Mastering Liquid-Gas Separation to Wire Mesh Demisters

In addition to being referred to as a mist pad or a mist eliminator, a wire mesh demister is a device that is used for the purpose of removing liquid droplets or mist from a gas stream. The device is made up of a wire mesh pad that is either knitted or woven, and its purpose is to collect and cluster together the minute liquid droplets that are present in the gas phase.

The operation of a wire mesh demister is as follows:

1. Contact between Gas and Liquid: The demister is filled with liquid droplets that are contained in the gas stream. There are a few different processes that might result in the formation of liquid droplets, including distillation, absorption, and evaporation.
2. Wire Mesh Pad: The second component of the demister is a wire mesh pad that is constructed from materials such as stainless steel or other alloys that are resistant to corrosion. For the purpose of providing a large surface area for gas-liquid interaction, the wire mesh is generally woven or knitted in a dense form during the manufacturing process.
3. Coalescence: When the liquid droplets come into touch with the wire surfaces, a process known as coalescence takes place. This occurs when the gas stream travels through the wire mesh pad. The droplets have a tendency to stick to the wire surfaces because of the surface tension of the liquid inside the liquid.
4. Coalescing Action: Coalescing action occurs when the liquid droplets that are present on the wire surfaces combine with other droplets to form a larger droplet. The droplets continue to migrate over the wire mesh pad, which results in the formation of bigger droplets as the coalescence process proceeds.
5. Droplet Separation: In the fifth step, known as droplet separation, the bigger liquid droplets that are produced by coalescence are removed from the gas stream because they are too heavy to stay in the gas stream. The force of gravity causes them to descend to the ground, where they are gathered in a sump or drain located at the base of the demister.
6. Exit of the Gas Stream: The gas stream, which is now mostly free of liquid droplets, leaves the demister and continues downstream for additional processing or release.
Demisters made of wire mesh are often used in a wide variety of industrial applications, particularly those that need the complete elimination of liquid droplets from gas streams. They find widespread use in a variety of methodologies, including gas-liquid separation, gas scrubbing, vapour recovery, and environmental pollution management, among others. In order to choose the appropriate wire mesh demister, it is necessary to take into consideration a number of criteria, including the gas flow rate, the droplet size distribution, the operating temperature, the pressure, and the kind of liquid that is being removed.
It is possible to construct wire mesh demisters out of a wide variety of materials, depending on the particular application needs, which may include the properties of the gas and liquid that are being discussed. In order to guarantee the demister’s efficiency and longevity, the selection of the material is of the utmost importance. Listed below are some of the materials that are often used for wire mesh demisters:
1. Stainless Steel: Due to its exceptional resistance to corrosion, mechanical strength, and thermal stability, stainless steel is a material that is often used for the construction of wire mesh demisters. Because of its resistance to a broad variety of chemicals and its ability to sustain a wide range of temperatures, it is appropriate for a variety of applications in the industrial sector.

2. Monel: Monel is a nickel-copper alloy that is well-known for its exceptional resistance to corrosion, especially in hostile settings such as saltwater or acidic conditions. Monel includes both nickel and copper. Demisters built of wire mesh that are produced from monel have an exceptional resistance to corrosion and may be used in situations where the process includes corrosive gases or liquids.
3. Inconel: Inconel is a family of alloys that are based on nickel and chromium and have great resistance to corrosion as well as high-temperature strength. Typical applications for inconel wire mesh demisters include those that involve high temperatures or settings that are characterised by harsh chemical conditions.
4. Polypropylene (plastic): Wire mesh demisters may be manufactured using polypropylene or other plastic materials in particular circumstances or situations. Plastic demisters are not only lightweight and cost-effective, but they also provide excellent resistance to chemicals. It is standard practice to use them in situations where metal demisters would not be appropriate owing to variables such as chemical compatibility or electrical conductivity.
When choosing the material for a wire mesh demister, it is important to take into consideration a number of parameters, including the chemical compatibility of the gas and liquid, the operating temperature and pressure, the mechanical stress, and any special industry requirements or laws. It is essential to choose a material that has the necessary corrosion resistance, mechanical strength, and long-term durability for the application that is being considered.
These are some of the applications that wire mesh demisters are used for:
1.Liquid Droplet Separation: The main purpose of a wire mesh demister is to remove liquid droplets or mist from a gas stream. This is accomplished via three distinct functions. In procedures where the presence of liquid droplets might create problems such as decreased efficiency, damage to equipment, or contamination, it is one of the most typical applications for this material. Through the process of catching and combining the droplets of liquid, the demister contributes to the process of ensuring that the gas stream that emerges from the demister is mostly devoid of liquid particles.
2. Separation of Gases and Liquids: Wire mesh demisters are an essential component in applications that include the separation of gases and liquids. In operations such as distillation, absorption, and scrubbing, they are used to separate liquid phases from gas phases using the separation process. By assisting in the effective separation of the gas and liquid phases, the demister makes it possible to achieve the appropriate level of product quality while also providing protection against liquid carryover.
3.Process Optimisation: Optimisation of the operation The presence of liquid droplets in a gas stream might have a negative impact on the efficiency of the operation. Wire mesh demisters contribute to the optimisation of process operations by strengthening the overall performance of separation equipment and improving the efficiency of gas-liquid interaction. They provide a contribution to the decrease of pressure drop, eliminate the possibility of fouling or clogging of equipment farther downstream, and enhance the overall efficiency of the operation.
4. Environmental Protection: Wire mesh demisters are used in environmental applications for the purpose of controlling pollutants and contributing to the decrease of emissions. In order to prevent the discharge of pollutants into the environment, they assist in the removal of liquid droplets or mist that carry contaminants from gas streams beforehand. This makes it easier to comply with environmental rules and guarantees that lower levels of air pollution are produced.
5.Equipment Protection: Wire mesh demisters are often used to safeguard downstream equipment from harm caused by liquid carryover. This is the fifth and last point on the list. The demisters prevent the buildup of liquids in equipment such as compressors, turbines, and heat exchangers by eliminating liquid droplets from the gas stream. This allows the demisters to increase the operational lifetime of the equipment and reduce the amount of maintenance that is required once it has been installed.
6. Vapour Recovery: Wire mesh demisters are used in operations that include vapour recovery in order to successfully remove liquid droplets from the vapour stream. The collecting of valuable vapour or the prevention of the loss of volatile chemicals, as well as the improvement of process efficiency and the reduction of environmental emissions, are all major reasons why this is vital.
Some of the industries that make use of wire mesh demisters include the oil and gas industry, the petrochemical industry, the chemical processing industry, the pharmaceutical industry, the power generating industry, the wastewater treatment industry, and environmental protection. The exact use of a wire mesh demister is contingent upon the needs of the process, the properties of the gas-liquid mixture, and the level of separation efficiency that is sought.