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Metal Super Raschig Ring (Intalox Saddle): Capacity, Efficiency and Sizing Guide

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Metal Super Raschig Ring (Intalox Saddle): Capacity, Efficiency and Sizing Guide

Metal Super Raschig Ring (Intalox Saddle): Capacity, Efficiency and Sizing Guide
October 24, 2026

 

Metal Super Raschig Rings (Intalox saddle shape) piled showing open saddle geometry

Figure 1: Metal Super Raschig Ring (Intalox-style saddle) — saddle geometry eliminates parallel stacking, boosting capacity and reducing pressure drop vs. conventional Raschig rings.

Metal Super Raschig Ring (Intalox Saddle): Capacity, Efficiency and Sizing Guide

Engineer's Brief: The metal Super Raschig Ring (often called Intalox-style saddle) is a second-generation random packing that replaced the cylindrical Raschig ring. The saddle shape prevents parallel alignment, increases gas-liquid contact, and cuts pressure drop by 20–40% at the same throughput. It sits between ceramic Raschig rings (cheap, brittle) and wire mesh structured packing (high efficiency, high cost). FXSINO stamps Super Raschig rings from SS304/316L/410S/Ti in #25–#80 sizes, with wall thickness tuned to corrosion allowance and mechanical strength.

1. Why the Saddle Shape Wins

A conventional Raschig ring is a cylinder. In a packed bed, cylinders tend to stack in parallel columns, creating large open channels with poor gas-liquid contact. The saddle (Super Raschig / Intalox geometry) fixes this:

  • • No parallel stacking — saddle curvature forces random orientation; each piece blocks the channel of its neighbor.
  • • Larger open area per piece — the central "window" (punched or stamped) increases internal surface area without adding drag.
  • • Self-distribution — liquid spreads along the saddle curve, reducing wall-flow tendency.
  • • Mechanical strength — stamped from strip metal; no welding, uniform wall, handles thermal cycling better than ceramic.
Close-up of single metal Super Raschig Ring showing saddle curve and stamped window opening

Figure 2: Single saddle showing curved body and central window — the window adds mass-transfer surface while keeping pressure drop low.

2. Performance Data (Generic Reference)

Size Surface area
(m²/m³)		 Void
(%)		 Bulk density
(kg/m³, SS316L)		 Pieces/m³
(approx.)		 Typical HETP
(m)
#25 (1") ~185–200 95–96 ~380–420 ~62,000 0.4–0.55
#38 (1.5") ~130–145 96–97 ~310–350 ~20,000 0.5–0.7
#50 (2") ~95–110 97–98 ~250–290 ~8,000 0.6–0.85
#70 (3") ~65–80 98–98.5 ~200–240 ~2,500 0.8–1.1

Values are generic reference for stamped metal Super Raschig rings; replace with FXSINO measured data before publication. HETP varies with system, F-factor and L/G ratio.

3. Super Raschig Ring vs. Conventional Raschig Ring

Parameter Metal Super Raschig (saddle) Metal Raschig ring (cylindrical)
Capacity (flood point) +20–30% higher Baseline
Pressure drop at same F 20–40% lower Higher
HETP 0.4–0.8 m (typical) 0.6–1.2 m
Channeling tendency Low (random orientation) Moderate (stacking)
Cost ~1.3–1.5× Raschig ring Baseline (cheapest metal random)

4. Material Selection

  • • Carbon steel (Q235/A36): Clean non-corrosive hydrocarbons, amine treating (low temp). Cheapest option.
  • • SS304/304L: General service, mild aqueous, organics. Most common economy alloy.
  • • SS316L: Chloride trace, weak acid, sour water strippers. Default for refinery/chemical.
  • • 410S / 430: High temperature, oxidation resistance, no chlorides.
  • • Duplex 2205: High chloride + mechanical stress, seawater stripping.
  • • Titanium Gr.2: Wet Cl₂, hot brine, severe chloride corrosion. Premium.
Metal Super Raschig Rings in four sizes #25 #38 #50 #70 arranged for scale comparison

Figure 3: #25 through #70 Super Raschig rings — smaller size = more surface = higher efficiency but lower capacity and easier to foul.

5. Sizing & Selection Rules

  • • Tower diameter vs. size: Minimum packing size ≥ Dtower / 30. For DN1200 tower → minimum #38 (1.5"). Using #25 in a large tower causes wall-channeling and poor distribution.
  • • Liquid load: Super Raschig handles 5–80 m³/m²·h comfortably. Below 5 → consider wire mesh structured; above 80 → verify flood margin.
  • • Fouling tendency: For dirty service, go one size up (#50 instead of #38) to reduce blockage risk.
  • • Bed height: Single bed ≤6m for random packing; above that, add a redistributor every 5–6m.
  • • Support grid: Opening size < packing nominal size; free area > packing void fraction. See camel-hump support grid.

6. Application Map

Service Recommended size Typical alloy
CO₂ / H₂S amine absorption #38–#50 CS / 410S
Sour water stripper #38–#50 316L
SO₂ / NOx scrubber #50–#70 316L / Duplex
Vacuum distillation (short bed) #25–#38 316L / Ti
Solvent recovery #38 304L / 316L
Metal Super Raschig Rings being charged into absorption column through manway

Figure 4: Charging Super Raschig rings through manway — dump evenly, no single-side piling; verify distributor alignment before closing.

7. FAQ

Q: Super Raschig Ring vs. Pall Ring — which is better?

A: Pall rings have more uniform gas-liquid distribution at very low liquid loads. Super Raschig rings typically give 10–15% higher capacity (flood point) and slightly lower ΔP. For most absorption/stripping services, Super Raschig is the better all-around choice unless liquid load is extremely low (<3 m³/m²·h).

Q: Can I use metal Super Raschig in hot concentrated acid?

A: Metal will fail in hot H₂SO₄ >70% or hot HNO₃ regardless of alloy grade. For those services, switch to ceramic Raschig rings or ceramic structured packing.

Q: Wall thickness — thin or thick?

A: Thinner wall = more pieces per m³ = higher surface area = better efficiency, but less corrosion allowance. For clean service, 0.4–0.5mm (SS) is standard. For corrosive/erosive service, specify 0.6–0.8mm or step up to 410S/316L thick-gauge.

Specify Metal Super Raschig Rings for Your Column

FXSINO manufactures metal Super Raschig rings (Intalox-style saddle) in SS304/316L/410S/Duplex/Ti, sizes #25–#80. We supply matched support grids, distributors, bed limiters and redistributors. Send tower ID, service fluid, temperature, pressure and target capacity — we return size recommendation, bed height and hydraulic check.

Email: jackieqiu9202@gmail.com  |  +86 18507999558

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