Pingxiang Daier Ceramic Intalox Saddle Ring for Sulfuric Acid Drying Tower Ammonia Scrubber Chemical

Ceramic Intalox Saddle Ring – Engineered Random Packing for Sulfuric Acid, Ammonia Scrubber & Chemical Absorption Columns | Pingxiang Daier

Pingxiang Daier Separation Tech Co., Ltd. (spelled D-A-I-E-R) is a Taiwan-invested manufacturer specializing in ceramic random packing for chemical, petrochemical, fertilizer, and environmental applications. Based in Pingxiang, Jiangxi – one of China's major industrial ceramics hubs – DAIER has been delivering engineered separation solutions since 2009.

This article examines how DAIER Ceramic Intalox Saddle Rings perform across three demanding industrial services: sulfuric acid drying and absorption towers, ammonia scrubbers in fertilizer production, and high-temperature chemical absorption columns.

What Makes DAIER Ceramic Intalox Saddle Ring Different

The Ceramic Intalox Saddle Ring is an improved random packing design evolved from the traditional ceramic arc saddle. By varying the radius of curvature on both arched surfaces, this design eliminates the nesting problem commonly found in earlier saddle packings. The result is more uniform porosity distribution, better fluid distribution, greater capacity, and lower pressure drop compared to ceramic Raschig rings.

DAIER Ceramic Intalox Saddle Ring – Key Specifications:

Standard sizes: 25mm (1"), 38mm (1.5"), 50mm (2"), and 76mm (3") with custom dimensions available upon request.

Application 1: Sulfuric Acid Drying and Absorption Towers

Sulfuric acid production relies on drying towers to remove moisture from SO₂ gas using concentrated sulfuric acid, and absorption towers to capture SO₃ for oleum or finished acid. Both operate under highly corrosive conditions at elevated temperatures.

Process Demands: Packing must resist concentrated sulfuric acid at temperatures often exceeding 400°C in the SO₃ absorption section. Traditional Raschig rings can suffer from channeling and uneven liquid distribution, reducing acid absorption efficiency.

DAIER Solution Advantages:

• Acid Resistance > 99.6% – DAIER ceramic saddle rings resist corrosion from concentrated sulfuric acid, nitric acid, and other inorganic acids common in acid plants.

• Thermal Stability up to 1000°C – Suitable for high-temperature absorption zones where SO₃ absorption occurs above 400°C.

• Elimination of Nesting – The saddle geometry prevents packing interlocking, ensuring uniform void fraction and consistent gas-liquid contact throughout the bed.

• Lower Pressure Drop – Compared with Raschig rings of the same material and size, DAIER Intalox saddles deliver significantly lower resistance to gas flow, reducing blower energy consumption.

Typical Applications in Sulfuric Acid Plants:

• Drying towers (moisture removal from SO₂ gas)

• Absorption towers (SO₃ capture)

• Regeneration towers

• Cooling towers in acid circulation loops

Application 2: Ammonia Scrubbers and Fertilizer Production

In the fertilizer industry, ammonia scrubbers recover ammonia from process gas streams and reduce emissions. Ceramic Intalox Saddle Rings are widely used in ammonia separation columns and scrubbing towers due to their chemical inertness and thermal stability.

Process Demands: Ammonia scrubbers often use acidic scrubbing liquors that can corrode metal packing. Packing beds must maintain structural integrity without thinning or collapsing, which would reduce separation efficiency. Liquid channeling – where liquid flows down the column walls instead of through the packing bed – is a common problem with ring-type packings.

DAIER Solution Advantages:

• Chemical Inertness – High‑alumina ceramic does not react with ammonia or acidic scrubbing solutions, ensuring long‑term bed stability and consistent performance.

• Superior Liquid Redistribution – Unlike rings that allow liquid to channel, the saddle shape constantly redistributes liquid toward the center of the tower, maximizing contact between NH₃ gas and scrubbing liquid.

• Reduced HETP – The optimized surface geometry lowers the Height Equivalent of a Theoretical Plate compared to traditional packing, enabling shorter columns or higher separation performance for the same height.

Typical Applications in Fertilizer Plants:

• Ammonia separation columns

• Ammonia scrubbers and absorbers

• Nitric acid absorption towers

• CO₂ removal systems

Application 3: Chemical Absorption Columns and Solvent Recovery

Chemical absorption columns are used across petrochemical, specialty chemical, and environmental protection industries for removing contaminants, recovering solvents, and purifying intermediate products.

Process Demands: Absorption columns handle varied streams – from organic solvents to acid gases. Packing must provide high mass transfer efficiency while maintaining low pressure drop to minimise energy consumption. Uniform liquid distribution is critical for achieving the required separation performance.

DAIER Solution Advantages:

• High Mass Transfer Efficiency – Combining ring‑like surface area with saddle‑like flow distribution, DAIER Intalox saddles promote uniform liquid distribution and increased gas passage, delivering higher overall efficiency than Raschig rings or Pall rings of the same size.

• Wide Chemical Compatibility – Resistant to inorganic acids, organic acids, and organic solvents (except hydrofluoric acid).

• Durable Construction – Al₂O₃ content of 92‑99% provides robust mechanical strength for long‑term service in demanding environments.

• Versatile Use – Applicable in drying columns, absorbing columns, cooling towers, scrubbing towers, and actifier columns across chemical, metallurgy, coal gas, and oxygen production industries.

Typical Applications in Chemical Processing:

• Drying columns for gas dehydration

• Absorption columns for acid gas removal (HCl, SO₂, CO₂)

• Cooling towers for process gas quenching

• Scrubbing towers for waste gas treatment

• Solvent recovery systems

• Wastewater treatment bio‑filters

Performance Comparison: DAIER Ceramic Intalox Saddle vs. Ceramic Raschig Ring

For engineers evaluating packing options, the performance differences are measurable:

Why Choose DAIER from Pingxiang?

• 17+ Years of Engineering Expertise – Established in 2009, DAIER brings extensive experience in ceramic random packing manufacturing.

• Superior Material Quality – Al₂O₃ content of 92‑99% with acid resistance exceeding 99.6% and water absorption below 0.5%.

• Integrated Supply Chain – Manufacturing base in Pingxiang (industrial ceramics hub) + export coordination in Xiamen + technical support from Taiwan.

• Quality Assurance – ISO 9001:2015 certified with full dimensional inspection and EN 10204 3.1 material certification available.

• Global Delivery – Products supplied to Europe, North America, the Middle East, and Southeast Asia.

• Free Engineering Support – Submit your tower diameter, gas/liquid load, and operating temperature for a complimentary packing selection and hydraulic calculation.

Pingxiang Daier Separation Tech Co., Ltd. (DAIER)
Manufacturing: Pingxiang, Jiangxi, China
Export Coordination: Xiamen, China
Engineering Support: Taiwan
ISO 9001:2015 Certified | EN 10204 3.1 Available

Contact DAIER for your ceramic Intalox saddle ring requirements. Submit your process conditions for a free packing selection recommendation.