Bubble Cap Trays by Kalyros Engineering LLP. At Kalyros Engineering LLP, we specialize in precision-engineered mass transfer solutions for the chemical, petrochemical, and refining industries. Our Bubble Cap Trays are a cornerstone of our product lineup, designed to deliver superior vapor-liquid contact in distillation and absorption columns.

With decades of expertise in fabrication and process engineering, we craft these trays to meet the highest standards of efficiency, durability, and performance. Whether you're upgrading an existing column or designing a new one, our Bubble Cap Trays ensure reliable separation processes tailored to your operational needs.

What Are Bubble Cap Trays?

Bubble Cap Trays are advanced distillation internals consisting of a perforated tray deck fitted with risers (chimneys) and inverted dome-shaped caps. Vapor rises through the risers, is redirected downward by the caps, and disperses through slots or serrations into the liquid layer on the tray.

This creates a bubbling action that maximizes contact between rising vapor and descending liquid, promoting efficient mass transfer for separation, absorption, or stripping.Our trays are custom-fabricated for columns up to 6 meters in diameter, with cap sizes ranging from 50-100 mm, ensuring optimal performance across diverse applications.

How We Make Bubble Cap Trays

At Kalyros Engineering LLP, we employ state-of-the-art manufacturing techniques to produce Bubble Cap Trays that combine robustness with precision. Our process emphasizes quality control, corrosion resistance, and seamless integration into your systems:

• Material Selection: We source premium alloys based on your process conditions, including corrosiveness, temperature, and pressure.
• Design and Engineering: Using advanced simulation software, we optimize riser height, cap geometry, and tray spacing for minimal pressure drop and maximum efficiency.
• Fabrication: Tray Deck Preparation: High-precision laser cutting and stamping create the perforated base plate.
• Riser Assembly: Risers are formed via extrusion or rolling and welded or swaged into the deck for a leak-proof seal.
• Cap Installation: Caps are bolted, press-fitted, or seal-welded atop risers. Slots or holes are machined for controlled vapor dispersion.
• Quality Assurance: Each tray undergoes non-destructive testing (e.g., dye penetrant, hydrostatic), dimensional verification, and performance simulation to ensure zero weeping and consistent bubbling.
• Finishing and Packaging: Surface treatments like passivation enhance corrosion resistance, followed by secure crating for global shipment.

Our in-house facility allows for rapid prototyping and full-scale production, with lead times as short as 4-6 weeks for standard designs.

Where Are Bubble Cap Trays Used?

Bubble Cap Trays from Kalyros Engineering LLP are deployed in demanding environments where precise separation is critical. Key applications include:

• Petroleum Refineries: Atmospheric and vacuum distillation units for crude oil fractionation, gasoline stabilization, and coking product separation.
• Petrochemical Plants: Ethylene production, benzene purification, and hydrocarbon separation columns.
• Chemical Processing: Absorption towers for gas scrubbing, amine contactors, and caustic towers.
• Gas Processing: Glycol dehydration units and natural gas sweetening (amine absorbers/regenerators).
• Pharmaceuticals: Solvent recovery and product purification to maintain purity and prevent contamination.
• Food & Beverage: Alcohol distillation and essential oil extraction.
• Environmental: Waste gas treatment and remediation systems.

These trays excel in both new installations and revamps, fitting columns from laboratory scale to large-diameter industrial units.

Why Use Bubble Cap Trays?

Bubble Cap Trays offer unmatched reliability in challenging conditions, making them the go-to choice when alternatives like sieve or valve trays fall short. Here's why our clients trust Kalyros Engineering LLP's designs:

• Zero Weeping and Leakage: The sealed riser-cap assembly prevents liquid bypass, ensuring stable operation even at low vapor/liquid rates.
• High Turndown Ratio (Up to 10:1): Handles flow variations without efficiency loss, ideal for batch processes or fluctuating feeds.
• Superior Mass Transfer: Enhanced bubbling promotes intimate vapor-liquid contact, boosting separation efficiency by 10-20% over basic trays.
• Low Liquid Load Capability: Perfect for high-vapor, low-liquid scenarios like reflux operations.
• Fouling Resistance: Open design minimizes clogging from solids or viscous fluids.
• Longevity and Low Maintenance: Corrosion-resistant materials and durable welds reduce downtime, with easy inspection via removable caps.

While they may have a higher initial cost than sieve trays, the operational flexibility and reduced risk of inefficiencies deliver superior ROI in precision-demanding applications.

Feature Benefit

Types of Bubble Cap Trays

Kalyros Engineering LLP offers a versatile range of Bubble Cap Tray configurations to suit specific process requirements. Each type is customizable in cap shape, slot design, and attachment method:

• Conventional Slotted Bubble Cap Trays Description: Standard design with serrated or slotted edges on round caps (2-6" diameter) for vapor dispersion. Risers are 4-12" tall.
• Best For: General distillation with moderate flows; high turndown in refineries.
• Key Specs: Tray spacing 18-30"; efficiency 70-90%.
• Enclosed (Non-Slotted) Bubble Cap Trays Description: Fully sealed caps with bottom perforations; vapor exits via controlled gaps.
• Best For: Low-pressure applications requiring minimal entrainment, like glycol dehydrators.
• Key Specs: Reduced pressure drop; ideal for clean services.
• Rectangular Bubble Cap Trays Description: Elongated caps for higher density packing; often used in multi-pass designs.
• Best For: Large-diameter columns (>4m) in petrochemical fractionation.
• Key Specs: Increases active area by 15-20%; customizable layouts.
• Flat or S-Shape Bubble Cap Trays Description: Low-profile caps with U-shaped slots to minimize height and pressure drop.
• Best For: Vacuum distillation or space-constrained towers.
• Key Specs: 10-20% higher capacity; easier installation.
• Dual-Flow or Multi-Orifice Variants Description: Caps with multiple outlets or integrated liquid channels for bidirectional flow.
• Best For: High-vapor-velocity absorption/stripping with viscous liquids.
• Key Specs: Enhanced throughput; anti-fouling orifices.

Benefits

• Durability: Constructed from high-strength materials to withstand heavy loads and prolonged use.
• Efficiency: Optimizes material flow and reduces operational effort.
• Versatility: Suitable for a broad spectrum of industries and conditions.
• Customization: Designed to meet specific client needs, ensuring optimal performance.

All types support fixed or removable caps for maintenance, with materials like SS 304/316L, Hastelloy, or Titanium.Specifications and CustomizationMaterials: SS 304/316L, Duplex 2205, Monel, Inconel, Hastelloy C-276, Titanium, Zirconium.

Dimensions: Tray diameters up to 6m; cap OD 50-150mm; riser height 100-300mm.

Operating Conditions: Pressures up to 50 bar; temperatures -50°C to 500°C.

Standards: ASME, TEMA, API; custom CFD modeling available.

Why Choose Kalyros Engineering LLP?

As a dedicated engineering firm, we prioritize innovation and client partnership. Our Bubble Cap Trays are backed by:ISO-Certified Quality: Rigorous testing for every batch.