In industries such as chemical processing, oil & gas, power generation, and sulfuric acid production, effective mist elimination is critical. Tiny liquid droplets carried in gas streams not only reduce process efficiency but also cause corrosion, equipment fouling, product loss, and regulatory compliance issues.
Two of the most widely used solutions are mesh pad mist eliminators and vane (chevron) mist eliminators. Each comes with unique strengths, limitations, and ideal use cases. This guide provides a deep dive into how they work, where they excel, and how to select the right solution for your application—with insights into Kimre’s B-GON® Mesh Pad technology for next-generation performance.
Understanding Mist Formation and the Role of Eliminators
Mist is formed when liquid is entrained in gas flow. This can happen in scrubbers, distillation towers, absorbers, or cooling systems. Droplets can range from submicron sizes (<1 µm) to large visible sprays (>100 µm).
Why removal matters:
- Process efficiency - Mist carries away valuable reactants or products.
- Environmental compliance - Many industries must meet strict particulate and acid mist emission limits.
- Equipment protection – Droplets cause erosion, corrosion, and scaling in downstream equipment.
- Worker safety – Aerosols can contain hazardous chemicals or acids.
Mist eliminators separate droplets from gas streams, usually by:
- Inertial impaction (large droplets >10 µm).
- Interception (medium droplets ~3–10 µm).
- Brownian diffusion (fine droplets <1 µm).
Mesh Pad Mist Eliminators
How They Work
Mesh pads consist of layers of interwoven fibers (metallic or polymeric) creating a high-surface-area matrix. Gas passes through the pad, and droplets collide with fibers, coalesce, and drain away.
Advantages
- Fine droplet capture: Typically effective for droplets ≥3–5 µm.
- High efficiency: Kimre’s B-GON® Mesh Pads capture 99% of droplets as small as 1 µm.
- Customizable design: Fiber diameter, thickness, and void fraction can be optimized.
- Cleanable & reusable: Unlike packed beds or disposable filters, mesh pads can often be cleaned and reused.
- Material versatility: Can be made from stainless steel, polypropylene, PVDF, ETFE, or PFA for corrosive services.
Limitations
- May face fouling in very dirty gas streams.
- Not ideal for extremely high liquid loads without structural reinforcement.
Common Applications
- Sulfuric acid towers
- Chemical scrubbers
- Chlor-alkali plants
- Oil & gas knockout drums
- Absorbers and distillation towers
Vane (Chevron) Mist Eliminators
How They Work
Vane pads (also called chevrons) consist of corrugated plates or vanes. Gas is forced to change direction multiple times as it flows through the vane channels. Droplets, due to inertia, cannot follow the bends and are separated onto vane surfaces, where they coalesce and drain.
Advantages
- Handles large droplets efficiently (>20 µm).
- Good for high gas velocities and large mist loads.
- Lower pressure drop compared to traditional random mesh.
- Durability: Robust against fouling and mechanical stress.
Limitations
- Poor efficiency for droplets <10 µm.
- May require larger footprint than mesh pads.
Common Applications
- Cooling towers
- Evaporators
- Brine and salt drying systems
- Desalination plants
- Gas scrubbers with high liquid loads
Mesh Pad vs. Vane Mist Eliminators: Side-by-Side
| Feature | Mesh Pad Mist Eliminators | Vane (Chevron) Mist Eliminators |
| Droplet Size Efficiency | Captures fine droplets (≥3 µm); Kimre’s B-GON®: down to 1 µm | Best for large droplets (>20 µm); limited fine mist removal |
| Pressure Drop | Low; ultra-low in structured mesh designs | Very low; ideal where pressure drop is critical |
| Fouling Resistance | Can clog in dirty service; cleanable designs available | More resistant to fouling due to open channels |
| Gas Velocity Range | Works in medium to high velocities; customizable | Handles higher velocities and heavy mist loads well |
| Materials | Polymeric, metallic, or composite for corrosion resistance | Stainless, alloys, plastics for rugged environments |
| Cost & Lifecycle | Cost-effective; long life when cleaned | Durable; may need secondary filtration for fine mist |
| Best For | Fine mist removal, emission control, chemical recovery | Large droplet removal, cooling/evaporation services |
Making the Selection: Key Considerations
- Droplet size distribution: For fine mist (<5 µm), favor mesh pads; for sprays and large droplets, vane pads perform better.
- Mist load and gas velocity: High loads may necessitate vane’s liquid handling; structured mesh design like B-GON® can handle varying velocities.
- Maintenance & Fouling: Choose cleanable, reusable media (mesh) for dirty processes; vane pads may be simpler to maintain in cleaner environments.
- Materials & Corrosion: Kimre offers advanced polymeric media (PVDF, PFA) for corrosive environments; steel vanes work in rugged contexts.
- Pressure Drop / Energy Efficiency: Lower drop = less energy use. Mesh pads like B-GON® offer ultra-low drop due to structured design.
- Compliance & Health Risks: Fine mist control improves emissions compliance and workplace safety.
Advanced Alternatives: Structured Mesh Designs
While conventional wire mesh has limitations, Kimre’s B-GON® Mesh Pads use thermoplastic fibers arranged in a structured grid.
Benefits over traditional mesh:
- Capture efficiency at 1 µm and below.
- High void fraction (94–97%) → minimal pressure drop.
- Customizable fiber diameters (0.05–0.94 mm) → balance fouling resistance and efficiency.
- Cleanable and reusable extending life cycle.
- Corrosion-resistant polymers ideal for aggressive environments.
This makes them superior for fine mist elimination compared to both standard mesh and vane pads.
Choosing Between Mesh Pads and Vane Pads
When deciding which mist eliminator to use, consider:
- Droplet Size Distribution: Fine mist → mesh pads; large mist → vane pads.
- Gas Velocity & Load: High velocity → vane; variable loads → structured mesh like B-GON®.
- Fouling Risk: Dirty service may favor a vane or cleanable mesh.
- Pressure Drop Limits: Both are low, but vane often has an edge at very high flows.
- Corrosion & Materials: Polymer mesh for corrosives; metal vanes for rugged duty.
- Regulatory Compliance: Mesh pads are more effective for tight emission standards.
Future Trends in Mist Elimination
- Hybrid systems combining mesh + vane + fiber-bed eliminators for multi-droplet capture.
- Advanced polymers for higher temperature and chemical resistance.
- Energy-efficient designs minimizing pressure drop for greener operations.
- Digital monitoring of mist load and eliminator performance.
Conclusion
Both mesh pad and vane mist eliminators are proven technologies—but they solve different problems:
- Mesh Pads excel at fine mist removal and emission control.
- Vane Pads are ideal for bulk droplet removal in high-load, high-velocity applications.
- For industries needing ultra-fine mist elimination with low pressure drop, Kimre’s B-GON® Mesh Pads deliver a next-generation solution.
At Kimre, we engineer mist eliminators tailored to your exact process needs. Whether you need fine droplet removal, fouling resistance, or ultra-low pressure drop, our B-GON® Mesh Pads and vane solutions can help you achieve cleaner, more efficient, and compliant operations.
Contact us today to discuss your mist elimination challenges and discover the ideal solution for your plant.
