KemFlo’s Commitment to Customer Service

by | Jan 31, 2020 | Top Plastic Random Packing Articles

Providing the highest quality plastic scrubber packing on the market backed by superior customer service is what sets KemFlo apart from other manufactures. KemFlo’s goal is to provide cost effective plastic scrubber packing solutions with the highest level of quality for our customers. We accomplish this by using innovative methods supported by a long history of experience and by utilizing current technological advancements and sound engineering solutions. Our employees are devoted to pursuing the challenges presented as a means to accomplish the end goal. We understand our customer’s demands and are committed to their complete satisfaction through open communication.

We understand the demands and expectations our customers face day in and day out which is why we focus on customer service in addition to high quality manufacturing. Having exceptional products such as the high performance plastic scrubber packing Tri-Pack or spherical packing, the Plastic Pall Ring and the Plastic Saddle Packing is not enough. That’s why special care and attention is given to customer inquires from the time we receive them to the time the Plastic Scrubber Packing is on site. Helping our customer’s through the process of selecting the best plastic scrubber packing solution for their application is extremely important to us. We help our customers select between our Tri-Pack style packing, Plastic Pall Ring and our Plastic Saddle Packing by evaluating the plastic random packing size, geometric surface area, operating temperatures, chemical environment and application. No one knows their system or application better than the customer themselves which is why we work closely with our customs from start to finish.

When an inquiry is first received by the KemFlo sales group the type of plastic scrubber packing is confirmed. If the customer knows exactly which plastic scrubber packing they require the process moves very quickly and the customer will have pricing and availability immediately. In many cases the customer wants freight cost as apart of the inquiry. KemFlo works closely with a number of logistic companies to ensure competitive freight rates for our customers. If a customer is uncertain of the style of Plastic Scrubber Packing they need we can provide the physical properties for our Tri-Pack, Plastic Pall Ring and our Plastic Saddle Packing for our customer’s review. In some cases our customers need assistance in selecting the appropriate resin for the plastic Scrubber packing. In these cases KemFlo offers general service temperature guide lines for common resins listed on our website at www.kempac-packing.com. Upon request corrosion resistance charts and temperature range data can be provided for specific resin types. Please note that all resin used in KemFlo’s manufacturing of plastic scrubber packing can be traced back to the specific resin supplier’s batch as apart of our quality assurance program.

KemFlo stocks significant amounts of packing at both their Richmond Hill and Houston locations which means many order can ship quickly. In cases where KemFlo has to manufacture a customer’s order from scratch, we provide customers with accurate delivery schedules and keep them informed regarding the progress of their order.

KemFlo works hard to earn your plastic scrubber packing business and looks forward to developing long lasting relationships with our customer. For more information regarding KemFlo’s Plastic Scrubber Packing product line including the Tri-Pack, Plastic Pall Ring and the Plastic Saddle Packing please give us a call or visit our website at www.kempac-packing.com.

Biological Filters

by | Jan 17, 2020 | Plastic Random Packing Articles

One of the most common applications for Kemflo’s Kempac plastic random media is biological filtration. Kemflo’s Tri-Pack style, Plastic Pall Ring or Plastic Saddle packing are ideal for use is biological filtration applications. From small systems to large systems Kemflo has a plastic random media for you.

Most modern biological filters have a bed of plastic random media over which wastewater is continuously distributed. The plastic random media bed can range in depth from one to more than ten meters deep. Wastewater is applied uniformly over the plastic random media by filter feeds and distribution systems. An underdrain system is provided to collect filter effluent for transport to a clarifier for solids separation. A biological filter does not actually purify wastewater by any filtering or straining action, but by absorption and biological oxidation of the soluble. Organic matter in the wastewater.

Wastewater applied to a biological filter usually has undergone primary treatment to remove suspended solids that can plug the filter, and to remove suspended biochemical oxygen demand or BOD that reduces filter organic loading. The function of the filter is to convert soluble and colloidal organics to settleable solids. These solids are then separated from the wastewater in a postfilter clarifier. The conversion of the soluble and colloidal organics to settleable solids is accomplished biochemically. As wastewater is applied, a biological film develops on the plastic random media. The biological film is responsible for the decomposition of the organic matter in wastewater. The film is a jelly-like slime composed of a very large and diverse population of living organisms including bacteria, protozoa, algae, worms, and insect larvae. The microorganisms that comprise the biological film use the organic matter in wastewater as their food source and the oxygen in the wastewater to metabolize this food. Oxygen is dissolved into the wastewater from the air that circulates through the filter. Metabolism of the organic matter entails numerous complex biochemical reactions within the cells of the microorganisms. Some filer organisms feed on complex substances in the wastewater and produce new cell material and compounds as waste byproducts. The process continues until the final waste products can no longer be used as food by any of the filter microorganisms.

To ensure fast, odor free decomposition of wastewater organics, the filter must remain aerobic. Sufficiently dissolved oxygen must be present in the wastewater at it trickles through the plastic random media. Although dissolved oxygen is only slightly soluble in wastewater, it is constantly being consumed by the microorganisms. Therefore, Oxygen must constantly be available for dissolution into the wastewater. This oxygen comes from the air that circulates through the filter. If there is insufficient air circulation, odorous anaerobic conditions will develop and treatment efficiency will decrease. Filters are classified as low or standard, intermediate rate, high rate or super high rate. Further designations such as single stage, two stage, series and parallel describe the hydraulic flow patterns. Super high rate filters involve plastic random media. Super high rate filters are loaded at hydraulic rates between 140,000 and 840,000 meters squared and organic loadings up to 4.5 kg/m. The major differences between super high and high rate filters are greater hydraulic loadings and greater filter depths. The greater depths are possible because lighter plastic random media is used.

For more information on Kemflo’s Tri-Pack style, Plastic Pall Ring or Plastic Saddle please visit our website at www.kempac-packing.com.

Distillation

by | Jan 17, 2020 | Plastic Random Packing Articles

Distillation is a common application where KemFlo’s plastic random media is utilized. KemFlo’s plastic random media has many advantages including overall efficiency, corrosion resistance, durability and weight. KemFlo manufactures their plastic random media under the Kempac brand name and offer a Tri-Pack style, plastic Pall Ring and plastic Saddle packing. All three packing styles are available in three different sizes and a variety of resins. Available resins include Polypropylene, Polypropylene with glass, CPVC, PVC, PVDF and more.

Distillation is a commonly used process for separating mixtures based on differences in the conditions required to change phase of components of the mixture. To separate a mixture of liquids, the liquid can be heated to force components, which have different boiling points, into the gas phase. The gas is then condensed back into liquid form and collected. Repeating the process on the collected liquid to improve the purity of the product is called double distillation. Although the term is most commonly applied to liquids, the reverse process can be used to separate gases by liquefying components using changes in temperature and or pressure. A plant that performs distillation is called a distillery. The column used to perform distillation is called a still. A crude oil refinery is a group of industrial facilities that turns crude oil and other inputs into finished petroleum products. A refinery’s capacity refers to the maximum amount of crude oil designed to flow into the distillation unit of a refinery, also known as the crude unit.

The diagram above presents a stylized version of the distillation process. Crude oil is made up of a mixture of hydrocarbons, and the distillation process aims to separate this crude oil into broad categories of its component hydrocarbons, or “fractions.” Crude oil is first heated and then put into a distillation column, also known as a still, where different products boil off and are recovered at different temperatures. Lighter products, such as butane and other liquid petroleum (LPG), gasoline blending components, and naphtha, are recovered at the lowest temperatures. Mid-range products include jet fuel, kerosene, and distillates (such as home heating oil and diesel fuel). The heaviest products such as residual fuel oil are recovered at temperatures sometimes over 1,000 degrees Fahrenheit.

The simplest refineries stop at this point. Although not shown in the simplified diagram above, most refineries in the United States reprocess the heavier fractions into lighter products to maximize the output of the most desirable products using more sophisticated refining equipment such as catalytic crackers, reformers, and cokers.

Packed bed columns may be used for distillation of vapor liquid mixtures. Random packing media provides a large surface area for vapor liquid contact, which increases the column’s effectiveness. The style of plastic random packing that is utilized in a distillation column can affect the overall efficiency of a unit so special consideration should be given to the selection of random media during the design stage of a distillation unit. KemFlo offer the Tri-Pack style packing in 1”, 2” and 3.5”, the plastic Pall Ring in 1, 2” and 3.5”, and the plastic Saddle packing in 1” 2” and 3”. Please contact Kemflo or visit our website at www.kempac-packing.com for more information on our plastic tower packing.

Spherical or Tri-Pack Style Plastic Random Packing

by | Jan 9, 2020 | Plastic Random Packing Articles

For over thirty years KemFlo has been manufacturing high quality injection molded products utilizing numerous materials and resins.  KemFlo offers complete product design, prototyping, mold making, post molding capabilities and assembly capabilities. Our custom capabilities and experience allows us to take a customer’s idea and turn it into an actual product.  Kemflo’s quality assurance program ensures that all products meet or exceed our customer’s standards. Our quality assurance program involves a review process where the product is evaluated for fit and function, engineering requirements and product validation. We manufacture products for a variety of industries including Industrial, Chemical, Agricultural, Environmental and more.  

One of KemFlo’s most successful products lines is their plastic random packing line which is marketed under the Kempac brand name.  The Kempac family of products include three styles of plastic random packing including the Tri-Pack, Pall Ring and Saddle type. Each style of packing is available in three sizes and in a variety of resin types.  

The most popular packing is the Tri-Pack style packing.  The Tri-Pack style packing is one of the most efficient plastic random products on the market today.  The Tri-Pack style packing is a hollow spherical packing constructed of a network of rids, struts and drip rods. Its spherical shape allows each part to roll into the packed position without forming void areas which are common to irregular shaped packing. There is no need for allowances for settling and nesting is virtually impossible. The Tri-Pack also offers reliable and predictable loading of your tower which means reliable and predictable performance. In addition to the superior geometric shape, an active surface area is vital to mass transfer.  The unique network of ribs, struts and drip rods have proven to give the Tri-Pack an advantage in providing excellent wetting qualities and maintaining liquid distribution throughout the packed bed. Some suppliers claim more surface area, but surface area alone is not an indication of performance. In fact, excessive surface area can impede proper gas and liquid contact and always results in higher pressure drop which increases horsepower requirements and operating cost. The Tri-Pack offer an optimum surface area to open space ratio which results in superior mass transfer efficiency and reduced operating cost.  

The Tri-Pack can be utilized in a variety of applications including air pollution, scrubbing, air stripping, absorption, distillation, extraction, humidification, dehumidification, biological filtration and more.  The Tri-Pack is available in three sizes, 1”, 2” and 3.5”. KemFlo manufactures this product using only prime, virgin resins and no recycled materials are every used. Almost any injectable resin is available, but the most common resins include Polypropylene, Polypropylene with Glass, Polyethylene, CPVC, PVDF, Halar and more. All of the plastic random packing that KemFlo manufactures in polypropylene resin has been certified by NSF to Standard 61 for water treatment plant applications.  

For more information in on the Tri-Pack or any of the other plastic random packing products please visit the Kempac website at www.kempac-packing.com.  Whether you are looking for plastic random packing or help with your custom injection molding project give us a call.        

Kempac Plastic Pall Ring

by | Jan 9, 2020 | Plastic Random Packing Articles

Kemflo, established in 1988, has developed a solid reputation for the design and manufacturing of high quality injection molded products. KemFlo has extensive experience in the injection molding of a wide range of thermoplastic resins both in commodity and specialty type resins. Our wide range of services in part, design, prototyping, mold design and post mold services allows us to provide our customers with a single complete source for their injection molding needs. Today Kemflo provides products and services into many different markets and has accumulated a wealth of experience in materials, design and processes. One of KemFlo’s most successful product lines is the Kempac plastic random packing line.  The Kempac plastic random packing line includes several different styles of high performance packing including the Tri-Pack style, plastic saddle packing and the plastic Pall Ring.  

The Kempac plastic Pall Ring is a Robust ring featuring an open wall construction which efficiently maintains liquid distribution. The Pall Ring has reinforced struts which provide additional surface area for gas and liquid contact and support the outer ring. The Kempac Pall Ring is available in 1”, 2” and 3.5” sizes. The Kempac Pall Ring is available in a variety of thermoplastic resins including Polypropylene, Polypropylene with Glass, High Density Polyethylene, Low Density Polyethylene, PVC, CPVC and PVDF.  Other resins may be available as well. Please feel free to contact Kemflo for more information regarding available resins.

The Pall Ring is utilized in a variety of applications including:

  • Air Scrubbing: This is a process used to clean industrial exhaust streams and gas emissions. An example would be the removal of Sulphur from a power plant exhaust system.
  • Air Stripping: Air Stripping is transfer of volatile compounds of a liquid into an air stream which is then treated. This process may be used to treat contaminated groundwater.
  • Distillation: Distillation is the process of separating the components or substances from a liquid by using selective boiling and condensation.
  • Deaeration: The removal of air molecules from another gas or liquid, such as the removal of oxygen from liquids.

Other applications include Absorption, extraction, humidification, dehumidification, biofiltration and more.

The Kempac plastic pall ring is typically shipped in either five for ten cubic foot cardboard boxes. The boxes may either ship loose or on wood pallets.  Super sacks or poly bags are also available upon request. Storage and handling of the packing filled cardboard boxes is important in order to keep the packing clean and to prevent the boxes from breaking thus the potential of loosing packing. Please note that the cardboard boxes are not designed for outside storage. Boxes should be stored indoors on level flooring and free from water damage or condensation.  

Proper installation of the plastic pall ring as with any random packing is important.  There are many different ways to install plastic pall rings depending on the tower size, packed bed height and the position of other internals.  Typically the pall ring can installed by simply dry dumping with reasonable care. Make sure that the packing fills all of the space in the packed bed area.

For more information on Kempac’s plastic pall ring of other plastic random products such at the Tri-Pack or plastic saddle packing please visit our website at www.kempac-packing.com.