PP INTALOX SADDLES
Manufactured by Plastic Fabricators
When packed towers don't function properly, issues with the packing rather than the tower itself are often the culprits. Poor liquid distribution as well as excessive pressure drop and inefficient gas-liquid contact all diminish process efficiency and increase costs.
To resolve these issues Plastic Fabricators launched the PP Intalox Saddle. These elements are designed to provide a high free volume and improved gas-liquid contact in a packtower. They outperform other designs and result in better process performance, reduced pressure drop, and increased mass transfer efficiency. For use in absorption columns, scrubbers, stripping towers, distillation units, and other process equipment, Plastic Fabricators manufactures high quality PP Intalox Saddles. Our random tower packing combines strength and hydraulic efficiency and is made of corrosion resistant polypropylene and is well suited for industrial applications.
TECHNICAL DATA
WHAT ARE PP INTALOX SADDLES?
PP Intalox Saddles are designed to optimize contact between the gas and liquid phases and are used in mass transfer operations in packed columns. Thousands of screw shaped packing are loaded into the tower in place of trays or solid internals in order to allow unobstructed flow and to create a large effective surface area. Random tower packing of polypropylene is well suited for industrial applications and packed columns.
PP Intalox Saddles differ from conventional rings since they are shaped like a saddle. Their curved shape and internal supports provide better liquid distribution, allowing a more uniform wetting of the surface, resulting in reduced channeling and enhanced absorption, stripping, and distillation operations.
WHY INDUSTRIES CHOOSE PP INTALOX SADDLES
COMPLETE PRODUCT RANGE
OUR PP INTALOX SADDLES
The level of performance of a packed column is highly dependent on the quality of the tower packing used. Even the best designed scrubbers and absorption towers will not function optimally when the packing limits flow, causes channeling, and/or produces a significant pressure drop.
Plastic Fabricators specializes in the production of Polypropylene Intalox Saddles used in industrial mass transfer applications that need both effective gas-liquid contact and resistance to all forms of liquid and atmospheric corrosion. Their one-piece molded design and optimized saddle profile provide strength coupled with free volume and large surface area.
When compared to traditional random packing that may create dead zones in a packed bed, Intalox Saddles naturally self-sort to create a highly open, irregular structure. This results in minimal resistance to gas flow and even distribution of the liquid phase.
PP INTALOX SADDLES
Description
Typically, two process streams move in opposite directions in a packed column. The liquid phase flows in a counter-current fashion to the gas phase across the packing.
When liquid flows through the packed bed, the saddle design deflects the liquid from flowing in a straight path. Consequently, there is repeated contact between the gas and liquid phases with thousands of different packing elements in a packed bed.
A larger portion of the packing surface actively engages in mass transfer because the liquid spreads more evenly. In addition, the open geometry lowers pressure drop while preserving high separation efficiency by allowing gases to flow through with comparatively little resistance.
Key Features
- Better liquid distribution
- Improved gas-liquid contact
- Lower pressure loss
- Higher operating capacity
- More stable tower performance
Common Applications
- Chemical Scrubbers
- Packed Absorption Columns
- Distillation Columns
- Stripping Towers
- Gas Washing Systems
- Chemical Processing Plants
- Fertiliser Plants
- Petrochemical Industries
- Acid Recovery Systems
- Water & Wastewater Treatment Plants
INDUSTRIES WE SERVE (APPLICATIONS)
PP Intalox Saddles are widely used wherever efficient gas-liquid contact is required inside a packed column.
Common applications include:
- Chemical Scrubbing Towers
- Acid Fume Scrubbers
- Packed Absorption Columns
- Distillation Columns
- Stripping Towers
- Cooling Towers
- Humidification Systems
- Dehumidification Systems
- Gas Washing Units
- VOC Removal Systems
- Air Pollution Control Equipment
- Water Treatment Plants
- Wastewater Treatment Plants
- Chemical Recovery Systems
- Solvent Recovery Units
- Odour Control Systems
- Fertiliser Plants
- Petrochemical Processing
- Pharmaceutical Processing
- Fine Chemical Manufacturing
ORDERING REFERENCE
SPECIFICATION APPROACH
Different process conditions, such as different gas flow rates, liquid loading, chemical compatibility, and operating temperatures, apply to each packed tower. Because of this, PP Intalox Saddles are produced in a variety of sizes to accommodate various tower diameters and process specifications.
For new installations, replacement projects, and OEM process equipment, Plastic Fabricators provides both standard and customized polypropylene Intalox Saddles.
| Product | Material | Construction | Typical Application |
|---|---|---|---|
| PP Intalox Saddles | Virgin Polypropylene | One-Piece Injection Moulded | Random Tower Packing |
| Available Sizes | Various Standard Sizes | Open Saddle Design | Absorption, Scrubbing & Distillation |
| Colour | Natural / Standard | UV Stable (on request) | Industrial Process Equipment |
Custom sizes and bulk supply are available for OEM manufacturers and project requirements.
APPLICATIONS BY INDUSTRY
WHY PROCESS ENGINEERS PREFER INTALOX SADDLES OVER CONVENTIONAL RANDOM PACKING ?
Random packing diminishes effective surface area for mass transfer as regions in packing can form where liquid flows unevenly and packing element gaps become narrow.
Uneven liquid flow regions and narrow gaps of the Intalox Saddle design are minimized due to the curved design, which has self resistant closure and therefore improved gas flow and more even liquid distribution. This increases operating capacity with less hydraulic resistance and improves column performance.
CUSTOM MANUFACTURING
WHY THE SADDLE DESIGN PERFORMS BETTER
The purpose of tower packing is to provide a maximum contact area for the two phases of the fluids while allowing free movement of the phases.
This is achieved in the Intalox Saddle by unique curved packing geometry.
Compared to the cylindrical packing geometry, the Intalox Saddle forms an open bed, and connects flow paths. While the gas streams move through the empty spaces in different directions, the liquid films spread along the curved surfaces. This results in increased opportunity and enhanced wetting of the packing surface.
Unlike traditional cylindrical tower packing designs, the Intalox Saddle packing geometry results in a packing configuration that helps control mass transfer in the bed and stabilizes the performance of the packed bed.
Improved absorption and stripping, reductions in required blower power, stable pressure drops, enhanced use of tower volume, and long stable operating conditions are some of the benefits experienced by plant operation personnel.
- ✓New Process Plant Installation
- ✓Expansion of Plants
- ✓Original Equipment Manufacturing Companies
- ✓Tower Overhaul
- ✓Packing Replacement
- ✓Process Upgrade
- ✓Bulk Quantities Supply
- ✓Standard Industrial Sizes
- ✓OEM Manufacturing
- ✓Custom Packaging
- ✓Project-Based Supply
- ✓Large Quantity Production Runs
TECHNICAL SUPPORT
We Provide Full Technical Support
Our technical team is available to help you select the right profiles, verify load capacities, and confirm chemical compatibility for your specific application.
When requesting a quotation, sharing the following information helps us recommend the most suitable product.
- ✓Load capacity calculations
- ✓Material selection guidance
- ✓Installation recommendations
- ✓Chemical compatibility data
- ✓Sample profiles for testing (charge applies)
- ✓Project quotations
- ✓Technical questions
- ✓Custom profile development
- ✓Bulk order pricing
ORDERING INFORMATION
How to Order
Getting the right polypropylene component starts with understanding your application. Share your operating requirements, and our team will recommend the most suitable product and configuration.
- →Tower Diameter
- →Tower Height
- →Packing Size Required
- →Process Application
- →Chemical Media
- →Operating Temperature
- →Required Quantity
- →Delivery Location
Call or message for pricing, stock availability, technical data sheets, sample requests, and custom quotes.
- 📞+91 98200 80431
- 📞+91 85919 42677
- ✉️mitesh@plasticfabricators.in
- 📍A-31, Second Floor, Ghanshyam Industrial Estate, Veera Desai Road, Andheri (West), Mumbai – 400053
All information accurate as of publication. Specifications subject to change with process improvements. Call to confirm current specifications for your application.
Ready to Order or Quote?
Call or message us directly. We provide load calculations, material selection guidance, chemical compatibility data, and sample profiles.