Mist Eliminators/Demister Pads for Oil-Natural Gas Separation

JD Hardware Wire Mesh Co., Ltd specializes in producing and exporting Mist Eliminators, also known as Demister Pads. These devices are essential for mechanically separating liquids from gases, playing a vital role in various industrial processes. Focusing on droplet sizes from 3 to 5 microns, our mist eliminators are effective in purifying gas or vapor streams, tailored to meet the specific needs of different industries.

Our knitted mesh mist eliminator stands out for its efficiency and practicality. With minimal maintenance requirements and no moving parts, it guarantees consistent performance over the long term. Designed for a broad spectrum of applications, it ensures excellent separation efficiency for droplets down to 3 microns, while maintaining a low pressure drop.

The operating principle of our Mist Eliminators is key to their effectiveness. As gas with liquid droplets ascends, it passes through our finely knitted wire mesh. The mesh, with its small openings, successfully captures the droplets. These droplets then collide with the mesh due to their inertia, adhere to the surface, and eventually merge, resulting in effective separation.

Customization Options for Mist Eliminators

• Material Variations:
  Mist Eliminators come in a diverse array of materials, each carefully chosen for their distinct qualities of corrosion resistance, efficient filtration, and durability. The primary material options include Stainless Steel, which is ideal for a broad spectrum of applications due to its robustness and rust resistance; Monel, renowned for its superior corrosion resistance, making it particularly suitable for marine and chemical environments; Titanium, valued for its exceptional strength and corrosion resistance, apt for use in high-temperature and severe conditions; and Polypropylene, known for its chemical resistance and appropriateness in less aggressive environments. This range of material options ensures that the mist eliminators can be precisely tailored to meet the specific demands of various industrial applications.
• Wire Diameter Options:
  The wire diameters for the knitted mesh in mist eliminators range from 0.2 mm to 0.35 mm, providing flexibility in design and ensuring precision in filtration. The available diameters include 0.2 mm, 0.22 mm, 0.23 mm, 0.25 mm, 0.28 mm, 0.3 mm, and 0.35 mm. This range allows for customization based on the desired strength and filtration efficiency.
• Mesh Size Range:
  The mesh sizes for these eliminators vary from 2 mm × 3 mm up to 12 mm × 6 mm. This variety in mesh sizes enables precise control over the filtration process, accommodating different particle sizes and flow rates.
• Height/Thickness Adaptability:
  Mist Eliminators can be customized in height or thickness, ranging from 100 mm to 150 mm. This flexibility allows them to be adapted for different systems and volumes of gas-liquid separation.
• Pad Diameter Customization:
  The pad diameter of Mist Eliminators can be tailored to specific needs, with options ranging from 300 mm to a large 6000 mm. This extensive range ensures that eliminators can be fitted to various vessel sizes and configurations, accommodating a wide array of industrial applications.

Classification of Knitted Mesh Mist Eliminators

Knitted mesh mist eliminators are versatile and essential components in various industrial processes, primarily used for the efficient separation of liquid droplets from gas or vapor streams. Their design and functionality can vary significantly, catering to a wide range of applications and operational requirements. Understanding the classifications of these mist eliminators is crucial for selecting the right type for specific industrial needs.

Classification by Material:
The choice of material in a knitted mesh mist eliminator is critical as it determines the eliminator’s suitability for different environmental conditions and applications. Common materials include stainless steel for general applications, Monel for corrosion resistance, especially in marine settings, and polypropylene for chemical resistance in less aggressive environments. Each material brings unique properties like durability, corrosion resistance, and chemical compatibility.

Metal mist eliminator

Plastic mist eliminator

Classification by Shape:
The shape of a mist eliminator can vary based on the installation requirements and the space constraints of the system. Some common shapes include circular, rectangular, or custom shapes designed to fit specific vessels or piping configurations.

Round Shap

Rectangular Shape

Ring Shape

Special Shape

Classification by Appearance
Appearance classification often relates to the visual design and the construction technique of the mist eliminator. This can include variations in the knitting pattern, the density of the mesh, and the overall aesthetic design, which might be important for certain visible applications or for branding purposes.

Standard Mist Eliminator

Wavelike Mist Eliminator

Classification by Component
This classification focuses on the different components that make up the mist eliminator. The simplest form is the demister pad, which consists solely of knitted wire mesh. More complex designs include additional components like supporting mesh and grating, providing extra strength and durability for more demanding applications.

Knitted Wire Mesh Mist Eliminator

Knitted Wire Mesh And Grating Mist Eliminator

Knitted Wire Mesh, Supporting Mesh And Grating Mist Eliminator

Knitted Wire Mesh, Supporting Mesh And Frame Mist Eliminator

Classification by Structure
The structural classification involves the overall build and configuration of the mist eliminator. This can range from basic, standalone meshes to more complex assemblies that incorporate multiple layers of mesh and support structures, designed for enhanced performance and longevity.

Integrated Mist Eliminator

Drawer Mist Eliminator

Classification by Knitted Wire Mesh Type
The type of knitted wire mesh used in the mist eliminator plays a significant role in its performance. Options include different wire diameters, round or flat wire types, and varying mesh sizes, each offering specific filtration characteristics and efficiencies.

Standard Knitted Wire Mesh Mist Eliminator

Ginning Knitted Wire Mesh Mist Eliminator

Advantages of Mist Eliminators

• High Efficiency in Separation: Mist eliminators are highly effective in separating liquid droplets from gas or vapor streams, achieving separation efficiencies of up to 98%. This ensures cleaner gas emissions and purer product streams in industrial processes.
• Versatility in Materials and Design: With a range of materials like stainless steel, Monel, titanium, and polypropylene, mist eliminators can be tailored for specific environments, whether corrosive, high-temperature, or chemically reactive. Their design flexibility also allows for customization according to different industrial needs.
• Low Operational Costs: Due to their design and material, mist eliminators generally require minimal maintenance. This, combined with their long service life, results in lower operational costs over time.
• Protection of Equipment: By removing corrosive or abrasive elements from gas streams, mist eliminators extend the life of downstream equipment, such as compressors, turbines, and scrubbers, by reducing wear and tear.
• Energy Efficiency: Mist eliminators operate with a low pressure drop, meaning less energy is required to move gases through the system. This contributes to overall energy efficiency in industrial processes.
• Compact Design: Despite their high efficiency, mist eliminators typically have a compact design, making them suitable for installation in limited spaces without sacrificing performance.
• Improved Product Quality: In processes like distillation or evaporation, mist eliminators prevent contamination of the product, leading to higher purity and quality.
• Safety Enhancement: In industries where flammable or combustible materials are handled, mist eliminators reduce the risk of fire and explosions by effectively removing these substances from exhaust streams.
• Customizable Performance: Depending on the application, mist eliminators can be customized for specific droplet size removal, ensuring optimal performance tailored to the unique requirements of each process.

Mist Eliminators Uses

• Oil and Gas: Separating oil from natural gas.
• Chemical Plants: Removing droplets from chemical vapors.
• Air Pollution Control: Capturing pollutants in industrial exhausts.
• Power Generation: Removing water from steam in turbines.
• Food and Beverage: Ensuring purity in processing and production.
• Pharmaceuticals: Maintaining clean air in manufacturing areas.
• Marine and Offshore: Removing salt and contaminants in ventilation systems.
• Refrigeration/Air Drying: Eliminating moisture from air streams.
• Pulp and Paper Industry: Reducing moisture and chemicals in air emissions.