Refiners, gas processors, petrochemical facilities, and hydrocarbon producers need precise phase contact to remove or convert contaminants while protecting product quality and downstream equipment. Conventional mass-transfer systems often rely on intense mixing. That approach can require larger separation equipment, longer settling time, and more energy while raising the risk of emulsions or aqueous carryover.
FIBER FILM® Contactor technology takes a different approach. The patented contactor creates controlled, co-current contact between a process stream and a liquid treating phase across proprietary fibers. This non-dispersive design supports efficient mass transfer without the aggressive mixing that can complicate phase separation.
FIBER FILM® is the core contactor technology within several Merichem Technologies units. Each licensed process pairs the contactor with specific chemical reagents and operating conditions to perform a defined reaction or extraction. That distinction matters because AMINEX™, THIOLEX™, MERICAT™, NAPFINING™, and AQUAFINING™ do not perform the same treatment task.
How FIBER FILM® Contactor Technology Works
Inside the contactor, caustic, amine, water, or another aqueous treating phase wets a densely packed bundle of metallic fibers, forming an ultra-thin film. The gas or liquid hydrocarbon stream moves co-currently through the bundle and contacts that film across a large interfacial area. Target compounds transfer into the treating phase or react according to the licensed process chemistry.
The contactor limits droplet formation and turbulent dispersion between phases. After mass transfer, the streams enter a separator where density differences support rapid bulk separation. This approach helps reduce the formation of stable emulsions, aqueous carryover, and product contamination. Co-current flow also supports low differential pressure and steadier operation during changes in hydrocarbon flow.
The process follows four basic steps:
- The treating phase enters the contactor and spreads across the fibers as a thin film.
- The process stream flows in the same direction and contacts the treating film.
- Contaminants transfer or react through the selected process chemistry.
- The phases separate with less dispersion than many conventional mixing systems.
Why the Core Technology Supports Different Units
The contactor provides the mass-transfer surface, whereas the reagent and process design influence the treatment outcome. At Merichem Technologie, we utilize this platform for both gas and liquid services, tailoring each unit to feed composition, contaminant profile, and product requirements.
AMINEX™ and THIOLEX™ for Extraction
AMINEX™ units use an amine treating solution to remove H₂S and other acid gases from applicable gas and LPG streams. THIOLEX™ units use caustic extraction for H₂S, mercaptans, and COS removal in selected gas or liquid hydrocarbon services. The FIBER FILM® Contactor promotes contact between the stream and the chosen reagent, while the chemistry performs the extraction.
MERICAT™ Units for Mercaptan Sweetening
MERICAT™ processes address mercaptans through sweetening rather than extraction. The treatment converts mercaptans into less objectionable disulfide oils in streams such as gasoline, condensate, kerosene, jet fuel, middle distillates, and diesel. This difference separates mercaptan sweetening from processes designed for direct mercaptan removal.
NAPFINING™ for Naphthenic Acid Removal
NAPFINING™ units use caustic extraction to remove naphthenic acids from hydrocarbon streams. The contactor supports efficient phase contact while limiting the emulsion problems associated with aggressive mixing. This treatment can help facilities manage corrosion concerns tied to acidic refinery streams.
AQUAFINING™ for Water Washing
AQUAFINING™ units use water as the treating phase to wash water-soluble impurities from hydrocarbon streams. The process shows how the same contactor platform can support a water wash when the treatment goal extends beyond sulfur chemistry.
Gas and Liquid Processing Applications
FIBER FILM® Contactor technology can support gas-liquid and liquid-liquid contacting. In gas service, a treating solution contacts streams such as natural gas, acid gas, off-gas, purge gas, or fuel gas. In liquid service, the platform treats hydrocarbons such as LPG, naphtha, condensate, kerosene, jet fuel, middle distillates, and diesel.
The process chemistry defines whether the unit performs H₂S removal, mercaptan removal, mercaptan sweetening, acid gas extraction, naphthenic acid removal, or a water wash. This service-specific design prevents operators from treating FIBER FILM® as a single chemical process. It functions as the contactor foundation for several distinct treatment systems.
How Design Features Support Operations
The performance of FIBER FILM® Contactor technology comes from the way its design features work together during the treatment process. Each element supports efficient phase contact while helping operators reduce common challenges associated with conventional dispersive systems.
Non-Dispersive Contacting
The contactor limits aggressive mixing between the process stream and the treating phase. This approach can reduce emulsion formation and lower the risk of aqueous carryover into downstream equipment.
High Surface-Area Fiber Film
The fibers create a large interfacial area and keep renewing the aqueous film as it moves through the bundle. The short diffusion path supports contaminant transfer or chemical conversion without requiring a large conventional contacting tower.
Co-Current Flow
Both phases move in the same direction through the contactor. This flow pattern supports stable contact across changing feed rates and avoids the flooding limits associated with some counter-current systems.
Compact Equipment Design
A compact contactor can reduce dependence on large towers and long settling systems. The smaller footprint can suit revamps, debottlenecking work, and sites with limited plot space.
Cleaner Phase Separation
Lower dispersion helps the treating solution and product stream separate after contact. Cleaner separation can protect product quality, reduce carryover, and support downstream reliability. Selected services may also use FFC Plus contactors, which combine the fiber bundle with coalescing elements to provide another separation step.
Operational Benefits Across Selected Services
The benefits depend on the licensed process and operating conditions. A properly designed unit may support:
- Compact equipment layouts
- Low pressure drop
- Reduced emulsion risk
- Lower aqueous carryover
- Stable performance across variable feed rates
- Revamp and debottlenecking opportunities
- Lower chemical use in selected applications
Engineers still need accurate stream data before selecting a process. Feed composition, contaminant concentration, phase behavior, temperature, pressure, reagent chemistry, and outlet specifications shape the final unit design.
When Operators Should Evaluate an FFC-Based Unit
Facilities may benefit from reviewing an FFC-based process when conventional treatment creates emulsions, carryover, long settling periods, high pressure drop, or space constraints. The technology may also suit projects that require tighter contaminant control under variable feed conditions.
A process review should address:
- The contaminant that requires removal or conversion
- The gas or liquid phase and full stream composition
- The required product specification
- Current emulsion, carryover, or separation problems
- Available plot space and pressure-drop limits
- Expected changes in flow rate or contaminant concentration
Selecting the Right Licensed Process
No single FIBER FILM® unit suits every stream. AMINEX™ and THIOLEX™ facilitate extraction, MERICAT™ units reduce mercaptans, NAPFINING™ eliminates naphthenic acids, and AQUAFINING™ offers a water wash. The contactor technology stays consistent, but the reagent, reaction, and system design vary depending on the treatment goal.
Merichem Technologies engineers each FFC-based unit around the application. Operators can use that process-specific approach to pursue mercaptan removal, H₂S removal, sweetening, acid gas extraction, naphthenic acid removal, or water-based impurity removal without relying on aggressive dispersion.
Contact Merichem Technologies to discuss the stream composition, operating conditions, and licensed process that fits the treatment goal.