MIST ELIMINATORS

LIFE STORIES
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
1. CORROSION OF METAL WIRES
This Lewmet demister was removed for
washing and there corrosion of one D
sections mesh was found.

There was an inlet pipe directly below
the position of this section in the tower,
with SO
3
vent vapour from an Oleum
tank.

The pipe was shut & the tank was fitted
with our Becoflex BFCF vent system
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
1. CORROSION OF METAL WIRES
There is often a detrimental effect of
ferrous sulphate falling down onto a
demister from the central carbon
steel exit duct above.


If left like that corrosion of the small
diameter wires can increase.
As the corrosion will attack the whole
circumference of the wire, the wire
can disappear quickly.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
1. CORROSION OF METAL WIRES
Sulphates and sulphuric acid left ignored
in a meshpad during a shutdown, or
during an outage where moist air can
enter the tower, have a high risk of
increasing corrosion as weak acid
attacks the wires.
In most European plants where metal
mesh is used, 316L Stainless Steel lasts
well. Alloy 20 and SX are examples of
more corrosion resistant wire materials
for non-EU duty.
We supplied SX wire demisters for the 3
Outotec Maaden plants in 2009.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
2. HEAT SHRINKAGE OF PLASTIC WIRES
Shrinkage of sides of sections of D.T. meshpad made
in Halar E.C.T.F.E. material





SO
3
effect on
Halar E.C.T.F.E.



Softening and relaxing of Halar E.C.T.F.E. mesh
material layers - all the formed crimp wave is gone
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
2. HEAT SHRINKAGE OF PLASTIC WIRES
Heat shrinkage of sides of sections of D.T. upper
meshpad made in Hostaflon E.T.F.E. material +
gaps filled with Halar E.C.T.F.E. material, which is
discoloured and damaged by SO
3
attack
Heat shrinkage of lower Hostaflon + PTFE fibre
coalescer + blackened Halar material in gaps
SO3 damaged
Halar E.C.T.F.E.
wire - melted
onto packing
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
3. SOLIDS BLOCKAGE AND WASHING DAMAGE
Sulphur sublimation in Smelter plant D.T.
meshpad





Sulphates





Nitrosyl crystals in Spent Acid Regen plant D.T.
meshpad
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
3. SOLIDS BLOCKAGE AND WASHING DAMAGE
Every time that a meshpad is washed
it is at risk from damage during
handling and poor refitting into the
vessel.

In this photo you can see a damaged
section of demister with the grid
obviously not fitted properly at the
end.
This then affects mesh-to-mesh (or
mesh-to-wall) seals
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
3. SOLIDS BLOCKAGE AND WASHING DAMAGE
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
3. SOLIDS BLOCKAGE AND WASHING DAMAGE
Although metal mesh
pads are generally
resistant to rough
handling, damage can
be done if the fitters are
not careful.
As can be seen when
aligning 2 sections on
the right, a mesh-to-
mesh seal will only be
possible if the sections
are over-compressed
when re-fitted, leading
to other gaps.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
4. MAINTENANCE SUGGESTIONS
All meshpads are made with
+/- 25mm space between
adjacent section grids. Use
simple U clips on the top
grids when fitting, to act as a
mesh compression guide.

Angle the final meshpad
sections in the remaining
space using a thin metal
sheet against the mesh sides
; push down on the ridge
and slide the sections in
place
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE OF MESHPAD DEMISTERS
4. MAINTENANCE-FRIENDLY DESIGN SUGGESTION
Early versions of an externally
removable meshpad used a
traditional horizontal
arrangement, with awkward,
risky results when removing
heavy, wet sections, high up a
tower.

The externally removable,
Vertical meshpad design was
developed between Begg
Cousland and Outotec, and
the new Noracid Chile plant
features it.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES
The wires of the inner and outer mesh
cages of a fibre bed mist eliminator are
the main victims of corrosive attack. The
wire is corroded over the whole
circumference, so a 2.5mm dia. wire
survives < 1.25mm corrosion.
The wires at the bottom of cages are the
most at risk, from un-drained acid /
sulphates on the tubesheet for standing
type, and residual acid in the fibre for all
types
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES
The use of raised stool
flanges (part of
tubesheet or part of
candle filter as shown),
avoid these extra
corrosion risks.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES
Inspection from below did not show
anything obvious.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES




From above the sulphate deposits on
the wall showed serious abnormality.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES






The missing top part of one filter was
then obviously the issue.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES








The cage was corroded by localised
weak acid formation, due to vent
pipe inlet below this filter.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES

Corroded hanging type candles
(or the bits that remained of them)
viewed at the distributor level.

This Russian customer had decided
to wash the tubesheet and filters
with water.

8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES
Corroded top flange (8mm)





Corroded
cage mesh





Corroded bottom plate (8mm)
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
1. CORROSION OF METAL FILTER STRUCTURES
High Velocity type candle filters from a D.T. in a plant
that had been shutdown for some months due to the
Financial Crisis.

No preventive maintenance, washing / neutralising
of the filters

Retained H2SO4 in the filters and sulphates led to
(random) weak acid corrosion of the cages

The wire of the cage mesh was 3mm dia.

Cage corroded here below the top plate
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
Corroded glass fibre in Asian Cu Smelter plant
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
2. CORROSION OF FIBRES
Corroded glass fibre in European Cu Smelter plant
Carbon Fibre :
Resistant to HF
Brownian Diffusion
efficiency
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
Hanging candle filters blocked by sulphates




Sublimed
sulphur
blocking
the fibre




5 year old hanging candle filters blocked by
insoluble solid dusts, with a new filter added.
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
3. BLOCKAGE WITH SOLIDS AND WASHING DAMAGE
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
Washing mist eliminators is an obvious way of extending filter life and saving money on a
new set. It is not always easy or quick, and can be expensive to do. Only wash when you
really need to. Washing can involve risk of damage.









Washing Guide available
from Begg Cousland
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
3. BLOCKAGE WITH SOLIDS AND WASHING DAMAGE
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
Only wash when you really need to. Washing can involve risk of damage.











Although these hanging filters look discoloured in the tower, when removed you can see
that there is no serious surface solids. Washing without reason can lead to fibre damage
and mishandling of the structures, which can finish a filters life.
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
3. BLOCKAGE WITH SOLIDS AND WASHING DAMAGE
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
The mist eliminator below was
automatic removed for washing
under a shutdown schedule.
THE LIFE AND DEATH OF FIBRE BED MIST ELIMINATORS
3. BLOCKAGE WITH SOLIDS AND WASHING DAMAGE
The PD had only risen by 10% over 18
months so neither the PD nor the
visible solids justify washing
The lighter density fibre beds can also
be damaged easily by too high water
pressure & handling
Unnecessary washing causes
abnormal liquid load stress to the
fibre, a risk to High Velocity fibres
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH AND REBIRTH OF FIBRE BED MIST ELIMINATORS
4. MAINTENANCE COST SAVING SUGGESTION
REPACKING STRUCTURES WITH NEW FIBRE BEDS / RECYCLING FLANGES
Why leave re-useable parts lying in
a scrap heap because they are not
able to be cleaned or have been
damaged when being removed /
washed. ?

Re-cycle the structure by sending it
to us for repacking in the USA, Italy
or India. Alternatively re-cycle only
the top and bottom flange sets.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE LIFE AND DEATH AND REBIRTH OF FIBRE BED MIST ELIMINATORS
4. MAINTENANCE COST SAVING SUGGESTION
REPACKING STRUCTURES WITH NEW FIBRE BEDS / RECYCLING FLANGES
If a structure has this amount of
damage and distortion, then it will not
be possible to repack it.

Cut off the top and bottom flanges
and only return them to us. So save
freight cost. So save fibre stripping
time and cost.

Those savings can off-set the cost of a
new set of cages welded to the
returned flanges, and boxes.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
EXTENDING THE MIST ELIMINATORS LIFE
1. COLLECTING INFORMATION
Mist eliminators performance can be monitored by :

Pressure Loss
Stack Exit Appearance
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
EXTENDING THE MIST ELIMINATORS LIFE
1. COLLECTING INFORMATION
Mist eliminators performance can be monitored by :

Pressure Loss
Acid Drainage

8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
EXTENDING THE MIST ELIMINATORS LIFE
1. COLLECTING INFORMATION
Mist eliminators performance can be monitored by :

Pressure Loss
Sludge Presence

8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
EXTENDING THE MIST ELIMINATORS LIFE
1. COLLECTING INFORMATION
Mist eliminators performance can be monitored by :

Pressure Loss
High Corrosion Rate

8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
EXTENDING THE MIST ELIMINATORS LIFE
1. COLLECTING INFORMATION
Mist eliminators performance can be monitored by :

Pressure Loss
Mist Sampling and / or Stick Test
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
EXTENDING THE MIST ELIMINATORS LIFE
2. UNDERSTANDING / INTERPRETING THE INFORMATION
Stick Test result changes with gas volume ?




Stick Test result changed noticeably
but the gas volume is the same ?
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
EXTENDING THE MIST ELIMINATORS LIFE
2. UNDERSTANDING / INTERPRETING THE INFORMATION
Stick Test result does not relate to stack plume?

Droplets not very visible Spitting marks on
& not seen at stack exit. ground may be
Droplets only usually seen or car owners
indicate reentrainment. may find paintwork
Check PD and trend. damaged & claim.

8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
EXTENDING THE MIST ELIMINATORS LIFE
2. UNDERSTANDING / INTERPRETING THE INFORMATION
An updated Troubleshooting Guide is available, as well as Guides to
Shutdown Inspection, Stick Tests and to Mist Eliminator Design & Selection
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
MIST ELIMINATORS LIFE STORY FOOTNOTE
OLEUM /SO3 TANK VENT SCRUBBER PACKAGE
The 1
st
use of our Becoflex Rotary Brush Scrubber in a
H
2
SO
4
plant was in the UK, at the plant where a tank
vent pipe led to corrosion of the candle filter shown.
The customer installed the Becoflex BFCF unit on top of
the Oleum tank, spraying water onto the rotating brush
to hydrolyse the SO
3
very effectively within the fan
volute.
All the H
2
SO
4
mist formation
took place before the 2
nd
stage
candle filter, so there is an
invisible exit.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
MIST ELIMINATORS LIFE STORY FOOTNOTE
OLEUM /SO
3
TANK VENT SCRUBBER PACKAGE
The unit has its own recirculation tank to minimise the
water effluent.
The combination of dynamic contact between gas and
liquid within the fan volute minimises unit size.





A key feature is the suction generated by the rotating
brush, which means that there is no need for a separate
fan unit. The Becoflex is also self-cleaning if any solid
matter is entrained from the tank.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
The 2
nd
user of our Becoflex Rotary Brush Scrubber was
in S. America, at the plant where the Oleum tank vent
pipe led to the corrosion of the demister seen earlier.

They also use the Becoflex to treat the fugitive vapours
from the wagon loading station.
MIST ELIMINATORS LIFE STORY FOOTNOTE
OLEUM /SO
3
TANK VENT SCRUBBER PACKAGE
For further information ask for a
copy of the Becoflex Brochure or
a copy of the Data Questionnaire.
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010
THE BEGG COUSLAND LIFE STORY
8
th
Mesa Redonda, Chile
Puerto Varas October 17 21 2010