Engineer's Brief: The ceramic saddle ring (also called ceramic Intalox saddle ring) is a classic random packing whose shape sits between a ring and a saddle. Its asymmetric double-arc body prevents nesting, promotes point contact between pieces, and keeps bed voidage high (70–85%). Molded from chemical porcelain or high-alumina ceramic, it resists all inorganic/organic acids except HF and runs continuously at 1000–1200°C — making it irreplaceable in sulfuric acid dryers, hot acid gas scrubbers, and high-temperature corrosive towers where plastic and metal packings fail.[8,21](@ref)
Figure 1: Ceramic saddle ring (Intalox saddle) — bulk chemical-porcelain pieces showing the characteristic saddle-shaped curved body.
The ceramic saddle ring evolved from the earlier Berl saddle (arc saddle). Its key modification is that the symmetrical arc saddle ends are changed into a rectangular-type contact surface, while the body keeps a saddle-like double curvature — one concave outer face, one convex inner face, open at both ends with no closed cavity.[8,15](@ref) This semi-ring, semi-saddle geometry is why it is also marketed as "rectangular saddle ring" or "Intalox saddle ring".
Unlike metal Intalox saddles or plastic hollow ball packings, the ceramic version trades some specific surface area for extreme chemical inertia and thermal endurance. It is a random dumping packing — poured loosely into the tower without stacking order.
The shape is engineered, not arbitrary. Each element is a continuous extruded/compressed ceramic body with the following structural traits:
Figure 2: Single ceramic saddle ring — rectangular ends, double-arc body, open through-channel.
Ceramic saddle rings are formed by extrusion or dry pressing of chemical-porcelain / high-alumina body, then fired at 1200°C+ to produce a dense sintered matrix (SiO₂ 65–75%, Al₂O₃ 17–23%, Fe₂O₃ <1.5%).[5,9](@ref) Design consequences:
Standard nominal sizes 16 / 19 / 25 / 38 / 50 / 76 mm. Typical geometry table:
| Size (mm) | D × H × T (mm) | Surface Area (m2/m3) | Voidage (%) | Bulk Density (kg/m3) |
|---|---|---|---|---|
| 25 | 25 × 19 × 3 | 250 | 74 | 610 |
| 38 | 38 × 30 × 4 | 164 | 75 | 590 |
| 50 | 50 × 40 × 5 | 142 | 76 | 560 |
| 76 | 76 × 57 × 9 | 92 | 78 | 520 |
Data per common ceramic Intalox saddle specs.[5,18](@ref)
The structure is purpose-built for hot, acidic, oxidizing gas-liquid contact where metal corrodes and plastic melts:[8,21](@ref)
Q: Saddle ring vs. Raschig ring in ceramic — structurally?
A: Raschig ring is a plain hollow cylinder — tends to stack in columns, creates dead zones, higher ΔP. Saddle ring's asymmetric double-arc + rectangular ends force point contact and uniform voids, giving lower pressure drop and better distribution at equal size.[8,21](@ref)
Q: Why not use metal Intalox saddle instead?
A: Metal versions (304/316) win on strength-to-weight and some efficiency cases, but dissolve in sulfuric/nitric/hydrochloric acid service and soften far below ceramic's 1000°C+ ceiling. In acid plants ceramic is mandatory.[21](@ref)
Q: Any structural weak point?
A: Ceramic is brittle — do not drop from height > 2m during charging; use chute. Avoid HF and hot concentrated NaOH. Otherwise the sintered body outlasts most tower shells.
FXSINO manufactures ceramic Intalox saddle rings, Super Intalox saddles, ceramic Raschig rings, and tower internals. Sizes 16–76mm, chemical porcelain or high-alumina, shipped worldwide.
Send tower diameter, bed depth, service fluid (note if HF present), operating temperature, and preferred size. We'll confirm material grade, packing volume, and lead time the same day.
Contact FXSINO: jackieqiu9202@gmail.com | +86 18507999558
Address : Intersection of Jinguang Avenue and Chongqing Middle Road, Anyuan Industrial Park, Anyuan District, Pingxiang City, Jiangxi
Tel : +86-18507999558
Email : sales@fxsino.com
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