Difference Between Wire Mesh Packing and Structured Packing

Wire mesh packing and structured packing are critical tower internals in chemical, petrochemical, and separation processes, differing significantly in structure, performance, and applications. Wire mesh packing, composed of woven metal or plastic wire mesh, often forms random or corrugated sheets. Its loose, irregular structure delivers high specific surface area (150-500 m²/m³), enhancing mass transfer efficiency. However, this random arrangement causes uneven fluid flow, leading to higher pressure drop and lower handling capacity, making it ideal for small-diameter towers, lab-scale experiments, or high-precision separations like distillation of heat-sensitive materials. Structured packing, by contrast, consists of ordered, stacked corrugated plates or wire gauze, aligned at fixed angles (e.g., 30°/45°). This regularity minimizes channeling, reducing pressure drop while boosting throughput and efficiency, and is suitable for large industrial towers, handling viscous or fouling fluids, and high-throughput processes like crude oil distillation. Key differences include structure (random vs. ordered), pressure drop (higher for mesh), capacity (lower for mesh), and cost (higher for structured due to precision manufacturing). Selection depends on tower size, separation requirements, and process conditions.