How Sulzer’s Katapak™ Boosts Reactive Distillation Efficiency and Selectivity

Introduction

When it comes to maximizing both reaction and separation in a single column, Sulzer’s Katapakstructured catalytic packing is the industry benchmark. Developed specifically for reactive distillation, Katapak enables manufacturers to achieve high efficiency, precise selectivity, and reliable long-term performance—even under challenging industrial conditions. But what makes Katapak fundamentally superior, and how does it deliver these results?

What Is Katapak and How Does It Work?

Katapak is an innovative packing designed by Sulzer that seamlessly integrates structured mass transfer elements with dedicated catalyst sections. The modular construction allows manufacturers to tailor both the catalyst volume fraction and separation efficiency as process needs dictate.

Basic structure of Katapak:

• Alternating layers of Sulzer’s highly efficient MellapakPlus separation sheets and catalyst-filled compartments ("catalyst bags") assembled in sequence.

• The flexible design ensures optimal contact between reactants and catalyst for maximum reaction rates, while MellapakPlus ensures high separation and low pressure drop.

  
  

Key Performance Advantages

1. Enhanced Efficiency for Reaction and Separation

Katapak achieves outstanding mass transfer and reaction rates by combining structured separation layers and catalyst zones. This synergy enables:

• High product yield via simultaneous reaction and continuous removal of products.

• Efficient operation even in equilibrium-limited reactions such as esterification, hydrolysis, and acetalization.

  
  

2. Low Pressure Drop and Optimal Hydrodynamics

Hydrodynamic investigations show Katapak maintains minimal dry and wet pressure drop across a wide range of gas and liquid loads—even as catalyst content or column diameter increases. This ensures:

• Lower energy consumption compared to traditional random packings or catalyst beds.

• Suitability for both laboratory and industrial-scale columns (supplied up to 2.2 meters diameter).

  
  

3. Customizable Catalyst Content and Longevity

• The ratio of catalyst to separation layers can be tuned for specific processes, maximizing flexibility and allowing up to 40% catalyst volume fraction for large-diameter columns.

• Katapak’s modular design protects catalysts from attrition and enables catalyst lifespans of 7+ years—minimizing both downtime and operational cost.

  
  

4. Maintenance and Process Reliability

• By alternating separation and catalytic layers, Katapak prevents channeling and fouling common in older catalyst carriers, resulting in uniform distribution and consistent column performance over time.

• When catalyst replacement is eventually needed, the structure allows more efficient handling versus older bale or bed packings.

  
  

Validated Across Industrial Applications

Katapak is proven in a wide range of continuous processes, including:

• Synthesis of acetates (methyl, ethyl, butyl acetate)

• Hydrolysis of esters (e.g., methyl acetate hydrolysis)

• Production of fatty acid esters (e.g., isopropyl palmitate, myristate)

• Acetal and ether synthesis (e.g., methylal, MTBE)

Sulzer’s units with Katapak are in operation across the globe, enabling clients to achieve:

• Higher purity and conversion in one column

• Dramatically reduced cycle times (often 20x faster than batch)

• Superior consistency—batch-to-batch and across campaigns

  
  

Conclusion

Sulzer’s Katapak represents the gold standard for reactive distillation packing. Its marriage of precision-engineered structured packing and catalytic functionality delivers:

• Unparalleled efficiency and selectivity

• Energy savings via low pressure drop

• Longevity and process flexibility that reduces costs and downtime

For any manufacturer seeking top-tier results in esterification, hydrolysis, acetalization, or specialty chemical synthesis—Katapak is the proven choice.