertical strut

2 psi uplift BDHTM tray equipped with through-bolting

assembly, shear clips and explosion doors

Lip-SlotTM Panel Connection

The Lip-Slot is an enhanced type of tray panel connection
which allows for:
safe and easy installation
up to 30% less installation time
less maintenance costs as it does not use any
bolted connection
same mechanical reliability as conventional connections

Natural frequency analysis of a full tray

Finite Elements Method (FEM) and

Computational Fluid Dynamics (CFD)
Sulzer also employs other advanced design tools,
for example verification of mechanical integrity and
functionality using finite element and CFD analysis.

Turn Around and Tower Field Services

Sulzers global manufacturing capabilities ensure fast
delivery of any tray hardware and replacement tray
parts, regardless of original supplier. These can be
manufactured from existing drawings or damaged parts
and supplied on site quickly to meet your turnaround
schedules. Replacement hardware can be supplied on
consignment in lockers or trailers for convenience.

The Lip-Slot is combined with universal clamps for the

fixation around the tray periphery.

14

Existing
support ring

Lattice
beam

Expansion
joint
0605 2524

15

www.sulzer.com
Please check for your local contact

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with

headquarters in Winterthur, Switzerland, is active in the field of process
engineering and employs some 4500 persons worldwide.
Sulzer Chemtech is represented in all important industrial countries and
sets standards in the field of mass transfer and static mixing with its
advanced and economical solutions.

The activity program comprises:

Process components such as fractionation trays, structured and
random packings, liquid and gas distributors, gas-liquid separators,
and internals for separation columns
Engineering services for separation and reaction technology such as
conceptual process design, feasibilities studies, plant optimizations
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

Distributed by:

22.88.06.40 - X.14 - 10

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
indemnity for effects resulting from its application.