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.

PLANT SHUTDOWNS AND EMERGENCY MAINTENANCE

by | Dec 2, 2019 | Plastic Random Packing Articles

Plant shutdowns and emergency maintenance at any chemical plant, refinery or manufacturing facility across the country creates many challenges for those involved. Whether the shutdown is planned or not, proper planning is critical to successfully completing the job.

Planning ahead to meet any potential shutdown or maintenance situation can save a facility significant time and money. Planning ahead can also help ensure that the proper products and equipment are available when needed. Keeping an inventory of long lead time or hard to find products can give a facility a major advantage in managing shutdown and emergency maintenance jobs.

An emergency inventory may or may not be possible for many facilities due to a variety of reasons such as cost and storage room for the inventory. KemFlo understands the challenges that facilities around the world face which is why we have significantly increased our manufacturing capabilities for producing the Tri-Packs, Saddle style and Pall Ring packing products. We have also increased the inventory levels for our plastic random packing in order to meet these demands. We also have several distribution locations for our plastic random packing which gives us a logistical advantage.

It is difficult to inventory the Tri-Packs, Saddle and Pall Ring packing in every available resin which includes polypropylene Polyethylene, Polypropylene with glass, CPVC, Kynar, Tefzel, Teflon, Halar and more. KemFlo addresses this in several ways. First, KemFlo has the most advanced injection molding equipment on the market today allowing us to produce high quality plastic random packing at a very fast rate. Secondly, KemFlo makes an investment in multiple raw material resin types so even if we do not have the Tri-Pack, Saddle style or Pall Ring packing in stock we can manufacture it quickly and efficiently.

Air scrubber internals are a very critical product so when a shutdown occurs it is very important to have access to all components especially the plastic scrubber packing. Whether the air scrubber internals include the Tripacks, Saddle style or Pall Ring packing, KemFlo has you covered.

In addition to our fast and efficiency production capabilities, our substantial inventory and several distribution locations, KemFlo employs a team of customer service experts who can assist in emergency and critical situations. Our customer service team works with customer to ensure the fastest and most cost effective shipping method available. They also keep the customer informed in regards to the progress of their specific order which allows the customer to plan and schedule the installation of the plastic random packing.

When is comes to plant shutdowns and emergency maintenance situations we know the importance of working closely with our customers to help ensure that their project or job is completed safely and efficiently. What ever size requirement you may have for plastic scrubber packing KemFlo can help. KemFlo’s Kempac plastic random packing is available in multiple sizes. The Tripacks are available in 1”, 2” and 3.5”. The Pall Ring packing is available in 1”, 2” and 3.5”. The Saddle style plastic scrubber packing is available in 1”, 2” and 3”.

For more information on KemFlo’s Tripacks, Saddle style and Pall Ring packing please visit our website at www.kempac-packing.com .

Troubleshooting Air Scrubber Internals

by | Oct 2, 2019 | Plastic Random Packing Articles

Having to troubleshoot air scrubber internals can be a complex process because there are so many things that can contribute to an under performing system. Air scrubber internals are typically designed based on very specific process data and performance parameters. Many details must be considered in the design and selection on Air scrubber internals such as material selection, configuration of the part and cost to name a few. All scrubber internals must be designed to work to gather in order to achieve maximum efficiency. Because there are so many factors involved in designing air scrubber internals troubleshooting an under-performing system can be complex and time consuming.

The first task that should be addressed when troubleshooting an air scrubber is to confirm and check all calculations and design data. In some cases a simple adjustment in the scrubber pressure or liquid rate may fix the efficiency issue. You can also consider making adjustments to the systems operations and settings. Secondary equipment such as blowers and pumps should also be tested to ensure that they are performing per their specific specifications.

It is important to check all process piping and connections for leaks. Leaks in piping, fittings or any other connection may result in significant pressure drop adversely affecting air scrubber’s performance. Another consideration when trouble shooting is the recirculation liquid. The solids concentration in the recirculation liquid may be too high and may require bleed-off and an increase in fresh water.  Air scrubbers and air scrubber internals may also be susceptible to corrosion which can lead to an increased amount of abrasive solids in the system which can cause plugging which affects the system’s pressure and may cause damage throughout the air scrubber. It is important to monitor the system’s PH levels in order to reduce corrosion.

A detailed inspection of the air scrubber internals may also be in order while troubleshooting. Each individual air scrubber internal including the mist eliminator, liquid distributor, bed limited, packing support, plastic random packing or any other internal may need to be inspected to confirm the design and check for damage. There are a number of potential issues related to the plastic random packing in a system. The plastic random packing or scrubber media is a very critical air scrubber internal because it provides an area for liquid and air contact.

The following are problems or concerns with respect to scrubber packed beds. If the system is experiencing water rate and pressure issues it may be because the liquid distributor is not evenly or fully distributing liquid over the bed of plastic random packing. The operator should check for plugs and confirm the liquid distributor’s pattern if possible. The packed bed may also flood if the liquid or gas flow is too high.

Careful inspection of the plastic random packing should also be done. The scrubber packing bed may become plugged due to solids. There are types of plastic random packing that are less susceptible to plugging such as the Kempac Tri-Pack or Pall Ring packing. Both the Tri-Pack and Pall Ring packing are specifically designed to prevent build-up and plugging. The chances of having to troubleshoot your air scrubber and air scrubber internals can be greatly reduced by implementing a maintenance program.

Packed Scrubber Components

by | Sep 24, 2019 | Plastic Random Packing Articles

KemFlo specializes in the manufacturing of plastic random packing which is utilized in air scrubbing, air stripping and other mass transfer applications. KemFlo is unique in that they have the ability to manufacture their plastic random packing in a variety of resins. While Polypropylene is the most common resin used in manufacturing plastic random packing, KemFlo also manufactures plastic random packing in specialty resins such as CPVC, PVDF, Polypropylene with glass, PFA and more. Please visit our website or call us for a complete list of available resins. Kemflo offers three different styles of scrubber packing, the Tri-Pack style, Pall Ring and Saddle. The Tri-Pack is available in 1”, 2” and 3.5”. The Pall Ring is available in 1”, 2” and 3.5”. The Saddle is available in 1”, 2” and 3”. While the packing type and size is one of the most important elements in the design of a scrubber there are other important components to consider such as packing supports, bed limiters, mist eliminators, liquid distributors and feed pipes.

Feed pipes are the initial stage of the distribution system and is vital to the performance of other components in a scrubber. The feed pipe typically consists of a header and may also include branches depending on the design. The header may be manufactured in plastic, metal or fiberglass. Another important component is the liquid distributor which ensures even distribution of a liquid over the packed bed of a scrubber column. Proper installation of the liquid distributor is critical to the performance of a system Ensuring that the liquid distributor is level during installation is very important in order to ensure proper distribution of liquid over the packed bed. The packing in a scrubber sits directly on the packing support and is held in place with a bed limiter which is installed directly above the packed bed. For example, KemFlo’s Tri-Pack packing would be sandwiched between a packing support and bed limiter ensuring proper positing of the packing and preventing the Tri-Pack from falling into the bottom of the system and creating pump issues or being blown into the upper levels of the scrubber and interfering with the performance of other components. Lastly the mist eliminator is used to remove mist from a gas stream. A mist eliminator typically consists of layers or coils of knitted wire mesh held together by support grids on the top and bottom. The wire mesh and support grids are typically available in metal alloys and plastics.

While the plastic random packing is only one of the critical components of a scrubber, KemFlo ensures that their plastic random packing is manufactured with the highest quality materials utilizing the latest technology. Whether a customer selects the Tri-Pack, Pall Ring or plastic Saddles are they getting the highest quality packing on the market. All of KemFlo’s resins can be traced back to the supplier’s specific resin batch ensuring a high level of quality control. For more information on KemFlo’s Tri-Pack, Pall Ring or Plastic Saddle please visit our website at www.kempac-packing.com or give us a call.

KemFlo Plastic Random Packing Products

by | Sep 24, 2019 | Featured Plastic Random Packing Article, Plastic Random Packing Articles

KemFlo manufactures a complete line of plastic random packing products for a variety of applications including Air Scrubbing, Air Stripping, Distillation, Biological Filtration and many more. KemFlo offers three different styles of plastic random packing, each offering unique physical properties and can be manufactured in a variety of plastic resins. Whatever your plastic random packing application is, KemFlo has a solution.

One of KemFlo’s most popular plastic random packing styles is the Tri-Pack. The Tri-Pack is a high-performance packing which helps customer achieve optimum performance from their system. The Tri-Pack is a hollow spherical column packing constructed of a unique network of ribs, struts and drop rods. Its superior geometric shape gives it an advantage over other products on the market. Their spherical shape allows each element to roll into the packed position without forming void areas common to irregular shaped packing. With Tri-Packs there is no need for allowances for settling and nesting is virtually impossible. The round Tri-Pack offers reliable and predictable loading of your tower which means more reliable and predictable performance of your system. In addition to the superior geometric shape, an active surface area is very important to mass transfer. The unique network of ribs, struts and drip rods have proven to give Tri-Packs a distinct advantage in providing excellent wetting qualities and maintaining liquid distribution through the packed bed. Excessive surface area can impede proper gas and liquid contact and always results in higher pressure. The Tri-Pack offers an optimum surface area to open area ratio which yields excellent mass transfer efficiency and reduced operating cost. Tri-Packs are available in 1”, 2” and 3.5”, and are manufactured using only prime, virgin resins. Almost any injection moldable resin is available. Some of the most common resins include PP, PE, PP-Glass, CPVC, PVDF, and more. Our Polypropylene material is NSF approved resin. Please feel free to contact us for a complete list of available resins.

The Kemlox plastic saddle is another plastic random packing product manufactured by KemFlo that offer excellent physical properties. The high capacity Kemlox plastic saddle packing offers distinct advantages over conventional saddle designs. The serrated edges promote high mass transfer rates through effective liquid surface removal. The serrated edges of the Kemlox reduce bed settling during operation and assist to maintain packing free space and create lower column pressure drop. The Kemlox plastic saddles are available in 1”, 2” and 3” sizes. They too are available in a variety of resins.

The KemFlo plastic Pall Ring is a robust plastic random packing featuring an open wall construction which maintains even liquid distribution. Reinforced struts provide additional surface area for gas-liquid contact and support the outer ring. The KemFlo plastic Pall Ring is available in 1”, 2” amd 3.5” sizes and numerous resins are available.

For more information on the KemFlo Tri-Pack, Saddle or Pall Ring, please feel free to call us or visit our website at www.kempac-packing.com.