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A stainless steel circular demister filter is a mist eliminator designed to separate liquid or water droplets from gas streams within industrial processes. They mostly come in rectangular and circular shapes. Circular designs are more prevalent in round vessels, headers, and flares. A stainless steel demister filter performs the same function as a typical demister, but it provides extra durability due to stainless steel's inherent qualities. Demister filters made of stainless steel will be less prone to wear and corrosion in harsh environments.
Stainless steel demisters can be made using various materials, including:
SS 304
SS 304, often known as 304 stainless steel, is a common alloy used for demister filters. Grade 304 stainless steel offers remarkable oxidation and cryogenic toughness resistance. It also has excellent resistance to a range of chemicals, making it an excellent material for demister filters in various industries.
SS 316
The material's enhanced corrosion resistance is provided by the addition of molybdenum to the demister filter made of SS 316. Demister filters made of SS 316 stainless steel are resilient even under high temperatures. It can also survive corrosive environments. As a result, they are suitable for use in marine applications and in contact with salty or chloride compounds.
According to the methodology utilized to manufacture the wires, demister filter components can also be classified:
Woven wire demisters
Knitting together fine wire mesh results in a woven wire demister. They have a sturdy frame structure that enables them to trap and catch mist efficiently. Woven wire demisters are typically found in oil refineries, chemical facilities, and power plants.
Fiberglass demisters
Fiberglass demisters are made of fiberglass filaments. They have lightweight properties with high tensile strength, enabling them to withstand aggressive corrosive environments where other materials would fail. Demisting efficiency is very high, and they are mostly found in petrochemical plants, offshore oil platforms, and pulp and paper industries.
Knitted wire demisters
A knitted wire demister is produced by knitting fine wires into loops, forming a three-dimensional, fluffy fiber structure. This fiber arrangement enables the tangled droplets to coalesce and drain down the mist eliminator while allowing the gas to pass through. They are typical used in chemical manufacturing facilities, petrochemical extraction, offshore oil rigs, and marine engines.
The last category of identifying demister filters is function. This includes:
Cyclone separators
- incorporate cyclone action and tangential inlets to separate particles according to size. Bigger droplets are flung outwards by centrifugal force, while smaller ones exit through the outlets.
Multifaceted demister filters
- Morbidity reduction is their main goal. They are typically installed before treatment facilities or discharge points.
Cylindrical demister filters
- come in round and rectangular forms. The cylindrical is more popular and easier to use.
Horizontal demister filters
- Would usually settle below, hence the name horizontal. They resemble shallow pans with a low profile.
Coalescing filters
- Take very tiny droplets, merge them into bigger ones, and release them into the header, performing a very complex elimination task.
Notably, the performance of a demister plate largely depends on the specification and design of the material used to make it. Here are some major specifications of a demister filter:
Material
Demisters can be made from a variety of materials, including plastic, ceramic, stainless steel, and carbon steel. Metal demisters are generally preferred because they are more durable and can resist high temperatures and pressures.
Mesh Size
A demister's mesh size, or amount of wires per inch, affects how well it works. Smaller mesh sizes with more wires per inch provide better mist elimination and pressure drop resistance.
Pocket Size
Refers to the demister's bag or pocket dimensions in terms of breadth and height. Larger pocket sizes offer more air flow but less mist removal, while smaller pocket sizes are the reverse.
Density
This refers to the number of cells in a filter or demister element per unit volume. High-density elements use more energy but are more effective in mist removal.
Pin Diameter
This diameter refers to the cross-thickness of the pins used to form the grid. Stainless steel demister filters with larger pin diameters have more stability and strength, while smaller ones provide better filtering.
Proper maintenance of a demister filter prolongs its life and ensures efficiency. Here are some maintenance tips:
Stainless steel demister filters serve a wide array of industrial applications. Here are some key uses of demister filters in various industries.
Petrochemical and Oil & Gas Industry
Demister filters are prominent in oil and gas refineries. They are useful in separating gaseous products from liquid phenols. Also, demister filters are great in eliminating gas condensates. This includes crude oil mist from products such as natural gas.
Power Generation
In thermal power plants, demister filters are supportive components. They help in controlling steam turbine condensate. This, in turn, enhances the quality of the condensate.
Pharmaceutical Manufacturing
In the pharmaceutical industry, demister filters are supportive tools for distillation processes. They help to separate harmful solvent vapors from liquid in the pharmaceutical farms.
Chemical Processing
In chemical industries, demister filters are helpful in separating chemicals from gaseous solutions. They are essential in chemical-reaction-related distillation processes. Also, demister filters serve as pre-filters for chemical recovery cyclones.
Food and Beverage Processing
Demister filters are prominent in the food and beverage processing industry. They assist in removing mist from the processing of dairy products. For example, demister filters can be useful in separating oily aerosols in beverage processing. This includes fruit juice and soft drink production.
Hydrocarbon Recovery
Demister filters are essential in hydrocarbon recovery. They enhance the recovery of valuable hydrocarbons from gas streams in cyclones.
Aerospace and Automotive Industries
Demister filters are useful in the automotive and aerospace industries. They support the separation of oil mist from ventilating gases in combustion engines and aircraft engines.
Picking a demister can significantly impact the functionality of a given industry. Some of the factors to consider when choosing a demister are:
Catcher efficiency
When choosing a demister, it is essential to examine the mist liquid loading that the demister can accommodate. This is usually measured in volume flow per unit split.
Operating parameters
Customers would need to evaluate various operational demister parameters that can affect the plant's efficiency. Some of the parameters to consider include temperature, pressure, fluid characteristics, and the quantity of the gas.
Quality
It is crucial to select a demister of quality construction. Low-quality demisters can be cheap, but they risk incurring additional costs for constant maintenance.
Design
In several industrial applications, gas-liquid separation is crucial. Therefore, it is essential to pick a demister with an accurate design to assist in effective separation.
Replacement requirements
When choosing a demister, it is important to identify the costs and availability of replacement demisters. In some cases, it can be more appropriate to select a demister that is not likely to require replacement frequently.
Q1: How does a demister function?
A1: The demister functions by a process called coalescence, whereby tiny water droplets collide with one another when passing through the demister panel. The water droplets then form larger droplets that ultimately fall back into the separator.
Q2: What are the two types of demisters?
A2: The two common types of demisters include the wire mesh demister and the vane demister. Each type functions in its way to eliminate mist from gas streams.
Q3: What are the benefits of using a demister?
A3: The demister offers some advantages, including reducing product loss, improving the quality of products, and preventing air pollution. The demister also helps to protect downstream equipment and enhances the overall efficiency of the separation process.
Q4: When should a demister be replaced?
A4: Several factors may indicate that it is time to replace the demister, such as a significant decline in the performance of gas treatment or an increase in the level of contaminants in the processed gas. Also, if the demister is structurally damaged or if there is persistent clogging despite regular cleaning, then the demister should be replaced.
Q5: How does a demister differ from a scrubber?
A5: While both the demister and scrubber aim to remove liquid droplets from gas streams, they accomplish the task in different ways. A scrubber operates by dissolving the contaminants in a liquid solution or reacting with the liquid, while a demister physically separates the liquid from the gas through coalescing filters.
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