Some of the most critical maintenance issues regarding air scrubbers and air strippers are scaling, fouling and disinfection. Scaling is the precipitation and deposition of water-insoluble salts on to column internals and plastic tower packing. Fouling is the formation of deposits other than salts and which may be due to corrosion or biological growth. Disinfection is required if the water is required to be potable or safe for human consumption. It is important that these potential issues are addressed an any maintenance program to help ensure optimal performance from your system.

Scaling can be one of the more complicated maintenance issues to deal with and requires constant attention. In order to prevent scaling the water pH must be adjusted by adding strong acids and bases to prevent salts from building up. It should be noted that the geometry or configuration of plastic random packing has little or no affect in regards to scaling. The rate of scale build-up on column internals is directly related to the water quality. Ammonia and Hydrogen Sulfide are two of the most common water contaminates which require that the water pH be adjusted so that effective air stripping and scrubbing can occur. Ammonia is a weak base while Hydrogen is a weak acid. The hardness and pH of the water must be maintained to prevent scaling problems due to water contaminates such as Ammonia and Hydrogen sulfide.

A maintenance program which includes regular evaluation of the water quality in an air stripping or scrubbing column is the best way to avoid costly shutdowns, repairs or replacements. A proper maintenance and cleaning program should be implemented, which may include acid or caustic washing of the plastic tower packing and internals. Scaling in a column can develop on plastic random packing and other internals like liquid distributors, redistributors, bed limiters or packing supports, requiring these products to be changed out for new ones. Scaling also affects the overall efficiency of a system by restricting flow and reducing liquid gas contact.

Disinfection refers to the elimination of microorganisms typically found in drinking water sources. Some of the more common microorganisms found in drinking water sources include Cryptosporidium, Giardia Lamblia and Legionella. The most common forms of disinfection include chlorination and ozonation which kill organisms by oxidation. UV or Ultraviolet disinfection, which kills organisms with ultraviolet radiation is also fairly common. Chlorination is by far the most common disinfectant in the United States of America. Ozonation is more commonly utilized in Europe.

The importance of developing a proper maintenance plan before an air stripper or scrubber goes into service can not be overstated. Protect the investment you made in your column by reducing or eliminating the affects that scaling and fouling has on plastic tower packing and internals.

For over 30 years, KemFlo has been manufacturing high quality injection molded products for the industrial, agricultural, environmental, construction and medical industries. Kemflo offers product design and engineering, prototyping, mold design, mold making and has complete assembly capabilities. All products are subject to Kemflo’s quality assurance process where all parts are evaluated for fit and function, engineering requirements and product validation.

One of Kemflo’s most successful product lines is their plastic random media which is known as Kempac. Kemflo manufacturers this product for a variety of applications such as air scrubbing, air stripping, distillation, biofiltration, absorption, extraction, dehumidification and degasification. This product helps to provide an important stage in a column where gas liquid contact can occur. The performance of plastic random media is dependent on maintaining good liquid and gas distribution throughout the system. This is accomplished through high performance product design which includes a unique network of ribs, drip points and struts which ensures maximum liquid gas contact. The overall design of the column is very important in achieving maximum efficiency. Design considerations include the selection of the type and size of the media, column height, column diameter and internals such as packing supports, bed limiters, mist eliminators, liquid distributors and redistributors. Some things to consider in selecting the most efficient plastic random media for your application include geometric surface area, pressure drop, uniform liquid distribution, uniform gas distribution, operating temperatures and gas / liquid contaminants.

In order to meet their customer’s most demanding requirements Kemflo manufactures Kempac in a spherical or Tripack style, saddle style and ring style plastic random media in three different sizes and multiple resins. Some of the resins available include Polypropylene, Polyethylene, Polypropylene glass filled, Polyvinylchloride, CPVC, Kynar, Teflon and Halar. All resins that Kemflo uses in their manufacturing process are traceable back to the resin supplier as part of their quality assurance program. NSF certified Polypropylene product is also available which meets NSF standard 61 for water treatment plant applications. Other specialty resins are available upon request.

The benefits of utilizing KemFlo’s plastic random media include high active service areas, low pressure drops, high operating capacities, excellent gas and liquid dispersion characteristics, resist nesting and high mass and heat transfer rates. KemFlo customers receive a high performance product at a economical price. Kempac is available in 5 and 10 cubic foot boxes and ships from either our facility in Richmond Hill, Ontario or our warehouse in Houston, Texas.

KemFlo’s primary goal is to provide cost effective product solutions with the highest level of quality for our customers. This is accomplished by using innovative methods supported by a long history of experience and by utilizing the latest technological advancements and sound engineering solutions. For more information on products manufactured by KemFlo please visit our website at www.kemflocanada.com or www.kempac-packing.com.

KemFlo’s Kempac plastic random packing is used in numerous applications where a
combination of surface area and open space are required. KemFlo manufactures three
different styles of plastic random media including the Tri-Pack, Pall Ring and Saddle Style, each
with distinct physical properties in regards to geometric surface area and void space. One of
the more common applications for plastic random media are trickling filters.

Trickling filters are one of the oldest water treatment processes in the United States and
around the world. The first trickling filter was built in Europe in the late 1800’s. In general, the
trickling filter is an aerobic treatment system which utilizes microorganisms attached to plastic
random packing or some other media to remove organic matter from wastewater that passes
over it. This is also referred to as an attached growth process. Trickling filters remove ammonia
nitrogen by oxidizing it to nitrate nitrogen. This process is known as nitrification. Nitrification is
a process in which ammonia nitrogen in wastewater is oxidized first to nitrite nitrogen and then
to nitrate nitrogen by autotrophic bacteria.

A trickling filter consist of media made from rock or plastic random packing, over which
wastewater is distributed and trickles through the media. These media beds of plastic random
packing media range in size and can be as large as 200 feet in diameter and three to eight feet
deep. Rotating distribution of wastewater over the media bed is preferred and is the standard
distribution method. A trickling filter design also includes an under drain system that collects
the filtrate and solids. The under drain also services as a source of air for the microorganisms in
the filter media. The treated wastewater and solids are piped to a settling tank where the
solids are separated. Some of the filtered liquid is recirculated over the plastic random packing
in order to keep the media wet and to maximize the system’s efficiency. Ventilation openings
located at the bottom of the system provide essential air flow. It is important that the plastic
random packing media had sufficient open area in order to accommodate the air flow
throughout the filter bed. The organic material in the wastewater is absorbed by the
microorganisms that attach to the plastic random packing as a biological film or slime layer.

As with any process there are advantages and disadvantages to consider. Advantages of
trickling filters include: Trickling filter are a simple and reliable process that are ideal in areas
where large tracks of land are not available for a treatment system. They may qualify for
equivalent secondary discharge standards. Trickling filters are effective in treating high
concentrations of organics depending on the type of plastic random packing used. Appropriate
for small to medium sized communities. High degree of performance reliability. Durability of
process elements. Low power requirements. Moderate level of technical expertise required to
manager the system. Disadvantages of trickling filters include: Depending on discharge
standards additional treatment may be needed. They generate sludge that must be treated and disposed of. Regular operator attention is needed. High incidence of clogging may occur.
Limited flexibility and control. There is a potential for odor problems.

There are a variety of factors that affect the nitrification performance of a system including
availability of oxygen, level of CBOD, ammonia nitrogen concentration, media configuration,
temperature and pH. In general trickling filters are very reliable but there are still a few
operational problems that may occur such as odor control, ponding on filter media, attracting
insects and rodents and icing in colder regions. When considering all of the positive and
negatives involved in a trickling filter process it is still a very reliable and efficient method for
treating wastewater.

Kempac plastic random media is an excellent option for trickling filter media beds and is
available in multiple configurations, sizes and materials. The Tri-Pack is available in 1”, 2” and
3.5”. The Pall Ring is available in 1”, 2” and 3.5”. The Plastic Saddle style packing is available in
1”, 2” and 3”. For more information on the kempac plastic random packing product line please
visit www.kempac-packing.com.

When customer contact KemFlo regarding plastic random packing they typically have an idea of what they are looking for in general terms but rely on Kemflo’s sales team to walk them through the various options in selecting the best random packing for their specific application. Every customer’s needs are different. Some customers are looking to optimize the performance of their scrubber while other are more concerned with overall cost, but most customers are looking for a balance between performance and operating cost. Therefore, it is important to present customer with all available plastic random packing options.

Typically the discussion begins with what style of packing the customer is looking for. Do they want a high performance packing such as the Tripack or do they want a more basic packing such as the Pall Ring or plastic saddle style? KemFlo’s Tripack plastic random packing is a high performance plastic random packing which is uniquely designed with a network of rids, structs and drop rods which optimize efficiency by providing both significant surface area but at the same time also has plenty of open space. The Tripack also has a spherical design which prevents settling and nesting in a packed bed.

While KemFlo’s Pall Ring offers a more basic design than the Tripack it has many excellent features and performs excellent in most applications. The Pall Ring consists of an open wall construction which maintains even liquid distribution throughout the packed bed. The reinforced structs of the Pall Ring also provide additional surface area for gas and liquid contact and also provide substantial support to the outer ring.

There is also the plastic saddles style random packing to consider. The Saddle style does not give the performance of the Tripack but it does offer durability and a very ling track record. The Saddle style plastic random packing has been used for many years and in many applications.

Determining the packing size is also critical. The Tripack and Pall Ring are available in 1”, 2” and 3.5” while the plastic Saddle style packing is available in 1”, 2” and 3”. Determining the proper packing size is based on column size and other date such as flow rates and pressure.

Another very important aspect when it comes to purchasing plastic random packing is the selection of resin. KemFlo’s Tripack, Pall Ring and Plastic Saddle style packing are all available in a variety of resins. Some of the more common resins include Polypropylene, Polypropylene with glass fill, PVC, CPVC, Kynar, Tefzel, Teflon and Halar. KemFlo offers other resins upon request. All of the resins that KemFlo uses to make their plastic random packing comes from manufactures in either the United States of America or Canada. Most importantly all of the resin that KemFlo uses is traceable back to the manufacture’s specific batch.

Once a specific packing is selected KemFlo ensures that our customer’s order is manufactured under strict quality control procedures and shipped is a timely fashion. Expediting emergency orders is also available upon request.

For additional information on our Tripack, Pall Ring or Plastic Saddle or to place an order please call us or visit our website at kempac-packing.com.

A major municipality in Southern Florida was experiencing significant problems with several odor control scrubbers. Heightened levels of Hydrogen Sulfide gas had resulted in major odor issues. In addition to the significant odor issues they were experiencing due to high levels of Hydrogen Sulfide there was also a problem with corrosion. The high levels of Hydrogen Sulfide gas was also greatly accelerating the rate of corrosion of the scrubber equipment. After a through inspection of the scrubber units the maintenance supervisor discovered that the plastic random packing had become brittle and was breaking into small pieces. The broken pieces of plastic random packing were collecting at the bottom of the scrubber restricting the liquid and gas flow. The flow restriction or plugging of the unit prevented the scrubbers from functioning properly resulting in increased odor and corrosion.

The facility maintenance supervisor wanted to find a plastic random packing that was more efficient and less prone to plugging so he reached out to KemFlo for assistance. We discussed the potential options which included the Tri-Pack, Pall Ring and saddle style plastic random packing. While all of Kemflo’s plastic random packing styles would have performed better than their existing random packing, he selected the Tri-Pack for a variety of reasons. The Tri-Pack’s efficiency, durability and resin quality were among the reasons it was selected to replace their under performing plastic random packing. The Tri-Pack has a spherical shape which makes it easy to install and prevents void areas within the packing bed unlike irregular shaped packing or random packing with excessive pins and appurtenances. Because of this there is no need to make allowances for nesting and settling. The Tri-Pack has a unique design made up of ribs, struts and drop rods which provide significant surface area for liquid and gas contact but still allows plenty of open area for liquid and gas flow. The Tri-Pack offers consistent loading which means reliable and predictable performance. It’s superior geometric shape and active surface area are vital to mass transfer. While some plastic random packing manufacturers claim to have more surface area, surface area alone is not an indication of performance. In fact excessive surface area can result in improper gas flow, improper liquid contact and always results in higher pressure drop which increases operating cost.

Another reason KemFlo’s Tri-Pack style plastic random packing was selected for this application was the high quality of the raw material used to make it. KemFlo uses only high grade plastic resins to manufacturer all styles of random packing including the Tri-Pack. For quality control all of the resin that KemFlo uses in their manufacturing process can be traced back to the resin manufactures specific resin batch. This ensures that KemFlo’s customers are receiving random packing made from high quality raw material.

Since installing KemFlo’s Tri-Pack style packing their scrubber has performed above expectations and they have had no further problems with odor or equipment corrosion. KemFlo manufacturers the Tri-Pack in 1”, 2” and 3.5” sizes and it is available is a variety of resins. In addition to the Tri-Pack, KemFlo also manufactures a Pall Ring and plastic Saddle style random packing. For more information on the Tri-Pack, Pall Ring and plastic Saddle style packing please visit our website at kempac-packing.com.