Jun. 05, 2025
The porous metal sparger is an element that can generate airflow uniformly and diffuse bubbles of a specific size. The porous sparger effectively transfers the gas to the liquid, and its surface has millions of tiny pores, which transfer countless tiny gas bubbles to the treatment liquid. The perforated metal sparger is used in a range of different applications in almost every industry. If you need to introduce gas into liquid in any type sparger of critical application, for example, sparger in bioreactors, sparger in fermenter. By controlling the porosity of the porous metal, it is possible to ensure uniform permeability and maintain consistent/repetitive performance every time.
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The bubble size is essential for optimizing mass transfer and reducing gas consumption and energy costs. As a manufacturer of porous media and components, we can specify, design, and manufacture high-efficiency products suitable for specific applications. The sintered porous sprinkler generates more and smaller bubbles than any other type of sparger, thus increasing the gas/liquid contact surface area, reducing the time and volume required to dissolve gas into liquid, and greatly increasing the transfer rate.
The advantage of the SAIFILTER porous gas sparger is that compared with all stainless-steel gas spargers, the pore structure is closely consistent. This consistent pore structure provides a higher bubble point, resulting in tiny and consistent bubbles.
Since the size of the bubbles formed by the sprinkler is 10-100 times the size of the aperture, there is a certain pressure drop during the operation of the sparger, and the aperture is easily blocked by solid particles during long-term operation. They are only suitable for laboratory-scale non-stirred containers and small-scale containers. Therefore, it is still a contradiction when reducing the pore size of the bubble and preventing clogging.
Rugged and Durable: Compared with other non-metallic materials, all stainless-steel structures can be used for many years. Due to the fully welded structure design and high structural integrity, the porous metal sprinkler will maintain trouble-free operation for many years.
High Strength: The porous sparger made of metal material sintering process can withstand high tensile strength, which makes it suitable for applications that work at high flow rates and high pressures.
Uniform porosity: The sintered metal process facilitates the construction of porous sparger with uniform pore diameters. For different grades of media materials with different pore diameters, you can control the size of the bubbles generated according to the specific application.
Reusability: Generally, an ultrasonic bath can be used to easily clean the porous gas sparger, and the efficiency of the metal porous sprayer can be restored to close to the original state.
Heat Resistance: The fully welded structure can withstand higher temperatures even in corrosive environments, and at the same time mechanical shock or thermal cycling has almost no effect on porous metals.
Jump Ahead:
When choosing random packing media, you must consider several selection factors. Understanding the reasons for using random packing instead of structured or stacked tower packing also plays an important role when servicing a tower. Use this guide to choosing random packing media to aid your selection process.
When considering how to choose tower packing, you have options for random and structured packing. These differ significantly in how contact occurs between fluids. For the purposes of this guide for the selection of tower packing, the focus will remain on random packing.
Towers allow for mass transfer or chemical separation in one of two ways, depending on whether they have trays or packing media. For trayed towers, vapor moves up through liquid to enable mass transfer by increasing the surface area. Packed towers use gravity’s force and the shape of the packed media to enable mass transfer. Ideally, there should not be anything left once the liquid passes through the packed material portion of the tower.
An optimal packing media will effectively spread out fluids that flow through them, increasing the surface area.
Random tower packing simply pours the filtration media into the tower. The uneven distribution and orientation of the parts increase the surface area and enhance the transfer of mass between two fluids. The benefits of random packing media only come from narrow towers without ready access. In some instances, random packing material may augment existing material to increase a tower’s capacity.
The media used for this type of packing have a variety of shapes. The shapes determine the total surface area, uniformity of distribution, wetting area and more. You can use these selection criteria of packing to find the best media for a specific application.
Random tower packing is used in several sectors. Most often, industries that handle the following may use random packing:
Several factors determine how to use packing in a tower. Random packing is suitable for any size tower, and the size of the tower will determine how much packing is needed. Packed columns have a lower pressure drop because the packing has a greater open area compared to trays. However, structured packings, such as corrugated sheets, have an even lower pressure drop than random packing. Also, packing works as a better alternative to trays in situations that require the media to come into contact with corrosive materials.
To use random packing, individuals pour the selected media into the tower. Selecting the correct media matters more than the pieces’ arrangement.
Both dry and wet packing methods exist based on the media used. Dry packing works best for durable materials, such as plastics and metals. Filling the tower requires either a rope and bucket method or a chute and sock method, both of which are variations of dropping the media into the column.
For delicate media like ceramic or carbon, it’s best to use a wet packing method. Filling the space with water before adding the media prevents breakage as the water cushions the pieces’ fall into the tower. Because wet packing allows for more randomness in the media arrangement, it reduces pressure drop in the column and increases capacity. Before using the tower, however, you must drain the packing water and allow the media to dry thoroughly. The extra steps required for wet packing are some of its only disadvantages.
Both methods of packing a tower make random media a preferred option for any towers that need a solution for increasing capacity.
Packing towers offer filtration benefits that multiple industries take advantage of. The material flowing through the tower often dictates the type of packing media required.
Multiple industries use random tower packing. The applications of tower packing within these sectors include the following:
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Random packing works best in some types of towers or when operation towers require certain characteristics of mass transfer, including:
To understand how to select random packing, you must know about the options available. These various shapes also have different materials in their construction. Both the shape and makeup of the media will affect the best applications for it. These eight options reflect a small number of the random packing media available. With customization options and proprietary designs from MACH like our MACH Bio-Media rings for wastewater treatment, you have many options for media in a random packing tower.
Raschig rings are one of the oldest packing media. These were first-generation media, introduced between and . Due to their simple design of a basic ceramic ring, Raschig rings are rarely used in towers today. The pall ring evolved from this media’s structure, improving upon the original design.
The Pall ring’s design features a more open variation of the closed Raschig ring to introduce openings on the sides. The updated design allowed for a greater surface area compared to its predecessor. Pall rings are among the second-generation designs, which came into use between the later half of the s and the s.
Pall rings come in plastic, metal and ceramic compositions. Customization of the polymers used and the sizes of the plastic rings allow for adaptation to multiple uses. Metal Pall rings made from aluminum, carbon steel or stainless steel can better resist corrosion and high temperatures than their plastic counterparts. Ceramic pall rings provide an increased absorbency because they are thicker than plastic rings.
We call this design the MACH Hi-Ring. The Hi-Ring features a large void space, low specific gravity and high physical strength. These rings work best in environmental applications, oil and gas industries, chemical sectors and alkaline chloride use.
The original saddle, the Berl saddle, was another first-generation fill product introduced between and . Over time, engineers have improved upon the simple original saddle design. Modern metal saddle rings, also known as IMTP, offer better performance in high-capacity situations. The metal saddle rings used today are a third-generation design, introduced after the s.
Super saddles are a third-generation design that has a wider shape than other saddle products. Made from ceramic or plastic, the larger saddle shape offers a greater surface area for more mass transfer compared to smaller products.
As a second-generation product, the metal Intalox saddle came into use between the s and s. Many designs today have improved on this saddle design. Like most older models, modern variations of Intalox saddles have replaced them.
Tri-Packs have an innovative design that works best in degasifiers, strippers and scrubbers. The industry introduced these plastic fill pieces in the late s. Each piece has a shape like an open sphere with ribs evenly spaced along the sides and on the interior. These ribs permit even liquid distribution to allow for unimpeded contact between gases and liquids.
We call these MACH Super Rings. As a third-generation design, our MACH Super Rings offer many benefits of later models. Made from stainless steel, the MACH Super Rings come in sizes varying from 0.1 inches up to 4 inches. The open weave design maximizes contact, reduces pressure changes, creates more stability and resists fouling.
Many applications use this ring, including the treatment of liquid natural gas, the production of butadiene, separating methane from heavy hydrocarbons and the removal of carbon dioxide and hydrogen sulfide from biogas and natural gas.
When choosing random packing materials, several factors will narrow down the options available for your application. Ask yourself the following questions:
To help decide if a media works with your process, consider its surface area, wetting area, friction and other performance factors to find the ideal option to use in your tower.
Increase efficiency by choosing random packings with a greater surface area. The more surface area per volume of the packing, the higher the vapor liquid contact. On average, the latest random packing media have a surface area of 300 square meters per cubic meter. The surface area you get from your media depends on multiple other factors, including the size and shape of the pieces.
Each material has an inherent wetting rate. If the liquid load drops below the wetting rate, the surfaces of the packings will dry out. The effects of liquids dropping below the wetting rate for the given material include decreased efficiency.
The benefit of random packing is the lack of structure the material creates. When pieces interlock, they can create paths for fluid flow. When fluids have the chance to move along channels, the system loses efficiency.
How the surfaces of the media spread fluids determines their efficiency. While surface area plays an important part in how efficiently the system operates, when pieces have a uniform spreading surface to allow more vapor liquid contact, the packing works better.
Increasing the amount of void space as much as possible reduces the chances the media will slow down the upward movement of vapor through the system. Due to more void space inside the parts, the capacity of a tower will rise when using larger random packing pieces.
Lower friction for packing media opens spaces between the pieces and inside them. With more space, the tower has a greater capacity and operates more efficiently.
The mechanical strength of the material should withstand compression and other damage from typical use in a tower. Resisting corrosion and thermal damage also contributes to the overall strength of a packing media.
The materials available include plastics, ceramics and metals. Within each of these categories, you have more options for the types of polymers or metals used:
Random tower packing is suitable for any size tower and provides numerous benefits. The advantages of random packing media include the following:
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