99% High-Purity Alumina Raschig Rings for Catalyst Support & Mass Transfer

Alumina Raschig Rings Applications

• Chemical Processing & Petrochemical Refining

  Scenario: In packed bed reactors, these rings serve as an inert top layer and support structure for expensive catalyst beds.

  ✅Key Advantages

  1.  Prevents catalyst crushing under a bed weight that can exceed 50,000 kg, avoiding reactor plugging.
  2. With <0.1% leachable silica, it protects catalysts from poisoning, extending catalyst life by up to 25%.
  3. Withstands exothermic reaction temperature spikes up to 1600°C without degradation.

  ✅ Problem Solved

  A European specialty chemicals producer was experiencing a 15% annual loss in catalyst activity due to support media fracturing. By switching to our high-strength Alumina Raschig Rings (Crushing Strength >30 KN), they eliminated premature catalyst replacement, saving an estimated €80,000 per reactor annually in material and labour costs.

• Environmental Engineering & Gas Treatment

  Scenario: Used as mass transfer media in absorption towers (scrubbers) for removing pollutants like SO₂ and H₂S from industrial exhaust gases.

  ✅Key Advantages

  1. Shows a weight loss of less than 0.2% after 1000 hours in 49% H₂SO₄, ensuring long service life in acidic environments.
  2. The defined geometry provides a consistent wetted surface for efficient gas-liquid interaction and pollutant capture.
  3. A typical void fraction of 68-75% ensures low pressure drop, reducing fan energy consumption by up to 10% compared to smaller, irregular packings.

  ✅ Problem Solved

  A US-based power plant's flue-gas desulfurization unit faced frequent maintenance due to the degradation of its previous ceramic packing. Our 99% Alumina Raschig Rings have been in service for over 5 years without replacement, maintaining >98% SO₂ removal efficiency and reducing operational costs.

• Thermal Processing & Heat Exchange

  Scenario: Functions as regenerative heat exchange media in Regenerative Thermal Oxidizers (RTOs) to capture and reuse thermal energy.
  ✅Key Advantages

  1. Withstands rapid thermal cycling from 200°C to 1100°C every 60-90 seconds without cracking, a common failure point for lower-grade ceramics.
  2. The high-density alumina material possesses a specific heat capacity of ~0.9 J/g·K, enabling efficient thermal energy storage and achieving >95% thermal efficiency in RTO units.
  3. The inert nature prevents any chemical reaction with volatile organic compounds (VOCs) in the waste gas stream, ensuring complete oxidation.

  ✅ Problem Solved

  An automotive paint shop's RTO system was failing to meet its designed thermal efficiency due to media degradation. Replacing the existing media with our thermal shock resistant Alumina Raschig Rings restored the system to 97% thermal efficiency, resulting in a 12% reduction in natural gas consumption.

Alumina Raschig Ring Usage Instructions

Proper handling extends the service life of your ceramic packing and ensures optimal process performance.

• Installation

  1. Wet Loading: For most applications, fill the tower with water first (water cushioning) and then slowly dump the rings to prevent breakage from impact.
  2. Dry Loading: If dry loading is necessary, use a chute or sock to minimize the drop height of the rings into the tower. Never dump directly from a large height.

• Operation

  1. Avoid sudden, extreme temperature changes (thermal shock) beyond the material's specified limits, especially during startup and shutdown.
  2. Ensure the liquid distributor is functioning correctly to provide uniform wetting of the bed, which prevents dry spots and localized overheating.

• Storage

  Store rings in their original, unopened packaging in a dry, covered area to prevent contamination from dust, moisture, or chemicals.

• Cleaning

  If fouling occurs, rings can often be cleaned via chemical washing or controlled bake-out procedures. Consult with our engineers for a recommended procedure based on the foulant type.

• Common Issues & Solutions

  1. Issue: Increased Pressure Drop. This often indicates ring breakage and bed compaction.
  Solution: During the next scheduled shutdown, inspect the top layer of the bed for broken pieces. If significant breakage is found, a bed replacement may be necessary. Review loading procedures to prevent future issues.

  2. Issue: Reduced Mass Transfer Efficiency. This can be caused by fouling or poor liquid distribution.
  Solution: First, check and clean the liquid distributor nozzles. If the problem persists, the packing may be fouled. A chemical cleaning cycle is recommended.

  3. Issue: Catalyst Contamination. If using as a support, this points to media degradation.
  Solution: Analyze the support media for signs of chemical attack. You may need to upgrade to a higher purity alumina (e.g., 99% to 99.7%) for improved corrosion resistance.

Alumina Raschig Rings FAQ

1. Q: What is the difference between Alumina Raschig Rings and ceramic saddles or Pall rings?
   A: Alumina Raschig Rings offer a simpler geometry, providing high mechanical strength and reliability. While saddles or Pall rings may offer lower pressure drop in some specific applications, Raschig rings are often the most cost-effective and robust choice for catalyst support and harsh chemical environments.
2. Q: How do I determine the right size of Alumina Raschig Ring for my tower?
   A: The general rule is that the packing diameter should be no more than 1/8th of the tower diameter to avoid poor liquid distribution from wall effects. Our engineers can help you select the optimal size based on your tower dimensions and process parameters.
3. Q: What is the maximum operating temperature for your 99% Alumina Raschig Rings?
   A: Our 99% Alumina Raschig Rings can be used continuously at temperatures up to 1680°C (3056°F) in most atmospheres.
4. Q: Can I get a small quantity of Alumina Raschig Rings for lab-scale testing?
   A: Yes, we support R&D and pilot projects by offering small quantity orders and sample packs. Contact us with your requirements.
5. Q: How does the alumina (Al₂O₃) content affect the performance of the Raschig rings?
   A: Higher alumina content directly correlates with better chemical resistance (especially against alkalis), higher temperature stability, and greater mechanical strength. 99%+ alumina is for the most demanding applications, while 92% can be a cost-effective choice for less severe conditions.
6. Q: What is the lead time for a custom order of Alumina Raschig Rings?
   A: Lead time for custom orders typically ranges from 4 to 6 weeks, depending on the complexity of the specification and current production schedules. Standard, in-stock items can be dispatched within 24-48 hours.

Client Reviews about Alumina Raschig Rings

• ⭐️⭐️⭐️⭐️⭐️
  The 99% alumina raschig rings we purchased from ADCERAX for our sulfuric acid scrubber have shown zero signs of degradation after two years of continuous service. The previous supplier's product lasted only 18 months. The quality is evident.
  -- David Schmidt, Lead Process Engineer, BASF Germany
• ⭐️⭐️⭐️⭐️⭐️
  We required a custom-sized alumina raschig ring with a very specific wall thickness for our pilot reactor. The ADCERAX team provided excellent engineering support, delivered on time, and the parts met every dimension on our drawing. The process was seamless.
  -- Dr. Kenji Tanaka, Senior Researcher, Mitsubishi Chemical, Japan
• ⭐️⭐️⭐️⭐️⭐️
  As a distributor, having a reliable source for high-quality inert packing is critical. The crushing strength of these alumina rings is consistently higher than that of other suppliers we've tested, which gives our customers confidence and reduces our liability.
  -- John Peterson, Product Manager, Core-Flow Technologies, USA
• ⭐️⭐️⭐️⭐️⭐️
  We replaced the media in our RTO with their thermal shock-resistant alumina raschig ring. Our natural gas consumption dropped by over 10% due to the improved thermal efficiency. The payback period for the investment was less than 12 months.
  -- Fatima Al-Jamil, Plant Manager, SABIC, Saudi Arabia