Mist Eliminators | Oil Mist Collectors

Mist eliminators are crucial components in industrial processes, tasked with the elimination of vapor and liquids contained in air or gas emissions. These systems not only enhance operational efficiency but also play a significant role in protecting the environment by reducing harmful emissions. According to various industry insights, effective mist collection is essential for ensuring safety within manufacturing environments by preventing equipment corrosion and minimizing health hazards associated with airborne contaminants.

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By employing mist eliminators, industries can effectively remove liquid particulates such as oil mist, coolant mist, and acid aerosols from exhaust streams. This process improves overall product quality, prevents slick surfaces, and mitigates health risks for workers. Mist eliminators can target droplet sizes ranging from 3mm down to less than 1 micron.

How Mist Eliminators Operate

The basic principle behind mist elimination involves channeling exhaust gas into confined spaces where filtration occurs to separate liquid from gas.

The three primary types of mist eliminators include mesh, vane (or Chevron), and fiber bed demisters. These systems can operate in isolation or cooperatively, depending on the specific application and requirements.

Each type employs unique mechanisms to efficiently remove tiny droplets from the gas stream, albeit in distinct manners.

Wire Mesh Mist Eliminators

Wire mesh mist eliminators are the most commonly utilized systems, proficient at removing droplets ranging from 3mm to under 1 micron in size.

These systems can have vertical or horizontal airflow designs. While vertical models are widespread, horizontal models find application in sectors such as battery production and chromic anodizing.

In a wire mesh demister, a randomly woven mesh, made of metal, polyester, acrylic, or glass fibers, is positioned between the gas inlet and clean air outlet. As contaminated air traverses the filter, liquid droplets coalesce on the mesh surface, pooling in a reservoir while a fan propels clean air through to the outlet.

The droplet removal mechanism relies on three principles: inertial impaction, direct interception, and Brownian diffusion.

Inertial impaction occurs when droplets hit the mesh fibers, removing them from the air flow. Direct interception happens as droplets close enough to mesh fibers adhere to them. In scenarios with increased airflow or larger droplets, the filtering efficiency improves—more droplets are captured effectively. Conversely, at lower speeds or with smaller particles, Brownian diffusion becomes essential as random particle motion lets droplets collide with the mesh fibers, enhancing separation efficiency.

However, increased filtration may lead to a pronounced pressure drop. Most mesh filters range around six inches thick, and in oil mist capture contexts, multiple layers may be utilized for varying droplet sizes.

Benefits and Limitations of Mesh Mist Eliminators

Advantages include affordability and effectiveness in removing particulates down to a certain size, while disadvantages comprise reduced efficiency with increasing droplet sizes and higher pressure drops compared to other methods.

Fiber Bed Mist Eliminators

Operating in a similar manner to wire mesh systems, fiber bed mist eliminators excel in handling horizontal gas flows. These cylindrical filters can range between 2 and 20 feet in height, capturing mist through inertial impaction, direct interception, and diffusion.

Materially, they feature rolled screens that encase fibrous media, trapping liquid droplets and channeling clean exhaust gas outward. Fiber bed mist collectors can achieve up to 99.9% efficiency in eliminating fine particulates.

Pros and Cons of Fiber Bed Mist Eliminators

Advantages include exceptional removal efficiency for droplets under one micron and large surface areas for processing high gas volumes. Disadvantages, however, involve reliance on horizontal airflow, substantial pressure drops, and a tendency for clogging.

Vane (Chevron) Mist Eliminators

Vane mist eliminators, also recognized as baffle-type systems, effectively extract larger droplets via inertial impaction. They accommodate both vertical and horizontal gas flows through blades oriented in a zig-zag pattern, guiding vapor streams and allowing droplets to condense on the plates where they can be collected.

Material selection for these systems often includes stainless or carbon steel, with specific designs tailored to various application requirements.

Pros and Cons of Vane Plate Mist Eliminators

Advantages here encompass usability for dual airflow directions, high filtering capacities, and low-pressure drops. However, they are less effective against sub-micron particulates and necessitate careful velocity management to prevent re-entrainment.

Applications for Mist Elimination

The utilities of mist eliminators include the removal of a wide range of vapors and particulates:

• Organic vapors
• Chemical mist
• Oil mist
• Acidic or caustic mist
• Soluble particulates

Industries leveraging mist elimination technologies span:

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• Oil and petroleum
• Metalworking
• Battery manufacturing
• Plating and anodizing
• Chemical processing
• Power plants and cooling towers
• Circuit board manufacturing

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