Demister pads, or mist eliminators, are essential filtration and separation equipment pieces. Demister pads are made using knitted wire mesh. Knitted wire mesh comprises a fine wire, usually 0.011&#; or 0.006&#; in diameter, knitted together to create a uniform-density mesh. A demister pad can consist of knitted wire mesh on its own or be constructed with a support frame. The support frames are made of welded-together bar stock, which adds structural support to the demister pad. Support frames are important for many knitted wire mesh applications because knitted mesh on its own does not have any structural strength. In many cases, the addition of the support frame extends the life of the demister pad.
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How Demister Pads are used in different applications.
Demister pads can be used in various applications for filtration or separation purposes. In the oil and gas industry, demister pads are commonly used in vapor-liquid separators to remove liquid droplets from vapor streams. As vapor rises through the vessel, the demister pad intercepts the light liquid droplets, which then coalesce into larger droplets. Once the droplets become large enough, they drain by gravity out of the bottom of the demister pad. This process allows for a dry vapor to exit the vessel and continue to the downstream equipment.
Demister pads are commonly used as filters in the food and beverage industry. Depending on the application, demister pads are used differently. In beverage filtration applications, demister pads, typically made from stainless steel wire, catch and remove unnecessary particles from the liquid. In grease trap applications, stainless steel demister pads are used to remove grease from air exhaust vents, allowing clean air to flow out. In distilleries, copper demister pads remove sulfur compounds from varying spirits, leaving you with a better-tasting spirit.
Demister pads can also be used in traditional air filtering applications, like HVAC systems. Knitted wire mesh filters out dust and other particles from the air stream, allowing clean air to pass through. The Central Wire Difference
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Central Wire can customize demister pads to your exact specifications. No matter your application, mesh density, or required alloy, CWI can deliver the perfect demister pad every time. For critical applications, we have a variety of stainless steel and specialty nickel alloy wire available that can withstand your corrosive environment. We also offer copper alloy knitted wire mesh, which is commonly used in the food and beverage industry due to its antimicrobial properties.
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What causes demister pad fouling and blockage?
The demister pad is placed at the flue gas outlet at the top of the absorption tower, where belongs to the &#;wet-dry&#; junction area and forms &#;wet-dry&#; fouling easily. As the absorption tower slurry contains CaSO4, CaSO3 and fly ash contains silicon, iron, aluminum and other substances that have a large viscosity, when the slurry collides with the surface of the demister pad and tower walls, some of them will adhere to the demister pad and tower walls and settle down. In addition, as the higher temperature of the flue gas accelerates the evaporation of the sediment layer, making the sediment layer gradually forms hard scale with a dense, cement-like structure.
The reasons for the fouling and blockage of the demister pad are summarized as follows:
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- The demister pad has a long wash cycle. Regular demister pad washing is an effective measure to ensure the cleanliness of the demister pad. Especially when the demister pad is relatively clean, a small amount of gypsum particles and fly ash attached to the demister pad can be washed off by washing. Therefore, when the demister pad is put into operation, it must be properly washed in accordance with the design requirements. A regular wash cycle is an important guarantee for effective washing. If the wash cycle is too long, gypsum particles and flue gas keep attaching to the surface of the demister pad, making the scale become thick and hard via repeat high-temperature flue gas washing and form a thick and dense hard scale. At this time, the scale cannot be washed away by merely washing. Generally, the optimal wash cycle of the demister pad is every one or two hours. When the pressure difference between the upper and lower demister pad tends to greater, the wash cycle shall be shortened accordingly.
- The demister pad flushing water has a low pressure. When the demister pad is put into operation for a short period, the surface of the demister pad is smooth and clean, and the scale formed during operation is dispersed, and can be washed away with the flushing water under a certain pressure. However, in practice, the unreasonable design of the pipeline may cause the pressure of the flushing water of the demister pad fails to meet the design requirements, making the flushing effect is undesirable and the scale on the surface of the demister pad become larger and harder. In order to ensure enough flushing pressure, on the one hand, the pipeline and orifice plate shall be designed reasonably, on the other hand, multiple flushing doors for simultaneous flushing shall be avoided.
- The demister pad flushing doors is damaged and cannot be washed normally. The normal operation of the demister pad flushing door is a prerequisite for flushing. As the demister pad flushing door is commonly arranged in the open air, flooding water often occurs during the operation, making the flushing door cannot be put into normal operation. Therefore, the flushing door must meet the relevant protection level, provide certain protective measures like shelters, and strengthen its daily maintenance.