Overview

Kalyros Engineering LLP proudly manufactures high-quality bubble cap risers with fittings, essential components for bubble cap trays used in distillation and absorption columns. These risers, paired with bubble caps, enhance vapor-liquid contact, ensuring efficient separation processes across various industries. Our precision-engineered risers are designed to meet the demanding needs of chemical, petrochemical, pharmaceutical, and refining sectors.

Manufacturing Process

• Material Selection: High-grade metals such as stainless steel, carbon steel, or corrosion-resistant alloys are selected based on the application requirements.
• Cutting and Shaping: Raw materials are cut into precise cylindrical shapes using CNC milling machines to form the riser structure.
• Perforation and Fitting: The risers are perforated or fitted with slots as per design specifications. Fittings, including bolts and supports, are integrated using precision welding or press-fitting techniques.
• Assembly: Internal supports or dividers (as seen in the image) are added to ensure structural integrity and proper vapor flow. The risers are then assembled with threaded bolts for secure attachment to the tray floor.
• Finishing: The components undergo surface treatment, such as polishing or coating, to enhance corrosion resistance and durability.
• Quality Control: Each riser is rigorously tested for dimensional accuracy, strength, and performance under simulated operating conditions before dispatch.

Our state-of-the-art facility, located in [insert location], ensures timely production and adherence to international standards.

Design and Functionality

Bubble cap risers are vertical cylinders fitted over holes in the tray deck of a distillation column. They are covered by bubble caps, which direct vapor upward through the riser and then downward through slots, allowing it to bubble through the liquid on the tray. This design ensures maximum vapor-liquid contact, preventing weeping (liquid leakage) and maintaining efficiency even at low liquid or vapor rates. The risers are secured to the tray using methods like seal welding, through bolting, or swaging, ensuring a leak-proof seal.

Materials and Grades

• Stainless Steel: Grades 304, 316, and 316L for excellent corrosion resistance and durability.
• Carbon Steel: Cost-effective for less corrosive applications.
• Alloys: Hastelloy, Inconel, Monel, and Duplex Steel (e.g., 2205/2507) for high-temperature and highly corrosive conditions.
• Other Materials: Titanium, brass, copper, and plastics (e.g., PP) for specialized corrosion-resistant systems.

The choice of material depends on factors such as media corrosiveness, operating temperature, pressure, and budget, with our engineering team providing tailored recommendations.

Types of Bubble Cap Risers

• Conventional Risers: Cylindrical with slotted or unslotted caps, ideal for standard distillation applications.
• S-Shaped Risers: Featuring an innovative S-shaped design for increased bubbling area (up to 80% of tray cross-section), offering 10-20% higher capacity and flexibility for large columns.
• Rectangular Risers: Used in tunnel trays for specific flow orientations, enhancing mass transfer in unique applications.
• Custom Risers: Tailor-made sizes (e.g., 2” to 6” diameter) and configurations based on client specifications, including variations in slot patterns and riser height.

Integration with Bubble Cap Trays

Bubble cap risers are integral to bubble cap trays, which consist of a perforated tray plate, risers, bubble caps, downcomers, and weirs. The risers work in tandem with dome- or umbrella-shaped caps to disperse vapor evenly, improving mass transfer efficiency. These trays are particularly effective in:

• Low liquid load applications.
• High turndown ratio scenarios (8:1 to 10:1), offering flexibility in variable flow conditions.
• Processes requiring minimal weeping, such as glycol dehydration columns.

Applications and Uses

• Petrochemical Industry: Separating hydrocarbons and refining crude oil in atmospheric and vacuum distillation columns.
• Pharmaceutical Industry: Solvent recovery and purification of active ingredients.
• Chemical Processing: Isolating compounds in multi-component mixtures.
• Alcohol Production: Ensuring high purity in spirits and industrial alcohol.
• Gas Treatment: Enhancing efficiency in absorption and stripping processes.

Benefits

• High Efficiency: Promotes uniform vapor distribution for optimal mass transfer.
• Versatility: Performs across a wide range of temperatures, pressures, and flow rates.
• Durability: Made from corrosion-resistant materials for long service life.
• Customizability: Designed to meet specific client requirements, including size, material, and slot design.

Why Choose Kalyros Engineering LLP?

With years of expertise in precision manufacturing, Kalyros Engineering LLP delivers bubble cap risers that meet the highest industry standards. Our commitment to quality, customization, and customer satisfaction, combined with a robust global supply network, makes us a trusted partner for your distillation needs. Contact us today to discuss your requirements or request a quote.