Anti-fouling Plastic Heilex Ring for Gas Cooling — What it is, how it works, and how to choose the right one

1. Short definition

The Plastic Heilex (also spelled Helix / Haier) Ring is an open-cell, crown-style random packing used inside scrubbers, cooling towers and gas-treatment columns to improve gas–liquid contact while minimizing pressure drop and fouling. Its unique perforated, crown/helix geometry increases surface area and void fraction so mass-transfer and cooling/absorption efficiency are improved compared with simple Raschig rings.

2. Why “anti-fouling” matters

In gas cooling and scrubbing, fouling (deposition of solids, scale, biological growth or sticky aerosols on packing surface) reduces performance by blocking flow paths, increasing pressure drop and reducing effective surface area. Anti-fouling Heilex rings are designed with open slots, smooth injection-molded surfaces, higher void fraction and geometry that discourages stagnant liquid films, making them more resistant to buildup and easier to flush.

3. What it’s made of — common materials

Plastic Heilex rings are typically manufactured by injection molding from a variety of engineering plastics, chosen for chemical resistance, temperature tolerance and mechanical strength. Common materials include:

• PP (Polypropylene) — most common, cost-effective, good chemical resistance for many scrubbing gases.
• PE / HDPE (Polyethylene) — good impact resistance and low cost.
• PVC / CPVC — used where better solvent resistance or higher temperature resistance is needed.
• PVDF (Kynar) — for aggressive solvents, acids or higher temps; excellent chemical resistance and low wettability (helps anti-fouling).
• PFA / PTFE / PPS or glass-filled PP — specialty variants for high-temperature or highly corrosive processes.

Typical production is precision injection molding so each ring has smooth surfaces and consistent geometry — critical for anti-fouling performance.

4. Typical sizes, geometry and physical properties

Common diameters: 25 mm, 38 mm, 50 mm, 76 mm, 100 mm (choose by column diameter and hydraulic load).

Void fraction: very high (often >90% depending on size/material) — large open volume reduces pressure drop and congestion.

Surface area: moderate to high (depends on design & size) — enough area for good mass transfer without trapping solids.

Bulk density: light — easy to load/unload and safe for retrofit into existing towers.

5. How it works — fluid dynamics in plain English

Gas flows upward through the packing and liquid trickles down the ring surfaces.

The heilex geometry breaks liquid into thin films and droplets, increasing gas–liquid interface area.

The many large openings maintain high gas velocity pathways, reducing wetting of the entire structure and discouraging solids deposition.

Because the rings have low pressure drop and a high flooding point, the tower can operate efficiently even under variable loads.

6. Main advantages & features

Anti-fouling behavior: open geometry and smooth molded surface limit stagnant zones where fouling starts.

Low pressure drop: reduces fan/blower energy in gas circuits.

High flooding point: handles higher liquid loads before operation is compromised.

Uniform gas–liquid distribution: gives predictable mass transfer and cooling.

Wide material choice: from inexpensive PP to PVDF for corrosive applications.

7. Typical applications

Cooling towers & gas coolers — to increase contact area and boost sensible/latent heat exchange.

Scrubber towers / gas absorption — acid gas removal, solvent recovery, SO₂/HCl scrubbing, ammonia removal.

Gas purification and refining — pre-treatment stages where fouling/particulates may occur.

Petrochemical & chemical process towers — where corrosion resistance or anti-fouling features are required.

8. Types and variants

Standard Heilex (PP / PE) — baseline for general-purpose gas cooling and scrubbing.

Anti-fouling variant — smooth, larger openings or modified blade geometry to reduce liquid hold-up and solids capture.

High-temp / high-corrosion (PVDF, PFA, PPS) — for aggressive chemistries or elevated process temperatures.

Glass-filled or reinforced plastics — for higher mechanical strength in packed beds that undergo mechanical stress.

Different heights/diameters — selected to match tower diameter and desired specific surface area.

9. How to choose the right Heilex ring

1) Match material to chemistry & temperature

• Use PP/PE for mild aqueous / alkaline conditions at ambient to moderate temps.
• Use PVDF/CPVC/PPS for acidic, solvent or high-temperature service.

2) Select size for hydraulic load and column diameter

• Smaller rings give more specific surface area but higher pressure drop per metre; larger rings reduce pressure drop and fouling risk. For gas cooling (where you often want low ΔP and high throughput), mid-to-large sizes (50–100 mm) are common.

3) Prioritise anti-fouling geometry where fouling risk is high

• Choose designs explicitly marketed as anti-fouling / open-cell / crown-type; these have features to avoid stagnation and let solids pass.

4) Consider specific surface area vs pressure drop trade-off

• If mass transfer is the primary goal and fouling is modest, use smaller sizes or higher surface designs. If fouling and pressure drop are the limiting issues (typical in gas cooling with entrained particulates), choose larger open-geometry anti-fouling rings.

5) Mechanical strength & lifespan

• Evaluate impact resistance (for loading/unloading and backwash) and creep under supported weight — reinforced or glass-filled materials can help in heavy beds.

6) Cost vs lifecycle

• Balance initial cost (PP low) against replacement and downtime costs from fouling or chemical attack (PVDF expensive but lasts longer in aggressive service).

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10. Installation & maintenance tips

Proper distributor design: even with anti-fouling packing, poor liquid distribution accelerates fouling. Use good spray headers or redistributors.

Periodic back-washing / flushing: design tower with spray nozzles for high-pressure cleaning where solids are expected.

Avoid excessive mechanical load: prevent point loads which can crack plastic rings. Consider reinforced materials for heavy columns.

Monitor pressure drop & efficiency: rising ΔP often indicates fouling—schedule cleaning or replacement early to avoid large performance loss.

11. Quick spec table (example)

If you are looking for high-quality anti-fouling plastic Heilex rings for gas cooling, scrubbing, or industrial tower applications, Zhongci Environmental Ceramics Materials is your trusted supplier.
We specialize in producing and supplying a wide range of plastic, ceramic, and metal tower packings, including advanced Heilex rings, saddle rings, and structured packings designed for optimal efficiency and durability.

With years of industry experience, Zhongci offers customized technical solutions based on your process conditions—helping you choose the most suitable material, size, and packing type for your tower system.
Our team provides professional consultation, engineering support, and fast worldwide delivery to ensure your project runs smoothly and efficiently.

📞 Contact us today to learn more or request a quotation.
🌐 Visit our website: www.chempackings.com
Let Zhongci Environmental Ceramics Materials help you improve your system’s performance with reliable, cost-effective, and long-lasting tower packing solutions.