Mesh Pads vs Vane Pads

Mist eliminators are designed to remove entrained liquid droplets from the gas streams such as oil mist during manufacturing or industrial process. Removal of contaminants will assist with recovery of valuable products, improve emissions, and protect downstream equipment. In this blog, we will discuss the basic similarities of vanes and mist eliminator mesh pads.

Both vane mist eliminators and mesh mist eliminators operate using the same principle of impaction to capture the droplets. As the droplets contact the filaments in a mesh pad or the surfaces of a vane, they will gather to form larger droplets and then drain with gravity. One of the primary differences between mesh pad mist eliminators and vanes is the ability to filter different size droplets. Vanes only work well for larger droplets and work well in high liquid loading situations as opposed to mesh pads that works for smaller droplets.

Vane mist eliminators are also known as chevrons. Typically, they consist of stainless steel, carbon steel, alloy steel, and sometimes plastic. They are constructed of various blades that are spaced to create difficult paths for the gas to follow. Vanes are used in columns, evaporators, and other vessels such as cooling towers, distillation towers. The blades can be smooth or hooked depending on the custom design. With each curve on the blade, the gas flow is forced to change direction, also known as “passes”. Vanes can be vertical or horizontal and are typically are round or rectangular.

Vanes can be custom made and offer high filtering and separating efficiency, long service life, they are resistant to fouling and offer low pressure drop. Unlike mesh mist eliminators, vane mist eliminators are not as efficient at collecting very fine droplets and are not effective for droplets smaller than 20mm in diameter, therefore, a mesh pad mist eliminator can be considered.

Mesh pads are made up of a collection of filaments. Much like vanes, mesh pads mist eliminators utilize inertial impaction to separate the gasses and can operate horizontally or vertically. As the gas rises within the mist at a certain speed, it will pass through the mist eliminator and collide with the different surfaces and strands of filaments through inertia. Fine droplets will collect to form larger droplets at which point, they separate from the gas, they will then fall with gravity from the pad. Typically, mesh pads are more economical than vanes.

Source- https://www.kimre.com/mesh-pads-vs-vane-pads/

Mist Eliminator Manufacturers

 

Mist eliminators have played a vital role in manufacturing and process operations for decades. It is now more important than ever to invest in high quality mist eliminators designed by experienced mist eliminator manufacturers. Mist Eliminators were created to remove contaminants or entrainments, such as oil mist, sulfuric acid mist, and chromic acid mist from the gas stream in absorption towers, separation tanks, evaporators, cooling towers, and gas separators. Industries such as metallurgy, petroleum, phosphates, and sulfuric acid rely on mist eliminators in their process. By using properly designed and installed mist eliminators, companies can meet and exceed state and federal standards, reduce operating cost, and protect downstream equipment, while increasing the amount of processing and recovery of valuable materials. As pollution rises due to an increase in manufacturing, there is a growing need for reputable mist eliminator manufacturers.

Mist eliminator companies that have experience, will know how to design both horizontal and vertical mist eliminators, also known as pads. The design of the mist eliminator is very much a science. The final product will depend on specifications such as orientation, thickness, flow, velocity, and spacing in the vessel amongst other considerations. The company must have through knowledge of the process and how droplets are generated and transported in the gas to design the best pad. It is imperative that the end user consult the mist eliminator manufacturer to ensure all aspects have been discussed.

Mist eliminator manufactures can often design mesh mist eliminators. These operate by utilizing composite mesh to capture and separate different size mist droplets from gas stream. Droplets are collected on the mist eliminator media by three different methods. Inertial Impaction, Interception, and Brownian diffusion. As the gas rises within the mist at a certain speed, it will pass through the mist eliminator and collide with the different surfaces and strands of fillaments through inertia. Fine droplets will collect to form larger droplets at which point, they separate from the gas, they will then fall with gravity from the pad. This is how the vapor is separated from the gases before emitted into the atmosphere.

Typically made of corrosion and rust-resistant materials such as stainless steel or polypropylene, mist eliminators are very durable and offer a long service life. Although typically round or square, they can be custom-designed in any size and shape. Larger pads may be designed in sections that are narrow enough to pass through a manway. This allows for easy installation and maintenance as they are lightweight and easy to transport. Mist eliminators are designed to have low-pressure drops and large surface area. It is important for mist eliminator companies to provide a training manual to the customer about proper maintenance. As time passes, the pad will become clogged and prone to flooding and pressure drop and will need to be cleaned to avoid these problems.

Source- https://www.kimre.com/mist-eliminator-manufacturers/

The Basic Hazards Of Oil Mist

 Oil mist will be produced anytime there is rotating machinery in the metal working industry. Oil mist, which is sometimes called organic vapor is formed from a combination of fluids that are used to cool and lubricate rotating machinery. Lubricating oil creates a layer between the moving parts of machinery in attempts to ensure optimal machine function. During the process of cutting, polishing and grinding of metals along with the combined use of cooling and lubricating fluids, fine oil mist and smoke is formed and released into the air. One way to capture the oil mist is to utilize an oil mist eliminator.

Oil mist eliminators such as Fiberbed Filters can help with oil smoke, which is formed when oil droplets are extremely small. Oil smoke is usually produced when machinery is operating at high speed and pressure. When oil contacts the hot machine surface, it vaporizes and condenses then releases sub-micron particles. These tiny droplets are too small to see with the naked eye, however, they are floating in the air until they settle. The residue can be seen on nearby walls, equipment, and machinery. If not captured and filtered, these particles could cause a plethora of problems for companies and operators. In a closed environment such as a factory or a machine shop, mist can linger in the atmosphere and pose a serious health risk to employees. Once released into the atmosphere, the particles leave a negative impact on the environment.

There are millions of people who work in the manufacturing and industrial field, for that reason, it is more important now that ever to prevent exposure to oil mist by investing in oil mist separators. As the oil settles on the surfaces, it will create a film which is slippery and hazardous. Oil mist can damage electrical equipment and circuit boards as well as machines and most importantly of all, people can slip and fall or breathe in the toxins.

Different oils will have different characteristics. Some mist will be dirtier than others, some oils will have larger particle sizes, sometimes it will be more like smoke rather than mist. For this reason, it is important to operate a properly designed oil mist separator. Oil mist by itself can be dangerous, but it can also quickly become contaminated with foreign material and chemicals. Many of these contaminants add to the hazards associated with oil mist.

By wearing PPE, employees can reduce the risk of exposure. However, to reduce the risk of the contaminated mist escaping into the atmosphere, oil mist eliminators are essential. The EPA has placed strict restrictions and mandates on companies to stay compliant. This leads to the pressing need for companies to engage an oil mist eliminator manufacturer that understands oil mist filtration and submicron particles.

Fiberbed filters are used as oil mist separators and are typically indicated for the successful filtration and removal of oil mist. Fiber bed filters are cylindrical filters that capture and collect oil mist from the airstream and optimize performance while protecting downstream equipment from failure. Fiber Bed filters are typically cylindrical and can range in size, reaching heights of 20 feet. The filter is composed of various structural materials known as cages or screens. These cages are made of various durable materials such as, stainless steel, carbon steel, corrosion resistant alloys and polymer materials.

Source: https://www.kimre.com/the-basic-hazards-of-oil-mist/

How Candle Filters can Capture Fine Oil Mist using Specially Designed Candle Filters

 

Fine oil mist is an aerosol mixture of oil droplets within the air that can look like smoke. These droplets are formed through processes such as, metalworking fluids— cooling fluids and lubricants— meeting fast rotating tools and objects. Such processes can include milling and drilling. The oil mist produced is so small that it gets dispersed into the air where it can cause many issues and malfunctions. The best way to avoid issues and capture oil mist is by using custom designed fiber bed candle filters.

Candle Filters are cylindrical filters composed of layered fiber bed media wrapped around an inner cage and typically surrounded by an outer cage. Filters can be anywhere from 1 ft to 20 feet in length. Each filter can be made to fit the requirements of the system. Dependent on the industrial process oil aerosol mist vary in size and distribution between .1μm to 10μm.As a result, each layer of media is composed of different densities that allow for efficient oil mist collection of any size. The cages that encompass the filter media are also made to fit the system. Cages can be constructed out of polymers, corrosion resistant alloys and carbon steel. The result is a filter that can be customized to best support your system properly.

What fiber bed mist eliminators (also known as fiber bed filters or candle filters) do is collect and capture oil mist in submicron form. This process of collecting and capturing oil mist can reduce many issues caused by oil mist. Sometimes a mist eliminator also known as a demister pad is also incorporated into the mist collection system. These pads are typically at the top of a system and can be composed of many kinds of materials to suit the needs of the system. For example, the pads can be made from Polypropylene or fine fibers or a combination of both. They typically capture larger particles. A different design would be a Candle Filter constructed of fine media combined with coarse media will capture the sub-micron particles and the larger particles as they pass through the filter. The particles will combine and form larger particles which are heavy, and they will fall to the bottom of the filter or collect in the media. Since these particles will be very heavy, they will not be able to drift back into the air.

Source: https://www.kimre.com/how-candle-filters-can-capture-fine-oil-mist-using-specially-designed-candle-filters/

How To Keep Your Scrubber Working Properly

 

Scrubbers are groups of different devices that come together to control air contamination through many mediums. A large component of scrubbers are the filters used to remove gases and particulates of different sizes in order to purify industrial exhaust streams. To keep the scrubber working properly, mist eliminator filters are used because they collect and remove dangerous mist that would contaminate the air.

Mist eliminators come in different diameters made to fit the needs of the scrubber/ system. The filter is composed of layers of filters piled on top of one another. The layers are made up of different materials, such as thermoplastic that can withstand high heat while collecting harmful particulates and acidic mists. Each layer can also be comprised of different diameter sizes based on the particle size that needs to be captured. Choosing the right diameter filter for your Scrubber will be the difference between an efficient scrubber and one that releases contaminants. For example, if the diameter of the filter is too large, unwanted particulates can escape and contaminate the air. If the diameter is too small, clogs can form in the system impacting flow. In either case, the result is an inefficient filter that will negatively impact the system as a whole.

When considering how to maintain your system, the type of mist eliminator is also important. Since each system is designed to handle different types of contaminants, the mist eliminator used should match the requirements of the system. For example, when running a system that deals with particles that tend to cause pressure drops within the system, using mist eliminator mesh as it is designed for that purpose will help to combat pressure drops.

Source: https://www.kimre.com/how-to-keep-your-scrubber-working-properly/

Components of a Fiber Bed Filter

Fiber Bed Filters are typically used in the removal of sub-micron particles and liquids in the gas stream through inertial and Brownian diffusion collection mechanisms. Fiber Bed Filters offer a high collection efficiency, up to 99.9% removal can documented. Fiber Bed Filters capture and collect oil mist from the airstream which optimize performance and protect the downstream equipment from failure. They can be used in organic applications, such as, asphalt roofing products, compressed air and gasses, food processing, metal matching oil mist, plasticizer, and rotating equipment lube oil reservoirs. Fiber Bed Filters can also be used in chemical processing applications, such as, sulfuric acid, chlorine and chlor-alkali, pulp and paper, semiconductor, acid storage tanks and platinum recovery. Overall, filters offer high removal efficiency, easy installation, simplified maintenance, and long filter life.

Fiber Bed filters are typically cylindrical and can range is size, reaching heights reaching 20 feet. The filter is composed of various structural materials known as cages or screens. These cages are made of various durable materials such as, stainless steel, carbon steel, corrosion resistant alloys and polymer materials. Sometimes Fiber Bed Filters are constructed with FRP inner and outer cages and plated, this design is often used for controlling fumes from toxic chemicals from waste incineration applications. The “bed” portion of the filter is typically composed of fine fibers of media consisting of various grades and densities packed between two cylindrical screens with flanges at the end. Pressure drop and collection efficiency are influenced by the fiber material, the diameter of the fibers and the density in which it is packed. Fiber bed filters can be either hanging filters or standing filters and typically can by handled by two technicians.

The contaminated airflow either enters from the center of the filter to the outside (forward flow) or from the outside to the inside (reverse flow). Only particles are collected by the filters, any vapors that enter the filter will pass through and be exhausted with the air. That is why the efficiency is given for particle collection. In addition, the Brownian diffusion collection is achieved through the design of a specific bed depth. This “deep bed” filtration makes it more important to limit the amount of insoluble solids that enter the filter. Insoluble solids will collect permanently in the filter, while liquid particulate, such as condensed asphalt light end will coalesce and drain from the filter.

Source: https://www.kimre.com/components-of-a-fiber-bed-filter/

Mesh Pads vs Vane Pads

 Mist eliminators are designed to remove entrained liquid droplets from the gas streams such as oil mist during manufacturing or industrial process. Removal of contaminants will assist with recovery of valuable products, improve emissions, and protect downstream equipment. In this blog, we will discuss the basic similarities of vanes and mist eliminator mesh pads.

Both vane mist eliminators and mesh mist eliminators operate using the same principle of impaction to capture the droplets. As the droplets contact the filaments in a mesh pad or the surfaces of a vane, they will gather to form larger droplets and then drain with gravity. One of the primary differences between mesh pad mist eliminators and vanes is the ability to filter different size droplets. Vanes only work well for larger droplets and work well in high liquid loading situations as opposed to mesh pads that works for smaller droplets.

Vane mist eliminators are also known as chevrons. Typically, they consist of stainless steel, carbon steel, alloy steel, and sometimes plastic. They are constructed of various blades that are spaced to create difficult paths for the gas to follow. Vanes are used in columns, evaporators, and other vessels such as cooling towers, distillation towers. The blades can be smooth or hooked depending on the custom design. With each curve on the blade, the gas flow is forced to change direction, also known as “passes”. Vanes can be vertical or horizontal and are typically are round or rectangular.

View Original Source: https://www.kimre.com/mesh-pads-vs-vane-pads/ 

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