Wire Mesh Demister Pad
Knitted Wire Mesh Demister • Mist Eliminator Pad • Gas-Liquid Separator
ECOGRACE wire mesh demister pads deliver 98–99.5% mist removal efficiency for droplets ≥10 μm. Manufactured from knitted wire mesh in SS304, SS316L, Monel, and polymer materials, our demister pads are engineered as high-performance tower internals for distillation columns, gas scrubbers, evaporators, and knockout drums — providing reliable vapor-liquid separation with minimal pressure drop.
SS304 / SS316L / Monel / PP
Custom Sizes & Shapes
Wire Mesh Demister Pad Product Range
ECOGRACE manufactures three density configurations of knitted wire mesh demister pads to match your specific separation requirements, vessel geometry, and process conditions.
How Does a Wire Mesh Demister Work?
Wire mesh demisters use the inertial impaction capture mechanism. As mist-laden gas passes through the tightly knitted wire mesh, liquid droplets collide with wire surfaces, coalesce into larger drops, and drain back by gravity — delivering clean, dry gas at the outlet.
Gas Entry
Vapor carrying entrained liquid droplets rises through the column and approaches the demister pad installed horizontally above the tray or packing section. Typical gas velocity is 1–5 m/s.
Inertial Impaction
Liquid droplets ≥10 μm possess sufficient inertia to deviate from the gas streamlines and impact onto the knitted wire mesh surfaces. The random 3D mesh structure maximizes collision probability.
Coalescence & Drainage
Captured micro-droplets coalesce on the wire surface into larger drops. Once the drops grow heavy enough, gravity pulls them downward through the wire mesh demister pad back into the column.
Clean Vapor Out
Dry vapor exits through the top of the mist eliminator pad with <0.1% liquid carryover. Product purity improves, downstream equipment is protected from fouling and corrosion.
Wire Mesh Demister vs Vane Type vs Fiber Bed
Selecting the right mist eliminator depends on droplet size, gas velocity, pressure budget, and fouling tendency. The wire mesh demister offers the best balance of cost, efficiency, and low pressure drop for most industrial vapor-liquid separation applications.
| Parameter | Wire Mesh Demister | Vane Type Separator | Fiber Bed Eliminator |
|---|---|---|---|
| Min. Droplet Size | 10 μm | 20 μm | 0.3 μm |
| Removal Efficiency | 98–99.5% | 95–99% | ≥99.9% |
| Pressure Drop | 0.1–0.25 kPa | 0.15–0.5 kPa | 0.5–2.5 kPa |
| Gas Velocity | 1.0–5.0 m/s | 3.0–12.0 m/s | 0.05–0.25 m/s |
| Fouling Tolerance | Low – Medium | High | Low |
| Relative Cost | $ (Lowest) | $$ | $$$ |
| Best For | General demisting, distillation, evaporation | High velocity, slug flow, dirty gas | Sub-micron acid mist, oil mist |
Wire Mesh Demister Industry Applications
ECOGRACE wire mesh demister pads are the most widely installed mist eliminator type across chemical process, petrochemical, power, and environmental industries worldwide.
Distillation Columns
Prevent liquid carryover from trayed and packed distillation columns. The #1 application for wire mesh demister pads globally. Improves product purity and protects condensers.
Distillation Column Demister
Oil & Gas Separation
Knockout drums, flash drums, and three-phase separators. Stainless steel demister pads remove oil mist and water droplets from natural gas and process vapors.
Oil & Gas Demister Pad
Gas Scrubbers
Prevent scrubbing liquid carryover from wet scrubber and absorber tower outlets. Knitted mesh demister pads ensure clean stack emissions and protect downstream fans and ducts.
Scrubber Mist Eliminator
Evaporators & Crystallizers
Capture entrained product droplets from evaporator vapor space. Recover valuable dissolved solids and prevent fouling of condensers and vacuum systems.
Evaporator Demister
Chemical Process Plants
Reactor vents, acid concentrators, and chemical vapor recovery. Monel demister pads and PTFE demister pads for corrosive chemical environments and HF acid service.
Chemical Process Demister
Power Generation
Steam drum moisture separators, FGD outlet droplet separators, and cooling tower drift eliminators. SS316L and alloy construction for high-temperature steam service.
Power Plant Demister Pad
Desalination & Water Treatment
MSF and MED desalination plant evaporator demisters. Titanium and duplex stainless steel wire mesh mist eliminators for seawater service and brine carryover control.
Desalination Demister
Pharmaceutical & Food
GMP-compliant SS316L demister pads for solvent recovery, spray dryer exhaust, and pharmaceutical reactor vents. Electropolished finish available for sanitary applications.
Pharma & Food Grade Demister
Wire Mesh Demister Pad Technical Specifications
Standard specifications for ECOGRACE knitted wire mesh demister pads by York mesh style equivalent. All pads manufactured with welded support grids.
| Parameter | York 326 | York 431 | York 421 | York 931 |
|---|---|---|---|---|
| Bulk Density (kg/m³) | 80 | 144 | 193 | Co-knit |
| Wire Diameter (mm) | 0.28 | 0.28 | 0.28 | 0.28 + 0.28 |
| Surface Area (m²/m³) | 158 | 284 | 381 | 220 |
| Void Fraction (%) | 99.0 | 98.2 | 97.5 | 98.5 |
| K-Factor (m/s) | 0.107 | 0.107 | 0.107 | 0.107 |
| Std. Pad Thickness (mm) | 150 | 100 – 150 | 150 – 200 | 150 |
| Max Diameter (mm) | Up to 10,000 (sectional assembly with tie rods) | |||
| Pressure Drop (Pa) | 25 – 250 (dry); design-dependent at operating load | |||
| Temperature Range | −196°C to 540°C (metal); −30°C to 120°C (polymer) | |||
Demister Pad Material Selection Guide
ECOGRACE offers wire mesh demister pads in a comprehensive range of metallic and polymer materials to resist corrosion in any process environment.
| Material | Max Temp | Corrosion Resistance | Typical Applications |
|---|---|---|---|
| SS304 / 304L | 540°C | Good – general purpose | Distillation, evaporators, general chemical |
| SS316 / 316L | 540°C | Superior – chloride, marine | Petrochemical, pharmaceutical, seawater |
| Monel 400 | 480°C | Excellent – HF, alkali | HF alkylation, fluorine, caustic soda |
| Alloy 20 (Carpenter 20) | 540°C | Excellent – H2SO4 | Sulfuric acid plants, phosphoric acid |
| Hastelloy C-276 | 540°C | Outstanding – universal | Severe corrosion, mixed acid environments |
| Titanium Gr.2 | 315°C | Excellent – chloride, seawater | Desalination, chlor-alkali, brine |
| PP (Polypropylene) | 120°C | Good – acid, alkali | Low-temp acid gas, FGD scrubbers |
| PTFE | 260°C | Outstanding – all chemicals | Highly corrosive, fluorine, strong acids |
Why Choose ECOGRACE Wire Mesh Demister Pads
As a leading demister pad manufacturer and demister pad supplier, ECOGRACE provides engineering expertise, competitive pricing, and fast delivery for projects worldwide.
Direct Factory Pricing
Buy direct from our production facility — no distributors, no middlemen. Competitive wire mesh demister pricing with 30–50% savings versus Western OEM brands for equivalent quality and certifications.
Engineering Support
Demister pad sizing using Souders–Brown equation and K-factor calculations. Our engineers verify design velocity, demister pad pressure drop, and material compatibility for every order.
Fast Global Delivery
Standard demister pads ship within 7–15 business days. Custom sizes, special alloys, and large-diameter sectional pads available with short lead times. Export packaging for safe ocean freight.
Quality Certified
ISO 9001 certified production. Material test certificates (MTC 3.1), dimensional inspection reports, and packing density verification provided with every shipment of wire mesh demister pads.
Demister Pad Sizing & Design
Proper demister pad sizing ensures optimal separation efficiency without flooding or re-entrainment. The Souders–Brown equation determines the maximum allowable gas velocity through the wire mesh demister.
Souders–Brown Equation
Vmax = K × √((ρL − ρG) / ρG)
Vmax
Maximum gas velocity (m/s)
K
Demister K-factor (typically 0.107 m/s for wire mesh)
ρL
Liquid density (kg/m³)
ρG
Gas density (kg/m³)
Design velocity is typically set at 75–85% of Vmax to provide a safety margin against flooding. ECOGRACE engineers perform full demister pad sizing calculations at no charge when you request a quotation — simply provide your process data sheet or operating conditions.
Wire Mesh Demister Pad FAQ
Common questions about wire mesh demister pads, selection, sizing, and installation.
What is a wire mesh demister pad?
A wire mesh demister pad (also called a mist eliminator pad, knitted mesh demister, or droplet separator) is a tower internal device made from layers of knitted metal or polymer wire mesh. It is installed inside process vessels to remove entrained liquid droplets from rising gas or vapor streams by inertial impaction and coalescence.
What is the standard thickness for a demister pad?
Standard demister pad thickness is 100–150 mm for most applications. High-efficiency or vacuum service may require 150–200 mm. The pad thickness directly affects separation efficiency and pressure drop — thicker pads capture more droplets but at higher ΔP.
How do I choose between SS304 and SS316L demister pads?
SS304 demister pads are suitable for general-purpose non-corrosive service (distillation, clean steam). SS316L demister pads are required when chlorides are present, in marine environments, pharmaceutical processes, or any service involving dilute acids. SS316L offers significantly better pitting and crevice corrosion resistance.
What is the K-factor in demister pad design?
The K-factor (Souders–Brown constant) is an empirical value used to calculate the maximum allowable gas velocity through a wire mesh demister. For standard wire mesh pads, K = 0.107 m/s at atmospheric pressure. The K-factor decreases at elevated pressures and is adjusted for foaming systems, high liquid loading, and vacuum operation.
Can wire mesh demister pads handle fouling service?
Knitted wire mesh demisters have limited fouling tolerance compared to vane-type separators. For moderately fouling applications, use low-density (80 kg/m³) pads with larger void fraction. For severely fouling or solids-laden service, consider vane-type or spray-wash designs. ECOGRACE also offers co-knit (York 931 style) pads that balance efficiency with improved drainage for fouling-prone processes.
What sizes of demister pads does ECOGRACE supply?
ECOGRACE manufactures demister pads from 150 mm to 10,000 mm diameter. Small pads (≤1,200 mm) are supplied as single-piece discs. Larger diameters are assembled from segments joined by tie rods and support grids. Custom shapes including rectangular, annular, and semicircular pads are available for non-standard vessels.
Request a Wire Mesh Demister Pad Quotation
Send us your vessel diameter, operating conditions, and material requirements. Our engineers will provide a complete demister pad sizing calculation and competitive quotation within 24 hours.