Ammonia recovery from biogas digestate is strongly affected by dissolved CO₂ because carbonate chemistry controls liquid pH and the equilibrium between ammonium and volatile ammonia. Removing part of the CO₂ before the ammonia stripper can raise pH naturally and reduce caustic demand, but excessive CO₂ removal can waste energy and increase ammonia loss. Recent recovery systems therefore combine a CO₂ degasser, structured-packed ammonia stripper and structured-packed ammonia quencher to produce both purified wastewater and concentrated aqueous ammonia. Structured packing is effective only when suspended solids and carbonate precipitation are controlled; dirty digestate may require screening, filtration or a more open contacting technology. Packing selection should therefore follow CO₂ chemistry, pH, solids content, gas composition and recovery targets—not surface area alone.

Crude glycerol from biodiesel production can contain water, methanol, inorganic salts, soaps, fatty material and non-glycerol organic matter. Although vacuum distillation remains a major route to high-purity glycerin, untreated salt-laden feed should not automatically be sent through fine structured packing. Industrial refining schemes commonly separate salts and heavy residue through pretreatment, decantation, filtration or wiped-/thin-film evaporation before using low-pressure-drop packed rectification for the cleaner glycerol separation. Structured packing is valuable because it provides high stage efficiency with limited pressure drop and thermal history, but excessive solids reaching the bed can increase ΔP, raise lower-column temperature and accelerate glycerol degradation. The key design decision is therefore where in the purification train the stream becomes clean enough for structured packing to operate reliably.

Ethylene carbonate purification has an unusual thermal constraint: EC has a high normal boiling point of about 246°C but a melting point near 36.4°C. Vacuum distillation is therefore used to reduce thermal exposure, and structured packing can help by providing efficient separation with low pressure drop and relatively low liquid residence time. However, high-purity battery-grade EC does not necessarily need to be produced entirely by distillation. Published processes use vacuum rectification to obtain approximately 99.5–99.8% EC and then employ controlled crystallization and sweating to exceed 99.99% while removing glycol, halogenated-alcohol and oligomer impurities. Structured packing should therefore be optimized to deliver the correct crystallizer feed quality—not automatically to chase the final product purity by adding more stages and reflux.

N-formylmorpholine extractive distillation recovers benzene and other aromatics by changing their relative volatility rather than relying on normal boiling-point differences alone. Lean NFM enters above the hydrocarbon feed, flows downward through the packed section and selectively retains aromatics, while non-aromatics leave overhead as raffinate. Structured packing must therefore handle substantial solvent circulation, provide uniform NFM distribution and support a separate upper washing zone that limits solvent carryover. Solvent/feed ratio, NFM composition, water content and phase behavior are as important as packing HETP. A higher-efficiency packing cannot correct poor solvent chemistry or maldistribution, so NFM circulation, feed elevations, distributor performance and column hydraulics should be reviewed together before a retrofit.

MTBE reactive distillation combines the reaction of isobutene and methanol with distillative separation inside one column. The catalytic reaction zone therefore requires a specialist structured internal that both contains acidic ion-exchange resin and allows vapor-liquid mass transfer; ordinary 250Y or 350Y structured packing cannot simply replace it. Published catalytic packing systems balance catalyst volume fraction against separation efficiency and hydraulic openness, while industrial scale-up studies show that incomplete catalyst wetting and liquid maldistribution can reduce the effective reaction rate even when the correct catalyst inventory is installed. Conventional structured packing can still be used in non-reactive rectification or stripping sections, so every MTBE retrofit RFQ should clearly separate catalytic and non-catalytic tower zones before packing is specified.