APPLICATIONS
Designed for
difficult chemistry.
Armour is not conventional packing with a protective layer. Its working structure is formed from silicon carbide ceramic—inside and out.
01 · INSTALLATION
Packing inside the tower
Easy installation with PTFE anti wall flow ring.
02 · APPLICATION
Operating environment
Suitable for high temperature environments such as organic acids, PTSA, HF and other distillation applications.
03 · HANDLING
Module loading
Module design makes it possible to assemble large diameter distillation towers.
CASE 01
Sulfuric + Nitric Acid
High-Temperature Mixed Acid Service | ≥180°C
Process Challenge
A high-temperature separation process involving a mixture of sulfuric acid and nitric acid was operating at temperatures of 180°C and above.
The original glass packing provided sufficient corrosion resistance, but its hydraulic performance created significant limitations. High pressure drop and relatively low mass-transfer efficiency restricted overall process performance.
Why the Previous Packing Was Limited
Glass is chemically stable in many strongly acidic environments, but conventional glass packing can impose compromises in hydraulic capacity and separation efficiency.
In this application, the existing packing showed:
-
High pressure drop
-
Limited gas–liquid contacting efficiency
-
Reduced overall process efficiency
The challenge was therefore not simply corrosion resistance, but achieving corrosion resistance without sacrificing hydraulic and mass-transfer performance.
Armour Packing Solution
Armour Packing SiC wire-mesh structured packing was introduced as a corrosion-resistant structured alternative.
Its open three-dimensional flow geometry provides continuous gas and liquid pathways while the silicon carbide ceramic body offers the material stability required for severe high-temperature acidic service.
Operating Result
After replacement with Armour Packing, the system achieved lower pressure drop and improved separation efficiency while maintaining the corrosion resistance required by the process.
The application demonstrates how SiC structured packing can address both material durability and process-performance requirements in high-temperature mixed-acid service.
01
02
CASE 02
Acidic Chloride
Acidic + Chloride-Ion Environment | ≥150°C
Process Challenge
A chemical separation process operating at 150°C and above combined an acidic environment with chloride ions — a particularly demanding condition for conventional packing materials.
Traditional ceramic packing was unsuitable for the process, while the previously installed Hastelloy packing suffered rapid deterioration and provided a service life of only approximately three months.
Frequent replacement created both operating disruption and significant material cost.
Why the Previous Packing Was Limited
The combination of acidity, elevated temperature and chloride ions created a highly aggressive corrosion environment.
Although high-performance nickel alloys are commonly selected for severe chemical service, even the Hastelloy packing used in this application could not provide an acceptable service life.
The result was:
-
Approximately three months of packing life
-
Frequent replacement requirements
-
Increased maintenance cost
-
Repeated production interruption
Armour Packing Solution
he metal packing was replaced with Armour Packing SiC wire-mesh structured packing.
Rather than relying on an increasingly corrosion-resistant metallic alloy, the solution changed the packing material itself to silicon carbide while retaining the structured geometry required for efficient mass transfer.
Operating Result
The Armour Packing SiC structured packing has remained in continuous service for more than five years and is still operating.
01
02
CASE 03
High-Temperature Organic Polyacid
Organic Polyacid Environment | ≥140°C
Process Challenge
A high-temperature organic polyacid separation process operating at 140°C and above required structured packing capable of combining strong corrosion resistance with reliable long-term operation.
The previously used Hastelloy packing typically lasted only around 1 to 1.5 years before replacement became necessary.
Because of the high cost of alloy packing, repeated replacement represented a significant lifecycle expense.
Why the Previous Packing Was Limited
The operating environment gradually attacked the metallic packing despite the use of a high-performance corrosion-resistant alloy.
The relatively short replacement cycle resulted in:
-
High recurring packing cost
-
Regular maintenance intervention
-
Planned and unplanned production downtime
-
Increasing lifecycle cost of the separation system
-
For this application, extending service life became an important economic as well as technical objective.
Armour Packing Solution
Armour Packing SiC wire-mesh structured packing was selected to replace the existing metallic packing.
Its silicon carbide ceramic body provides corrosion resistance without depending on expensive alloy chemistry, while the structured wire-mesh architecture preserves the gas–liquid contacting characteristics required for efficient separation.
Operating Result
The SiC structured packing has now operated continuously for more than four years, with no apparent corrosion observed, and remains in service.
Compared with the previous Hastelloy replacement interval of approximately 1 to 1.5 years, the application demonstrates a significant improvement in service life.
01
02
CASE 04
Acidic Bromide
Acidic + Bromide-Ion Environment | ≥150°C
Process Challenge
An acidic chemical separation process containing bromide ions was operating at temperatures of 150°C and above.
The process proved highly aggressive toward conventional tower-packing materials. Ceramic packing degraded during operation to the point of becoming powder-like, while metallic packing also provided only limited service life.
A more durable material solution was required without compromising separation performance.
Why the Previous Packing Was Limited
The combination of acidity, bromide ions and elevated temperature created a severe material environment.
Previous solutions faced two different failure mechanisms:
-
Conventional ceramic packing experienced severe degradation
-
Metallic packing suffered limited service life due to corrosion
-
Repeated deterioration made long-term stable operation difficult and increased the burden of inspection and replacement.
Armour Packing Solution
Armour Packing SiC wire-mesh structured packing was installed as an alternative to both the conventional ceramic and metallic packing previously used.
The solution combines a highly stable silicon carbide ceramic body with an engineered structured geometry designed for gas–liquid mass transfer.
Operating Result
After two years in service, the SiC structured packing remained intact and the key operating parameters were maintained.
The packing continued to provide stable performance without the severe degradation observed with the previous ceramic packing.
01
02
CASE 05
PTSA
p-Toluenesulfonic Acid (PTSA) | ≥150°C
Process Challenge
A PTSA-containing separation process operating at temperatures of 150°C and above required a packing material capable of maintaining both corrosion resistance and stable mass-transfer performance over extended service.
The previously installed Hastelloy structured packing provided a service life of less than two years before replacement was required.
For a continuously operated chemical process, this replacement interval created recurring cost and maintenance requirements.
Why the Previous Packing Was Limited
PTSA service at elevated temperature can create demanding conditions for metallic tower internals.
Despite the use of corrosion-resistant Hastelloy, the existing packing could not provide the desired long-term operating life.
Repeated replacement meant:
-
High alloy-material expenditure
-
Increased maintenance frequency
-
Shutdown requirements
-
Higher lifecycle operating cost
Armour Packing Solution
Armour Packing SiC wire-mesh structured packing was introduced as a non-metallic alternative.
The silicon carbide body provides strong chemical and thermal stability, while the structured wire-mesh geometry maintains the surface characteristics and open flow paths required for efficient gas–liquid contact.
Operating Result
The SiC structured packing continues to operate with no apparent corrosion observed.
Compared with the service life of less than two years achieved by the previous Hastelloy packing, the SiC solution has demonstrated strong long-term stability in this PTSA application.
01
02
CASE 06
Hydrofluoric Acid
Hydrofluoric Acid (HF) Environment | ≥130°C
Process Challenge
A hydrofluoric-acid process operating at temperatures of 130°C and above required structured packing capable of maintaining its shape and separation performance under severe chemical and thermal conditions.
The previously used PTFE packing offered chemical resistance but softened under the operating temperature and eventually lost its structural integrity, resulting in packing collapse.
Why the Previous Packing Was Limited
PTFE is widely used where chemical resistance is required, but its mechanical rigidity decreases as operating temperature rises.
In this application, elevated temperature caused the packing to soften and deform.
The resulting structural collapse affected:
-
Gas and liquid flow distribution
-
Available mass-transfer area
-
Hydraulic stability
-
Overall separation efficiency
The challenge was therefore to retain chemical resistance while achieving substantially higher structural and thermal stability.
Armour Packing Solution
Armour Packing SiC wire-mesh structured packing was selected to provide a rigid ceramic alternative.
The silicon carbide structure maintains its geometry at elevated temperature, while the engineered wire-mesh configuration creates open flow channels and extensive gas–liquid contacting surfaces.
Operating Result
The Armour Packing SiC structured packing has remained intact for more than three years and continues to operate.
During service, the packing has maintained high separation efficiency and low pressure drop, without the softening and collapse experienced with the previous PTFE packing.