Unlike ‘industry standard’ mist eliminator design methods, which predict performance using bulk density and filament diameter of the separation media, the 9797 modeling techniques consider the characteristics of individual mesh layers as a mathematical model so that the entire process within the separator (capture, coalescence and drainage) can be predicted on a layer by layer basis.
This enables Sulzer to produce unique structures where the free volume and mesh free area can be varied through the depth of the pad, giving the best balance of mist eliminator characteristics, such as liquid holdup and efficiency, from inlet to outlet.
Additionally, separation efficiency can be predicted in terms of liquid entrainment concentration, providing meaningful, measurable information on separator performance. This represents a considerable improvement on droplet size efficiency predictions which are extremely difficult to verify in practice.
An extensive range of mesh styles have been analyzed for a variety of process systems ranging from air/water to more challenging hydrocarbon conditions.
The performance of the mist eliminator is established by calculating the cumulative effect of combined mesh layers and their characteristics. The model allows a high degree of optimization so that layer specifications can be varied to meet specific process challenges. For example, high free volume/low liquid hold-up may be an important feature of the inlet region of the mist eliminator with a gradual increase in separation efficiency towards the outlet.
- Glycol contactors - minimization of TEG entrainment from natural gas dehydration columns
- Gas sweetening - installation in amine absorbers
- Dew-point separators - 9797 designs have helped reduce water and hydrocarbon dew-points in natural gas processing
- Rotary screw compressors - reduction of entrainment of synthetic oil from compressor system knock-out drums
- Steam drums - guaranteed steam dryness can be achieved using Sulzer KnitMesh 9797 mist eliminators