5 Must-Have Features in a fiber bed mist eliminators

In a world of online information, you will find many options when searching for mist elimination solutions. While many companies can sell you a mist eliminator, it is a wise choice to find a company that will design the right mist eliminator for your process. Below we will talk about the basics of mist eliminators, also known as demister pads.

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In the manufacturing of fertilizers, chemicals, and other processes, liquid will encounter flowing gas, as a result, the entrainment of liquid droplets will generate a mist. Mist is corrosive and can result in process inefficiencies and damage your equipment.

A properly designed and installed mist eliminator will collect and remove droplets from the gas stream. Removal happens when droplets within the flowing gas strike the mist eliminator and are then captured. The material coalesces on the surface of the demister pad, causing larger droplets to form. The droplets will join and flow by gravity into the drainage area below where they are recovered or removed.

One major concern in mist elimination is plugging. This occurs when a substance builds upon the surface of the mist eliminator causing a blockage and then pressure drop. It is common for process and gas stream problems to result from plugging of the demister pad. Plugging can result in product loss, excessive energy use, corrosion, reduction of equipment life, plant run times being affected, and not meeting output requirements. Structured media mist eliminators are less prone to plugging than conventional knitted mesh.

When choosing a mist eliminator, it is important to choose a company that will understand your chemical process and design a mist eliminator for your system and process needs. Being a retrofit or a new design, many considerations will come into play for the design of the demister pad. Particle size will determine the type of mist elimination for the application, such as Fiber Bed Filters vs. Structured Mesh Pads. Definition of the droplets size in the current system will be necessary to determine the proper design. Droplets definition are based on diameter. For example Sprays are larger than 10 microns. Mist are 10 microns to 1 micron. Aerosols are smaller than 1 micron.

Droplets are collected on the mist eliminator media by three different methods. Inertial Impaction, Interception, and Brownian diffusion.

For larger droplets, inertial impaction happens when droplets ≥ 20-30 travel in a straight line, away from the gas flow, and then they strike the surface of the media and stick together.

Interception happens when droplets down to 1 to 3 microns in diameter travel along the path but are caught or intercepted because they cannot pass through the fibers of the media.

Brownian diffusion happens when particles smaller than 1 micron collide with gas molecules, then the molecules gain momentum and random motion, therefore likelihood increases that the molecules will contact the fibers.

Mist Eliminators Are Available in Several Different Styles:

Vane packs, also known as chevron or plate-type mist eliminators are composed of corrugated plates that are spaced close together. This creates a tortuous path for the gas to follow. Vanes are more effective for larger droplets and can be quite costly.

Fiber bed Filters are made of fine fibers, typically glass or plastic, and packed or wound around a cylinder. Fiber bed filters can be repacked and replaced. They should not be used where solids exist.

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Wire mesh also known as knitted mesh is composed of multiple layers of mesh that is knitted of metals or plastic monofilaments. These pads can be cleaned and reused.

Structured mesh mist eliminators are made of interlocking plastic monofilaments. These pads can also be cleaned and reused. When designed properly, larger diameter polypropylene mesh pads can easily handle particulates that would usually cause pressure drop.

Poorly designed mist eliminators can lead to corrosion of downstream equipment, product waste, and shutdown times that are longer than desired.

Properly designed mist eliminators can reduce plugging and mist carryover, have lower pressure, reduced energy consumption, less cleaning and maintenance, less damage to downstream equipment, reduced corrosion, and longer equipment life and reduced atmospheric emissions. All which will lead increased profitability.

When designed properly, custom engineered Mesh Mist Eliminators and Fiber Bed Filters will provide the final user with many years of optimal performance and minimal maintenance requirements.

Kimre™ Clean Air technology has been designing custom mesh pad mist eliminators since . Our sophisticated line of mist eliminators such as our B-GON® Mist Eliminator is available in the widest range of fiber diameters in the industry, from the finest (0.05 mm / 0.002”) to the coarsest (0.94 mm / 0.037”) and has been used in more than 40,000 installations worldwide.

It is imperative to do your research when choosing a mist eliminator company for your filtration needs. Should your application require a mesh pad filter or a fiber bed mist eliminator, there are many reputable vendors. For over 50 years, Kimre has been known for being a world leader in innovative products, including custom fiber bed filters.

In this article, we will take a closer look at the technology behind fiber bed candle filters and mist eliminators, their applications, and how they contribute to meeting stringent emission requirements and regulations.

Understanding Candle Filters:

In Scrubber Systems, mist eliminators of different styles play a crucial role in the overall performance of the vessel. Fiber Bed Filters play a crucial role in creating a safer and healthier environment, particularly for submicron filtration. These filters can offer 99.9% of particle collection. They are optimal in flow rates of 10 CFM to 250,000 CFM (15 Cubic Meters/Hr to 425,000 Cubic Meters/Hr).

Candle filters, also known as Fiber Bed Filters, are highly efficient for the filtration and separation of gases and liquids. They are constructed using a cylindrical vessel composed of multiple filter elements. Ideally, these elements should consist of quality materials. Depending on the design, the candle filter will consist of a structural inner cage, outer cage, and an end plate. Cage materials could include carbon steel, alloys, FRP and plastic. Between the inner cage and outer cage is the filter media. The media usually consists of fiberglass, polyester, or polypropylene. Proper filtration media will be determined based on the identified particulate that needs to be collected. The fibers create a tortuous path, causing impurities to impact and adhere to their surfaces, ultimately draining as clean liquid.

Key Features and Benefits of Candle Filters:

• High Filtration Efficiency: Candle filters are extremely efficient in the removal of sub-micron-sized particles from the gas stream. This ensures enhanced process efficiency in various industries and applications. Candle filters can be used in a variety of applications, including organic applications such as, asphalt roofing products, compressed air & gasses, food processing (vegetable oil & lard frying. Other applications include metal machining, oil mist plasticizer, rotating equipment, lube oil and reservoir urethane. Candel filters are also used in chemical processing, such as in sulfuric acid, chlorine, and hydrogen (Chlor-Alkali), pulp and paper, semi-conductor, acid storage and vent tanks, platinum recovery, polymerization, and styrene & urethane.
• Their versatility makes them a preferred choice for diverse industrial processes.
  Candle filters are known for their compact design, making them suitable for installations with space constraints. They can be easily integrated into existing systems, providing a seamless filtration solution.

Fiber Bed Mist Eliminators: Advanced Air Cleaning Technology

In addition to fiber bed mist eliminators, Kimre offers custom designed mesh mist eliminators. These mist eliminators are composed of layers of material specially designed to capture liquid droplets and particulate matter from gas streams.

Significant Features and Applications of Mesh Pad Mist Eliminators:

• Kimre can custom design mesh pad mist eliminators that can handle the widest range of gas velocities and contaminant levels. They excel in the removal of mist and droplets from gas stream and offer efficient performance ensures compliance with stringent emission regulations while offering the highest collection efficiency of ANY mesh-type media: 99+% @ 1 µm. Our mesh pad mist eliminators provide collection efficiencies for mist droplets down to 3-5 microns in size but can have limited liquid handling capabilities and are susceptible to fouling from insoluble contaminants.
• Custom mesh pad fabrication conforms to any vessel configuration and orientation. Composite pads of various mesh styles allow for optimization of efficiency, pressure drop, and pluggage resistance while offering lower pressure drops than traditional knitted mesh.
• The custom mesh mist eliminators are engineered using a wide range of high-quality materials of construction, including polypropylene, PVDF, ETFE and PFA, to meet any level of temperature and corrosion requirements.
• These materials ensure durability and longevity in the most demanding environments. This longevity translates to cost-effectiveness and prolonged system reliability. The media is cleanable & reusable for extended service life in the harshest environments.

Conclusion