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.