This publication presents a general approach for the enhancement of packings using 3D printing. Within a joint research project of the Ulm University, the Technical University of Munich and BASF SE, the presented methodology is used to develop miniaturized, scalable distillation columns for process development and scale-up applications. Therefore, a combination of design, computational fluid dynamics, 3D printing and experiment is used to overcome current limitations in the design of structured packings. The packing to be developed should have a high, constant separation efficiency independent of the F-factor at the target diameter of 20 mm. Based on a 3D printable version of the Rombopak 9M, an improved structure is introduced using the proposed methodology. This packing is an intermediate step, but already exhibits a higher, more constant separation efficiency and an improved reproducibility. This publication acts as proof of concept for this methodology.

Additive manufacturing is increasingly being used to develop innovative packings for absorption and desorption columns. Since distillation has not been in focus so far, this paper aims to fill this gap. The objective is to obtain a miniaturized 3D printed packed column with optimized properties in terms of scalability and reproducibility, which increases process development efficiency. For this purpose, a flexible laboratory scale test rig is presented combining standard laboratory equipment with 3D printed components such as innovative multifunctional trays or the column wall with packing. The test rig offers a particularly wide operating range (F=0.15 Pa0.5…1.0 Pa0.5) for column diameters between 20 mm and 50 mm. First results regarding the time to reach steady-state, operational stability and separation efficiency measurements are presented using a 3D printable version of the Rombopak 9M. Currently, innovative packings are being characterized, which should exhibit a optimized bevavior regarding scalability, reproducibility and separation efficiency.