Gas/Liquid Separation Technology

Sulzer Chemtech
Introduction
2
Content Page
Introduction 2
Product Summary 4
Mist Elimination 8
KnitMesh Mist Eliminators 11
Mellachevron 14
Axial Cyclonic Devices 17
Combined Systems 18
Applications 20
Sulzer is a major player in the eld of gas/
liquid and liquid/liquid separation tech-
nology, offering a full range of innovative
products and related services. Our com-
mitment to development of technology,
combined with application knowhow and
consistent fabrication standards ensures
that a well-engineered solution is available
for most separation problems.
Our expertise gained from hundreds of
successful installations in a broad spec-
trum of applications ensures that the best
possible product is recommended foe
each individual duty.
Our strategic alliance agreement with Shell
Global Solutions International B.V. pro-
vides access to state of the art separation
technology, including the Shell Swirltube
TM

and Schoepentoeter
TM
. The acquisition of
the KnitMesh Separation Business has
added KnitMesh
TM
Mist Eliminators and
Coalescers to our existing product range.
Specialists in Retro-Fit and
Performance Enhancement
Our engineering team relishes the chal-
lenges associated with existing installa-
tions. Professional advice and tailor-made
equipment designs, founded on decades
of experience, can overcome a host of
separation problems related to:
changes in process conditions
de-bottlenecking
aging plant
sub-optimal equipment layout
Introduction
3
Service and Supply
Sulzer offers a exible and comprehensive
range of service which can be tailored to
suit your project requirements, including:
process design
feasibility studies
detailed engineering
equipment manufacture and supply
installation
0604 2500-11
Emergency Delivery
Sulzer can react to the most challenging
deadlines and can assist with urgent re-
placement or repair of separator internals.
For emergencies, contact your nearest
Sulzer Chemtech ofce - details of which
can be found at www.sulzer.com
If installation services are required, our
technicians are available on your worksite
to make sure your equipment meets spec-
ications and your project goes smoothly
from start to nish. A Sulzer technician
inspects your equipment before it leaves
our plant. At your worksite, you can count
on our technicians, who are specialists in
separation and mass transfer systems, to
monitor each phase of your installation to
ensure you are up and running on time.
Research and Development
We recognize that investment in research
and development is an essential com-
ponent for long term success. We have
laboratories where separation internals
and design techniques can be tested and
developed in fully instrumented pilot scale
columns.
Increasingly, computer models are being
used to aid the design of new products.
Sulzer uses computational uid dynamics
(CFD) models to simulate product perfor-
mance. This technique not only eliminates
the requirement for expensive prototypes
to be constructed, but provides a much
greater understanding of the products
operation in advance of any laboratory or
operational trials. CFD simulations have
also been used to great effect in solving
ow distribution problems in a variety of
systems.
0607 2503-15
4
Type of Separator
KnitMesh
TM
Mist Eliminator
KnitMesh V-MISTER
TM
Mellachevron
TM
Mist Eliminator
Shell Swirltube
TM
Shell Swirltube Light
TM
Materials
Stainless steels
Alloy C22, C276, 400, 625,
825 and 20,
Copper
PP, FEP, ETFE, PTFE,
Glass bers
Stainless steels
Alloy C22, C276, 400, 625,
825 and 20,
Copper
PP, FEP, ETFE, PTFE,
Glass bers
Stainless steels
Alloy C22, C276, 400, 625,
825 and 20,
PP, PVC, PVDF, FRP
Stainless steels,
Alloy 625, 825
Stainless steels,
Alloy 625, 825
Applications
Broad range of gas/ liquid separation
problems.
Scrubbing systems and absorbers
Evaporators
Steam drums
Knock-out pots
Glycol dehydration
Inert gas scrubbers
MSF/MED desalination
Sulfuric acid absorbers and dryers.
Broad range of gas/ liquid separation
problems.
Scrubbing systems and absorbers
Evaporators
Steam drums
Knock-out pots
Glycol dehydration
Inert gas scrubbers
MSF/MED desalination
Sulfuric acid absorbers and dryers.
Broad range of gas/ liquid separation
problems.
Scrubbing systems and absorbers
Evaporators
Steam drums
Knock-out pots
Glycol contactors
Inert gas scrubbers
MSF/MED desalination
Sulfur condenser
Flue-gas desulfurization (FGD)
Gas processing applications; inlet sepa-
rators, turbo-expander suction drums,
dew-point separators, compressor
suction drums, glycol contactors.
Gas processing applications; inlet sepa-
rators, turbo-expander suction drums,
compressor suction drums. Scrubbing
systems and absorbers, PEB neutraliza-
tion column.
Product Summary
0607 2507-12
0607 2512-1
0607 2504-10
5
Typical operational Range
Relatively low capacity with K-values
typically up to 0.107 m/s (0.35 ft/s).
High efciency separation down to droplet
sizes of 2 to 3 m.
Pressure drop typically less than 2.5mbar.
Designs available for installation in either
horizontal or vertical gas ow.
Enhanced capacity with K-values typically
up to 0.15 m/s (0.49 ft/s).
Limited to horizontal installation with verti-
cal gas ow.
High efciency separation down to droplet
sizes of 2 to 3 m.
Pressure drop typically less than 2.5 mbar
Very effective for heavy liquid loadings/
irrigated systems.
High capacity systems available with
K-values up to 0.45 m/s (1.47 ft/s) at the
vane face inlet.
Effective droplet separation down to ~20 m.
Efciency can be enhanced by combina-
tion with KnitMesh pre-conditioners.
Generally for use at:
- surface tension > 10 dynes/cm.
- operating pressure < 60 bar in hydrocar-
bon systems.
Pressure drop is typically in the range 1 to
10 mbar.
Designs available for installation in either
horizontal or vertical gas ow.
High capacity systems with K-values up to
typically 0.25 m/s (0.82 ft/s) in the vessel.
Effective droplet separation down to
~10 m.
Efciency can be enhanced by combina-
tion with wire mesh pre-conditioners.
Pressure drop is typically in region of
30 mbar.
High capacity systems with K-values up to
typically 0.25 m/s (0.82 ft/s) in the vessel.
The Shell Swirltube Light is suitable for
higher operating pressures,
offers higher capacities than vane packs
installed for vertical gas ow and is there-
fore a useful complement to our Mel-
lachevron mist eliminators.
Characteristics
Manufactured as a knitted wire mesh packing.
Can be easily tailor-made to suit most vessel shapes
and sizes.
Cost effective and versatile solution for most mist elimi-
nation applications.
Manufactured as a knitted wire mesh packing. Support
grids tted with special V-MISTER drainage channels to
enhance drainage characteristics.
Can be easily tailor-made to suit most vessel shapes
and sizes.
Cost effective and versatile solution for most mist elimi-
nation applications.
Constructed from banks of parallel corrugated, chevron
proles.
High capacity designs provide compact separators -
ideal for gas processing applications.
Lower capacity designs available for fouling
service and heavy liquid loadings.
High performance Swirltubes (HPST) arrayed in boxes
or banks provide compact separators designed as Shell
SMS, SVS, SMSM and SMMSM units, and are ideal for
gas processing at all pressures.
Suitable for use in fouling or waxy services.
Array of axial cyclones originated from the
Shell ConSep
TM
Swirltube design. The device can be
combined with a Sulzer Mellachevron or KnitMesh pre-
conditioner. The separation efciency of the Shell Swirl-
tube Light is lower than the Shell Swirltube and is in the
range of vane packs.
Product Summary
0608 2502-6
0604 2512
0607 2504-18
0607 2512-3
6
Type of Separator
MKS Multi Cassette
TM
Mist Eliminator
Shell
Schoepentoeter
TM
and
Schoepentoeter Plus
TM

Inlet Device
Treelnlet
TM
Device
GIRZ Cyclone
Inlet Device
GITV
Vapor Horn
Vanta
TM
Inlet Device
GITD
Materials
Stainless steels,
Alloy 625, 825
Stainless steels,
Alloy 625, 825
Stainless steels,
Alloy 625, 825
Stainless steels,
Alloy 625, 825
Stainless steels,
Alloy 625, 825
Stainless steels,
Alloy 625, 825
Applications
Gas processing applications; inlet separators,
turbo-expander suction drums, compressor
suction drums, glycol contactors.
The Schoepentoeter is the most commonly
used vane inlet device for introducing gas/liquid
mixtures into columns.
The Schoepentoeter Plus is an advanced feed
inlet vane device with considerably increased
de-entrainment efciency and rst choice for all
demanding tasks such as in vacuum towers,
crude distillation and hydrocracker main frac-
tionators and high pressure separators.
The Sulzer Treelnlet is an axial ow vane gas
inlet device for vertical feed nozzles. Ideal for
bulk liquid disengagement in a wide range of
services and applications.
The GIRZ is used as defoaming cyclonic inlet
device to suppress and break many types of
process foams. Some typical applications in-
clude FWKO drums, ash drums, test separa-
tors, 2 and 3-phase production separators.
The Sulzer Vapor Horn GITV as well as the new
Sulzer Vanta
TM
inlet device GITD are primarily
used in fractionators where ashing feeds re-
quire high pre-separation of any free liquids.
Product Summary
0604 2507-4
0600 2505-3
0607 2505-13
7
Typical operational Range
High capacity device with K-values up to
0.3 m/s (1 ft/s) in the column.
High efciency separation down to drop-
let sizes of 8 to 10 m.
Efciency can be enhanced by combina-
tion with KnitMesh pre-conditioner.
No limitation in operating pressure.
Very suitable for glycol contactors. Meets
glycol loss requirement of 0.1 USgal/
MMSCF (~ 14 lt./MMNm3) or less
Generally designed at dynamic pressures
< 8000 Pa, but can perform well at higher
values.
Is typically used for feeds having a gas
volume fraction of > 70 vol%.
Suitable for installation in horizontal or
vertical separators.
Suitable for liquid slugs.
The Treelnlet provides a superior liquid
pre-separation and gas distribution and
is normally effective up to dynamic pres-
sures of about 10000 Pa.
The GIRZ cyclonic inlet device utilizes the
momentum of the feed stream inlet in or-
der to generate high g-forces. Defoaming
is achieved as gas bubbles are separated
from the liquid phase by the centripetal
forces in the cyclone tubes. Gas is re-
leased from the top of the device and the
bottom opening of the cyclones is sub-
merged below the liquid in the separator
in order to avoid a gas blowout.
The tangential vane gas inlet device GITV
and GITD can be used for very high vapor
velocities in the feed pipe of F-Factors
up to 120 Pa. The feed ows radially
around the vessel projecting and collect-
ing the liquid droplets on the inner wall of
the vessel.
Characteristics
The patented MKS Multi Cassette device combines axial
cyclonic and cross ow separation technology to create
an efcient and attractive mist eliminator. One or more
MKS Multi Cassette candles are assembled on a support
plate acting as liquid collector with drain pipes.
Constructed from banks of swept vanes. Designs avail-
able for operation in most gas/liquid ow regimes.
The Schoepentoeter Plus is equipped with sophisticated
catching rims to minimize entrainment.
By installing a Treelnlet and a high efciency KnitMesh mist
eliminator, liquid carryover losses are reduced to virtually
zero.
The GIRZ consists of an arrangement of two or more
cyclones symmetrically arranged off a common, centrally
located header. The device can be installed in vertical or
horizontal vessels. If required, mixing elements at the cy-
clone gas outlet will improve the distribution to the down-
stream device.
The gas distribution is performed by bafes according to
a vane gas inlet device. The device is suitable for vessel
inner diameters larger than 4 m.
The new Sulzer Vanta
TM
inlet device combines high liquid
separation efciency with high gas distribution quality.
Product Summary
Flash zone
8
Liquid entrainment in a process gas stream
can be formed by either dynamic process-
es, such as contact between gas and liq-
uid phases in a mass transfer operation,
or thermal processes such as condensa-
tion. For example, droplets can result from
bubbles bursting or jetting at a gas/liquid
interface - typically in distillation columns,
evaporators, bubble columns and ooded
packed bed scrubbers. Where there is
a high relative velocity between gas and
liquid, droplets can be sheared from the
wet surfaces. This type of problem is likely
to occur in venturi scrubbers, two-phase
ow in pipes and packings.
Droplets can also be formed by thermody-
namic changes in a system. For example,
vapor condenses when saturated gases
are cooled in condensers and heat ex-
changers and, although most of the liquid
will remain on the heat transfer surfaces,
the gas can become supersaturated in
places causing droplet formation. This
type of condensation mist can occur dur-
ing heat exchange processes, the sudden
release of pressure or by mixing hot and
cold gas streams. Similar mists can result
from gas phase reactions which yield a liq-
uid product. Typical applications suffering
from mist contamination include sulfuric,
phosphoric and nitric acid plants.
If the gas is travelling too fast to allow the
liquid droplets to settle out under gravity,
they become suspended (or entrained) in
the gas or vapor. In most cases, the en-
trainment must be removed to purify the
gas and prevent potential process or envi-
ronmental contamination.
Mist Elimination
Rain
Drop Drizzle Mist Fog

Entrainment
from water
cooling & spray
cooling towers
Spray produced by bubble
bursting at a liquid vapor interface
Entrainment from evaporators,
distillation & absorption
Condensate Condensate from
from intercoolers on
gas coolers compression plant
Condensate from high
pressure compression plant
Knock out drums & collectors tted mesh mist eliminators
Knitted mesh mist eliminators
Vane mist eliminators
Cyclonic devices
Bafes, Fiber bed
louver separators mist eliminators
500 200 100 50 20 10 5 2 1 0.5
Droplet diameter (microns)
Typical
process
applications
Types and
operating
range of
equipment
Sulzer mist eliminators provide an effective
solution to liquid entrainment problems in
many types of equipment including:
scrubbing, absorption, stripping or distil-
lation columns
evaporators
falling flm condensers
knock-out vessels
3 phase separators
desalination plants
refrigeration plants
gas dehydration plants
compression systems
9
Assuming that gravity separation can be disregarded as an effective option, the remain-
ing mechanisms provide the design basis for Sulzer mist elimination equipment:
Sulzer Mellachevron
TM
inertial interception
Shell Swirltube
TM
inertial interception
Sulzer KnitMesh
TM
inertial/direct interception
Sulzer MKS Multi Cassette
TM
inertial/direct interception
Mist Elimination
Each mechanism is critically dependent
on the droplet size distribution for a given
application. For example, in gas drying ap-
plications using glycol contactors, droplet
size distributions are often in the range of
5-25 m and high separation efciency is
critical. In these circumstances, direct and
inertial interception are the most appropri-
ate mechanisms and separation is best
achieved by impingement of droplets on
the wires and bers of high performance
mesh mist eliminators.
Diffusional deposition is an important
mechanism in the design of ber bed mist
eliminators (candle lters) used for remov-
al of sub-micron droplet dispersions found
in applications such as acid mists.
Droplets
Inertial interception
Diffusion
Direct interception
Flow streamlines
Gravity
0607 2510 11
Several types of mist eliminators are avail-
able for the separation of entrained liquid.
To choose the appropriate equipment, the
four basic mechanisms of droplet capture
should be considered.
Diffusional Deposition is only effective in
the separation of very nely dispersed
aerosols with droplets typically smaller
than 1m - that are small enough to be
affected by Brownian Motion.
Direct Interception assumes that a drop-
let of a given diameter and negligible
mass follows the stream line around the
target wire or ber and is separated as
it touches the target or collection ber.
Inertial Interception considers the droplet
mass and predicts how momentum will
make it deviate from the gas stream.
Gravitational Deposition works on the
principle that large, slow moving drop-
lets may separate from a gas stream
under gravity. This is restricted to large
droplet sizes and low supercial gas ve-
locities making separator dimensions
both prohibitively large and uneconomi-
cal.
10
v = maximum supercial gas
velocity
r
l
= liquid density
r
v
= gas density
K = a constant which is specic to
the separation equipment and
is a function of process
parameters such as:
r
l
- r
v
r
v

v = K
Table A: Summary of relative performance characteristics for mist elimination
Design Advice
Comprehensive performance information
is available on a wide range of standard
designs, enabling Sulzer engineering staff
to tailor the mist eliminator design to suit
most applications.
For best performance, it is important to
achieve uniform gas ow distribution and
maximum effective area, and recommen-
dation can be given on the most appropri-
ate positioning, in terms of disengagement
distances from vessel inlet, outlet and oth-
er vessel internals.
Sizing
For equipment based on direct and/or
inertial interception, gas stream veloc-
ity affects all three principles involved in
separation (impingement, coalescence
and drainage). Flooding, or re-entrainment
of liquid, can occur if the ow of gas pre-
vents drainage, and the effective area of
the mist eliminator is therefore established
by determining an appropriate supercial
velocity for the equipment. The overall
performance of the mist eliminator is then
a balance between efciency and pres-
sure drop.
Liquid loading
Gas and liquid viscosity
Gas pressure
Surface tension
Equipment Type K-Value
m/s ft/s
Gravity 0.07 0.23
Sulzer Mellachevron
simple proles 0.13 0.17 0.42 0.56
Sulzer Mellachevron
high capacity proles with drainage channels 0.15 0.45 0.49 1.46
Sulzer KnitMesh
Mist Eliminator 0.08 0.107 0.26 0.35
Sulzer KnitMesh V-MISTER 0.08 0.15 0.26 0.49
Sulzer MKS Multi Cassette 0.10 0.30 0.33 1.00
Shell SMS, SMSM 0.25 0.82
Derating factors are often applied to allow
a safety margin for exceptional conditions
such as liquid slugs and gas surges, and
the K-value can be optimized to suit spe-
cic process conditions, and challenging
physical properties such as low surface
tension systems. The selection of K-value
is therefore critical and we recommend
that designs should be checked by our
engineering team.
Gravity Bafes/louvers Vane packs Vane packs Axial Knitted Candles/
separators/ simple vanes with drainage Cyclone mesh mist ber beds
knockout drums channels separators eliminators
Separation Gravitational Inertial Inertial Inertial Inertial Inertial/direct Direct interception/
mechanism deposition interception interception interception interception interception diffusional deposition
Gas handling Low High High High Very high Moderate Low
capacity
Turndown Very high 30 % 30 %-50 % 30 %-50 % 30 % 25 % Very high
capacity Higher with
preconditioner
Efciency Low except Low except High down to High down to High down to Very high Very high at
for large for large approx. 25 m approx. 25 m approx. 10 m down to 2-5 m sub-micron
droplet sizes droplet sizes droplet sizes
Liquid load Very high Very high Moderate High High Moderate Low
capacity
Solids handling Very high Very high Moderate Low Moderate-high Low Very low
capability
Liquid viscosity Suitable for Suitable for Suitable for high Prone to fouling Suitable for high Prone to fouling Unsuitable for high
high viscosity high viscosity viscosities/waxes with high liquid viscosities/waxes with high liquid liquid viscosities
viscosities/waxes viscosities/waxes
Pressure drop Very low Very low Low Low Moderate Low High
Mist Elimination
11
Sulzer KnitMesh
TM

Wire Mesh Mist Eliminators
Sulzer KnitMesh mist eliminators have an
excellent track record as a low cost, highly
versatile and efcient method of removing
liquid entrainment from gas streams. They
are produced as a bed of knitted mesh
which presents a tortuous path and large
surface area to the droplets entrained in
the gas stream. Separation is achieved
by impingement on, and capture by, the
laments of the mesh where the droplets
coalesce and drain.
Installation can be made in a variety of
ways but gas ow is usually either verti-
cally upwards, with the liquid draining
counter-current to gas ow, or horizontal,
with the liquid draining in a direction per-
pendicular to the gas ow.
Each mist eliminator is tailor-made to suit
the dimensions of the vessel or housing
into which it will be installed. Most Knit-
Mesh wire mesh mist eliminators are sup-
plied complete with rigid support grids,
which allow direct installation onto appro-
priate supports such as beams and rings
within the vessel. Sectional installation al-
lows ease of handling and access through
vessel manways.
Accessories such as tie wire, bolting,
clamps and support beams can be sup-
plied where necessary.
KnitMesh Mist Eliminators
Metal Designs
Material Type Free Density Specic Surface Area Application
number volume (lb/ft
3
) (kg/m
3
) (ft
2
/ft
3
) (m
2
/m
3
)
Metal 9001 97.5% 12 192 196 643 Very high efciency, very clean service
9033 97.5% 12 192 110 350 Heavy duty
9032 97.75% 10.5 170 93 305 For general use
9030 98% 9 144 79 258 Standard general purpose media
9030-L2 98% 9 144 147 482 High efciency for ne entrainment
9059 98.5% 7 107 109 358 Fine entrainment
9036 98.75% 6 96 52 172 High velocity, dirty service
4530 98.75% 6 96 52 172 High velocity, clean service
4540 99% 5 80 44 145 Minimum pressure drop, dirty service
Plastic and Other Materials
Glass Wool 9036 93% 12 195 450 1500 Coalescer-very ne mists
9048 95% 8.25 135 300 1000 Coalescer ne mists
Polypropylene 9008 95% 2.75 45.5 320 1050 High performance-acid mists
9030 93% 4.5 74 250 820 Acid mists and marine engine intakes with
9036 95% 2.75 44.5 150 495 minimum pressure drop
9048 97% 2 41 110 360
Multilament 9033 94% 19 305 340 1115 Fine mist conditions where stainless steel
(glass wool/ 9030 95% 13.5 215 250 820 can be allowed and minimum pressure drop
stainless steel) 9036 96% 9 145 160 525 is important
FEP 9048 94% 8 128 250 820 Highly corrosive conditions
ETFE 9048 95% 5.25 85 220 725 Highly corrosive conditions
Table B: Standard Sulzer KnitMesh Mist Eliminator Types
Standard designs are available for routine
applications, providing excellent separa-
tion efciency down to droplet sizes as
small as 2 m, and with a pressure drop
typically less than 2.5mbar. A selection of
standard styles is described in Table B.
Alternatively, we can provide optimized
designs to suit specic duties using so-
phisticated design tools.
Gas outlet
Gas inlet
Liquid outlet
Sulzer KnitMesh
mist eliminator
Schoepentoeter
Gas inlet
Liquid outlet
Sulzer KnitMesh
mist eliminator
Gas outlet
Liquid drains perpendicular
to direction of gas ow
Liquid drains counter-
current to gas ow
12
Sulzer KnitMesh V-MISTER
TM
The Sulzer KnitMesh V-MISTER (formerly
Sulzer KnitMesh VKR Mist Eliminator)
provides high performance wherever liq-
uid entrainment must be removed from a
vertically owing gas stream. Mist elimi-
nators with Sulzer KnitMesh V-MISTER
technology employ the mechanism of a
Von Karman Roll around a bluff body (see
Figure 1a) to obtain high vapor and liquid
handling capacity. A vortex develops in
a low pressure zone downstream of the
channel that has been attached to the
bottom of the mesh pad. Collected drop-
lets deposit in the trough and form a ow-
ing liquid stream there. Contrast this with
the standard mesh pad (see Figure 1b)
where a two phase uidized zone of gas
and liquid develops in the bottom third
to half of the pad and from which large
coalesced droplets must ultimately drain
counter-current to the ascending stream.
The high capacity channels of the Sulzer
KnitMesh V-MISTER shield the collected
liquid and then drain it in steady streams
from two sides of the mist eliminator at the
column wall, where gas velocity is so low
that re-entrainment is limited.
(see Figure 2)
This simple enhancement to a standard
mesh pad improves mist elimination be-
cause the higher velocities increase the
droplets inertial impaction with the wires
or laments. Summarized the V-MISTER
collecting channels provide an increased
liquid capacity of up to 300 % and a higher
gas throughput of up to 20 %.
0607 2512 -2
KnitMesh Mist Eliminators
0607 2512-9 0607 2512-10
Fig. 1a Fig. 1b
Fig. 2
Flood
Flood
Conventional Pad V-MISTER Pad
Liquid load: 1.1 m
3
/m
2
hr
8
7
6
5
4
3
2
2.5 3 3.5 4 4.5 5
Velocity (m/s)
P
r
e
s
s
u
r
e

d
r
o
p

(
m
b
a
r
)
8.2 10 12 14 16.4
Velocity (ft/s)
Sulzer KnitMesh XCOAT mist eliminator for a
sulfuric acid drying column
The New and Unique Sulzer KnitMesh XCOAT Mist Eliminator:
The Perfect Solution for Corrosive Services
Sulzer has developed a completely new KnitMesh mist eliminator for corrosive services.
The Sulzer KnitMesh XCOAT is based on a metal wire which is coated with 100% pure
PTFE. This new mesh material is unique and available exclusively through Sulzer.
Sulzer KnitMesh XCOAT mist eliminators are characterized by a high deformation, corro-
sion and temperature resistance, and are therefore ideal for applications which have to
deal with acids such as sulfuric, acetic and nitric acid.
The advantage of longer service time of the Sulzer KnitMesh XCOAT mist eliminator com-
pared to common wire mesh pads using Teon laments or higher alloyed and acid-
resistant steel wires has been demonstrated with rst industrial applications.
13
High Performance
Sulzer KnitMesh
TM

9797 Mist Eliminators
The Sulzer KnitMesh 9797 Mist Eliminator
technology provides a means of optimiz-
ing designs to meet the challenges of spe-
cic applications.
Unlike industry standard mist eliminator
design methods, which predict perfor-
mance using bulk density and lament
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, co-
alescence and drainage) can be predicted
on a layer by layer basis. This enables Sul-
zer 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
KnitMesh Mist Eliminators
Liquid drains
towards
adjacent pore
D1
D2
D4
D5
D3
Fig. 3: The stages of droplet separation on a
wire mesh.
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 es-
tablished by calculating the cumulative
effect of combined mesh layers and their
characteristics. The model allows a high
degree of optimization so that layer speci-
cations can be varied to meet specic
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 efciency towards the outlet.
Existing applications for Sulzer KnitMesh

9797 Mist Eliminators include:
glycol contactors minimization of
TEG entrainment from natural gas dehy-
dration columns (see p 20).
gas sweetening installation in amine
absorbers.
dew-point separators 9797 designs
have helped reduce water and hydro-
carbon dew-points in natural gas pro-
cessing (see p 22).
rotary screw compressors reduc-
tion of entrainment of synthetic oil from
compressor system knock-out drums.
steam drums guaranteed steam dry-
ness can be achieved using Sulzer Knit-
Mesh 9797 mist eliminators.
Fig. 4 represents a bed with N layers of
mesh.
By assuming that:
V
0
is the volume of droplets entering
Layer 1
V
N
is the volume of droplets leaving
layer N
E
i
is the individual layer efciency,
then the overall efciency of the mist elimi-
nator can be expressed as:
i = N
V
N
= V
0
(1 E
i
)
i = 1

D
i
r
e
c
t
i
o
n

o
f

G
a
s

F
l
o
w
i = N
i = n+1
i = n
i = n-1
i = 2
i = 1
Fig. 4
characteristics, such as liquid hold-up and
efciency, from inlet to outlet. Additionally,
separation efciency can be predicted in
terms of liquid entrainment concentra-
tion providing meaningful, measurable
information on separator performance; a
considerable improvement on droplet size
efciency predictions which are extremely
difcult to verify in practice.
Fig. 3 illustrates one layer of mesh within
the mist eliminator and stages of sepa-
ration considered by the performance
model:
D1 avoids capture and moves in to the
next layer of mesh.
D2 is captured by the mesh.
D3 and D4 coalesce to form a bigger
droplet or lm.
D5 drains from the mesh surface.
14
Sulzer Mellachevron
TM
Mist Eliminators
Sulzer Mellachevron vane mist eliminators
are high capacity inertial separators con-
structed as banks of parallel, chevron pro-
les which cause the gas to change direc-
tion several times from inlet to outlet. Mo-
mentum forces entrained liquid droplets to
impinge on the vane surfaces where they
form a liquid lm and drain.
The Sulzer Mellachevron range is divided
into a number of categories depending on
direction of gas ow and the complexity of
the vane prole.
Simple Sulzer Mellachevron proles sepa-
rate liquid by impingement, coalescence
and drainage on the vane surface with no
disengagement of the liquid from the gas
stream. They are particularly suitable for
applications with a signicant risk of foul-
ing due to solid particles or high viscosity
liquids in the feed but have relatively low
gas handling capacity.
Mellachevron
Sulzer Mellachevrons are available in various proles and materials such as stainless steels, alloys
or plastics.
Simple Mellachevron prole with countercurrent
drainage of liquid from vane surface.
More sophisticated designs provide spe-
cial separation channels to allow disen-
gagement of liquid and drainage from the
vane surface. This increases the capacity
of the separator and gas load factors of
up to 0.45 m/s are possible. This makes
them an excellent choice when equipment
size is critical, for example, in offshore ap-
plications or for de-bottlenecking existing
equipment.
Complex Mellachevron proles require
housings which ensure that the vanes are
assembled accurately and provide a liquid
sump for drainage of liquid into the vessel
or column.
Drainage slots on vane
surface allow liquid to
disengage from gas stream
Liquid drains in special
channels separated from
the gas ow
Liquid collects at bottom of
drainage channels and moves
laterally to Mellachevron hous-
ing where it is collected in a
sump and drained through
downcomer pipes
Liquid drain channel
integrated in beam
Liquid drain
channel
integrated in
vane housing
Removable spacer channel to
allow installation of the vanes
Jacking bolts
Gas
15
Mellachevron designs are available for in-
stallation in either vertical or horizontal gas
ow. When gas ow is horizontal, the liq-
uid lm on the surface of the vane drains
vertically downwards into a liquid sump.
Complex Mellachevron proles are used
with hooks or drainage channels which
help to disengage the liquid from the gas
stream and prevent re-entrainment from
the downstream face.
Mellachevron
Typical housing arrangement for cross-
ow Mellachevron. Sectional installation
allows installation and removal through
manway and vane proles can be disman-
tled individually for cleaning if necessary.
Liquid is collected in the sump and drained
through the downcomer pipe connection.
Horizontal gas ow arrangement.
0608 2502-6
Table C: Sulzer Mellachevron Mist Eliminator Styles
Mellachevron Mellachevron
simple vanes Complex proles with drainage channels
Type C prole Z - prole C or Z - prole with Complex prole - inte- Z-prole with Z-prole with
large vane spacing gral drainage channel drainage hooks large vane spacing
Prole

Flow Direction Vertical Vertical Vertical Vertical or horizontal Horizontal Horizontal
Installation No housing No housing No housing Housing and drainage Housing and drainage Housing and drainage
system required. system required. system required.
Gas handling 0.17 m/s 0.14 m/s 0.14 0.17 m/s 0.17 0.45 m/s 0.35 m/s 0.35 m/s
capacity
(K-values)
Turndown 30 - 50 % 30 - 50 % 30 - 50 % 30 - 50 % 30 - 50 % 30 - 50 %
capability
Efciency Medium Medium High Low Medium High Medium Low Medium
down to down to down to down to down to down to
30 40 25 30 50 10 15 25 30 35 40
Liquid load Moderate Moderate High Moderate to High High Very High
capacity
Solids handling Moderate to High Moderate High Low Low Low to Moderate
capability
Liquid viscosity Suitable for high Suitable for high Very suitable for high Prone to fouling with Prone to fouling with Suitable for high
viscosities/waxes viscosities/waxes viscosities/waxes high viscosities/waxes viscosities/waxes viscosities/waxes
Typical Vacuum, general Desalination, general As for C and Z Debottlenecking, off- Horizontal scrubbers As for C and Z proles
applications use, fouling service use, fouling service proles but high shore, clean services, but high fouling / low
fouling / low gas & steam processing pressure drop services
pressure drop
services
Pressure drop Very low Low Very low Moderate Low Low
Liquid drains down vane surface to a sump.
Gas
16
Mellachevron
Sulzer Mellachevrons can be installed
in a variety of vessel congurations and
as arrangement of multiple vane boxes
to provide optimum ow and drainage
characteristics within the space available.
Typical box and vessel arrangements are
illustrated below in Fig. 5a and 5b.

Fig. 5b
1. Vertical Flow
2. Cross ow Horizontal vessel
3. Cross ow Two-stage separator
4. V-bank
5. Cross ow In-line separator

Fig. 5a
Double Box
with KnitMesh Pre-conditioner
Four Box V-bank
Sulzer Mellachevron H45D cross ow high
capacity vane pack for installation in a dis-
charge drum of an ethylene plant.
The sophisticated vane prole and integral
drainage channels of our Mellachevron
H45D high performance mist eliminator
provide signicant advantages over con-
ventional vane mist eliminators, including:
reduced pressure drop at high gas load
factors
improved liquid drainage based on hol-
low blade concept
up to 40 % higher gas load capacity
17
Shell Swirltube
TM
The Shell Swirltube is, in essence, a stain-
less steel tube with a swirler at the inlet
and longitudinal slits in the tube wall. Liq-
uid is separated by impaction of droplets
on the tube wall by the centrifugal forces
induced by the swirling gas ow.
Re-entrainment of this liquid is prevented
by draining the lm via the slits to the liquid
collection chamber outside the tube. To
ensure the proper functioning of the Swirl-
tube it is essential that some gas is also
bled through these slits. This gas leaves
the liquid collection chamber via the sec-
ondary outlets at the top of the Swirldeck
assembly. Performance can be improved
by using a secondary KnitMesh mist elimi-
nator to separate entrainment from the
gas leaving the secondary outlets. The
main fraction of the gas leaves the Swirl-
tube via the primary gas outlet at the top.
Drain pipes guide the liquid, collected in
the space between the tubes and on the
upper cover of the Swirldeck, to below the
liquid level.
Scaling-up of a separator equipped with a
Swirldeck is done simply by increasing the
number of Swirltubes proportional to the
gas ow in the separator.
Axial Cyclonic Devices
Shell Swirltube Light
TM
The Shell Swirltube Light is available as
an attractive alternative to vane packs for
high capacity bulk separation. The Swirl-
tube Light is based on the sophisticated
de-entrainment device used in the Shell
ConSep
TM
Tray.
Recommended use:
comparable effciency but higher capac-
ity compared to vane packs.
operation possible at higher pressures/
lower surface tensions than vane packs.
compact design makes it suitable for
offshore industry or in general for high
pressure conditions.
for debottlenecking of existing separa-
tors.
for high turndowns with pre-conditioner.
(up to factor 10).
application for slightly fouling service
and may be used where complex vanes
or wire mesh mist eliminators may be-
come plugged.
Swirldeck Swirldeck with secondary KnitMesh
Sec. gas
Liquid
Droplets
18
Combined Systems
Increasing gas capacities and higher per-
formance requirements in mass transfer
equipment are challenging the capabilities
of conventional mist eliminator equipment.
To solve this, Sulzer offers combined sys-
tems which optimize the benets of indi-
vidual types of equipment and improve
overall performance.
For example, KnitMesh mist eliminators
can be used in combination with Sul-
zer Mellachevron vane packs or Shell
High Capacity Separators with Sulzer Mellachevrons
Combined Systems
Swirltubes to produce very high separa-
tion efciencies at high gas loadings. By
using the KnitMesh mist eliminator as a
pre-conditioner for the Mellachevron, it is
operated above its normal re-entrainment
or ooding point and consequently liquid
is stripped away from the downstream
surface.
The liquid dispersion re-entrained from the
mesh mist eliminator has a larger mean
diameter (See Figure 6) and is suitable
for subsequent separation by secondary,
high capacity equipment.
By analysis of the inlet uid conditions,
Sulzer can design optimized mesh struc-
tures to provide the best possible outlet
conditions for the downstream separator.
Additional benets of combined systems
include:
The ability to design the equipment to
provide very high turndown capabilities
At low gas velocities, where high capac-
ity separators tend to be ineffective, the
mesh pre-conditioners behave as con-
ventional mist eliminators
Gas with ne mist
KnitMesh as primary
preconditioner oper-
ates beyond ooding
point
Coalesced large
droplets fed to sec-
ondary Mellachevron
mist eliminator
Mist free gas
Coalesced large
droplets ef-
ciently removed
by Mellachevron
Separated liquid
drains
Provisional gap,
if required
0 10 20 30 40 50
Drop size (m)
F
r
e
q
u
e
n
c
y
Vertical ow Separator In-line Separator Two-stage Separator
Mellachevron
KnitMesh
Pre-conditioner
Downcomer
pipe
High capacity
packing
MellapakPlus
Gas outlet
Mellachevron
mist eliminator
Liquid sump
Gas inlet
KnitMesh
Pre-condi-
tioner
Downcomer
pipe
Liquid outlet
Gas outlet
Mellachevron
mist eliminator
Schoepen-
toeter
Liquid sump
Liquid outlet
KnitMesh
Pre-condi-
tioner
Downcomer
pipe
Fig. 6
19
0604 2508-8
Combined Systems
Shell High Capacity Separators
Shell proprietary high-capacity gas/liquid
separators, such as Shell SMS, SVS,
SMSM and SMMSM separators,
combine the best features of the separa-
tion products from Sulzers portfolio. Shell
gas/liquid separators combine Swirldeck,
KnitMesh, and Schoepentoeter separa-
tion technologies in a single vertical ves-
sel drum. Selection of separation tech-
nologies is function of the dispersed liquid
phase concentration, droplet size and the
required separation efciency. Their typi-
cal application window is for separation
of liquid/gas or three-phase liquid/liquid/
gas mixtures, when a high capacity and
high separation efciency is required,
SMS(M) Technology is the lowest weight
and volume solution for phase separation
offshore and onshore. It gives up to 2.5
times more capacity compared to a con-
ventional KnitMesh mist eliminator without
vessel replacement.
Description
Shell SMS, SMSM and SMMSM gas/liquid separators are named after the conguration
of the different internals used for each type of separator:
Schoepentoeter or Schoepentoeter Plus (S) - used as feed inlet device for vapor distri-
bution with bulk liquid removal
KnitMesh (M) - which acts as coalescer and separator, depending on the gas fow
rate
Double Primary KnitMesh (MM) - specially developed for applications with two immis-
cible liquid phases in the feed to the separators (such as glycol/condensate in Dew-
Point Separators)
Swirldeck (S) - comprising multiple Swirltubes
A second KnitMesh (M) is used downstream of the Swirldeck in SMSM gas/liquid separa-
tors for demisting secondary gas.
In fouling or waxy service the KnitMesh can be replaced by a Sulzer Mellachevron vane
pack (SVS systems).
100
95
90
85
0 0.1 0.2 0.3
Gas load factor, m/s
E
f

c
i
e
n
c
y
,

%
KnitMesh
SMS
SMSM
SMMSM
Gas load factor, ft/s
0 0.33 0.66 0.99
Swirldeck
Mellachevron
Vane pack
Schoepentoeter
KnitMesh
Swirldeck
KnitMesh
Schoepentoeter
KnitMesh
Swirldeck
2
nd
Primary KnitMesh
1
st
Primary KnitMesh
Schoepentoeter
SVS SMS/SMSM SMMSM
20
Applications
Using Sulzers sophisticated KnitMesh 9797 Tech-
nology in Glycol Contactors
The rst application for Sulzer KnitMesh 9797 mist eliminators
was for installation on an offshore platform in the North Sea. The
requirement was to control and reduce the glycol entrainment
(as liquid drops) in the gas prior to compression and export. In
off-shore facilities the implications of entrainment from the dehy-
dration columns are not only on the value of the glycol lost (and
re-supply from shore), but also the consequences of admitting
the excess glycol into the gas export pipeline. Not withstand-
ing possible operational problems for the pipeline, the increased
separation load at the shore terminal to separate gas condensate
and glycol, and disposal of the glycol phase, are signicant costs.
The industry standard gure dening the maximum entrainment
of 0.1US gallons per MMSCF gas was therefore challenged and
had to be improved upon. The mist eliminator supplied with this
application was shown to signicantly reduce the free glycol loss
in the exit to < 0.05 US gallons per MMSCF gas, a gure veried
after measurement of total glycol loss from the dehydration unit.
Old Fashioned
Bubble Cap trays
and KnitMesh
mist eliminators
State of the Art
Mellapak and KnitMesh
mist eliminators
incl. the sophisticated
KnitMesh 9797 type
High Capacity
MellapakPlus and our high
capacity mist eliminators such
as MKS Multi Cassette,
Mellachevron, Shell SMS
The Ultimate
Shell Swirl Tube Trays
and Shell SMS
(see also the Brochure Trays for
any Applications)
Natural Gas Dehydration with TEG
Characteristics
100 % capacity
~ 1.5 F-Factor ( Pa)
Characteristics
190 % capacity
> 20 % more efciency
~ 2.9 F-Factor
Characteristics
300 % capacity
> 20 % more efciency
~ 4.5 F-Factor
Characteristics
400 % capacity
20 % more efciency
~ 6.0 F-Factor
TEG
TEG
TEG
NG NG NG
Dry gas outlet
Sulzer KnitMesh
9797 Glycol contactor
mist eliminator
Lean TEG
Chimney tray
Wet gas inlet
Schoepentoeter
Liquid outlet
Manway
Sulzer KnitMesh
9798 Scrubber section
mist eliminator
Rich TEG
Sulzer Mellapak/
MellapakPlus
Liquid distributor
Manway
TEG
NG
21
Applications
Using Sulzers MKS Multi
Cassette
TM
Technology in Glycol
Contactors
The rst application for Sulzer MKS Multi
Cassette mist eliminators was for instal-
lation in Glycol Contactors in Russia. The
contactors were revamped from trays to
Sulzer MellapakPlus and were operated
at very high gas loading factors. In order
to keep the glycol loss low at this high
column gas throughput the MKS Multi
Glycol Dehydration Process using Shell SMSM internals in the
Feed Inlet Scrubber and MKS Multi Cassette in the Glycol Con-
tactor
Highly efcient liquid scrubbing from the gas feed to glycol contactors is needed in or-
der to avoid bottlenecks in the dehydration system caused by hydrocarbon carry over
which can lead to foaming and excessive overall glycol losses. Sulzers mist elimination
products such as Sulzer KnitMesh, Sulzer MKS Multi Cassette and Shell Separators
meet for these high process demands.
Condensate Treatment Unit
Application of Sulzers liquid/liquid sepa-
rator products such as:
Sulzer Mellaplate plate pack
4 Cassettes
equipped with
structured
wire demisting
packing
Collector Tray
Swirl Tube
Swirling
Elements
Drain Pipe
Vapor is free of mist
Cassette mist eliminators were installed in
the contactor top section. The application
was shown to meet measured glycol loss-
es of < 0.1US gallons per MMSCF gas.
The patented Sulzer MKS Multi Cassette
mist eliminator combines the useful cen-
trifugal forces in cyclones with the high
separation efciency of wire mesh pack-
ings to give a new superior demisting de-
vice.
Vapor carries mist
SMS(M)
Separator
Glycol
Contactor
Glycol
Regenerator
Flash Drum
Sulzer DC Coalescer
Sulzer Dusec and Dusec Plus
Sulzer Static Mixers
Glycol Regeneration Unit
Application of Sulzers mass transfer
products in the glycol regeneration
facility.
Sulzer MKS Multi Cassette at top of glycol
contactor
22
SMS
Inlet Separator
SMMSM
Exp. Suction Drum
SMMSM
Dew Point Control Separator
From Slug
Catcher
Glycol Injection
Expander
Compressor
JT Valve
To Compression
SMS
Compressor
Suction Drum
Applications
Low Temperature Separation (LTS) Process
The performance of the gas separators in LTS Processes is crucial in order to meet the
hydrocarbon and water dew point specications. The dew point separator is especially
essential for the overall performance of the plant. Even small amounts of entrained
liquids will rapidly appear as increased dew point in the sales gas. To obtain the best
from the LTS Process, our high performance Shell SMMSM separator internals are
implemented in the Expander Suction Drum and in the Dew Point Control Separator,
and Shell SMS separator internals in the Inlet Separator and in the Export Compressor
Suction Drum.
Molecular Sieve Dehydration Process
The effect of a high performing Feed Inlet Separator on the deactivation rate of the
molecular sieves is substantial. The water absorption capacity deteriorates badly over
time as the co-adsorbed hydrocarbons accumulate in the molecular sieve. Sulzer rec-
ommends the use of a drum with Schoepentoeter and a high efciency KnitMesh mist
eliminator or the Shell SMSM separator internals when high capacity and efciency are
required.
Compressor
Mol Sieve Driers
Feed Inlet Separator
SMSM Separator
Compressor
Suction Drum
KnitMesh
Separator
Flash Gas to
Fuel Gas System
Water/HC
Dried Gas
to LNG Unit
23
Mist Eliminators in Desalination
Processes
Desalination by multi-stage ash evapora-
tion or multiple effect distillation units is by
far the most widely used method of gener-
ating fresh water from brine or sea water in
the world. It is extremely reliable and can
produce high purity water from almost all
forms of feed. The process involves evap-
orating water from a brine solution and
condensing the vapor as fresh water.
However, the performance of any ash
evaporator can deteriorate if liquid entrain-
ment is carried over from the ash cham-
bers into the condenser tube bundles.
This is a very likely occurrence in view of
the high velocities and volumetric ow-
rates experienced in these plants, and can
lead to problems such as:
Reduced water purity
Scaling of condenser tube bundle and
downstream equipment such as boilers
Corrosion of downstream equipment
Sulzer Mist Eliminators are designed to re-
duce these problems and are installed in
most desalination systems.
Our experience in desalination has helped
us develop a range of equipment to meet
the specic process needs of our custom-
ers, and great care is taken to ensure that
the optimum design is offered for any par-
ticular duty. The main factors to consider
in desalination applications are:
Effciency
Pressure drop
Fouling characteristics and the tendency
to scale
Materials of construction
Cost
Sulzer KnitMesh Mist Eliminators
Sulzer KnitMesh mist eliminators are ide-
ally suited to most desalination applica-
tions. In multi-stage ash evaporators
the mist eliminators are installed directly
above the ash chambers. Water vapor
rises vertically upwards through the mist
eliminator and passes into the condenser
tube bundle. Any entrained liquid droplets
are captured on the wires where they co-
alesce and drain, counter-current to the
vapor ow, back into the ash chambers.
The separation mechanism is similar to
this in multiple effect distillation systems.
The combination of high free volume and
specic surface area mean that excellent
efciencies can be achieved for droplets
as small as 5 m while presenting mini-
mum pressure drop.
Applications
High capacity designs
To achieve the required capacity, the evap-
orators are often very large and the mist
eliminators usually cover a large effective
free area above the ash chambers. The
total area required is determined by calcu-
lation of the mist eliminator capacity and is
a very important part of the plant design.
Clearly, any opportunity to reduce the
capital cost of the evaporators is very at-
tractive and the capacity of the mist elimi-
nation equipment is of vital importance in
this calculation.
Most installations are designed using a
conventional K-value of 0.107 m/s but
Sulzer has developed the high capac-
ity type 4540NS KnitMesh mist eliminator
which can operate at up to 20% higher K-
values, providing the opportunity for either
reduced equipment size or an increase in
capacity. Major projects have been suc-
cessfully commissioned using the Sul-
zer KnitMesh 4540NS mist eliminators in
Oman, Algeria and the UAE.
Sulzer Mellachevron
Mist Eliminators
Precipitation of salts and scale on the
wires of KnitMesh mist eliminators can be
a problem in some plants, particularly in
the rst two or three effects of the evapo-
ration. In these circumstances, the Mel-
lachevron Type V20Z has been used to
overcome the problem. This simple vane
prole provides high separation efcien-
cy performance for droplets larger than
30 m, and its ability to withstand heavy
scaling applications makes it an ideal al-
ternative to the KnitMesh mist eliminators
when fouling is of concern. Its robust con-
struction makes it easy to clean, and the
Mellachevron V20Z also has a relatively
low pressure drop compared to the more
complex Mellachevron designs with drain-
age hooks and channels an important
factor when designing for large volumetric
owrates at low pressure.
Steam
Condensate
pump
Product
pump
Brine
pump
Vent ejector
KnitMesh or Mellachevron
Mist Eliminator
Feed
pump
22.84.06.40 - II.14
Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any
warranty or guarantee of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.
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Recovery of virtually any solvents used by the pharmaceutical and
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(skids)
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Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquar-
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