Koch Asia Pacific Product Lineup

This product is a solution composed of high-performance internal devices (Proflux Severe Service Grid, high-performance Structured Packing, Enhanced Vapor Horn) developed to achieve high reliability, low pressure loss, and high processing capacity in "Severe Service" applications such as heavy oil processing and vacuum distillation towers. The wash bed and flash zone of the vacuum distillation tower operate under harsh conditions with high temperatures (700–760°F), high fouling, and significant coking risks, making cleaning performance, de-entrainment performance, and fouling resistance extremely important. This solution achieves a 10% increase in processing capacity, a significant reduction in pressure loss, and improvement in HVGO quality that cannot be obtained through conventional equipment "like-for-like replacement (RIK)," and significant operational benefits have been confirmed at the Canada CCRL refinery.

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The FLEXIPRO valve tray is the latest generation of fixed valve tray technology developed by Koch-Glitsch, achieving improvements in capacity, separation efficiency, and operating range beyond the conventional FLEXITRAY and PROVALVE. This technology was born from an advanced development process utilizing CFD analysis, 3D CAD, and metal 3D printing, designed to meet the industry's demands for "high efficiency, low pressure drop, high reliability, and wide operating range" with a single valve. ■ Key Technical Features - Newly developed fixed valve structure: high reliability and stable performance - Side curtain + louver shape: improved efficiency through enhanced mixing - Extruded deck openings: suppression of liquid backflow/weeping - High capacity performance: up to 27% improvement compared to conventional (FRI test) - High efficiency: over 90% tray efficiency - Wide operating range (4:1): strong against load fluctuations ■ Achievements and Third-Party Evaluation The FLEXIPRO valve has been confirmed to have high performance in the U.S. FRI test, achieving a 7% capacity improvement compared to the conventional PROVALVE (calculated at the same pitch).

• Distillation Apparatus

The performance of a distillation column is greatly influenced by the contact efficiency between vapor and liquid on the trays, and the valve structure is a crucial factor directly related to energy efficiency, processing capacity, and operating range. Conventional sieve holes and T-type movable valves are effective, but they have challenges such as: - Vapor tends to be biased upward - Insufficient mixing near the deck - Limitations in stability during load fluctuations The latest FLEXIPRO floating valve features a design based on CFD analysis and actual machine testing, providing the following advantages: - Suppression of liquid entrainment with downward vapor flow - Improved mass transfer efficiency through strong mixing at the deck level - Uniformization of froth through forward extrusion action - Significant reduction of weeping at low loads with an extrusion molding structure - A wide operating range (approximately twice the turn-down of T valves) As a result, it is possible to achieve up to a 35% increase in processing capacity and energy savings compared to conventional valves. In the case of a diisobutylene separator, effects such as approximately 30% reduction in equipment weight have been confirmed through tower diameter reduction, tower height reduction, and tray spacing optimization, leading to CAPEX reduction.

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This case study presents an example of resolving tray blockage caused by phosphates in a crude oil distillation unit (CDU) using fouling-resistant tray technology. Phosphate esters contained in high TAN crude oil and corrosion inhibitors decompose inside the tower and adhere to the openings as phosphates. This leads to the obstruction of vapor flow and results in the following issues: - Abnormal increase in differential pressure (DP) due to blockage of openings - Liquid accumulation in the LK-HK section - Deterioration of product quality such as color and flash point - Increase in tower pressure → decrease in evaporation rate → deterioration in yield - Resulting in a reduction in processing capacity To continue operations, a portion of the internal reflux was first bypassed (LKPA → HKPA) to adjust the section load. DP improved, and quality was restored. Furthermore, as a long-term measure, Koch-Glitsch's Superflux fouling-resistant trays were adopted. Key features: - Self-cleaning effect due to fixed valves - Suppression of solid retention and stable froth flow - Directional valves that reduce peripheral retention - Long-term stable operation even under severe fouling conditions Inspection after implementation showed that the phosphorus content, which was previously over 21%, was reduced to below 2%, and DP stabilized at 0.4 kg/cm². The fouling suppression effect was confirmed.

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Koch-Glitsch's KY-FIBER media is a high-efficiency product specially designed to separate fine dispersions of one liquid phase from another liquid phase. KY-FIBER media is a high-efficiency product specifically designed to separate fine dispersions of one liquid phase from another liquid phase. Depending on chemical compatibility and wettability, these elements incorporate glass fibers, carbon, or plastic fibers, which are arranged between concentric screens within a metal or plastic cage. Similar to the FLEXIFIBER(R) mist eliminator, these elements are mounted via a flange attached to the tube sheet contained in the separator. The liquid phase is forced to flow radially through the media, allowing small droplets of the dispersed phase to coalesce and separate from the continuous liquid phase. Due to the performance characteristics of KY-FIBER media, it is suitable for dispersions that create a hazy appearance. Typically, these dispersions are difficult to separate with long settling times or conventional media. KY-FIBER media is not recommended for fouling services.

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The handling of corrosive chemicals such as sulfuric acid and chlor-alkali requires robust equipment designed to withstand harsh operating conditions. Koch-Glitsch provides durable and efficient solutions that ensure the safe and reliable processing of corrosive chemical streams. Chlor-alkali production Chlorine is a widely used industrial chemical produced through the chlor-alkali electrolysis process. The first step is the decomposition of salt solution under electrolytic conditions, resulting in the following reaction: 2NaCl + 2H2O → Cl2 + H2 + 2NaOH This reaction produces both elemental chlorine and sodium hydroxide (caustic soda) as secondary desirable products. After the initial electrolysis, the products are separated and concentrated through a series of evaporator vessels, including a mist eliminator made of nickel alloy. Sulfuric acid production The amount and type of mist generated at specific locations in sulfuric acid plants can vary significantly depending on the type, age, design, and operation of the acid plant. There are many types of mist eliminators used in sulfuric acid drying and absorption towers and tail gas scrubbers.

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Reduce energy consumption, increase capacity, optimize installation area, and streamline complex separation using Dual Wall Column (DWC) technology.

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We will verify the performance of the tower and separator, reduce uncertainty, and improve reliability through computational fluid dynamics (CFD) modeling based on real-world expertise.

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Bed limiter regulation filler

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Bed limiter

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Vapor horn

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Collector tray

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Feed pipe

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Distributor

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Flexipac plastic

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CMR

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Snowflake Random Packing

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KY-MESH liquid-liquid coalescing media consists of a mixture of metal and non-metal wires and fibers designed for specific chemicals involved. Applications where droplets are small and sedimentation is very slow or does not occur at all pose significant challenges. The solution focuses on increasing droplet size so that droplets can quickly separate due to gravitational sedimentation, minimizing the length of the container. The KY-MESH liquid-liquid coalescer is composed of a mixture of metal and non-metal wires and fibers, designed to match the properties of the specific chemicals involved. The internal shape promotes the growth of droplet size and maximizes liquid throughput at the minimum container diameter.

• Atmospheric distillation unit
• Vacuum Distillation Apparatus

Super INTALOX(R) random packing from Koch-Glitsch is favored by designers and industries using ceramic saddles but needing the superior performance of plastic.

• Distillation Apparatus
• Distillation and fractionation equipment
• Atmospheric distillation unit

CASCADE MINI-RINGS(R) random packing offers high mass transfer efficiency, low pressure drop, and mechanical strength, making it ideal for applications requiring optimal separation performance.

• Distillation Apparatus
• Distillation and fractionation equipment
• Atmospheric distillation unit

FLEXIRING(R) random packing is an economical and versatile industry standard, featuring openings in its cylindrical design that enhance internal mass transfer area and reduce pressure drop compared to traditional Raschig Rings.

• Distillation Apparatus
• Distillation and fractionation equipment
• Atmospheric distillation unit

FLEXIGRID(R) and GLITSCH GRID(R) severe service grid packing from Koch-Glitsch are advanced solutions engineered to improve the efficiency and reliability of separation processes in severe industrial environments. These grid packings are characterized by greater material thicknesses compared to conventional structured packing and feature welded construction, providing additional resistance to fouling, upsets, and erosion.

• Distillation Apparatus
• Distillation and fractionation equipment
• Atmospheric distillation unit

VORSOMAX(R) mist eliminators deliver very high gas handling capacity combined with excellent droplet removal efficiency at elevated pressures.

• Distillation Apparatus
• Distillation and fractionation equipment
• Atmospheric distillation unit

FLEXICHEVRON(R) mist eliminators collect particles greater than 8 to 40 microns in diameter, depending on design parameters and operating conditions. These mist eliminators are baffle or zigzag blade modules tailored for either vertical or horizontal flow installations. They can be manufactured in almost any size from a wide range of metal alloys, thermal-set plastics and fiber-reinforced plastic (FRP), offering versatile options to meet specific application needs.

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• Distillation and fractionation equipment
• Atmospheric distillation unit

For over 70 years, the DEMISTER(R) mist eliminator, originally developed by Otto York, has been delivering reliable and efficient mist removal, enhancing process performance, and protecting equipment across industries.

• Distillation Apparatus
• Distillation and fractionation equipment
• Atmospheric distillation unit

PROFLUX(R) severe service grid packing delivers superior performance in high-fouling and high-capacity applications, combining exceptional mechanical strength with low pressure drop to meet the demands of challenging operating environments.

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• Distillation and fractionation equipment
• Atmospheric distillation unit

INTALOX® random packing and other advanced models provide industry-leading solutions for mass transfer with improved efficiency, low pressure drop, and optimized separation performance across various applications.

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• Distillation and fractionation equipment
• Atmospheric distillation unit

The existing spare parts manufactured by Peabody Engineering are currently handled by John Zinc.

• Heating device

The existing spare parts from TODD Combustion are currently handled by John Zinc.

• Heating device

The existing spare parts manufactured by COEN are currently handled by John Zinc.

• Heating device

Our Steamizer XP steam-assisted flare is an advanced system that embodies the pinnacle of steam-assisted flare technology. It is designed to achieve high-efficiency combustion and smokeless operation, significantly contributing to the reduction of emissions and improving compliance with environmental regulations. With its innovative design and robust structure, it delivers reliable performance across a wide range of industrial applications. This flare promotes the mixing of steam and exhaust gases through optimized steam injection, enabling cleaner and more efficient combustion. This minimizes smoke generation and suppresses the production of harmful pollutants, supporting compliance with stringent environmental regulations. Additionally, its durability-focused design ensures long-term reliability and reduced maintenance burdens, making it a cost-effective solution for industrial flare systems.

• Heating device

The COOLstar burner embodies the latest advancements in ultra-low NOx combustion technology. Its unique tile design and integrated Coanda surface achieve high levels of fuel and exhaust gas mixing performance as well as flame stability. Additionally, this burner has a wide range of applications and can accommodate various fuel compositions, including natural gas and hydrogen co-firing. It can be applied to a broad range of equipment, from oil refining processes to ethylene production. Through various tests and practical applications, its high reliability, low emissions (low NOx) performance, and excellent operational efficiency have been confirmed.

• Heating device

•　Chentronics •　KEU •　McGill •　KAIDAR •　Peabody Engineering •　HAMWORTHY COMBUSTION •　TODD Combustion •　COEN

• Industrial Furnace

The FLEXIPRO(R) floating valve tray has up to a 30% increase in capacity compared to traditional floating valve trays. - High efficiency with an expanded operating range - up to 9:1 turndown - Improved reliability due to anti-fouling features

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• Distillation and fractionation equipment
• Atmospheric distillation unit

FLEXIPRO(R) Fixed Valve Tray

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• Distillation and fractionation equipment
• Atmospheric distillation unit

SUPERFRAC(R) trays by Koch-Glitsch encompasses a suite of high-performance distillation trays, including SUPERFRAC(R) and SUPERFRAC(R) XT, designed to maximize capacity and efficiency in separation processes.

• Distillation Apparatus
• Distillation and fractionation equipment
• Atmospheric distillation unit

FLEXITRAY(R) valve trays are versatile and cost-effective, combining high capacity and excellent efficiency with a wide operating range, making them suitable for various liquid-vapor contacting applications.

• Distillation Apparatus
• Distillation and fractionation equipment
• Atmospheric distillation unit

MONTZ STRUCTURE PACKINGS MONTZ MASS TRANSFER TRAYS MONTZ COLUMN INTERNALS MONTZ DIVIDING WALL COLUMNS MONTZ MINI PLANT COLUMNS MONTZ FALLING FILM EVAPORATORS MONTZ REFLUX SPLITTERS

• Concentration Equipment

Alcohol/Beverage Montz Processing Units for Beer and Wine

• Concentration Equipment

Demister/DEMISTER(R) Mist Eliminators FlexiChevron/FLEXICHEVRON(R) Mist Eliminators FlexiFiber/FLEXIFIBER(R) Mist Eliminators KOCH-OTTO YORK(R) separations technology

• filter

FLEXIPAC(R) structured packing technology enhances mass transfer efficiency with its high surface area, low pressure drop, and versatile material options, making it ideal for distillation and absorption processes

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• Distillation and fractionation equipment
• Atmospheric distillation unit

FLEXIPAC(R) structured packing FLEXIPAC(R) HC(R) structured packing

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FLEXIRING(R) random packing IMTP(R) random packing CASCADE MINI-RINGS(R) Random Packing (CMR Random Packing)

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• Atmospheric distillation unit

Polypropylene, PVDF, ETFE, and others.

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