AMACS DeMister Randing Packing

BROCHURES
PRODUCT SHEETS
TECHNICAL ARTICLES
AMACS History
Corrugated Grid Packing
Amine Still Column Revamp
Mesh & Vane Mist Eliminators
Pall Ring Packing
Knockout Drum Revamp
Liquid Liquid Coalescers
Metal Raschig Ring Packing
TEG Recovery
Structured & Random Packing
Carbon Raschig Ring Packing
Compressor Suction Drums
Fractionation Trays
Saddle Ring Packing
Wedge Wire Products
Knitted Structured Packing
Mist Eliminator Installation Guide
Woven Gauze Structured Packing

MisterMesh Mist Eliminator
Multipocket Vane
Liquid Liquid Coalescer
Insertion MistFix Mist Eliminator
Knitted Metal Filters
Distributors Orifice Riser
Distributors Weir Trough
Inlet Feed Devices
Packing Support Plates
Hub & Header Laterals
Water Well Screen
Structured Grid Packing
High Performance Structured Packing
Improved Pall Ring
AMACS Process Tower Internals

14211 Industry Street
Houston, TX. 77053
Toll Free USA & Canada: (800) 231-0077

Main Office phone: (713) 434-0934
24-hour Emergency Line: (281) 716-1179
Fax: (713) 433-6201
www.amacs.com
Email: amacs@amacs.com
Amacs Process Tower Internals
AMACSs liquid-liquid separation technology can solve a wide
Process
Amacs
Company
HistoryTower Internals
Amacs, a specialist in Process Tower Internals, was formed through the 2011 merger
or Products
of Amistco Separation Products Inc., and the Separations & Mass Transfer
division of ACS Industries. Amistco and ACS were both well respected suppliers of a full
complement of process tower internals.
ACS was founded in 1939 in Rhode Island to manufacture knitted copper wire
mesh. By the 1950s, it had expanded into stainless steel wire mesh and established
the Separations Technology Division to manufacture entrainment separators.
To better serve the petrochemical industry, the division relocated to Houston
in 1979. Over time ACS developed process engineering capability and expanded
s into vane separators,
f the North American

liquid - liquid coalescers as well as mass transfer products. In 1998, it became
r ACS opened a factory

licensee for Julius Montz GmbHs structured packing product line. In 2010
AMA
in Monterrey, Mexico to add capacity to meet its growing sales.
Amistco was founded in Houston in 1991 to manufacture mist eliminators based on its own wire knitting technology. It too
expanded into vane separators and mass transfer products as it expanded its in-house process engineering capability. Amistco
also invested in w edge wire screen manufacturing to serve the petrochemical as well as other industrial markets.
Today, Amacs operates factories in Houston and Monterrey. Headquarters are in Houston where its process engineering and
mechanical engineering groups provide customers with custom solutions for new build and replacement product needs. Amacs
serves a broad industry group including oil rening, natural gas processing, biofuels, and chemicals. Amacs is a vertically integrated
manufacturer with wire knitting, laser cutting, plasma cutting, metal punching, metal stamping, roll forming, welding, and assembly
capability.
Additional information is available at www.amacs.com
For more information please call:
1-800-231-0077
www.amacs.com
Amistco Separation Products Inc, and ACS Separations and Mass Transfer Products, are Registered Trademarks of AMACS
The Engineered Mist Eliminator
REDUCE COSTS
INCREASE CAPACITY
IMPROVE PERFORMANCE
DEBOTTLENECK EQUIPMENT
SIMPLIFY INSTALLATION
CUSTOMIZE PADS
800-231-0077
14211 Industry Street Houston, TX 77053 TEL: 713-434-0934 FAX: 713-433-6201

Email:amacs@amacs.com Visit our website www.amacs.com
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Droplet Formation and Size Distributions . . . .1
Mechanisms of Droplet Removal . . . . . . . . . . .2
Types of Mist Eliminator Mesh & Materials . . .4
Design Equations . . . . . . . . . . . . . . . . . . . . . . . .6
Predicting Pressure Drop . . . . . . . . . . . . . . . . .7
Inlet Diffusers . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Vessel Configuration . . . . . . . . . . . . . . . . . . . . .8
Advanced Mist Eliminator Designs . . . . . . . .10
Mesh-Vane Assemblies . . . . . . . . . . . . . . . . . .11
Use of Geometry . . . . . . . . . . . . . . . . . . . . . . .11
MultiPocket Vanes . . . . . . . . . . . . . . . . . . . . .11
History of ACS Industries, Inc. . . . . . . . . . . . .12

MaxCapTM Mist Eliminator . . . . . . . . . . . . . . . .14
Case Studies & Examples . . . . . . . . . . . . . . .15
Plate-Pak and AccuFlow are trademarks of AMACS Process Tower

Internals. MisterMesh and MultiPocket
are registered trademarks of
AMACS Process Tower Internals. The
information contained in this bulletin is
believed to be accurate and reliable but
is not to be construed as implying any
warranty or guarantee of performance.
The Engineered Mist Eliminator
Mist elimination, or the removal of entrained liquid droplets from a vapor

stream, is one of the most commonly encountered processes regardless
of unit operation. Unfortunately, mist eliminators are often considered
commodity items and are specified without attention to available technologies and design approaches. The engineered mist eliminator may
reduce liquid carryover by a factor of one hundred or more relative to a
standard unit, drop head losses by 50% or more, or increase capacity by
factors of three or four. This manual summarizes input practical approaches
to reducing absorbent losses, product contamination and entrainment
carry over, extending equipment life and maintenance cycles - using
proven and cost effective technologies and techniques.
Droplet Formation and Size Distributions
Entrained liquid does not consist of same-sized droplets, but as a broad

range of droplet sizes that may be characterized with a Normal or Bell
Distribution centered about some mean or average. The average droplet
size depends very much on the mechanism by which they are generated.
Sizing equations are expressed in terms of the probability of removing a
droplet of a given diameter, and mist eliminator performance is the
integration or cumulative sum of individual removal efficiencies. It is
therefore critical to know the approximate droplet size distribution in
order to properly design a mist elimination system. Figure 1 shows some
typical size distribution
FIGURE 1
curves from different
sources.
VOLUME FRACTION FREQUENCY DISTRIBUTIONS
FOR DISPERSIONS OF VARIOUS MATURITIES
In practice, designers
or engineers do not
quantify or measure
droplet size distributions, rather they are
assumed based on
empirical data or experience. Fortunately, an
experienced engineer
can
assume
an
approximate distribution based on the
means or mechanism
by which the droplets are generated. Typical examples from common
mist sources are given to illustrate these concepts.
Fine droplet distributions, often called fogs (<3 m diameter particles
with an average typically in the submicron range), occur in high speed
metal stamping in which cycles of extreme frictional heating and shock
condensation of lubricating oils form droplets in the submicron range,
so-called "blue smoke". This smoke is removed to comply with health
and environmental regulations.
Fog is also produced when gas phase reactions form a liquid product as
in the case of vapor phase SO3 and water yielding H2SO4. Downstream
THE ENGINEERED MIST ELIMINATOR

TEL: 800-231-0077 FAX: 713-433-6201 WEB: www.amacs.com EMAIL: amacs@amacs.com
equipment corrodes rapidly without the removal of this

liquid. Similar concerns are found in ammonia prill
towers, many chlorine applications, as well as
phosphoric and nitric acid plants.
A mist consists of droplets in the range of 3m and
greater, though distributions with average diameters
of 20 m and greater are termed Sprays. Mist coming
off the top of packing or trays, or generated by surface
evaporation, are typically in the broad range of 5-800 m.
In towers used in glycol dehydration and amine sweetening in which mists are a major source of costly
solvent losses, removal of droplets down to 5 m is
recommended.
ical evidence shows that the target size - important in

the first step of removal - must be in the order of
magnitude as the particles to be removed. These
steps are shown schematically in Figure 3 for mist
elimination using a wire mesh mist eliminator.
FIGURE 3
DROPLET CAPTURE IN A MESH PAD
Hydraulic spray nozzles generate particles with diameters

greater than 50 m and pneumatic nozzles generate
particles with diameters greater than 10 m, with upper
limits reaching 1000 m.
The first step in engineering a mist eliminator is to
determine the mechanism by which the droplets are
generated and assume an average droplet size.
Figure 2 summarizes typical particle size distributions
caused by various mechanisms:
FIGURE 2
For fogs in which the bulk of the droplets are characterized with submicron diameters, the energy to bring
about the collision with the target is derived from
Brownian Diffusion, the random motion of fine liquid
particles as they are
FIGURE 4
pushed about by
molecular action as
4a
shown in Figure 4a.
Fog elimination with
so-called fiberbed
technology is beyond
4b
the scope of this
manual.
This manual contains basic design concepts used by
engineers to remove droplets greater than 3 m in
For particles in the
diameter, so called mists and sprays.
mist region between
4c
3-20 m, knitted wire
Mechanisms of Droplet Removal
Droplets are removed from a vapor stream through a mesh is the most comseries of three stages: collision & adherence to a target, mon type of mist
coalescence into larger droplets, and drainage from eliminator used and
the impingement element. Knowing the size distribu- interception is the
tions as explained above is important because empir- primary mechanism.

Consider a droplet approaching a mesh filament of

much larger diameter as shown in Figure 4b. The
more dense the droplet relative to the gas, the larger
the droplet relative to the filament, and the higher the
gas velocity, the more likely it is that the droplet will
strike the filament. If the velocity is too low, or the
droplet too small or too light compared to the gas, the
droplet will simply flow around the filament with the
gas. If the velocity is too high, liquid clinging to the filaments will be re-entrained, mostly as larger droplets,
and carried away by the gas. Re-entrainment is also
promoted by low relative liquid density (making it easier for the gas to pick up a droplet) and low liquid surface tension (as less energy is required to break up a
film or droplet). The engineered wire mesh mist eliminator may remove 99.9% of particles 2 m and
greater diameter. Figure 5 shows a typical removal
efficiency vs droplet size distribution for a wire mesh
mist eliminator.
FIGURE 5
SEPARATION EFFICIENCY FOR VARIOUS
DROPLET SIZES IN A TYPICAL
WIRE MESH MIST ELIMINATOR
momentum, tend to move

in straight lines. By studying this figure, it is easy to
understand why in the
Stream of
design equations to follow
gas curves
the removal efficiency is back and forth
directly proportional to the between plates
difference in densities of
the liquid droplet and carrying gas. With each change
in direction of the gas,
some droplets collide with
the surface and adhere,
eventually coalescing into
larger droplets which then
drain by gravity. Properly
designed vane mist eliminators can remove 99% of
particles as low as 10 m
in diameter, especially at
FIGURE 6
lower pressures.
At each
curve,
liquid
droplets
strike
plates
Droplet
capture in a
Plate-PakTM unit
Figure 7 illustrates typical

wire mesh and Plate-Pak
vane mist eliminators,
and Figure 8 shows some typical performance curves
for both mesh and vane mist eliminators.
FIGURE 7
Typical AMACS
Mist Eliminators
Mesh pad Style 4CA
Droplets ~20 m and greater are primarily collected

by means of Inertial Impaction whereby the target is
directly in the path of the streamline, as shown in
Figure 4c. Figure 6 depicts a profile of the ACS
Plate-Pak vane. The entrained droplets, due to their
Plate-Pak unit

FIGURE 8
THEORETICAL EFFICIENCY VS. VELOCITY FOR VARIOUS
DROPLET SIZES (WATER IN AIR AT AMBIENT CONDITIONS
FOR TYPICAL MESH PADS AND PLATE-PAK UNITS
WITH LIGHT LIQUID LOAD)
eliminator becomes choked with liquid, a condition

called flooding. Flooding is often noticed by high
pressure drops or massive carryover of liquids.
Typical wire mesh mist eliminators accommodate
liquid loads up to about one US GPM per square foot
and vanes twice as much.
The key operating ranges and suitability of mesh and
vane mist eliminators are summarized in Figure 9. It
emphasizes that vanes are more effective at higher
velocities and greater droplet sizes while mesh is more
suitable for removing smaller particles at lower velocities. Gravity settling alone is sufficient for very large
particles, and co-knit mesh pads, discussed below, for
particles in the range of sizes from 2-8 m. Finally,
fiberbed technology is used for submicron fogs.
FIGURE 9
APPROXIMATE OPERATING
RANGES OF MIST ELIMINATORS
It is worthwhile to discuss Fig. 8 and mist eliminator

performance. The dotted curves correspond to different
styles of vanes and the solid to wire mesh styles. Note
first of all that vanes can be engineered to operate at
higher gas velocities and flow rates relative to mesh,
but that mesh mist eliminators can approach 100%
removal efficiency at smaller droplet sizes. This
agrees with the discussions above on Interception
and Inertial Impaction removal mechanisms. Note the
drastic efficiency drop off at low velocities, in which
droplets drift around the filaments or vane blades
without striking them. This phenomenon defines the
lower operating range of a mist eliminator. The other
extreme is when the velocity is too high. In this case,
the droplets are captured but the velocity of the gas
provides sufficient energy to tear-off and re-entrain
droplets. It is in the context of re-entrainment that the
design equations which follow show that the removal
efficiency is directly proportional to the surface tension
of the liquid. As the surface tension increases, so it
requires greater kinetic energy (i.e. gas velocity) to
break the bond between droplet and target, and the
droplets collect and coalesce until drainage by gravity. Re-entrainment defines the upper capacity limit of
a mist eliminator.
Types of Mist Eliminator Mesh Styles & Materials
Most designers believe that all wire mesh mist eliminators behave basically the same in terms of capacity
and removal efficiency. It is true that for meshes of
same filament diameter, the denser mesh offers superior
removal efficiency. For meshes with differing filament
diameters, a lighter (less dense) mesh may offer
considerably better removal efficiency. The key is that
Operating range is also affected by the liquid loading
the working part of the mesh is the target density, not
(proportion of liquid) of the gas. If too great, the mist

As far back as the 1950's researchers (C. LeRoy

Carpenter et al) determined that specific surface area
and target or filament diameter play a great role in
removal efficiency. Target or filament diameter must
be on the order of magnitude as the smallest droplets
to be removed. Due to limitations in metal wire ductility
and corrosion considerations, co-knits provide finer
targets and hence remove finer droplets. Figures 10
Table 1 shows a few of the more common mesh styles and 11 are enlarged images of crimped wire mesh
available, together with mesh density and void fraction, and a co-knit with fiberglass respectively.
and most importantly, the diameter and specific
FIGURE 10
surface area (i.e. the target density) of filaments used.
the mass density. For example, the most common
9-lb density mesh, AMACS style 4CA, exhibits ~85 sqft/cu-ft of surface area. Compare this to the co-knit of
a metal with fiberglass (AMACS style 6BE) which also
exhibits 9-lb mass density but exhibits a specific surface
area approaching 3,700 sq-ft/cu-ft, some 40X greater
targets per unit volume.
TABLE 1 Wire and Plastic Mesh Styles
CRIMPED WIRE MESH
FIGURE 11
CO-KNIT MESH WITH FIBERGLASS YARN
In summary, it is important to report mesh styles in

terms of the specific surface area - a measure of the
target density, and filament diameter -a measure of
the smallest droplet size that can be removed with
high efficiency. The mass density is only relevant insofar
that a metal mesh of density 12-lb exhibits a greater
specific surface area than one of density 7-lb provided
the wire diameter remains constant.
It is the amount of targets per unit volume which influences removal efficiency, not the density of mesh (the Selecting the material of mesh style(s) is also important.
greater the number of targets the greater the proba- Corrosion rates as low as 0.005"/year is not serious in
vessel walls but will quickly destroy 0.006" or 0.011"
bility of a successful collision).
wire mesh. Table 2 gives preliminary guidelines, but
In a co-knit such as a metal alloy and fiberglass, the AMACS draws wire and knits mesh with any ductile metal
alloy provides a skeleton for structural support and for special applications.
prevents the high specific surface media from collaps- When applying non-metal materials operating tempering on itself.
ature limits must be considered.

TABLE 2
Mesh Corrosion & Temp. Considerations
the upper end of the range: about 10 fps for plain wire
mesh pads, about 8.5 fps for co-knits, and 14 fps for
Plate-Pak elements. As discussed, effectiveness
drops off at lower velocities as the droplets have
sufficiently low momentum to negotiate paths through
the targets, and at higher velocities because the vapor
carried sufficient kinetic energy to re-entrain droplets.
For typical designs, acceptable velocities range
between 25% to 125% of the ideal value.
The Capacity Factor may be thought of as an indication
of ability of a mist eliminator to drain liquids and avoid
re-entrainment under various conditions. See Table 3
for some typical baseline values.
TABLE 3
Standard Souders-Br
(k factors) for mesh and Plate-Pak Units
Design Equations
To determine mist eliminator cross-sectional area (and

hence vessel size) and predict performance in terms of
removal efficiency, the optimum design gas velocity is
determined first. The Souders-Brown equation is used
to determine this velocity based on the physical properties of the liquid droplets and carrying vapor:
Vd = k(L-G/G)1/2
where Vd
k
L
G
=
=
=
=
(1)
design gas velocity (ft/sec)

Capacity Factor (ft/sec)
Liquid Density (lbs/ft3)
Vapor Density (lbs/ft3)
Note that Souders-Brown equation provides correction for only gas and liquid densities. Should any
conditions exist which affect drainage or re-entrainment,
the Capacity Factor must be pro-rated as appropriate.
After selecting the appropriate Capacity Factor and

calculating the ideal vapor velocity, the cross-sectional
The capacity factor is determined through experience area of mist eliminator is readily determined by dividing
and for each application, and is influenced by type the volumetric flow rate by the velocity.
and style of mesh or vane targets used, the geometry
of the targets (vertical or horizontal relative to the Having established this design velocity for the applivapor flow), as well as by properties such as operating cation, you can now predict the efficiency of a mesh
pressure, fluid viscosities, and liquid surface tension.
pad for droplets of a particular size. This procedure is
laborious and therefore well suited for a computer.
The design velocity Vd for a given application is the
value that produces the best performance in terms of First, calculate the inertial parameter K as follows,
capturing droplets and avoiding re-entrainment. using consistent units of measurement:
Referring to Figure 8, this ideal velocity for a given
class of mist eliminators would be somewhere toward

K = [( L- G)Vd 2] / 9 D
(2)
Where K = dimensionless inertial parameter
V = gas velocity in fps
d = Liquid droplet diameter in ft
= Gas viscosity in lb/ft sec
D = Wire or filament diameter in ft
design consideration in certain applications, particularly vacuum systems or larger columns requiring the
movement of great quantities of gas. It has been
shown that each inch of head loss requires some 0.16
hp/scfm. A simple correlation has been developed to
describe the pressure drop through a dry mist
eliminator (no mist):
Use this calculated K value with Figure 12 to find the Pdry = 0.4VD2 GST/gc w
(3)
corresponding value of the impaction efficiency fraction
E. From Table 1, find S, the specific surface area for Where V = Gas Superficial velocity = Ft / Sec
G = Gas Density lbs / ft 3
the mesh style of interest.
Subsequently determine SO of the mist eliminator
perpendicular to vapor flow and with a correction factor of 0.67 to remove that portion of the knitted wire
not perpendicular to the gas flow:
S = Specific surface area of mesh ft2 / ft3

T = Mesh Pad Thickness - Ft
Gc = gravitational constant, 32.2 ft / sec2
= Mesh Void Fraction
w = Ambient Density of water lbs / ft3
SO = Specific Surface Area x 1/ x Thickness (ft) x 0.67

Using these values and T, the thickness of the pad, Note: Applicable for wire diameter 0.0045 to 0.015.
calculate the capture efficiency:
The overall pressure drop is the sum of the head loss
Efficiency % = 100 - (100/eESO)
incurred as the gas travels through the mesh, as well as
Where SO = Corrected Pad Specific
that
due to the resistance to captured liquids. Liquid
Surface Area, ft2 / ft3
accumulates as a pool in the bottom of the mist eliminator.
E = Impaction efficiency fraction
If the liquid loading and velocity are such that a 2" deep
This efficiency is the percent of all incoming droplets pool accumulates in the bottom of the mesh pad, this
of the given diameter which will be captured rather amount must be added to that calculated using
than passing through the mist eliminator. The Equation 3. Figure 13 summarizes pressure drop and
percentage will be higher for larger droplets and lower velocity test data collected on the AMACS pilot plant for light
and medium liquid loading.
for smaller.
FIGURE 12
DETERMINING IMPACTION EFFICIENCY
FRACTION E USING INERTIAL PARAMETER K
With due consideration given to the mist eliminator

itself, the flow of fluid to and from it requires the same
attention.
Inlet Diffusers
At high flow rates, primary removal of bulk liquids

upstream of the mist eliminator is very important to
prevent flooding. This is typically done in a cost effective manner by using a simple inlet diverter as shown
in Fig. 15.
With this design, liquids impinge upon the diverters,
the flow is forced to flow laterally to allow bulk liquids
to escape by gravity and eliminate the countercurrent
momentum of the gas.
The Force of Inertia, expressed as 2, is typically
used to quantify the flow entering a vessel to determine
whether a simple baffle will suffice. AMACS recommends
Predicting Pressure Drop
inlet
diverters to a Force of Inertia up to 2,500 lb/ft s2.
Although the operating pressure differential across a
properly sized mesh pad or vane is never more than a Above this, more sophisticated distributors are
few inches of water, pressure drop is an important recommended.

FIGURE 13
ACTUAL PRESSURE DROP VERSUS VELOCITY FOR TYPICAL AMACS MESH PADS AT LIGHT AND MEDIUM LOADS
Decades ago, Dutch Shell Chemical Company introduced Schoepentoeter style bladed designs (Fig. 14).
As the fluid flows
FIGURE 14
axially towards the
shell opposite of
the inlet nozzle,
liquids are captured by specially
p l a c e d blades.
This design is
superior because it
allows the escape
of liquids over a
much
greater
region of the vessel. A simple inlet diverter ( Fig. 15)
would simply shear bulk liquids into smaller droplets
at great flow rates:
FIGURE 15
AMACS AccuFlow
Inlet Diffuser (Fig.
16) is a similiar
style of the bladed
design in which
the body of the diffuser maintains its
shape, the restriction of flow which
allows the escape
of liquids over the

diameter of the
vessel is accomplished using internal blades of concentric and decreasing cross-sectional
areas.
FIGURE 16
Vessel Configuration
Several factors must be considered when deciding on

the configuration of vessel internals. The first step is
to determine the cross-sectional area needed. Then a
tentative geometry and shape appropriate for both the
vessel and plant location is selected. Figure 17 shows
the most typical, but by no means complete, configurations. Mist eliminators can be of virtually any size or
shape to accommodate all factors.
The performance of the mist eliminator depends
strongly on an even velocity distribution over the
cross-sectional area. As a general rule, a distance of
either half the vessel diameter or 72", which ever is
smaller, is sufficient spacing both upstream and downstream of the element. Representations for specific
cases are illustrated in Figure 18.

FIGURE 17
SIMPLIFIED VIEWS OF TYPICAL MIST ELIMINATOR CONFIGURATIONS IN SEPARATOR VESSELS
Small velocity differences across the surface are

acceptable, but should be minimized at the design
stage. Otherwise, some regions of the mist eliminator
may be subjected to heavy loading leading to reentrainment while other regions are unused.
Most often, the mist eliminator is located just
upstream of the outlet nozzle with insufficient disengagement space. Vapor tends to channel through the
pad in the region closest to the outlet nozzle and

peripheral regions of the pad remain unused. To rectify
this, AMACS engineers apply an Integral Flow Distributor
which is welded to region(s) of the downstream face
of the pad. This technique allows the engineer to
selectively increase the pressure drop through
regions of the pad likely to suffer from channeling, and
is cost effective.

Advanced Mist Eliminator Designs
Drainage & Collection Layering
There are several modifications to mesh pads and Recall the discussion on pressure drop through a mist
vanes to dramatically enhance performance.
eliminator in which liquid tends to pool in the lower layers
of mesh. The simplest technique to promote drainage
FIGURE 18
is to use a few inches of open, porous mesh such as
AMACS style 7CA (5-lb density with specific surface area
Guidelines for maintaining even flow distribution across
as low as 45 sq-ft/cu-ft) in the upstream position. As
mesh pads or vane units with axial flow in cylindrical vesdrainage occurs through the interstitial regions of the
sels. Height of vessel head is assumed to be 1/4 of vessel
diameter. Flow distribution devices can minimize required
mesh, opening the
disengagement space above mesh pads.
FIGURE 19
knit enhances liquid
Contact AMACS for assistance.
drainage.
An extension of this
approach is to use
higher specific surface
area mesh in downstream positions to
enhance separation
efficiency,
with
intermediate mesh
between the collection and drainage zones. Figure 19
illustrates a multilayer mist eliminator.
MisterMesh Drainage Coils
A second technique used by AMACS to enhance liquid

drainage, and often in conjunction with multi-layering,
is to append drainage coils to the upstream face of a
horizontal mist eliminator as shown in Figure 20.
The coils are also made of mesh and "fill" with liquid.
FIGURE 20
MISTERMESH PAD WITH DRAINAGE ROLLS

Once filled, liquid from the pad above is drawn by
gravity and The Coanda Effect to the coils, thereby
establishing distinct regions for liquid drainage and
liquid collection in the upstream layers. Figure 21
compares the pressure drop and flooding point of
both conventional and MisterMesh Mist Eliminators.

10
Mesh-Vane Assemblies
shown in Figure 22 for smaller and larger diameters.

In grass root design of larger vessels and retrofit of An AMACS engineer should be consulted for such designs.
existing ones to accommodate greater flow rates, meshFIGURE 22
vane assemblies are often used. In an assembly, mesh
is placed upstream of the vane and acts as a flooded
agglomerator. The capacity factor used corresponds to
the downstream vane element. This approach combines the efficiency of mesh with the capacity of vanes
and has been used by AMACS engineers with tremendous
success over the past two decades.
FIGURE 21
ACTUAL PRESSURE-DROP PERFORMANCE
OF MESH PADS VERSUS VELOCITY.
NOTE RAPID INCREASE AS FLOODED
CONDITION IS APPROACHED
MultiPocket Vanes
The capacity of vertical vanes (with horizontal vapor

flow) can also be increased by enhancing liquid
drainage. As discussed, captured liquids are re-entrained
when the velocity of vapor exceeds the ideal. To
prevent liquid re-entrainment, the serpentine path
offered by the vane is augmented with obstructions to
allow for the pooling of liquid with protection from the
passing vapor stream. This design increases the
capacity of the vane by as much as 25%. In vertical
gas compressor knock-out drums, in which the vessel
size is dictated by the capacity of the mist eliminator,
MultiPocket
FIGURE 23
Vanes considerably
reduce the Foot-print
and cost of skids.
Figure 23 summarizes
the approaches used
by AMACS and the
reduction in vessel
dimensions possible
using these advanced
designs.
Throughout the industry there is ongoing debate as to

whether the mesh should be positioned up- or downstream of the vane element. Engineers at AMACS have
performed exhaustive comparative testing on pilot
plants and have much field data proving that the mesh
is indeed affective upstream of the vane, unless the
vane element is used as a pre-filter to protect a down- The MultiPocket Vane
has been patented by
stream mesh pad.
AMACS.
Use of Geometry
Another approach used in the industry when the size

of the vessel is limited is to arrange the mist eliminator at
an angle. The capacity increase is equal to the sine of
the angle though it should not exceed 45. This is

11
(Now AMACS Process Tower Internals)

12
MistFix Insertion Mist Eliminators
Mist Eliminators
MistFix U.S. Patent #5985004
Advantages:
The patented AMACS MistFix can solve carryover problems in

vessels without a mist eliminator, as well as in vessels with a less
efficient or damaged mist eliminator.
No Welding
In existing vessels that do not have a manway, the MistFix Insertion

Mist Eliminator is an ideal choice. It is suitable for any vessel having
an 8 or larger gas outlet nozzle at the top. It also eliminates the need
for hazardous entry permits. Since there is no need to enter the
vessel, this drastically reduces downtime, resulting in quicker
turnarounds, reduced maintenance cost and production gains.
No Cutting of existing vessel

No Hazardous Entry
No ASME re-certification
No Scaffolding
Minimal Downtime
MistFix also eliminates the need for modifications to vessels. For

new vessels MistFix may eliminate the need for a manway and
.
reduce vessel
cost. It also makes future maintenance easier and
simpler.
Figure 3. MistFix
insertion mist eliminator
AMACS MistFix can easily be installed and replaced from the

outside. Existing vessels require no modifications to accommodate the
MistFix.
1-800-231-0077
www.amacs.com

13
Our
are registered trademarks

of AMACS Process Tower Internals.
Try AMACS Plate Pak vane

our
we
14
FIGURE 24
APPLYING COMBINATIONS OF AMACS MESH PADS
AND PLATE-PAKTM VANE UNITS TO MINIMIZE VESSEL
SIZE
CASE STUDIES & EXAMPLES
Case Study Number 1

Problem: In an HCl scrubber, an air stream of 60 acfs
is coming off a bed of random packing and contains
droplets of a weak acid. The unit operates at 122 psia
at 82F. Determine the size of mist eliminator required
to remove this mist and the removal efficiency possible.
Solution: Since the acid is dilute we assume the density
and viscosity of water at the operating pressure and
temperature:
L = 62.4 lb/ft 3
G = 0.60 lb/ft 3
P = 122 lb/ft 2
T = 82F
F = 60 ft 3/sec
The first step is to select the mist eliminator type and

mesh style. As shown in Figure 24, mist coming to the
mesh pad is typically comprised of droplets ranging in
size from as small as 5 m, so we select a mesh style
mist eliminator to achieve this level of performance. From
experience, the capacity factor for poly mesh at moderate liquid loading and lower pressures is ~.27
fps. Using the Souders-Brown equation the ideal
velocity is calculated:
Videal = k [ ( L- G) / G]1/2
Videal = 0.27[(62.4-0.60)/0.60] 1/2
Videal = 2.74 fps
The cross-sectional area of mist eliminator is determined by dividing the volumetric flow rate by the ideal
velocity:
Area Mist Eliminator = Volumetric Flow Rate/
Superficial Vapor Velocity
Area Mist Eliminator = [60 ft3/sec]/2.74 fps
Area Mist Eliminator = 21.9 ft2
The corresponding diameter is 63.4", rounded up to a
standard 66" scrubber vessel. Note that performing
the same calculations using a vane (and a capacity
factor of 0.50) yields an ideal vessel diameter of 46.7",
rounded up to a standard 48" ID vessel. To calculate
the removal efficiency at 5 m, several parameters
must be identified to use equation 2 to determine the
inertial parameter K:

15
K = [( L- G)Vd 2]/9 D
K = 0.32 fps
From experience, AMACS engineers knew that the

droplet size distribution for glycol coming off the top of
a packed dehydrator extends down to diameters
of 5 m and greater. Also, if the diameter of the
From Figure 12, the corresponding Impaction packed column was sized in accordance with the
Efficiency Fraction E is ~0.08. In the Removal hydraulic requirements of the packing, the wire mesh
Efficiency Equation there is a term for the corrected mist eliminator would be undersized.
specific surface area SO:
SO= Specific Surface Area x 1/ x

Thickness (ft) x 0.67
The capacity factor for 12-lb density mesh in this service is ~0.23 0.27, having been de-rated for the high
liquid viscosity of 18 cP (which retards liquid drainage)
and relatively high operating pressure. Using the gas
For ACS style 8P, the specific surface area is
2
3
density,
volumetric flow rate and cross-sectional area
(185 + 36) = 221 ft /ft , we will try both 4" and 6" thick
of the mist eliminator, the actual superficial velocity is
mist eliminator thicknesses (1/3 and 1/2ft):
readily calculated. Next, using known densities of the
gas and glycol, the actual or operating Capacity
SO = 221 x 1/3.14 x 1/3 x 0.67
Factor
k is determined:
SO 4"thick = 15.7 and SO 6"thick = 23.6
And Removal Efficiency E at 5 m is:

Efficiency = 100 100/eESO
Efficiency = 100 100/e(0.08)(15.7)
Efficiency = 71.5%
V actual = k actual [( L- G) / G] 1/2

Re-arranging for
k actual = V actual / [( L- G) / G] 1/2
= 0.44 fps
For the 6" thick element, the removal efficiency is
84.8%. By using a composite pad containing a 2"
layer of regular monofilament polypropylene, style 8P, A Capacity Factor of 0.44 fps is almost twice as high
upstream of a 2" thick layer of 8PP, mono- and as the optimum, and is in the range of that of an AMACS
multi-filament co-knit, the removal efficiency is 99.9% . Plate-Pak Vane mist eliminator. However, the vane
will not remove particles down to 5 m, so a meshCASE STUDY #2
vane assembly was proposed. The assembly has a
Traditionally, trays are used to bring about contact
multiple layers of mesh. The first layer is composed of
between glycol and natural gas in dehydration conhighly porous mesh (AMACS style 7CA), followed by a
tactors. In recent years, the industry moved towards
layer of the high specific surface area (AMACS style 8DT)
smaller diameter columns by exploiting the higher
co-knit mesh of stainless and Dacron Fibers.
capacities achieved with structured packing.
MisterMesh drainage coils were appended to the
However, the lower capital investment associated with
bottom face of the mist eliminator. Downstream of the
a smaller diameter packed tower is often offset by
mesh was placed a Plate-Pak vane. The total
dramatically increased glycol losses.
thickness was 12" and was accommodated using the
Consider a mid-western sour gas plant operating a same supports as the mist eliminator it replaced.
96" glycol contactor and processing 1,310,000 lb/hr of
gas at 116F and 1214 psia. The gas and liquid specific Carryover from a glycol contactor occurs through two
densities were 4.4 and 68 lb/cu-ft respectively. The mechanisms, evaporative losses and mechanical
plant was experiencing 0.13 US gal of carryover per (carryover losses). In this example, simulations
mmscf, amounting to some 65 gal/day of lost triethylene showed evaporative glycol losses of 0.0054
glycol, several hundred dollars worth per day. A 10" gal/mmscfd. The total losses after the revamp were
thick wire mesh mist eliminator of 12-lb mass density less than 0.008 gal/mmscfd, and carryover losses had
been reduced from 0.13 gal/mmscfd, a 94% reduction!
was installed above the packing.

16
17
18
HIGH CAPACITY MIST ELIMINATORS

O UT PERFORM CONVENTIONAL TECHNOLOGY!
PLATE-PAK
M IST ELIMINATOR
M ISTER M ESH
M IST E LIMINATOR
WITH DRAINAGE ROLLS
ADVANCED TECHNOLOGY
FOR DEBOTTLENECKING !
Our MisterMesh Mist Eliminator out performs conventional pads. The drainage rolls
accelerate liquid removal thus increasing
capacity and reducing pressure drop. Used
in conjunction with our Plate-Pak vane,
the MisterMesh drain
rolls can increase capacity
by over 200% while separating droplets down to
3 microns.
24-hour emergency service Free technical support 50 years experience

800-231-0077
14211 Industry Street Houston, TX 77053 TEL: 713-434-0934 FAX: 713-433-6201
Email: amacs@amacs.com Visit our web site www.amacs.com
AMACS AccuFlow Inlet Diffusers
Feed Inlet Devices
Top View
Benefits:
AMACS AccuFlow Inlet Diffusers will correct flow imbalances and

improve the operation of separators and distillation towers. Higher
gas flows into existing separators create poor gas distribution.
Localized high velocities can also cause the gas to jet into the
liquid surface. This in turn creates additional liquid entrainment and
may flood the mist elimination device, resulting in liquid carry over.
Eliminates high liquid loads on

vessel internals
Dissipates high inlet gas velocities
Prevents reentrainment of liquid
droplets from the liquid level in
the vessel
A properly designed inlet diffuser removes liquids and solids and

evenly distributes the gas flow over the downstream separator.
Maximizes gas distribution and

avoids channeling
Made in sections to go through
a manway
In a similar manner, an inlet diffuser will improve operation of

a distillation tower. Applications with flashing feeds or reboiler
returns will see significant improvements. Diffusers give improved
phase distribution with negligible pressure drop.
Can be designed for vertical or

horizontal separators
Gas
Outlet
AccuFlow Inlet Feed Device
1-800-231-0077
www.amacs.com
Amine still column revamp

With the old trays in the scrap yard and no working drawings available, an amine
still revamp called for engineering detective work
Vilas lonakadi
Amistco Separation Products
Amistco Separation Products is a registered trademark of AMACS
he amine still column at an

energy plant was designed to
treat 300 million scfd of sour
gas containing H 2 S and CO 2 with
alkanolamine. The sweet gas after
treatment is routed to an energy
company. The unit, on the Gulf
coast of the US, was shut down in
September 2009 for regular maintenance. On opening the amine still,
engineers found that the trays were
all damaged, corroded and plugged
with iron sulphides and scale.
Almost all of the trays had fallen
to the bottom of the still. Due to a
very tight schedule, the turnaround
contractor removed all of the
damaged trays and threw them
away in a scrap yard. The operator
then realised that it no longer had
drawings of the existing trays and
there was not enough time to carry
out a complete process and equipment design for replacement trays.
Hence, the company decided to
replace the trays with new versions
to the same design. However, no
process data were available and
there were no existing tray draw ings, factors that together posed
great challenges in duplicating the
design and fabricating replace ments. Amistco was called in to
design and supply new trays.
Conventionally, the design of
distillation
column
internals
involves two main steps: process
design and optimisation, and equipment design. The process design,
after a number of iterations and
optimisations, specifies the internal
vapour and liquid flow rates and
properties across the number of
theoretical stages required to
achieve
separation
efficiency,
while the equipment design and
www.eptq.com
P rocess design
Equipment design
Equipment fabrication,
installation and commission
Project Objective
Figure 1 Conventional steps in the design of distillation column internals
fabrication step uses this data to

design the actual hardware (see
Figure 1). Ideally, the equipments
Conventionally, the
design of distillation
column internals
involves two main
steps: process design
and optimisation, and
equipment design
design and fabrication would also
evolve from an earlier set of design
operations and drawings.
The process design and optimisa tion step mainly determines how
close the tray geometry is to reaching maximum capacity. However,
in this case, due to the nonavailability of process data, this first
step was bypassed. However,
detailed discussions with the opera tional and process staff of the gas
plant concluded that the column
and existing trays were working to
their satisfaction in terms of capac ity and efficiency, and there were
no plans to either increase or
decrease the units operations in the
near future. Hence, the decision
was taken to duplicate the existing
geometry in new trays.
Since drawings for the existing
trays were not available, an inspection crew consisting of engineers,
designers
and
drafters
was
REVAMPS 2010 37
Tray 1
Tray 2
C
Figure 2. Schematic of a four-pass tray arrangement showing panel designation
dispatched to the plant to inspect

the tower. The tower diameter was
measured at several locations and
confirmed to be 156in (400cm).
Although, at some locations, the
vessels internal diameter was not
uniform, the inspection crew recognised that the out of roundness
was within the tolerance level of
1% of vessel internal diameter, in
accordance with ASME UG80.
An inspection of the welds inside
the tower revealed that the tower
consisted of 20 trays, comprising
four-pass trays with side and centre
downcomer trays at the top tray,
ending with off-centre downcomer
trays at the bottom. Although some
corrosion was observed at the
support rings and downcomer bolt ing bars, with some cleaning
required, they were deemed acceptable for the next run. An ultrasonic
inspection of these weld-ins
revealed that the support rings
were 0.5in thick and 2.5in wide.
Based on a turnaround schedule of

five years, the support rings thick ness was deemed adequate to
withstand the maximum allowable
working pressure.
Given that this

tower has four-pass
trays, balancing the
number of passes
is critical, to avoid
poor distribution of
vapour and liquid
Based on the chord lengths of
various support rings, width of
inlet panel and the minor beam
dimensions, it was concluded that
the side downcomer widths were
Tray geometry
Tower diameter
# of passes
# of valves
Type of valves
Valve lift
Side downcomer width
Centre downcomer width
Off-centre downcomer width
Distance of off centre downcomer from tower wall
Metallurgy
Table 1.
38 REVAMPS 2010
Measurement
156in
4
1056
0.4395in
11.75in
12in
12in
43.125in
SS 304L, 14 Ga./12Ga.
11.75in (30cm), the centre downcomer widths were 12in and the
off-centre downcomer widths were
also 12in. At the same time, and
based on the recovery of some
material from the scrap yard, some
of the downcomer panels were
reassembled, to the point where it
was possible to verify these dimen sions. It proved interesting to note
that the judgment made through
chord lengths matched closely the
widths of the downcomer panels.
Measuring between the support
rings provided an idea of tray spac ing. An inspection of the tray panel
indicated that the trays were round
floating valves with 0.4375in (1.1cm)
lift and they were 1056 in number.
Following discussions with the
operator to confirm that the existing
trays did not have any operational
problems, the tray layout was
decided upon, considering that the
existing trays were operating in
froth regime and there was no
excessive entrainment, excessive
downcomer backup or excessive
downcomer choke, with reasonable
pressure drop. Although some
corrosion and fouling was observed
on the trays, it was felt that their
condition was acceptable following
a five-year ????.
The column was required to oper ate in different cycles with varying
gas rates. As a result, the percent age turndown would be most
important. Hence, the decision was
taken to continue using floating
valves.
Given that this tower has fourpass trays, balancing the number of
passes is critical, to avoid poor
distribution of vapour and liquid,
which would reduce the efficiency
and/or the capacity of the trays. It
is important to ensure that the
vapour and liquid contact each
other uniformly across each panel
and to make sure that the vapourto-liquid ratio is as close to unity
on each of these panels. All fourpass trays have two different sets of
configurations. One set consists of
two side downcomers and a centre
downcomer, while the other set
consists of two off-centre downcomers, and these alternate in a
given column. As a result, the trays
will have four active panels, with
www.eptq.com
panels A and B designated for the

side and centre downcomer trays,
and panels C and D designated for
the
downcomer trays (see
Figure 2).
Within the still, the vapour and
liquid streams are split, but recombine on each path. Hence, if the
split is not uniform across each of
these paths, the tray will flood
prematurely or it will loose its efficiency. The liquid flows on the tray
deck and downcomer are controlled
by modifying the downcomer clear ances and/or outlet weirs, while
the vapour flows are balanced using
the vapour tunnels or by providing
the same bubbling area. Four-pass
trays are balanced either by the
equal bubbling area method or by
providing equal flow path length.
In this case, the active bubbling
area concept was used and the
outlet weir lengths and weir heights
for panels A and B were kept the
same, with the same number of
valves on each panel. As these
downcomer panels were available,
a study of all of these panels
revealed that they were made of SS
304L, and ultrasonic measurements

indicated that the downcomer
trusses were 7 gauge thick and the
tray panels were 14 gauge thick.
Thus, even in the absence of proc ess data and drawings of the trays,
a systematic evaluation of all the
calculated and found to be 90%

allowable at design conditions and
0.173 respectively. The trays were
then fabricated and delivered to the
customer a week later. The amine
column has been commissioned and
is operating satisfactorily.
Four-pass trays are

balanced either by
the equal bubbling
area method or by
Conclusion
path length
In the absence of process data and

existing tray drawings, an innova tive and systematic evaluation of all
the damaged internals, inspection
of the tower, and application of
experienced engineering judgment
and teamwork resulted in the
tive design and fabrication of
replacement fractionating trays for
an amine still.
recuperated scrap, inspection of the

tower and experienced engineering
judgment helped to finalise the tray
geometry for this four-pass mass
transfer tray for an amine still (see
Table 1).
Based on the calculated geometry,
mechanical designs such as stress
calculations and deflections were

1-800-231-0077
www.amacs.com
www.eptq.com
REVAMPS 2010
39
Liquid-Liquid Coalescer Design Manual
20 Ft. Gravity Separator
THREE
PHASE
IN
GAS OUT
THREE
PHASE IN
GAS
OUT
LIQUID LEVEL
36" ID
LIGHT
PHASE
OUT
16"
INTERFACE
LEVEL
12 Ft. Coalescer Vessel
30"
60" ID
LIQUID LEVEL
HEAVY
PHASE
OUT
800-231-0077
14211 Industry Road Houston, TX 77053 TEL: 713-434-0934 FAX: 713-433-6201
eMail: amacs@amacs.com Visit our web site www.amacs.com
LIGHT
PHASE
OUT
LIQUID-LIQUID COALESCER DESIGN MANUAL

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Stokes Settling Using Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Basic Design Concepts The Emulsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Basic Design Concepts Operating Principles of a Coalescer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Basis for Sizing and Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Intra-Media Stokes Settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Direct Interception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Gravity Separation Downstream of a Coalescer Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Coalescer Congurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Case Studies
-Oil-Water Separators - Environmental Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
-Gas Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
-Alkylation Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
-Oil/Water Separator on a Production Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
-Upgrading a Three-Phase Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
General References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Ranges of Application for Coalescing Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
AMACS Oil / Water Separators utilize patented* technology to separate oily waste water.
Applications include oil spill clean up for marine, power plants, reneries, vehicle terminals, and
countless others. The separated water is puried for
direct sewer or ocean discharge. The oil is captured
1992 Vaaler Award
and recycled.
for AMACS
Oil-Water Separator
*US Patent Nos. 5,023,002 & 5,246,592
20L x 8W x 9-6"H
LIQUID-LIQUID
COALESCER DESIGN MANUAL
Introduction
flowing and the opposing forces of buoyancy and viscous drag balance (Figure 1), the droplet has achieved
its Terminal Settling Velocity. This vertical velocity is
constant because there are no net forces acting upon
the droplet. This mechanism of separating liquids by
gravity is called Stokes Settling after the nineteenth
century English researcher Sir George Stokes.
Whether engineering a new coalescer vessel, or

debottlenecking an existing separator, full knowledge
and understanding of the basic principles involved are
required. Often overlooked are the capabilities of properly selected and designed internals for the enhancement of simple gravity separation. This Liquid-Liquid
Coalescer Design Manual describes the use of various The equation he developed for the terminal settling
media and methods employed for decades to increase velocity is still used today:
plant productivity. Typical applications include:
Removal of Bottlenecks in existing
Decanters and Three Phase Separators.
vt = 1.78 X 10-6 (S.G.) (d)2 /
Reduction in New Vessel Sizes Up to five

times relative to gravity settling alone.
d = Droplet Diameter, microns
Improvements in Product Purity Carry-over

entrainment reduced to 1 ppm and less.
Compliance with Environmental Regulations
Cost effective solutions to wastewater
treatment and oil spill cleanups.
(1)
vt = Terminal Settling Velocity, ft/s
S.G. = Specific Gravity Difference

between the Continuous
and Dispersed Phases
= Continuous Phase Viscosity, centipoise
The size of a gravity decanter is derived from 1) the

terminal settling velocity of a minimum sized droplet
and 2) the inertial force imparted to the droplet due to
the velocity of the emulsion through the vessel. At
these conditions, all droplets larger than a minimum
will be removed at a quicker rate and hence need not
be considered. The minimum sized droplet must be
estimated if empirical data is not available. Typically
the minimum droplet size is estimated to be between
75 to 300m. For example, API Publication 421 uses
minimum sized droplets of 150m for oil/water systems in refineries. Note that in Stokes Settling the
vessel must be sized to ensure laminar or streamline
Stokes Settling Using Gravity
flow; turbulent flow causes remixing. An example of
Traditionally, gravity separators were used to handle this sizing method in a decanter is contained in Case
emulsions before the use of coalescing media became Study 2, see page 12.
commonplace. In this
FIGURE 1
equipment, differences in In order to settle fine droplets and ensure laminar flow,
Forces on a light droplet
densities of the two liquids large vessels and long residence times are required.
dispersed in a heavy liquid
cause droplets to rise or It may take five, ten, and or even thirty minutes to
fall by their buoyancy. The make a separation, depending on the physical propBouyant Force
greater the difference in erties of the stream. With the capacity intensification
densities, the easier the forced on modern refineries and chemical plants and
Inertial Force
separation
becomes. achieved with advanced mass transfer internals, catd
Rising (or falling) droplets alysts, and heat exchanger designs, operators find
are slowed by frictional that their separators only have half or a third of the
forces from viscous effects time originally anticipated. This results in hazy, off
of the opposing liquid. spec products or intermediates that cause problems
Viscous Drag
Force
When the stream is not in downstream equipment.
When two liquids are immiscible, or non-soluble in

one another, they can form either an emulsion or a
colloidal suspension. In either of these mixtures, the
dispersed liquid forms droplets in the continuous
phase. In a suspension, the droplets are less than one
micron in diameter and the liquids cannot readily be
separated with the technologies described here.
Fortunately, in the chemical and hydrocarbon process
industries droplet sizes are typically greater than this
and/or the purities required can be achieved without
addressing the ultra-light colloidal component of the
stream.
LIQUID-LIQUID
With Coalescer Media and Internals, unit performance can be restored. Typical applications include:
Upgrading 3-Phase Separators
and Decanters
FIGURE 2
VOLUME FRACTION FREQUENCY DISTRIBUTIONS
FOR DISPERSIONS OF VARIOUS MATURITIES
Removing haze from finished

products such as diesel and jet fuel
Oil/Water Separators
Solvent recovery from liquid/liquid
extraction towers
Basic Design Concepts

The Emulsion
In selecting and designing a coalescer, it is important

to understand and characterize the emulsion that has
to be treated. The finer the droplets dispersed in an
emulsion, the more stable it is, because the buoyancy
force diminishes in magnitude as the diameter
decreases. The manner in which the mixture is created
effects the droplet size distribution. For instance,
centrifugal pumps shear liquid droplets much more
severely than progressive cavity, thereby creating finer
droplets. It is also important for the designer to know
how much time has elapsed since the mixing/shearing
occurred. This is because as time goes on, smaller
droplets aggregate (or coalesce) and larger droplets
are more likely to have joined a separate layer so that
they are no longer considered to be entrained.
An important tool to quantify an emulsion is the Droplet
Size Distribution Curve generated by plotting the droplet
diameters against the volume or mass fraction at that differential diameter. As stated above, the shape of the distribution is affected by the manner in which the emulsion
was formed, and its age. Consider a stream with a fine
emulsion (or immature dispersion) as in Figure 2.
Overtime, the peak of the volume fraction curve shifts to
greater droplet diameters until there are more large
droplets than fines.
Another key characteristic of an emulsion and the distribution that describes it is the existence of a Maximum
Droplet Diameter (1000m in Figure 2). The maximum
stable droplet size that an emulsion will develop in a
given situation depends on the mechanism of their creation, the amount of energy imparted to the mixture,
and the interfacial tension between the phases.
Droplets larger than the maximum quickly leave the
dispersed phase to form a separate liquid layer and
therefore need not be considered part of the emulsion.
Generating distributions can be done by collecting and

plotting empirical data. Alternately, Mugele and Evans
(see General References) showed they have a reliable
method for modeling this data as a function of standard
deviations that requires only knowledge of the maximum
droplet diameter and two different values of the mean.
In the typical interconnecting piping between a condenser and a two or three phase separator; from a
centrifugal pump and a distillation column feed
coalescer; etc., a dispersion develops to where the
Sauter (volume/ area) mean is roughly 0.3 and the
mass (volume/ diameter) mean is roughly 0.4 of the maximum diameter, respectively.
A coalescer is often needed, though, for mature distributions (when the mean will be larger than a Gaussian
0.5 of the maximum diameter). Examples are the dispersion of produced water in crude oil that has traveled
for weeks in a tanker and the water that has settled in
a product storage tank over several days. Therefore,
with minimal data, an experienced designer can have
an accurate idea of the dispersion that a coalescer
must treat.
When the average droplet is greater than roughly 1/2 millimeter (500 microns), an open gravity settler is appropriate. Table 1 shows some typical sources that can generate
dispersions that require the use of liquid-liquid coalescers.
Also given are some characteristics of the emulsions that
are created.
LIQUID-LIQUID
Source
Stability
Droplet Size
Range
Flash Drum Emulsions

with >5 % Dispersed Phase,
Static Mixers
Weak
100-1000 microns
Flash Drum Emulsions with

<5 % Dispersed Phase,
Impellor Mixers, Extraction
Columns
Moderate
Step 1 Droplet Capture

The first step of coalescing is to collect entrained
droplets primarily either by Intra-Media Stokes Settling
or Direct Interception. Figure 4 gives the useful zones of
separation for various mechanisms. Elements that
50-400 microns
Centrifugal Pump Discharges,

Caustic Wash Drums, Low
Interfacial Tension Emulsions
Strong
Haze from Condensing in Bulk

Liquid Phases, Surfactants
Very Strong
Giving Emulsions With Very
Low Interfacial Tensions
10-200 microns
0.1-25 microns
Target Size, Microns
1000
FIGURE 4
ZONES WHERE DIFFERENT
COALESCING MECHANISMS APPLY
100
10
0.1
0.1
Table 1
Basic Design Concepts

Operating Principles of a Coalescer
10
100
1000
Droplet Size, Microns
depend on Intra-Media Stokes Settling confine the disLiquid-Liquid Coalescers are used to accelerate the tance a droplet can rise or fall between parallel plates
merging of many droplets to form a lesser number of or crimps of packing sheets (Figure 5). This is comdroplets, but with a greater diameter. This increases pared to simple gravity separators in which the travelthe buoyant forces in the Stokes Law equation. Settling
FIGURE 5
of the larger droplets downstream of the coalescer
element then requires considerably less residence
OIL DROPLETS RISING TO A COLLECTION SURFACE
time. Coalescers exhibit a three-step method of operaL
tion as depicted in Figure 3.
FIGURE 3
THREE STEPS IN COALESCING
Submicron droplets
flow around target Several captured droplets
coalesce, forming larger
drops...
Droplets strike
target and adhere
...which trickle down
and fall, becoming
separated
1) Collection of Individual Droplets

2) Combining of Several Small Droplets into Larger Ones
3) Rise/Fall of the Enlarged Droplets by Gravity
ing distance is equal to the entire height of the pool of

liquid present in the separator. This effect is also seen
in knitted wire mesh, but their high void fractions mean
the surface is very discontinuous.
Meshes, co-knits of wire and yarns; and wire and glass
wools all depend primarily on Direct Interception
where a multiplicity of fine wires or filaments collect
fine droplets as they travel in the laminar flow streamlines around them (Figure 6). As can be see in Figure
4, in general they can capture smaller droplets than
those that depend on enhanced Stokes Settling. A
general rule with Direct Interception is that the size of
the target should be close to the average sized droplet
in the dispersion. Finer coalescing media allow for the
LIQUID-LIQUID
been retained. Whether a coalescer medium is

hydrophilic (likes water) or oleophilic (likes oil) depends
DROPLET INTERCEPTION
on the solid/liquid interfacial tension between it and the
Liquid Flow
Streamlines
Droplet Trajectory
dispersed phase. In general an organic dispersed
d
DROPLET
phase wets organic (that is plastic or polymeric)
Filament
d/2
Area for efficient
media, as there is a relatively strong attraction between
droplet collection
d/2
D
the two, while an aqueous dispersed phase preferably
wets inorganic media, such as metals or glass. This
DROPLET
Droplet
Trajectory
d
aids in the coalescence step as the droplets adhere to
the media longer. Also assisting coalescing is the denseparation of finer or more stable emulsions (Table 2). sity of media: lower porosities yield more sites available
Note that fine media will also capture or filter fine solid for coalescing. In the case of yarns and wools, capillary
particulates from the process stream. Therefore, unless forces are also important for retaining droplets.
the emulsion is very clean, an upstream duplex strainer
Once several droplets are collected on a plate, wire, or
or filter is needed to protect a high efficiency coalescer.
fiber, they will tend to combine in order to minimize their
interfacial energy. Predicting how rapidly this
Max Droplet Flow Range
will occur without pilot testing is very difficult to
Media
Source
2
Diameter,
gpm/ft
do. Judgments of the proper volume, and
therefore residence time, in the coalescers
Separators with
15-75
Corrugated
40-1000
Coarse Emulsions
Sheets
(35-180 m3/hr/m2) are guided by experience and the following
& Static Mixers
properties:
Overhead Drums,
7.5-45
Wire Mesh, Extraction Columns,
20-300
(20-110 m3/hr/m2) Coalescing Media:
Wire Wool Distillation Tower Feeds,
Impeller Mixers
Media/Dispersed Phase
Steam
Stripper
Bottoms,
Interfacial Tension
Co-Knits of
7.5-45
Caustic Wash Drums,
10-200
Wire &
3/hr/m2)
Porosity
(20-110
m
High Pressure Drop
Polymer
Mixing Valves
Capillarity
Haze from Cooling in
Glass Mat,
Bulk Liquid Phase,
Co-Knits of
7.5-45
Liquid Phases:
1-25
Surfactants Giving
Wire &
(20-110 m3/hr/m2)
Emulsions with Very
Continuous/Dispersed
Fiberglass
Low Interfacial Tension
Interfacial Tension
Continuous/Dispersed
Media
Hydro/Oleophilic Porosity Target Size Fouling/Cost
Density Difference
Metal/Plastic
H/O
98-99%
3/8" - 1"
Low/Low
Spacing/Crimps
Corrugated Sheets
Continuous Phase Viscosity
Superficial Velocity
.002" - .011"
Wire/Plastic Mesh
H/O
95-99%
FIGURE 6
Wire Wool
Coalescers work better in laminar flow for several reasons. First, as mentioned above,
8 - 10 micron
High/High
Wire/FG Co-Knits,
H
92-96%
droplets will stay in the streamlines around a
Glass Mat
wire or fiber target. Second, high fluid velocities
Table 2
overcome surface tension forces and strip
droplets out of the coalescer medium. This results in reStep 2 Droplet Coalescence
The second step is to combine, aggregate, or coa- entrainment in co-current flow and prevents droplets
lesce captured droplets. Increasing the tendency for from rising/sinking in counter-current flow. Lastly, slowdroplets to adhere to a medium, increases the proba- er velocities result in greater residence time in the
bility that subsequent droplets will have the opportuni- media and therefore more time for droplet-to-target
ty to strike and coalesce with those that already have impact, droplet-to-droplet collisions, and Intra-Media
Stokes Settling.
Wire/Polymer
Co-Knits
94-98%
21-35 micron
LIQUID-LIQUID
The guidelines in Table 2 are used for selecting the

proper coalescer for a given source based on the
medias Droplet Collection ability. Also given are typical
flow ranges for each type of coalescer media.
Step 3 Stokes Settling With Coalesced Droplets
The third step is the Stokes Settling of the coalesced
droplets downstream of the medium. The degree of
separation primarily depends upon the geometry of the
vessel and its ability to take advantage of the large
coalesced droplets that were created through steps
one and two as described above.
taking into account the effects of any particulates or

surfactants present. AMACS has several of these available,
both as hand-held batch testers and continuous units
gle, double, or triple coalescer stages (Figure 7). This
allows a coalescer system to be developed that is
optimized for its removal efficiency, on-stream time,
and cost effectiveness.
FIGURE 7
PILOT FILTER AND COALESCER
Basis for Sizing and Selection
A preliminary procedure for determining how difficult it

is to separate two immiscible liquids involves the performance of a simple field test. A representative sample of the emulsion is taken from a process pipeline or
vessel. It is either put it in a graduated cylinder in the
lab or, if it is under pressure, in a clear flow-through
sample tube with isolation valves. The time required to
observe a clean break between phases is noted. If the
continuous phase has a viscosity less than 3 centipoise, then Stokes Law says the following:
Separation
Time
< 1 minute
< 10 minutes
Hours
Days
Weeks
Emulsion
Stability
Very Weak
Weak
Moderate
Strong
Very Strong
Droplet Size,
Microns
>500
100-500
40-100
1-40
<1 (Colloidal)
Fortunately, the experienced designer with knowledge

of the application, equipment, and physical properties
can often estimate the strength of the emulsion and
determine which medium will be successful. A more
definitive approach, and one that is often needed to
provide a process warranty, is the use of an on-site
pilot unit.
Liquid-liquid coalescer performance is often rated in
parts per million of dispersed phase allowable in the
continuous phase effluent. Even trace amounts of contaminants such as emulsifiers and chemical stabilizers
can have dramatic effects on results at these levels. In
a pilot program, several alternate media are provided
to the customer so that their performance can be
documented on the actual process stream, thereby
For liquid-liquid coalescers, as with any process equipment, successful sizing and selection is always a
combination of empirical observation/experience and
analytical modeling. Of the three steps in coalescing
droplet capture, combining of the collected droplets,
and gravity separation of the enlarged droplets the
first and the last can be modeled with good accuracy
and repeatability. The modeling of the middle and the
actual coalescing step is a complex function of surface
tension and viscous effects, droplet momentum, and
the dynamics of the sizes of the droplets in the dispersion. This has been done successfully in porous
media, but is beyond the scope of this brochure.
Droplet capture, the first step in liquid-liquid coalescing, is the most important. The next two sections
describe the formulas used for the collection mechanisms of Intra-Media Stokes Settling and Direct
Interception.
LIQUID-LIQUID
Intra-Media Stokes Settling
VC = (C1) Q h
( S.G.) d2
(2)
In a horizontal 3-phase separator, in order for efficient separation to take place, droplets of some min- Where
imum size which exist in both the gas and the liquid
VC = Coalescer volume, cubic feet
phases must be captured within the equipment.
When coalescing media is installed in the lower segment
C1 = 164 for Plate-Pak w/horizontal sheets
of the vessel, the furthest a droplet has to travel is
219 for STOKES-PAK w/horizontal sheets
from plate to plate or sheet to sheet, rather than
312 for STOKES-PAK w/vertical sheets
down from the liquid level to interface level and/or up
Q = Liquid/liquid emulsion flow, US GPM
from the vessel wall to the interface level (depending
whether the dispersed phase is heavier or lighter
h = Corrugated plate spacing or structured
than the continuous phase).
packing crimp height, inches
AMACS offers a number of Corrugated Plate Interceptors
d = Minimum droplet diameter, microns
(CPI) to enhance coalescence, such as Plate-Pak and
= Continuous phase viscosity, centipoise
STOKES-PAK crimped sheet packing (Figure 8).
FIGURE 8
COALESCING MEDIA THAT
DEPENDS ON STOKES SETTLING
Plate-Pak is the most efficient CPI and thus has the

smallest C1. The reason for this is that the height, h, a
droplet must traverse before hitting a solid surface is
minimized in this construction (see Figure 9 a-c).
FIGURE 9
Operating by enhanced gravity

settling, Plate-Pak vanes
are especially effective
for removing larger
droplets.
DISTANCE BETWEEN PLATES IN

VARIOUS STOKES-PAK COALESCERS
9a Plate-Pak corrugations perpendicular to the flow

Oil Droplets
h=
Emulsion
Clear liquid
Plate-Pak
Axis of Corrugation
Axis of Corrugation
9b
Stokes-Pak with
Horizontal Sheets
h
1/2"
Axis of Corrugation
Stokes-Pak
9c
They make more efficient use of a vessel volume than
a straight PPI (Parallel Plate Interceptor) since more
metal is used and the specific surface area is greater.
It can be shown from Equation 1 for Vt that the volume
of media necessary to remove virtually all droplets
equal to a minimum, typically 30-60 microns, is given
by:
Stokes-Pak with
Vertical Sheets
1/2"
LIQUID-LIQUID
In order to decrease solid retention the axis of the cor- can be found by trial-and-error substitution of the terminal
rugations of Plate-Pak should be parallel to the flow. settling velocity from Equation 1 into Equation 3 below
However, vessel geometry often necessitates that the
s = (vt/h)/ (vs/L) = .999
corrugations be perpendicular to the flow, especially in
(3)
round vessels. Due to its light, self-supporting struc- where
s = Fractional Collection Efficiency
ture and ease of installation, the overall project cost is
by Stokes Settling
normally less for STOKES-PAK than Plate-Pak when
vs = Superficial Velocity
L = Element Length
vt/h = Droplet Rise Time
vs/L= Droplet Residence Time
FIGURE 10
GAS OUT
OIL OUT
ADJUSTABLE
OIL WEIR
ADJUSTABLE
WEIR
OIL
WATER
OUT
FLOW
DISTRIBUTION
BAFFLE
WASTEWATER
INLET
In horizontal flow when this length is over four elements, ~32" (813 mm), the coalescer is usually split in
two or more beds with intermediate spacers or spacer
rings. Also, cross-flow designs are often used in this
situation to allow for more frequent removal of the
collected dispersed phase.
Direct Interception
SOLIDS
DRAIN
SOLIDS
DRAIN
they both have sheets in the horizontal. STOKES-PAK

with vertical sheets, on the other hand, retains fewer
solids than the horizontal sheet version and so is often
required in fouling situations. In this case, there is
some loss in coalescer efficiency due to the longer distance a droplet could travel (see Figure 9 b and c). The
entire CPI unit can also be put on a 45 to 60 angle in
order to retard fouling. However, this requires much
more support structure and an additional 40 to 100%
of coalescer volume since droplet trajectory is lengthened (Figure 10).
Direct Interception occurs when a droplet follows a

streamline around a target but collides with it because
the approach distance is less than half its diameter,
d/2 (Figure 6). The formulas for Direct Interception in
mesh, co-knits, wire and glass wools are given below.
Given first is a formula for the collection of a droplet on
a single target. Following that is a formula which,
based on this factor, calculates the depth of the coalescer element necessary to achieve a desired overall
collection efficiency at a selected minimum droplet
size.
(4)
Equation 2 incorporates empirical factors that increase

the coalescer design volume over the theoretical in
D =Collection Efficiency of a Single
order to compensate for the effects of bypass and
Target by Direct Interception
back mixing. With knowledge of the cross-sectional
area of a fully flooded coalescer vessel or the lower
segment available in a horizontal 3-phase separator, E =Effective Length Multiplier
the required depth can easily be calculated from Vc.
AMACS Plate-Pak and Stokes-Pak both come in units =Volume Fraction of Fibers or Wires
which are 8" (203 mm) deep as a standard, but custom
depths are also available.
d =Droplet Diameter, inches
Once the final coalescer length is selected the minimum

droplet size that can be collected at 99.9% efficiency K
=Kuwabaras Hydrodynamic Factor

-0.5 ln -0.25 2 + -0.75
LIQUID-LIQUID
The formulas for Direct Interception have no velocity

term in them, but to allow coalescence to take place
designs are normally done for the middle of the flow
ranges given in Table 2. K, the Kuwabara
Hydrodynamic Factor, above is a correction to the collection efficiency term that assumes a laminar/viscous
flow field. The effective length multiplier, E, is an
empirical factor that takes into account the uneven distribution of curved and crinkled targets in a wool medium and/or the shielding effects of the loops of knitted
mesh and twists of adjacent filaments in a strand of
yarn. The idealized layout of fiber targets where E=1 in
a coalescer is shown in Figure 11, while what actually
exists in a co-knit is shown in Figure 12. The finer the filament or wire the more the nesting/shielding effect and
the lower the value of E.
FIGURE 11
INTERCEPTOR LAYOUT IN AN IDEAL COALESCER
Ordered
Targets
FLOW
FIGURE 12
(5)
= Overall Collection Efficiency by Direct Interception

L = Element length required for removal of all droplets
> a minimum size at a = .999, inches
As can be seen in Figure 4, there are two broad categories of Interceptor-PakCoalescers that depend in
Direct Interception, those that are made with fine wires
and those that are made with fine fibers. The factors to
Droplet
Application Min.
Diameter
microns
Coalescer
D
microns/in.
Wastewater
Sheen
4.5
0.037 .04
Fiberglass Mat
Fiberglass Co-Knit 8.9/0.00035 0.027 .02
Interceptor-PakTM
Caustic
Wash Drums
11.0
Teon
21/0.00083 0.019 .07
Co-Knit
Interceptor-PakTM
Impeller
Mixers
12.5
Polyester
24/0.00095 0.021 .07
Co-Knit
Interceptor-PakTM
Mixing
Valves
22.0
Wire
50/.002
Wool
Interceptor-PakTM
0.028 .40
Extraction
Columns
79.0
Knitted
152/.006
Mesh
Interceptor-PakTM
0.014 .60
Table 3
be used in the formulas above for these media, the

appropriate minimum droplet size to use; and the
CO-KNIT MESH COALESCER THAT
applications where they have found success are given
DEPENDS ON DIRECT INTERCEPTION
in Table 3. In wire-yarn co-knits the wire occupies as
much as a third of the volume fraction as the yarn, but
As with CPI coalescers, sizing of a liquid-liquid coalescer exhibits only a few percent of the surface area.
that operates primarily on Direct Interception also corre- Therefore, for the sake of conservatism, the constants
lates well to an Overall Collection Efficiency of 99.9% of given in the table do not take into account either factor.
a minimum droplet size. Once this droplet size, empirically found to be approximately half the target diameter, The equations for droplet collection above can also be
is substituted into Equation 4, the length, L, required for used to derive the dispersed phases concentration in
the effluent stream. First, a measured distribution or
a clean break can be predicted as follows.
the curve estimated with Mugeles droplet size distri-
LIQUID-LIQUID
bution equations is broken up into a large number of

discrete diameter ranges. The fractional collection
efficiency is then calculated at the mid-point of the
range using either equation 3 or 5 (rewritten to be
explicit in ) thereby deriving the volume of dispersed
phase that penetrates at that diameter. The effluent
curve is then plotted. The area under both curves is
found with the influent normalized to 1 (Figure 13).
With knowledge of the influent dispersed phase concentration, the effluent level is found by multiplying by
the ratio of these areas.
Volume Fraction per Micron
FIGURE 13
Droplet Diameter, microns
Gravity Separation Downstream

of a Coalescer Element
Successful gravity separation downstream of a coalescer element depends primarily on vessel geometry.
Various schemes are used with horizontal vessels
depending on whether there is a significant amount of
gas present as with Three-Phase Separators (Fig. 14A)
and/or the volume percent of the dispersed phase. The
formation of a wedge between a coalescer and a sharp
interface level as seen in Fig. 14B is well documented.
A boot is desirable when the amount of dispersed phase
is <15% v/v (Fig. 14C) where the control of the interface
level is linear with the volume of dispersed phase discharged. A dispersed phase velocity of 10 inches (254
mm)/minute is desirable to allow disengagement of the
continuous phase, while keeping the boot diameter
<40% of the diameter of the horizontal portion to minimize the necessity for weld pads. The most common
applications for coalescers in vertical flow are
extraction/liquid-liquid absorption towers (Fig. 14D)
and entrainment knockout installations (Fig. 14E)
where the available plot plans in the plant are at a pre-
mium. The coalescer is located downstream of the

interface so that entrained continuous phase is
removed from the dispersed. Lieberman (see General
References) recommends that the liquid loading in a
vertical wash tower be limited to at most 1.6 ft/min of
the dispersed phase. With the installation of a coalescer this can safely be increased to 2 ft/min (15
gpm/ft2) thereby decreasing the cross-sectional area of
the column by 20 to 40%.
In pressure vessels with full diameter coalescers such
as those shown in Figures 14B and 14C, it is important
economically to keep the L/D ratio in the range of 3 to
5. It is typical and desirable that coalesced droplets
emerge from media that operates either on IntraMedia Stokes Settling or Direct Interception at a size
of from 500 to 1,000 microns. The vessel length necessary for inlet distribution devices upstream of the
media (such as sparger pipes, picket fences, and perforated plates used to assure uniform flow through the
media as in Figures 14B and 14C) and the depth of the
typical coalescer element itself with supports is typically 1 to 1.5 D. In order to keep the vessels aspect
ratio in the economical range, assuming an average
750-micron droplet emerging from the coalescer, the
axial velocity of the two liquid phases should be
limited to:
UMax = 0.78 | |
(6)
Where
UMax =Emulsion velocity, feet/minute
| | =Absolute value of the difference
between the densities of the
continuous and dispersed
phase, pounds/cubic feet
=Continuous phase viscosity,
centipoise
The successful design of a liquid-liquid coalescer starts
with knowledge of the source of the emulsion and the
streams physical properties. It has been shown that a
combination of empirical experience and analytical
modeling of available coalescing media based on
removal of 99.9% of a minimum droplet size can then
be used to predict allowable entrainment concentrations
in the effluent stream. Once the coalescer is properly
located in an existing or new vessel a project that has a
high rate of return is achieved that gives many years of
reliable service.
LIQUID-LIQUID
COALESCER
FIGIRE 14 D
Congurations
Vertical Extraction Column with Coalescer

Light Stream Out
Vertical Coalescers
Coalescer
Heavy
Stream
In
Horizontal Coalescers
FIGIRE 14 A
Trays,
Packing
or Agitated
Internals
3-Phase Horizontal Coalescer Vessel

Mixed
Phase
Inlet
Inlet Device
Plate-Pak
Mist Eliminator
Vapor
Outlet
Vapor & Mist Flow
Light
Stream
In
Collected Mist Drain

Liquid
Flow
Hydrocarbon
Two
Liquid
Phases
Hydrocarbon
Aqueous
Coalescer
Aqueous
Outlet
FIGIRE 14 E
FIGIRE 14 B
2-Phase Horizontal Coalescer Vessel
Emulsion In
Wedge
Heavy Stream Out
Hydrocarbon
Outlet
Vertical Decanter with Coalescer
Light Product
Light
Stream
Out
LC
Liquid
Distributor
Coalescing
Medium
Coalescer
Heavy
Product
FIGIRE 14 C
2-Phase Horizontal Coalescer Vessel with Boot
Emulsion In
Light Product
Emulsion
In
Heavy Stream Out

Coalescing
Medium
LC
Heavy
Dispersed
Phase
LIQUID-LIQUID
10
CASE STUDY #1
Oil-Water Separators Environmental Response

The Oil-Water Separators (OWS) developed by AMACS to
handle accidental offshore spills have three stages of
coalescing, one using Stokes Settling and two using
Direct Interception. It can, therefore, serve as an example of how to apply all the equations for droplet coalescing given above. After the Exxon-Valdez incident the
US government was looking to set up a quick response
system with ship-board equipment to skim potential
large spills of crude oil that on the frigid ocean waters
congeals to a viscosity of up to 50,000 centistokes, separate out all contaminants on board, and return the sea
water with less than the EPA mandated 10 ppm hydrocarbons present. The Marine Spill Response
Corporation (MSRC) was set-up for this purpose with 16
locations in all major US ports including Puerto Rico,
Hawaii, and Guam. AMACS engineers quickly developed,
tested, and proved to MSRC the viability of the 525-gpm
OWS system shown in Figure 15 below, two of which
were installed on each quick-response vessel. AMACS was
awarded the prestigious Vaaler Award and two US
patents (Nos. 5,023,002 and 5,246,592) in developing
the coalescers for this application.
Typical conditions are removing 25 gpm of oil with a
specific gravity of 0.85, and a viscosity of 12,000 centistokes from 500 gpm of water with 3% salinity, a specific
gravity of 1.02, and a viscosity of 1 centistoke. The overall dimensions of the OWS for the MSRC are 8 square
by 25 long at a full of water weight of 25,000 lbs.
Interceptor-Pak Co-Knit coalescing media were

used. Their efficiency was maintained despite the
presence of the highly viscous oil by cleaning both of
them with diesel oil which was injected at an amount
equal to only 0.5% by weight of the amount of oil anticipated to be collected. This media works on Direct
Interception so equations 4 and 5 are used. Media
properties are given in Table 3. First Kuwabaras
Hydrodynamic Factor is calculated as follows.
K=
-0.5 ln .027 - 0.25(.027)2 + (.027) - 0.75
=
1.083
According to Table 3 fiberglass co-knit can remove
99.9% of all droplets 4.5 microns and larger.
Therefore
D = 0.02 (1-.027)(4.5/8.9)
1.083 (1+(4.5/8.9))
= 0.00305
L = (.00035") (1-.027)ln (1-.999)
-4(0.00305) 0.027
= 22.4"
For safety each stage was supplied with a
24" thick fiberglass co-knit element.
FIGURE 15
CPI media, such as AMACS Plate-Pak which in this case

had 3/4" plate spacing to accommodate the highly viscous oil, is known to be able to remove 99+% of all
droplets down to about 100 microns.
Putting these factors into equation 2 yields
Vc
=
=
164 (525) 0.75(1.02)

0.17 (1002)
ADVANCED OIL/WATER SEPARATOR

Oil
Dual
Pre-Filters
38.0 cubic feet
The Plate-Pak was designed for 25gpm/ft2, requiring

21 square feet (installed at 7 feet wide X 3 feet high to
accommodate the design shown in Figure 15 and the
shipping dimensions given above). Therefore, the
required depth is 38.0 cubic feet/21 square feet, or
1.81 feet. This was rounded up to two feet for safety.
LC
Advanced
Capacitance
Probes
Oily
water
drawn in
by suction
LC
Water
FC
Solvent
Injection
Solvent
Injection
In order to meet stringent EPA regulations for discharging wastewater overboard, two stages of A M ACS
LIQUID-LIQUID
11
CASE STUDY #2
Coalescers in Gas Plants

A major South American engineering company was
designing a 100 MMSCFD natural gas plant that used
ethylene glycol (EG) for dehydration and for inhibiting
hydrate formation. There is a horizontal Three Phase
Cold Separator with a boot in this process that does mist
elimination in the free board above a large liquid hold-up
section that extends the length of the vessel. The latter
volume is used to recover the glycol that has become
emulsified as fine droplets in the NGLs (natural gas liquids)
and the dispersed hydrocarbons that have stabilized in
the EG. Since the glycol continually re-circulates in the
system, fine NGL droplets tend to build up in the inventory
causing an emulsification of both liquid phases. The EG
droplets are thought to be as small as 30 microns in the
organic phase, so 30-minute hold-up times for gravity
separation are not uncommon in the industry. AMACS was
asked if a coalescer could be provided to significantly
reduce the resultant vessel size.
viscosity of 7.2 cp. A quick design for a gravity separator

can be done with equation 2 if the maximum height that
a 30-micron glycol droplet would have to fall from the liquid level to the boot at the bottom of the vessel is used as
if it was the CPI coalescers h. In this case 42" was
assumed for a 60" ID vessel. Thus
V=
162(45) 42 (.11)
(.818-.496)302
215 cubic feet
This means with gravity alone a 5 dia. x 20 tangent

to tangent vessel would be required. In order to improve
control and to allow for disengagement at 10/min., a
16 dia. x 30 tall boot was specified. AMACS recommended
and supplied a 24" thick mesh coalescer of a co-knit of
fiberglass yarn and stainless steel wire. The liquid loading sizing criteria required the installation of a 24" high
segment in a 36" ID vessel. This vessel was 12 tangent
to tangent with the same 16" diameter X 30" tall boot.
Thus, as compared to a conventional gravity separator,
The process conditions for the coalescer sizing was for it
the use of an engineered coalescer was successful in
to handle 37.5 gpm of NGLs that had a density of 31
reducing the vessel volume by a factor of 4.5.
lbs/ft3 and a viscosity of 0.11 cp; and 7.5 gpm of 75%
ethylene glycol that had a density of 51.1 lbs/ft3 and a An illustration of this is shown on the cover of this bulletin.
FIGURE 16
GAS PLANT WITH JOULES-THOMPSON DEW POINT CONTROL
Compressor
Gas Product to Pipeline
70F
Gas-Gas
Exchanger
25F
Hydrocarbon Vapor
90F @1150 PSIG

Feed From
Gas Field
Flash Tank
Lean
Glycol
J-T Valve
Steam
COLD SEPARATOR
WITH COALESCER
AT 250 PSIG
Reboiler
Condensate
LC
Rich Glycol
Make-up
Ethylene Glycol
Lean-Rich Exchanger
Lean Glycol
Rich
Glycol
Pump
Lean Glycol
LIQUID-LIQUID
12
D = 0.07 (1-.019) (15/21)
1.251 (1+(15/21))
Putting this value in equation 6 gives

L
Thus a 16" thickness of Alloy 20 Stokes-Pak was

used in the 78" ID X 5 long horizontal boot.
As mentioned above, counter-current flow in the vertical portion of the tower necessitates liquid loads on the
coalescer below 15 gpm/ft2 (2 ft/min). This required a
15 diameter vertical section. The Teflon Multi-Filament
Co-Knit Coalescer was chosen due to corrosive conditions and the tight residual acid specification.
Experience has shown that a 15-ppm spec requires
(.00083") (1-.019)ln (1-.999)

-4(0.0163) 0.019
14.3"
Thus a 15" depth of a 15 diameter Alloy 20/Teflon

Multi-Filament Interceptor-Pak Coalescer was chosen
for the second stage element.
Process conditions were 2480 GPM of alkylate that

had a specific gravity of 0.59 and a viscosity of 0.21 cp
was mixed with 110 GPM of acid (2/1 ratio of recycle
to fresh) that had a specific gravity of 1.85 and a viscosity of 25 cp. The mix valve is reported to create an
average droplet size of approximately 400 microns for
the washing, but also generates a significant amount
of fine droplets. Stokes-Pak with horizontal sheets
and 1/2" crimps was chosen to remove 99+% of all
droplets down to about 35 microns. The volume of
coalescer required was estimated with equation 2:
Vc = 219 * 2590 * 0.5 * .21 = 38.6 cubic feet
(1.85-.59) 352
= 0.0163
FIGURE 17
COALESCER IN ALKYLATION UNITS
HYDROCARBON OUT
15"
STAGE 2
Teflon Multifilament Co-Knit
180" DIA.
HC/
ACID
IN
60" T/S
180" T/T
Coalescers in Alkylation Units

A refinery was using a 15-psi mix valve to acid wash
the reactor products of their H2SO4 alkylation unit. This
is done to extract both acidic and neutral ester side
products that readily polymerize, reduce acid strength,
and cause foaming. A vertical two-stage coalescer
drum with a horizontal boot (Figure 17) follows immediately in order to make a clean break between the two
immiscible phases and lower the free acid concentration in the hydrocarbon to less than 15 ppm. The first
coalescer stage in the horizontal section, used to
remove the bulk of the acid, is a vertical Stokes-Pak
element, which is preceded by a 20% open perforated
plate liquid distributor. The second stage is a horizontal AMACS Interceptor-Pak with Teflon Multi-Filament
Co-Knit. The inlet section of the large diameter vertical
section removes the fine acid droplets and allows
them to drain counter-current to the ascending continuous hydrocarbon stream.
removing essentially all droplets down to 15 microns.

A Kuwabara hydrodynamic factor for this media of
1.251 is found using the data from Table 3. The collection efficiency of a single Teflon fiber is found when
this factor and the data above are plugged into equation 4 as follows
72" I.D.
CASE STUDY #3
Hydrocarbon
Acid
Liquid
Distributor
V.B.
Acid Out
Drain
LIQUID-LIQUID
13
Case Study #4
Oil-Water Separator on a Production Platform

Produced water enters an oil and gas production platform
along with the organics and forms a distinct separate
phase after several let downs in pressure through First,
Second, and even Third Stage Separators; FWKO (Free
Water Knock Out) Treaters, Test Separators, etc.
According to the governing regulations for the Gulf of
Mexico all water must be treated to remove oils down to
<25 mg/l before it can be discharged overboard. Plot plan
area is at a premium on a platform. This often necessitates a vertical Oil Skimmer Vessel and, even though a
significant amount of fine sand comes in with the process
stream, it must still be high efficiency. In many cases
these are also four phase separators as a small amount
of residual gas needs to be handled as well.
AMACS worked with a Gulf Coast fabricator to both design
the pressure vessel shown in Figure 18 and then supply
the internals. Here 10,000 BWPD (barrels of water per
day) of salt water are handled in an 8 diameter X 15
seam-to-seam vessel with a cone bottom. The inlet nozzle
extends into a tee immediately inside the vessel. One
arm extends vertically above the liquid level where
gasses can be discharge. It was determined that the
amount of gas is so small that the use of a mist eliminator was not necessary. Simultaneously the contaminated
water jets down toward the cone via the opposite arm. A
vertical baffle retains the water in a low velocity zone at
the bottom of the vessel where the flow is sufficiently slow
for the sand to drop out. Lastly, at the top of the vessel
there is an overflow weir that collects the oil which flows
by gravity off all the coalescers and then flows through
the oil outlet nozzle under pressure to a suitable, atmospheric holding tank.
The water is then forced through two stages of coalescing media. The first is 24" depth of vertical Plate-Pak
with its plates also in the vertical. When the spacing in this
media at 1/2" there is no line-of-sight and the oil droplets
in the stream are forced to hit 33 baffles in series. Very
fine ones could still float up 42" before striking the roof of
the housing, but are collected at the oil/water interface. At
an effective width of 92" the liquid load is ~11gpm/ft2.
Nonetheless, this is the less efficient orientation, but also
the least susceptible to fouling.
The second stage is in vertical down flow. First there is a
liquid distributor made from 10% perforated plate. This is
needed in order to take full advantage of the entire volume of coalescing media. The element is 22" depth of coknit of stainless steel wire and fiberglass yarn that has 2"
of a fiberglass mat below it. The latter media has the
same size target collectors at 8.9 microns as the yarn
material. Besides being denser at an of 0.037, its
needled, non-woven construction exposes much more
surface area so that it has been found to have an E of

0.04. The additional high efficiency polishing of the effluent water stream obtained with the mat is allowable at this
point since it is well protected from particles of sand by
the co-knit mesh above.
It is difficult to tell exactly which media did the most to
achieve the effluent produced waters compliance with
the <25 mg/l level as is regularly confirmed by an EPA
approved lab. However, the following calculations show
that the fiberglass mat is up to three times more efficient
than fiberglass yarn in coalescing oil droplets from water.
The Case Study on page 11 showed that 22.4" of co-knit
were required to remove 99.9% of all droplets > 4.5
microns.
Similarly, the Kuwabara Factor for fiberglass mat is
K=
-0.5 ln .037 -0.25(.037)2 +(.037) -0.75
=
0.935
Equation 4 is then used to calculate the collection efficiency of a single target by Direct Interception as follows:
D= 0.04 (1-.037) (4.5/8.9)2
0.935 (1+(4.5/8.9)
=
.00699
Finally, by Equation 5 the required element length for
fiberglass mat is only
L=
(0.00035) (1-.037) ln (1-.999)
-4 (.00699) .037
=
7.1"
FIGURE 18
VERTICAL 10,000
BPWD PRODUCED
WATER OIL SKIMMER
LIQUID-LIQUID
14
Case Study # 5
Upgrading a Three Phase Separator

A major refiner in the Central US was reluctant to
put any internals in a critical Three Phase
Separator, the Naphtha Stripper Overhead Drum
of the FCC Unit. However, slugs of water entraining in the hydrocarbon phases outlet were continually causing cycling of its transfer pump which
was a high head centrifugal. Water must be
injected upstream of an air cooled condenser to
dissolve ammonium sulfide. The rate of injection
had recently been raised 20% due to an increase
in salt forming components in a new slate of
crudes. Nonetheless, any solution had to be able
to operate over a 30 month turn-around cycle.
Another problem was that their engineers did not
want to weld to the vessels shell since the sour
water service required stress relieving.
The three phase inlet consisted of 3900 BPD of
naphtha that at operating conditions had a specific gravity of 0.82 and a viscosity of 1.6 cp,
1200 BPD of foul water that had a specific gravity of 0.99 and a viscosity of .55 cp, and 2.2
MMSCFD of Off Gas at 0.1136 lbs/ft 3. AMACS engineers worked around the constraints of an existing 60" ID X 15 T/T separator with a 24" diameter X 36" tall boot that was now undersized (see
Figure 19). Calculations of the gas velocity of 1.8
ft/s showed that the Normal Liquid Level (NLL)
had to be left at 39" to allow for mist droplets to
fall out in the vessel. However, the velocity of
water in the boot was 20"/minute, double that
allowable for oil disengagement (see page 9).
Because of this AMACS recommended that the
oil/water interface be relocated to the main horizontal section of the vessel and that the naphtha
outlets internal standpipe with vortex breakers
on a tee be raised from 6" to 24". This also

helped to prevent water droplets coming off the
top of the downstream coalescer face from
entraining into the HC outlet nozzle.
A Stokes Law analysis of the separator while it
was cycling showed that mean and maximum
aqueous droplet sizes were 105 and 350
microns, respectively, as they entered with the
naphtha. In order to achieve the specification of
<1/2% water in the naphtha at normal flow and
<1% at 120% of design, a Stokes-Pak
Coalescer segment that extends to a 39" height
and has horizontal sheets with 1/2" crimps needs
to be 48" deep. Due to the low pressure drop of
this media a liquid distributor of 10% open perforated plate was held 6" away with integral trusses. In order not to weld to the vessel expansion
rings of 1-1/2" angle were installed upstream of
the distributor and downstream of the coalescer.
These rings incorporate jack bolts at several
splits in the hoops which forced the ring up
against the inside of the vessel wall.
In order to achieve the < 1% outlet spec above at
120% of design flow, 99.9% of all droplets > 60
microns must be removed. Equation 3 shows
VC=
219 (178.5) .5 (1.6)

0.17(60)2
= 51.1 cubic feet

The 39" high segment of 60" ID is equal to 13.5
square feet. Thus 45" of depth is required. This
was rounded up to the 48" used. After installation
the cycling problem stopped, outlet specs were
achieved, and the Stokes-Pak made it to the next
turn-around without significant fouling.
FIGURE 19
COALESCER RETROFIT INTO AN

EXISTING THREE PHASE SEPARATOR
LIQUID-LIQUID
15
APPROXIMATE RANGES OF APPLICATION FOR VARIOUS COALESCING MEDIA
Plate-Pak
Coalescer
Wire Mesh
Interceptor-Pak
Teflon Fiber
Interceptor-Pak
Fiberglass
Interceptor-Pak
125 micron
75 micron
15 micron
7.5 micron
Human hair
Mist
Fog
Bacteria
Three-Phase
Separators
Static
Mixers
Extraction
Columns
Two-Phase
Pump Discharges
Mix
Valves
Caustic Wash
Drums
Condensation
in Pipelines
Anti-Foam
Surfactant
Stokes-Pak
Wire Wool
Interceptor-Pak
Polyester Fiber
Interceptor-Pak
General References:
Holmes, T. L., AIChE

Symposium Series,
77, 211, pp. 40-47, 1981.
Mugele, R. A., and Evans, H. D.,

Industrial and Engineering
Chemistry, 43, 6, 1951.
Lee, K. W. and Liu, B.Y.H.,

Journal of the Air Pollution
Control Association, 30, 6,
4/80.
Paragon Engineering
Services, Produced Water
Theory and Equipment
Description, Houston, TX.
Gas Processors Suppliers

Association, Engineering Data
Book, Volume 1, 11th Edition,
Tulsa, OK, 1998.
Monnery, W.D. and Svrcek,

W.Y., Chemical Engineering
Progress, pp. 29-40, 9/94.
Hoffmann-La Roche Standard

Design Practice for Decanters
(Liquid-Liquid Settlers), Nutley,
NJ, 11/84.
Lieberman, N. P.,
Troubleshooting Process
Operations,
3rd Edition, PennWell Books,
Tulsa, OK, 1991.
Perrys Chemical Engineers

Handbook, 6th Edition,
McGraw-Hill, New York, NY,
1984.
American Petroleum Institute

Publication 421,
Design and Operations of OilWater Separators, API
Refining Department,
Washington, DC, 1990.
Reist, P.C., Aerosol Science

and Technology, 2nd Edition,
McGraw-Hill, New York, NY,
1993.
Fiberglass Mat
Interceptor-Pak
AMACS presents the information

in this publication in good faith,
believing it to be accurate. However,
nothing herein is to be construed as
either an express or implied guarantee or warranty regarding the
performance, merchantability,
fitness, application, suitability, nor
any other aspect of the products and
services of AMACS
No information contained in this
bulletin consti tutes an invitation
to infringe any patent, whether now
issued or issued hereafter.
All descriptions and specifications
are subject to change without
notice.
Stokes-Pak, Interceptor-Pak and PlatePak are trademarks of AMACS
Teflon is a registered trademark of
E. I. Dupont de Nemours.
AMACS Corrugated Grid Packing
AMACS Corrugated Grid Packing combines the high surface area of

traditional structured packing with the rugged construction of the
common grid configuration, to provide high heat transfer efficiency,
high mechanical strength and antifouling characteristics in severe
services that are prone to plugging, coking, erosion and containing
solids. The smooth surface provides low liquid hold up reducing the
residence time and the possibility of coke formation.
ACGP
Specific surface area -m2/m3
Layer height (mm)
Thickness (mm)
Structured Packing
Applications:
Quench Towers in Steel Mill
Coker Fractionator wash section
Atmospheric Crude Unit wash section
Crude Vacuum Unit was section
40Y
40X
64Y
64X
Reactor Off Gas Scrubbers
40
40
64
64
Flue Gas Absorbers
228
228
231
231
0.2-2.0 0.2-2.0 0.2-2.0 0.2-2.0
AMACS Corrugated Grid Packings are constructed with rigid sheet metal,
held together with studs, allowing it to be replaced easily when
necessary. Manufactured to the industry standard design, corrugated
packing is available in a wide range of steel and alloy materials to
handle high fouling services.
.
AMACS
manufactures a full line of tower internals, mist eliminators and
other complimentary components critical to effective mass transfer
and separations. For more information regarding these products.
please visit our website www.amacs.com, or call to speak to one of
our product specialists.
Key Characteristics and Benefits:

High heat transfer efficiency.
Open packing ensures high wettability
and open area.
Smooth surface provides low liquid hold
up and high resistance to coking.
Studs between corrugated layers provide
better resistance to uplift conditions.
Corrugated products perform well in
de-entrainment services.
1-800 231 0077

www.amacs.com
AMACS Liquid Distributors

Orifice Riser Type
AMACS Orifice Type Liquid Distributors are mainly suitable for low turn-down ratios.
Three basic types are available Plate Type, Pan Type for smaller sized towers and Ladder
Type.
For the Plate and Pan Type distributors, the gas flows through risers that are either round
or rectangular in shape. The liquid collects on the deck and flows through the orifices to
the packing. In Pan Type designs, the gas also flows through the annulus between the
distributor and the vessel. By varying the size and number of orifices, the distributor can
be made adaptable to a wide range of flow rates.
For high-efficiency designs, AMACS can provide drip tubes instead of orifices. Ladder Type
distributors are suitable for liquid feed under pressure, and where limited space is available
for the distributor. These provide a high amount of free area for gas flow and uniform liquid
distribution over the entire tower cross section.
All types are available in diverse materials metals, thermoplastics and FRP. The basic
distributor design can be modified for use as either Redistributors or Liquid Collectors.
For Redistributors hats are incorporated on top of the risers, while with Liquid Collectors
the orifices are not provided. Other variants include adding anti-migration bars at the
bottom of the distributors that eliminate the need for separate bed limiters.
Ladder Type
Plate Type
Distributors
Benefits:
Uniform liquid distribution
Low vapor phase pressure drop
High resistance to fouling
Minimal liquid resistance time
Optimal use of vessel height for
proper performance
Mixing capability for distribution
to other beds
Pan Type
1-800-231-0077
www.amacs.com
AMACS Liquid Distributors

Weir Trough Type
AMACS Weir Type Liquid Distributors effectively handle a wide variety of gases and
liquids. They feature a series of closed end troughs that have slots through which the
liquid is uniformly dispersed over the packed bed. Liquids feed evenly to one or more
of the parting boxes, which in turn distribute the flow to the troughs. The parting boxes
receive the liquids through sparger type feed pipes. The tower diameter and the liquid
flow determine the number of parting boxes. Up to three parting boxes may be required
depending upon tower size and flow rates. Mid-span supports are required for 120 and
larger sizes. Typical turn down ratio for LDWs is 4:1.
AMACS LDWs are self-cleaning, resistant to fouling, and are suitable for liquids with
high solids content.
AMACS offers other variations in the distributor design including:
Distributors with high drip density for low liquid flows
Rectangular slots with flow guides for precise liquid control
AMACS Separation Products, Inc. manufactures a full line of tower internals, mist
eliminators and other components critical to effective mass transfer and separation. For
more details regarding these products, visit our website or consult with an AMACS
Distributors
Benefits:
Uniform liquid distribution
Low vapor phase pressure drop
High resistance to fouling
Minimal liquid resistance time
Optimal use of vessel height for
proper performance
Mixing capability for distribution
to other beds
Separations representative.
1-800-231-0077
www.amacs.com
AMACS Improved Pall Ring
Random Packing
AMACS AIPR tower packing is basically a more finely tuned

and better performing Pall ring. This AMACS improved Pall
ring design allows greater capacity and lower pressure drop.
Although similar in outward appearance to Pall rings, AIPR
packing offers more interior surface area due to more twists
and bends in the internal geometry.
Applications:
The AIPR geometric configuration creates greater gas/liquid

contacting and 25 to 30% more drip points per cubic foot than
standard Pall ring designs. In addition to improved vapor/liquid
contacting, test results show 10% or greater capacity
advantage over standard Pall rings. The AIPR provides
superior distribution and avoids channeling towards the vessel
walls. AMACS improved pall ring packing can improve performance in a wide range of applications.
CO 2 removal
Name
#1
#1 /2
#2
#3
1
Size
mm.
30
45
60
90
Bulk Density (SS MTL)

lbs/ft3
kg/m3
202
12.6
176
11.0
10.4
166
11.0
176
Gas dehydration
Demethanizing
Tall oil fractionating
Vacuum crude stills

H2 S contacting
Liquid/liquid contacting
Number of Pieces
ft3
m3
847
29,900
266
9,390
104
3,670
31
1,090
Free Space
%
97
97
98
98
Packing
Factor F
43
26
18
15
The AMACS AIPR tower packing high strength geometry makes them well suited to deep beds. AIPR tower packings are
available in a wide range of metal and alloy materials. AMACS Process Tower Internals, manufactures a full line of tower
internals, mist eliminators and other components critical to effective mass transfer and separation. For more details regarding
these products, visit our website or consult with an AMACS Separations representative.
1-800-231-0077
www.amacs.com
MistFix Insertion Mist Eliminators
Mist Eliminators
MistFix U.S. Patent #5985004
Advantages:
The patented AMACS MistFix can solve carryover problems in

vessels without a mist eliminator, as well as in vessels with a less
efficient or damaged mist eliminator.
No Welding
In existing vessels that do not have a manway, the MistFix Insertion

Mist Eliminator is an ideal choice. It is suitable for any vessel having
an 8 or larger gas outlet nozzle at the top. It also eliminates the need
for hazardous entry permits. Since there is no need to enter the
vessel, this drastically reduces downtime, resulting in quicker
turnarounds, reduced maintenance cost and production gains.
MistFix also eliminates the need for modifications to vessels. For
new vessels MistFix may eliminate the need for a manway and
.
reduce vessel
cost. It also makes future maintenance easier and
simpler.
No Cutting of existing vessel

No Hazardous Entry
No ASME re-certification
No Scaffolding
Minimal Downtime
Figure 3. MistFix
AMACS MistFix can easily be installed and replaced from the

outside. Existing vessels require no modifications to accommodate the
MistFix.
1-800-231-0077
www.amacs.com
Re-usable Metal Filters (RMF)
Mist Eliminators
Knitted mesh Filters have a great advantage over conventional

cartridge filters e.g. pleated, paper, polymer and others. The
knitted wire filters can be cleaned and reused. This reduces the
disposal cost to a fraction of current levels. These filters are also
heat, shock and corrosion resistant.
Benefits:
Increases machine tool life
Cleans your recycled oil and other
industrial fluids
Removes metal contaminants from coolants
Applications
Reduces expenditures on new fluids
Oil Filtration
Less down time of your system
Fuel Filtration
Cleaner fluids mean less erosion of your

equipment
Filters
Solvent Filtration
Chemical Filtration
Metal Cutting Fluids
Oily Wastewater Filtration
Typical Micron Rating for all Metal

Units 1
Filter Density
Rating
1
2
3
.006 In
Dia Wire
10
20
30
Pressure Drop Characteristics

11/2
.011 In
Dia Wire
15
30
40
1
P 3/4
(PSI)
1/2
Typical Dirt-Holding Capacities for all

Metal Units 2
Filter Density
Rating
1
2
3
.006 In
Dial Wire
10 lbs.
7 lbs.
4 lbs.
To clean,
simply backwash
1/4
.011 In
Dial Wire
8 lbs.
3 lbs.
2 lbs.
10
20
30
40
Micron Rating
NOTE: Based on 20 gpm/per F2
NOTE
1
Refer to particle size for 99.9% removal
2
Based on 9 O.D. 36 L. filters standard
RMF-1-10
100% please call:

For more information
RMF-2-20
RMF-3-25
1-800-231-0077
80%
www.amacs.com
60%
Amistco Separation Products Inc, and ACS Separations and Mass Transfer
Products, are Registered Trademarks of AMACS
P
(PSI)
Knitted Structured Packing
Structured Packing
AKSP Tower packing is the AMACS Separation Products Goodloe

equivalent. AMACS high-efficiency structured packing is ideally suited
for applications that demand high separation efficiency with a lower
pressure drop. Its low HETP requirements result in smaller column
heights.
The packing is made from multiple strands of fine wire that are knitted
together in a tubular pattern and then crimped and coiled or layered to
provide a three dimensional structure of peaks and valleys. The multistrand fine wire provides a high surface area and a capillary effect on
the descending liquid to promote intimate vapor-liquid contact,
uniform liquid distribution, and a thin layer of liquid film. This results
in higher mass transfer efficiencies, lower pressure drop, and high
turndown ratios, up to 20:1. Typical HETP values range from 3 to 12.
For high vacuum services, 4 to 6 HETP is typical.
The AKSP Structured Packing is available in a wide range of metal
and alloy materials. For availability and lead times consult the factory.
Applications:
High Purity Product distillations
(fragrances, flavors, dyestuff
intermediates, fluorinated
hydrocarbons, lubricating oil
additives, specialty monomers,
pesticides, rubber processing)
Mass transfer (de-aeration,
carbonation)
Solvent and Byproduct recovery(resins, coatings, fibers, films,
pharmaceuticals, plasticizers, and
custom distillations)
Scrubbing (sulfur recovery, air
purification)
PACKING DATA
Packing
Style
Strand
Diam., in.
Density
lbs3 ft.
Pct. Void
Vol.
Sp. Surf.,
ft2 per ft3
AKSP-12
0.0045
27.5
94.5
580
AKSP-8
0.0045
20.0
96.0
420
The AKSP Structured Packing is available in a wide range of metal and alloy materials. For availability and lead times consult the factory.
AMACS Separations Products, Inc. manufactures a full line of tower internals, mist eliminators and other components critical to effective mass
transfer and separation. For more details regarding these products, visit our website or consult with an AMACS Separations representative.
1-800-231-0077
www.amacs.com
Liquid/Liquid Coalescers
Mist Eliminators
AMACSs liquid-liquid separation technology can solve a wide

range of separation problems involving immiscible liquids.
Whether it is capacity constraints, loss of valuable solvents or
more stringent environmental compliance, AMACS can help you
meet these requirements.
AMACS offers different types of coalescer media and has
solutions for even the most difficult to separate applications. For
new applications or for retrofits, AMACS can provide cost-effective
solutions for your liquid-liquid separation requirements.
AMACS also offers complete skid-mounted packaged systems
with piping, controls and instrumentation. For an evaluation of
your liquid-liquid separation application, please contact your
AMACS Separations specialist.
Applications:
Oil-water separations
Removal of aqueous solutions
from hydrocarbon streams
Removal of haze from fuels
Enhanced separation of reflux
streams
Three phase separations
Advantages:
Dry Oil
Capital cost savings due to

smaller vessel size
Increase in capacity for existing
vessels
Wet Oil
Savings due to recovery of

solvents
AMISTCO Coalescer
Better product quality

Reduced tank inventory
Compliance with regulatory laws
Field proven worldwide
Water
1-800-231-0077
www.amacs.com
M ist Eliminator
Installation Guide
AMACS Mesh Mist Eliminators are designed to
AMACS Process Tower Internals appreciates
provide exceptional performance in a wide range
and thanks you for your business. AMACS
of applications. A proper installation is required
technical representatives are always available
to realize this performance. Proper installation
to assist you if questions arise during your
involves a degree of common sense. However,
installation. Our contact number is 800-716-1179.
this guide provides numerous helpful hints

and recommendations that will simplify your
installation and answer the most common
questions we receive from customers.
Table of Contents
New Mist Eliminator Inspection
Removing Existing Mist Eliminator
Hold Down Option
6-8
I n s ta l l a ti o n
9 - 13
Maintenance & Cleaning
14
Tr ou bl es h ooti n g
15
Key Observations Before You Begin

Your AMACS Mist Eliminator
M ist eliminators are manufac-
Mesh is oversized slightly to
tured from knitted wire, and it is
Please Note:
important to maintain as much
The following information contains
vessel wall and the mesh. Grids
spring and uniformity as
general guidelines. No guarantees
are undersized to provide
possible. Avoid any cutting or
and warranties are expressed or
clearance from the vessel wall.
puncturing of the mesh during
implied. Disregard of these guide-
Over sizing the mesh will also
installation to assure optimum
lines or a
compensate for a vessels out of
performance and service life.
product without written consent
ensure a snug
between the
to any
roundness. Any gaps between
from AMACS may invalidate any
the vessel wall and the mesh will
warranties. If you have questions,
diminish
please call 1-800-716-1179.
and hamper
mist eliminator performance. A

tight
ensures optimum mist
eliminator performance.
Step One
Check the Shipment
Always make sure you have the right
mist eliminator for the job prior to
doing anything, especially removing
the old mist eliminator. Always
check your shipment to make sure
you have received the correct size
and installation hardware (if
ordered with the job) and for
potential mist eliminator damage.
U pon receipt of an AMACS mist
eliminator, inspect and verify the
dimensions. Also check for any
hardware and documentation that
New Mist Eliminator Inspection

M ist Eliminator
Storage
Store in a clean environment. Dust,
sand and other contaminants may
foul the mist eliminator. A ware-
Ready to Install
Lay out the sections of the mist
eliminator in a clean area close to
the vessel. For dual density pads,
check tags for correct orientation
house is recommended for long
of ow direction.
term storage.
By laying out the mist eliminator

pieces you can
rm you have
the right size, all of the pieces, etc.

before you move any further forward. You can also make a better
installation game plan when the
time comes.
is part of the order. If drawings
Keep in mind the mesh pad will be
are present, make sure that the
manufactured slightly larger than
mist eliminator corresponds to
the diameter of the to be installed
the drawing.
into vessel.
Step Two
Removing Existing Mist Eliminator

(For new process vessels proceed to page 6.)
When replacing a mist eliminator,
so pulling the center section
it is a good idea to study how the
may require a more aggressive
existing one was installed prior to
tug. Once the center section is
any actual removal procedures.
removed, the other sections
Compare the existing pad to
should remove much more easily.
the pad you have laid out on the

ground. Some installers even like
to orient or turn the new pad into
the exact position as the pad that
is to be removed for reference
purposes later on. This is also an
opportunity to inspect the old pad
for indications of excessive corrosion or fouling, which can cause
dislodged sections. Your AMACS
engineer can assist you with
recommendations to upgrade the
materials and implement process
improvements. AMACS can
provide systems that include dual-
After removing all of the mist

pad sections, it is important
to carefully inspect all of the
support structures. Look for
cracks, excessive corrosion,
and damaged support hardware.
Repair all defects that might
impair the proper installation
and operation of the new mist
eliminator. Make certain the
existing supports are suitable for
your new mist eliminator, taking
Safety Considerations:
t P rior to entering any vessel, it is
important that
space
entry requirements have been

met, and all federal, state and
industry safety regulations have
been addressed.
t Mist eliminators are not designed
to support a person. Do not step
directly on a mist eliminator.
Place boards across several
sections to distribute weight.
Verify that spans of more than 6
have heavy-duty metal grids or
intermediate supports.
note as to what hold down hardware you will be employing.
density mesh pads, wash systems,

mesh/vane combinations and
relief doors.
If the existing pad was built in
sections, pull the center section
area
Remove one section
at a time and remove section by

section to avoid accidentally
dropping anything. Remember
that a properly installed mist
eliminator is going to
snug
H old Down Options

Tie Wires
J-Bolts
L atch Keys
Tie wires are the most common and
J-bolts can be used instead of tie
Latch Keys can be used to secure
simplest way of attaching the mist
wires and are stronger. The hook
a mist eliminator when having to
eliminator to its supports. The tie
portion of the J connects around
work from the top, and access to the
wires are typically .051 in diameter
the mist eliminators bottom grid,
bottom is not possible. Simply turn
and are made of the same material
extends through a clamp or holes
the
as the mesh. This can be achieved
in the annular ring and is secured
tighten the double lock nuts.
by looping the tie wire between the
by a nut and lock nut. Once again,
bottom support grid and the annular
4 bolts should be used per section.
ring hole and twisting the ends to
Another variant is a welded stud.
tie it in place. (Do not run the wire
Flag
through the mesh, just the support

and grid.) Tie down the four corners
of the grids in each section. Annular
ri ng hole spacing is typically 4 to 5
apart with 1/4 diameter holes.
Please Note:
Bottom Grid
connections are secure and can

withstand heat and vibration.
We recommend double nuts
several loops of tie wire. AMACS
or locknuts.
recommends optional Tefzel
Top Grid
Wire M esh
It is important that your J-bolt
For plastic mesh materials, use

TM
toward the vessel wall and
tie
straps as a more secure fastener.
Optional Latch Key
Caution:
If your mist eliminator is installed
in a critical or severe service,
AMACS recommends a more
secure hold down method. Check
with your AMACS sales representative about optional relief
doors, heavy duty grids and other
special features.
Tie Wires
J-Bolts
H old Down Options

Dual Support Rings
D ual support rings have removable
Offset Rings
rings are held away from the
Secure
ring sections on the manway side.
vessel wall by a
After the last mist eliminator
the mist eliminator using tie wire
section is installed, bolt the ring
or J-bolts and clamps.
sections into place. Dual support
Pipe Sleeve and

Spacer Bolt
These designs have through-bolt
sleeves that run through the mist
eliminator spacer bolts. Although
more secure for process upset
rings are more common for topside
applications, these designs are not
installations but are also used in
recommended because they are
bottom installations. Dual support
to install (matching up the
ri ngs also help prevent wall bypass.
holes particularly in replacement

applications) and often distort the
mesh and allow gas by-pass.
I nstead AMACS recommends
either dual support rings or J-bolts.
Through Bolts
Relief Doors
D ual Support Rings
Tie Wire with Offset Ring
Relief doors can be incorporated

into your mist eliminator design for
fouling service to prevent blowout
in upset conditions.
Gas
Re movable Section
of Support Ring
Relief Door
Relief door moves up and
down on the guide rods.
H old Down Options

H old Down Bars
B asket Cages
Expansion Rings
Hold down bars bolt into position
Basket cages for one-piece mist
E xpansion rings can be used for
above the mist eliminator after it
eliminators are held in place by
either a support ring or a hold
is installed and are an
the vessel top
down ring when welding to the
e. You simply
means to keep the mist eliminator
slide the cage on top of the mist
pieces intact.
eliminator and fasten the head

or top
shell is a problem.
e, when installing one-
piece mist eliminators.
E xpansion Ring
Hold Down Bar
Hold Down Basket
For mist eliminators installed

in small diameter vessels with a
anged top, the pad must be made
Hold down method with

exit ab ove mist eliminator
If installers must exit from manway
in two sections to clear hold
above the mist eliminator, install
down bar clips welded to shell.
mist eliminator tie wiring from

below working from the outer
sections toward the center. Install
the last section from the top and
secure to adjacent sections by
placing 3 hold down bars (1/4 x 1
t bar) across the last section
installed and tie wiring or J-bolting
to adjacent sections.
M anway Section and

Hold Down Bars
Step Three
Installation
One Piece Mist Eliminators

Any fastening method except J-bolts
can be used for one piece mist
eliminators. For new vessels make
sure the vessel walls are smooth
and free of weld splatter and other
debris before pushing the mist
eliminator into the vessel. Keep in
mind the mesh diameter should
slightly exceed the vessel diameter
to ensure a snug
Installing Multi-Section Mist Eliminators in Vertical Vessels

Larger AMACS Mist Eliminators
are manufactured in manageable
sections to facilitate installation
through the manways of vessels.
Remember to have the new mist
eliminator set up outside the
vessel before you begin.
indicate where each section edge should sit. Align the sections in
accordance to your marks as you install each section.
2. Work from the outside in on each side by placing the end sections
3. Compress the installed sections to
With last sections expect resistance.

Some installers use a thin piece of
sheet metal or cardboard sized to t
the last section to help slip it into
place. With opposing rough mesh
services, you will need to push or
pull alternating ends of the last secin mind a compressed
1. Before installing any sections, mark lines on the support ring that
on top of the support ring.
Please Note:
tion of the mesh pad to
Vessels with Single Support Rings
it in. Keep
is neces-
sary for optimum mist eliminator

performance. (See figure, p.12.)
your measurements and keep
opposing sections parallel.

4. Use a hold down to secure each section after it is properly in place.
5. Move toward the center as you add sections until only one section
remains. Use sheet metal or cardboard to facilitate installation.
6. If you are installing from below, lift the entire last section through
the void space between the opposing pad sections, position it
carefully and then pull it down into place.
7. If you are installing from above, simply push the section into place
after a careful alignment.
L arge Pads :
For large pads, total compression can be several inches. It is very
to work out all of the compression when installing the last section.
AMACS recommends this easy method: Loop tie wire around adjacent
grids as the sections are installed. This loop should be close to the down
rods, where the mesh is xed to the grids. Twist the tie wire, pulling the
grids towards each other, until the grids of each section are spaced 1 1/ 2
apart. Using this procedure will ease installation of the last sections.
10
Installing Multi-Section Mist Eliminators in Vertical Vessels

Generally with this type of support
design, support rings secure the
mist eliminator sections from
below and above. Wider vessels
may also have a center support
beam or beams. With standard
metal grids AMACS does not
recommend greater than a 6 ft. span
between support beams (for plastic
grids a 3 ft. maximum span). Use
Vessels with Dual Support Rings

1. Mark lines on the support grids that indicate where the mesh
sections should sit. Align the sections in accordance to your marks as
you work from the vessel wall inward, one side of the vessel at a time.
2. Compress the installed sections to
your measurements and keep
the opposing sections parallel. Use C-Clamps or an equivalent on

the ring to hold the sections in place as you proceed.
3. To install the
section, make a simple installation aid using two
greater care when installing plastic
thin pieces of sheet metal or some smooth yet strong material that
mist eliminators to avoid breakage.
extends the length of the section and is taller than the section.
The top ring and support beams
You may even wish to cut handles in the aid. Place the installation
have removable sections for remov-
aids on either side of the mesh to reduce the friction of the mesh
ing and replacing mist eliminators.
surfaces. A compression
you push the
is necessary, so expect resistance as
section into place. Push the section in and pull
the aids out.

4. Replace the removable section on the support ring and beam(s).
11
Installing Multi-Section Mist Eliminators in Horizontal Vessels
ring on the manway side will have
H orizontal Vessels with a

Vertical Mist Eliminator
removable sections to allow access
1. Mark the support ring and beams indicating where each
M ist eliminators are generally

secured by two support rings. The
to the mesh pads. Other fastening
compressed section of mesh should sit.
methods may be used if there is
2. Work from the vessel wall toward the center aligning each
only one support ring. In horizontal
compressed section to your support ring and beam marks.
vessels we recommend vertical

seams to prevent settling.
3. To install the
Installing Final Section:

1
extends the length of the section. You may even wish to cut handles
in the aid. Place the installation aids on either side of the mesh to
reduce the friction of the mesh surfaces. A compression

necessary, so expect resistance as you push the
is
section into
place. Push the section in and pull the aids out.

4. Replace the removable sections on the support ring and beam(s).
Top View
12
Installing Multi-Section Mist Eliminators in Horizontal Vessels
housing below the gas outlet nozzle.
H orizontal Vessels with

H orizontal Mist Eliminators
Common hold down methods
1. Mark the supports to indicate the position of each section.
In this
ration the mist
eliminator is mounted inside a
include tie wire, J-Bolts, double

annular rings and hold down
beams. Each mist eliminator
support structure (beam or strut)
will most likely employ some sort
of removable section.
2. Start at the ends, making sure each section is properly aligned,

compressed and tied down securely. Move toward the removable
section, adding sections to both sides until the
3. To install the
section remains.
extends the length of the section. Place the installation aids on
either side of the mesh to reduce the friction of the mesh surfaces.
A compression
is necessary, so expect resistance as you push the
section into place. Push the section in and pull the aids out.
Final Notes:
2
M ake certain and check your

work when you complete
installation procedures.
1. Check for any gaps between
3. If your mist eliminator is of
sections. A uniform com-
a dual density design, make
pression t throughout the
certain all of the sections
mist eliminator is important.
are installed with the
2. Check to make sure your

tie-downs are secure and
correct ow orientation.
4. Be sure to remove all tools
even with one another.
and installation materials
M ake sure the rings and
before start-up.
beams adequately support

4
your mist eliminator.
13
Maintenance and Cleaning

Routine Maintenance
D epending upon the degree of
to excessive pressure drop and
Removing Fouled
M ist Eliminators
for Cleaning
reduced performance. A cleaning
To achieve thorough cleaning, it is
the mist eliminator. Contact your
regimen is a good idea and as with
often helpful to remove the mist
any piece of equipment, should be
eliminator. Keeping a spare mist
performed before accumulations or
eliminator is ideal in such situations.
Solids in a mist eliminator will

eventually cause plugging, leading
plugging severely
mist elimi-
continuously or intermittently wet
When your mist eliminator is

removed, examine the cleaned
plugging issues.
mesh carefully for corrosion and
boiling or soaking, or passing

steam will help clean the mist
eliminator. In choosing any of
these options, be sure that they
will not damage the mesh pad.
reduced wire diameter. When your

mist eliminator is new, it is a good
practice to measure the wire
diameter using a micrometer.
When you reach a 20% reduction
in wire mass, replacing the mist
eliminator should dramatically
increase your
14
economical to go ahead and replace

AMACS separations specialist if
you are experiencing continuous
plugging problems, dislodged
sections and short intervals between
selections such as dual density
Important Note:
the mist eliminator to minimize
Spraying with cleaning liquids,
polymerization), it is often more
maintenance. Alternative design
nator performance. AMACS can

design integral spray systems to
plugging (for instance coking or
y.
mesh pads, spray systems, mesh/

vane combinations and relief door
options may extend your maintenance intervals. In severe fouling
applications, AMACS recommends
you consult with your separations
specialist for more secure hold
down options.
Troubleshooting
M onitoring pressure drop across
If pressure drop increases more than an inch of water column
the mist eliminator may be the best
above start-up conditions, some sort of plugging is most likely
option for determining acceptable
taking place. To rectify the situation, clean the mesh pad.
operation. It is a good practice to

record initial pressure drop at
start-up under clean conditions
for future observation.
When pressure drop decreases across the mist eliminator, there are
likely holes or voids in the pad or
reduced mesh density.
Corrosion over time will reduce the mesh wire diameter, mesh
density and in turn reduce pressure drop. Gaps in the mesh pad will
cause channeling and a
reduction in collection
y.
In addition to pressure drop,

monitor downstream process conditions, particularly after an upset.
Increased liquid accumulation in
downstream low points or vessels
may indicate bypassing through
the mist eliminator. Decreased
pressure drop may indicate holes
in the mist eliminator.
AMACS mist eliminators are manufactured under strict conformance
and quality control guidelines. They
are designed to provide optimum
performance in a variety of process
applications. If you are experiencing
chronic plugging problems or
frequent maintenance, contact your
AMACS separations specialist.
Alternative mesh selections may
extend your maintenance intervals.
Note:
For mist eliminator design and
performance information, ask for
the AMACS Mesh and Vane Mist
Eliminator brochure.
15
O ther AMACS Products

When it comes to
mass transfer separations and pollution control,
come to AMACS Process Tower Internals. With the full range of separation
products, we
individual components or turnkey systems built to your

and/or performance requirements.
MESH and VANE MIST ELIMINATORS
from knitted mesh pads to vane mist eliminators.

We also manufacture our patented MistFix
insertion cartridge mist eliminator for applications
where vessel access is prohibitive.
RANDOM PACKINGS
to facilitate mass transfer under a wide

range of applications.
STRUCTURED PACKING
AMACS provides a choice of sheet metal, woven

wire gauze or knitted wire mesh structured packing.
STRUCTURED GRID PACKING

for severe fouling applications
LIQUID/LIQUID COALESCERS
we manufacture a variety of mesh and plate

internals as well as turnkey systems for liquids
and oil/water separations.
INSERTION MISTFIX
MIST ELIMINATOR
LIQUID DISTRIBUTORS
for effective distribution of liquids over the

packing, AMACS offers options to meet
a variety of performance requirements.
INLET DISTRIBUTORS
many designs available including diffuser

plates and cyclonic type distributors.
TRAYS
for gas liquid contacting in distillation,

absorption, and stripping applications-valve,
sieve, bubble cap & special designs.
TURNKEY POLLUTION
CONTROL PACKAGES
for asphalt, oleum, plasticizers, metal working,

compressor stations, marine bilge and a wide
range of specialty indoor air cleaning and
outdoor removal of visible plumes. We also
manufacture turnkey systems for separating
a wide variety of gas, liquid and solid regimes.
GAS INJECTION PACKING SUPPORT

supports packing and provides effective
gas distribution with low pressure drop.
Call Our 24 Hour Number 1-281-716-1179
14211 Industry Street, Houston, TX. 77511 Ph: 713-434-0934 Fax: 713-433-6201
e-mail: amacs@amacs.com www.amacs.com
AMACS Raschig Ring Packing
Random Packing
AMACS
AMACS Raschig Ring Packing is proven in a wide range of
mass transfer applications. A full range of Raschig Ring sizes
and materials are available to tackle a wide range of separation
applications.
handles heavy
The AMACS Raschig Ring structure provides one of the largest
among tower packing options and surface areas loading,
process upsets and temperature shocks.
Applications:
Petrochemical distillation and
extraction applications
in
Absorption gas processing
and combustion plants
Desorption in water treatment
PACKING DATA
Size
in.
1/4
1/4
5/16
3/8
3/8
1/2
1/2
5/8
3/4
3/4
1
1
1 /4
1 /2
2
2 /2
3
1
Size
mm
6
6
8
10
10
13
13
16
19
19
25
25
32
38
51
64
76
Weight*
lbs/ft3
91.5
132.0
61.0
51.0
95.0
75.0
136.0
129.0
52.0
94.0
39.0
71.0
62.0
53.0
49.0
37.0
20.0
Weight*
kg/m3
1466
2114
977
817
1522
1201
2179
2066
833
1506
625
1137
993
851
785
593
320
Surface Area
ft2/ft3
213.3
215.6
191.8
152.2
153.9
130.9
132.1
106.6
91.4
92.5
67.0
68.2
53.1
45.7
39.6
33.5
22.8
Surface Area
m2/m3
700
707
629
499
505
429
433
350
300
303
220
224
174
150
130
110
75
Free Space
%
72
68
91
89
81
85
84
87
89
83
92
86
87
89
90
92
95
* Weight refers to Carbon Steel
1-800-231-0077
www.amacs.com
AMACS MisterMesh MaxCap

Plate-Pak Mist Eliminator
High Capacity
Mist Eliminator

Conventional knitted mesh pads are ideal in most horizontal mist
eliminator applications. However, rising gas impedes drainage of
captured liquids.
At moderate gas velocities and liquid loads, a thin layer of the
liquid forms at the bottom of the pad. If velocity or loading increases
Greater Throughput
Higher Liquid Loads
Improved Separation Efficiency
High Performance for micron size fog
Finally, liquid becomes re-entrained as large droplets are carried over

from the pad.
AMACS proprietary MisterMesh Mist Eliminator simply out-performs
conventional pads. Its draining rolls accelerate liquid removal yielding
When used in conjunction with our Plate-Pak, MisterMesh can

increase capacity by over 200% as it separates droplets down to 3
microns. To prevent liquid re-entrainment, the serpentine path offered
by the vane is augmented with obstructions to allow for the pooling of
liquid with protection from the passing vapor stream.
Applying Mesh and Plat-Pak Vane combinations to minimize Vessel size
1-800-231-0077
www.amacs.com
ACS Style 8P mesh,

air and water,
ambient conditions.
AMACS Plate-Pak
Vane Mist Eliminators
Multipocket Vane
AMACS Multipocket Vane features a revised pocket design which enhances droplet
capture while being less intrusive in the gas flow path. This allows greater liquid
capture with less in-pocket turbulence and shearing while also reducing the inherent
pressure drop.
The 8 thickness allows easy application with minimal adaptation of existing
systems. With no tack welds or loose pieces, every part of the vane is securely
through bolted eliminating the possibility of weld failure.
The Multipocket Vane is truly bi-directional. The inlet and outlet sides are
symmetrical about the centreline, greatly simplifying installation. For models without
a flow distribution plate, the inlet and outlet sides are identical. During prototype
testing, test pieces run in both directions confirmed that performance remained
consistent with the initial orientation.
Applications:
Gas processing facilities
Inlet to gas production facilities
Compressor protection
Gas gathering stations
Where high efficiency liquid

separation is needed
The Multipocket Vane is also available with perforated flow distribution plates.
For optimum performance the plate should be located on the upstream side of the unit.
AMACS Multipocket Vane

0
0.2
0.4
0.6
0.8
1.2
6.00
0.100
0.090
0.080
0.070
4.00
0.060
3.00
0.050
0.040
2.00
0.030
Liquid Entrainment, gal / MM SCF
Pressure, inches of water column
5.00
0.020
1.00
0.010
Greater efficiency
Reduced pressure loss
8 Standard thickness for easy retrofit
Bi-Directional Flow easily reversible
for field installation
Available with or without flow distribution

plates
0.000
0.00
0
0.2
0.4
0.6
0.8
1.2
Gas Load Factor, K (ft / s)
No welding, all parts are securely

through bolted
1-800-231-0077
www.amacs.com
AMACS Packing Supports
Tower Internals
To support packing and aid in gas/liquid distribution, AMACS offers a wide variety of
packing support plates. These supports are available for both random and
Benefits:
structured packing.
This design supports random packing and aids liquid distribution without impeding
gas flow. The support plate consists of a series of perforated arches. The vapor
Aids liquid distribution without impeding

gas flow
passes through the slots in the arches while liquid passes through the slots in the
deck. Normal pressure drop across the plates is usually below 1/4 W.C. with the slot
Prevents distortion of packing
area being 80% to 110% of the tower cross-section area. The support plate rests on
support ledges which are welded to the tower. Clamps and mid-span beams are
Wide range of opening available
available as required. Bed depths of 30 feet and higher can be achieved using gas
injection type supports.
Grid type packing supports are used for structured packing to provide a horizontal
contact surface and to prevent distortion of the packing. This design can also be
Sectional designs standard for larger

towers with manways
considered for random packing. A wide range of openings is available to prevent the
packing from falling through. The supports typically rest on support ledges. For larger
towers with manways, sectional designs are standard.
1-800-231-0077
www.amacs.com
AMACS Pall Ring Packing
AMACS Pall Ring Packing is a proven design that provides higher

capacity and lower pressure drop than trays and other random packings.
By minimizing the number of contours and crevices that can cause liquid
hold-up and potential entrainment, the AMACS ring geometry enables
high gas and liquid transfer rates. The opened cylinder walls and inward
bent protrusions of the AMACS Pall Ring allow greater capacity and
lower pressure drop than standard cylindrical rings.
This open ring design also maintains an even distribution and resists
wall-channeling tendencies. The interior and exterior contacting surfaces
of the AMACS ring provide for an effective distribution of liquids and
gasses and resist plugging, fouling and nesting. Pall rings are available
from our stocked inventory in a wide range of materials.
Random Packing
Applications:
Absorption
Aeration
Degassing
Desorption
Distillation
Stripping
Heat Recovery
Extraction
Packing Data
Size
in
5/8
1
1 /2
2
1
Weight
LB/c F
30.78
24.23
20.16
19.15
Surface Area
ft2/ft3
100
61
39
30
Free Space
%
93
94
95
96
n umber
(Pcs./ft3)
5882
1374
374
164
AMACS Separation Products, Inc. manufactures a full line of tower internals, mist eliminators and other components critical to effective mass
transfer and separations.
1-800-231-0077
www.amacs.com
AMACS Carbon/Graphite Raschig Rings
The AMACS Carbon Raschig Rings offer more than a 30%

greater load capacity over conventional metal packing.
Although lightweight, the Raschig ring design provides a large
surface area for gas-liquid contacting.
AMACS Separation Products, Inc. manufactures a full line of
tower internals, mist eliminators and other components critical to
effective mass transfer and separation. For more details
regarding these products, visit our website or consult with an
AMACS Separations representative.
ACRR
Applications:
Halogen acid processing
Hydrofluoric acid manufacturing
Phosphate fertilizer manufacturing
Sodium/potassium hydroxide
scrubbers
Applications involving high
thermal shock
Packing data
Size
in
Size
mm
Weight*
lbs/ft3
Weight*
kg/m3
Surface Area
ft2/ft3
Surface Area
m2/m3
Free Space
%
Wall
Thickness in.
3/4
19
34
546
75
244
67
1/8
25
27
433
57
185
74
1/8
1 /2
38
34
546
38
124
67
1/4
51
27
433
28
91
74
1/4
76
23
369
19
62
78
5/16
* Weight refers to Carbon
1-800-231-0077
www.amacs.com
AMACS High Capacity

Random Packing
Saddle Ring
Saddle Rings were originally introduced to the industry under the product
Applications:
name IMPT Intalox Metal Tower Packing, a registered trademark of KochGlitsch, LP. Today, AMACS offers a similar high performance, third
Sour Water Stripper
generation random packing in primarily 304SS and 316SS metal alloy for
Atmospheric and high pressure
quick replacement in kind from stock materials.

AMACS High Performance Packing combines the performance advantages
distillation
of saddle and ring styles into one high performance packing. Its unique
Demthanizer / deethanizer
shape ensures low liquid hold-up and low pressure drop.

The external geometry prevents the packing from interlocking or entangling,
Acid Gas Removal
ensuring the randomness and optimum surface area within the packed bed,
Quench Tower and Main Fractionator
while the internal fingers, arches and vanes promote optimum interfacial gas/
liquid contact with minimal drag or hold-up.
Available in various sizes, this random packing type allows for combinations
of efficiency and pressure drop and can be fabricated from a variety of
metals.
High capacity and low pressure drop allow for smaller column diameter.
High efficiency and capacity
High mechanical strength
Available in a variety of sizes and materials
PACKING DATA
AHPP
Style
AHPP 25
AHPP 40
AHPP 50
AHPP 70
Number of Pieces
Per ft3
3,825
1,420
416
131
Surface Area
ft2/ft3
Free Space
%
Packing Factor
F
68
47
30
18
96.7
97.3
97.8
98.1
41
25
16
13
1-800-231-0077
www.amacs.com
AMACS Structured Grid Packing
Structured Packing
Applications:
AMACS Structured Grid Packing (ASGP) is a good choice for applications
that have fouling, erosion, coking and process upset tendencies. ASGP is
Scrubbers with High Solids
extremely structurally durable and has a high void space percent suiting it
Coker Fractionators
well for turbulent vapor streams in the 1000 F (538C) range.
Atmospheric Crude Units
The AMACS structured grid packing surface design reduces coking and fouling
Vacuum Crude Units
due to stagnant overheated droplets by providing rapid drainage. For the most
Resid Cracker
part, the rapid drainage of ASGP makes it self-cleaning. The grids install in
successive layers. They can be removed and cleaned, or replaced, easily
Reactor Off-Gas Scrubbers
when necessary. AMACS Structured Grid Packing can be made to industry
Cracked Gas Quench Towers
standard design and is available in a wide range of steel and alloy materials
Edible Oil Deodorizers
to handle high fouling services
1-800-231-0077
www.amacs.com
Structured - Random Packing

Liquid Distributors
Process Tower Internals
MONTZ STRUCTURED PACKINGS

SYNONYMOUS FOR QUALITY IN THE FIELD OF THERMAL FRACTIONATING
Structured packings are characterized by a very

efficient technique and a versatile range of applications.
The packings offer a high separation efficiency, good
wettability and a low pressure drop. They can be
adapted to address any fractionation problem for
distillation, absorption and liquid-liquid extraction.
The special features of Montz packings allow for

variable geometric dimensions and the choice of
different surface structures. This flexibility can solve
nearly any fractionation problem.
Packing types A3, B1, BSH, C1 and M feature a
variety of configurations, for example:
n A3-type packing uses a woven wire gauze,
ribbon or strip
n B1-type packing uses a cold rolled sheet metal
foil ribbon or strip

n BSH-type packing uses an expanded metal
ribbon or strip
n M-type packing has a curved shaped crimping
regardless of the base material (wire gauze,

cold rolled foil or expanded metal)
We also now offer an MN-type packing that has
a NEW curvature to the crimping regardless of
the base material (wire, gauze, cold rolled foil or
expanded metal).
The waves are inclined toward the vertical,
and together with the adjacent plate, they form
intersecting flow ducts. This packing structure
results in large interfacial areas and provides an
intimate contact between the gas and liquid phase.
An exact adaptation to the respective
requirements is ensured by special internals such
as liquid distributors, flash equipment, liquid
collector trays and vapor distributors. All these
internals are carefully adapted to the packings and
to the problem to be solved. They are subject to a
permanent quality control.
Packing element of Montz-Pak

Type BSH-400 with wall wipers
These internals include:

n exactly operating liquid distributors
n low pressure drop collectors for the liquid
phase
n uniformly operating vapor and gas distributors
n wall wipers to avoid bypass flows and to
compensate for manufacturing tolerances

n flash equipment for an overheated feed
n support systems with large net-free areas
A basic requirement for the high efficiency

of Montz structured packings is their precise
manufacturing.
The packings are manufactured on computercontrolled lines to assure maximum accuracy and
mechanical stability.
The high accuracy of fit and stability of Montz
products are essential criteria for an economic
and problem-free installation of the packings in
either newly built or existing columns.
All Montz packings are manufactured in
segments and are mounted through manholes or
shell flanges.
The Montz-Pak Type M is a new generation of structured packings.
MONTZ-PAK TYPE A3
SPECIAL WIRE MESH PACKING TO FRACTIONATE THERMALLY INSTABLE SUBSTANCES UNDER VACUUM
Montz-Pak Type A3 fulfills the special requirements demanded

by the fractionation of thermally instable substances under
vacuum. It has a special wire mesh with a capillary
effect whose corrugated lamellae form the packing
layers. With its low pressure drop and its high
separation efficiency, it is also ideal for very low
liquid loads.
Characteristics
Materials
n ideal for vacuum columns
n stainless steels such as 304, 410 S, 316,
n very low liquid loads (< 100 l/m /h) are possible
2
n low pressure drop per theoretical stage

n high separation efficiency thanks to the good wettability of
the packing surfaces

n capillary effect of the special wire mesh
Applications
316 Ti, 316 L, and 904 L

n Hastelloy C4, aluminum, copper, titanium,
monel, etc.
n other materials are available upon request
Column Data
n diameters from 40mm up to 7m and more
The main fields of application are in the fractionation of

thermally instable substances which are rectified under
vacuum from approximately 1 mbar.
n liquid load from 20l/m2/h
Applications include:
Corrugation angles:
n ethereal oils
n standard type with 60o
n isomer mixtures
n 45o or other angles upon request
n fatty acids
Fractionating stages
n fatty alcohols
If using mixtures with good wetting properties, approximately

5 to 12 theoretical stages per meter are obtained in technical
columns, depending on the packing surface.
n deodorizing of edible oils

n degassing of transformer oils
n pilot columns
n operating pressures from approximately 1mbar.

n minimal liquid hold-up
Assembly
The packing layers are manufactured either as one piece or

in segments. Installation can be made through shell flanges
or manholes.
Detail shot of the
plate of Montz-Pak
Type A3-500
MONTZ-PAK TYPE A3-500M

LOWEST PRESSURE DROP AT HIGH EFFICIENCIES
The new A3-500M offers a reduced pressure drop of 20%

compared to the standard packing A3-500.
Higher throughputs, lower total pressure drops, smaller tower
diameters and tower debottlenecking are possible due to the
optimized crimp geometry. The A3-500M is ideal in applications
that are under high vacuum and have the smallest liquid
distribution densities.
Characteristics
n lowest pressure drop per theoretical stage
n higher capacity
n equal separation efficiency to A3-500
Applications
The main applications are the separation of thermal unstable

products that are separated under high vacuum up to 0.5 mbar.
n essential oils
n isomer mixtures
n vitamins
n fatty acids
n fatty alcohols
n isocyanates
Structure of a Montz-Pak
Type A3-500 with a diameter
of 3000mm
PAK-TYPE
SPECIFIC SURFACE
A3-500
500
A3-750
750
m2/m3
A3-1000
1000
A3-1200
1200
A3-1500
1500
A3-1900
1900
Other surface sizes are

available upon request
MONTZ-PAK TYPE B1
THE EFFICIENT METAL SHEET PACKING
Montz-Pak Type B1 is the result of many years of experience

and developments in the field of thermal fractionating
technology with structured packings. Montz-Pak
Type B1 has proven its reliability in many technical
applications. The excellent characteristics are assured
by the regular arrangement and the special Montz
surface structure.
Characteristics
Column Data
n high throughput
n column diameter 70mm up to 11m and more
n high flexibility
n liquid load from 201/m2/h
n high separation efficiency almost up to capacity limits
n operating pressures from vacuum up to 100 bar
n low pressure drop
n liquid loads from 0.2 to >250 m /m /h
Revamping
n can be adapted to any fractionating task by a variable
The performance and capacity of existing columns such as

crude-oil columns, natural gas dryers, vacuum distillations (for
fatty alcohols, fatty acids, methyl ester, etc.) can be increased
by revamping.
specific surface
Applications
n vacuum columns
n normal and high-pressure columns
n absorption of components and pollutants from gas
and air flows

n natural gas drying with glycols
n refinery columns (atmospheric and under vacuum)
Angles of inclination of the corrugations:

n standard type with 45o
n 60o for particularly high throughputs (suitable to increase
the capacity of existing columns)

Separation stages
n petrochemical columns
More than five theoretical stages per meter are possible

depending on the design.
n exhaust air washing in aluminum rolling mills
Assembly
n recovery of lube and rolling oil
The packings are manufactured as one piece or in segments.

Installation can be made through shell flanges or manholes.
n wastewater treatment with stripping columns

n revamping existing tray or random rings columns to
improve the performance and capacity

Materials
n stainless steels such as : 304, 410S, 316, 316 Ti,
316L and 904L

n carbon steel
n Hastelloy C4, aluminum, copper, titanium, monel, etc.
n other materials are available upon request
6
Montz-Pak Type B1-250,

Diameter 4000mm
STANDARD TYPE (45O)

PAK-TYPE
TYPE FOR HIGH THROUGHPUTS (60O)

SPEC. SURFACE
m2/m3
PAK-TYPE
SPEC. SURFACE
m2/m3
B1- 65
65
B1- 65.60
65
B1-125
125
B1-125.60
125
B1-150
150
B1-150.60
150
B1-200
200
B1-200.60
200
B1-250
250
B1-250.60
250
B1-300
300
B1-300.60
300
B1-350
350
B1-350.60
350
B1-500
500
B1-500.60
500
Other surface sizes available upon request.
MONTZ-PAK TYPE BSH

HIGH-PERFORMANCE PACKING FOR THERMAL MASS TRANSFER
The BSH-packing combines the essential features and characteristics of

metal sheet and wire mesh packing. A remarkable characteristic of the
BSH-packing is the special surface structure. This consists of rhombic
perforations with alternating burred-up edges. This structure
ensures an excellent and uniform wetting under lowest and
high liquid loads. Turbulences caused by the burred-up
rims of the orifice ensure a permanent mixing of the
liquid film on the packing surface.
Characteristics
n Hastelloy C4, aluminum, copper,
n high capacity and flexibility
titanium, monel, tantalum, etc.

n other materials are available
upon request
n good wettability, thus

ensuring excellent contact
surfaces between vapor and
liquid
n high fractionating efficiency
almost up to capacity limit
n liquid loads 0.2 to >150 m3/m2/h
n low pressure drop
n solutions for any fractionating problem thanks to a
variable specific surface
Applications
n vacuum columns
n normal-pressure and high-pressure columns
n absorption
n natural gas drying
n refinery columns
n petrochemical columns
Column Data
n column diameter 70mm up to
11m and more

n liquid load from 20 l/m2/h
n operating pressures from
vacuum up to 100 bar
Separation stages
Eight theoretical stages per meter

and more are possible depending
on the design.
Assembly
The packing layers

are manufactured either as one piece or in segments.
Installation in the columns is effected either through shell
flanges or manholes.
n wastewater stripping columns

n fractionating columns for the chemical industry
n columns for dealcoholizing beer
n revamping of existing tray or random rings columns
STANDARD TYPE (45O)

PAK-TYPE
SPEC. SURFACE
m2/m3
TYPE FOR HIGH

THROUGHPUTS (60O)
PAK-TYPE
SPEC. SURFACE
m2/m3
BSH-250
250
BSH-250.60
250
Materials
BSH-300
300
BSH-300.60
300
n stainless steels such as : 304, 410S, 316, 316 Ti,
BSH-350
350
BSH-350.60
350
316L and 904L

n carbon steel
BSH-400
400
BSH-400.60
400
BSH-500
500
BSH-500.60
500
BSH-750
750
BSH-750.60
750
to improve their capacity
Other surface sizes available upon request.
MONTZ-PAK TYPE M / MN
THE NEW HIGH-PERFORMANCE PACKING
The Montz-Pak
Type M and Type MN are
further developments of the tried and
trusted Montz structured packing Type B1, A3
and BSH. It has its own patent coverage. The optimized
crimp geometry creates two packing types that
meet the demands for high separation efficiency
and throughput exceptionally well.
The new Type MN-series gives 30% more separation
efficiency along with higher throughput capacity when
compared to standard packing crimps. Higher purities,
small column heights and simple tower debottlenecking
are now possible.
The Type M-series allows throughput increases of 30%
compared to columns equipped with standard packing
types due to the reduced pressure drop. This packing only
offers the same efficiency as standard packing types.
Both packing types are patented in the USA and
Europe. Layer height depends upon crimp shape which
prevents liquid hold-up at the lower end of the packing
layer at high gas loads.
Type M and Type MN packing are ideal for new
columns or tower revamps. Revamps from standard
packed columns to the new high performance packing
types consistently deliver outstanding performances.
Applications
n vacuum columns
n normal-pressure and high
pressure columns
n absorption
n natural gas drying with
glycols refinery columns
n revamping existing packing,
random rings or
tray columns
Corrugation form of the

Montz-Pak Type M / MN
Characteristics Type M
n maximized capacity
n lowest pressure drop
n same separation efficiency
compared to standard
packing types
Characteristics Type MN
n higher capacity
n lower pressure drop
n highest separation efficiency
Structure of the
Montz-Pak Type M / MN
Detail photo of the Montz-pak

Type M / MN from below
AVAILABLE PACKING
TYPES
PAK-TYPE
SPEC. SURFACE
m2/m3
B1-250M
250
B1-350M
350
B1-250MN
250
B1-350MN
350
B1-500MN
500
Other surface sizes available

upon request.
RANDOM TOWER PACKINGS

SADDLE, PALL AND RASCHIG RINGS
Random packings are an economic solution to

increase tower efficiency/capacity and are ideal for
new and existing towers.
SADDLE RINGS
Ideal For Both High Pressure And
Vacuum Towers
PALL RING
Perfect In-kind Replacement
Packings
Metallic saddle rings (formerly sold as M/s.

Norton Type IMTP or Nutter rings, now
owned by Koch and Sulzer respectively)
give the best of both worlds in terms
of performance i.e. low-pressure drop
and high efficiency. Hence it can be
effectively used in both high pressure
as well as vacuum towers. Some of its
other advantages include large effective
interfacial area, high mechanical strength
(its monolithic construction overcomes
the problem of opening out at ends
as experienced in ring shaped packings)
and low cost. It is available in various
sizes, which give different combinations
of efficiency and pressure drop. Stainless
Steel 304ss and 316ss are offered for
immediate shipment.
The following sizes are currently
available: No.25, No.40, No.50, No.70.
These traditional ring type packings are

mostly made for in kind replacement.
They are offered for immediate shipment
in 304ss and 316ss stainless steel and in
other specialty metallic alloys by special
request.
Currently available in various sizes
such as 16mm, 25mm, 38mm, 50mm
and etc.
ITEM
Piece
Density
pcs/m3
Surface
Area
m2/m3
Voidage
(%)
Packing
Factor
MSR # 25 135000
225.8
96.6
41
MSR # 40 50000
150.8
97.7
24
MSR # 50 15000
100
98
18
MSR # 70
60
98.5
12
10
4625
ITEM
Piece
Density
pcs/m3
Surface Voidage Packing

Area
(%)
Factor
m2/m3
MPR# 16mm 214000
344.2
93.1
81
MPR# 25mm
51000
206.7
94.8
56
MPR# 38mm
14300
130.4
96.08
40
MPR# 50mm
6500
102.1
95.9
27
METALLIC AND CARBON

RASCHIG RINGS
Corrosion And Thermal Shock
Resistant
Raschig rings are commonly made

from carbon steel, exotic metallic
alloys, or graphite carbon black and
are used in specific applications
demanding good corrosion and
thermal shock resistance. They are
resistant to most acids, alkalis and
solvents at high temperatures and
also display good erosion and
thermal shock resistance. At the
same time they have high crushing
strength due to increased thickness
over other random packing and
therefore have a long service life.
They are currently available in
variable sizes such as 25mm,
38mm and 50mm.
LIQUID DISTRIBUTORS
KNOW-HOW FROM MONTZ FOR MAXIMUM PERFORMANCE
Liquid distributors are the most important elements in rectifying

columns with structured packings. The high separation efficiency
of structured packings can only be achieved with high-precision
liquid distributors. Over the years, Julius Montz has
acquired the know-how necessary
to design efficient liquid
distributors.
Liquid distributor type R for assembly

through manholes DN 600
Each of the distributors consists of a centrally

arranged main channel with side channels
branching off from this. Central and side channels
form a communicating system so that liquid level
gradients within the distributor are avoided.
The individual channels are fixed at a supporting ring
and are individually and exactly adjustable (i.e. the distributor
is not situated on the packing bedding). The liquid is fed via a
pre-distributing system into the main channel of the distributor.
Assembly can be made through shell flanges or manholes.
Liquid distributor type R DN 10600

on the distributor test bench
General features of all Montz Liquid Distributors:

n uniform distribution: deviations between the individual drain tubes< =3 to 5%
n numbers of drip points: 70 to <250 per m2 (depending on application and liquid load)
n liquid loads: depending on the design of the distributor 0.1 to >250m3/m2/h
n
n
n
n
n
n
n
n
n
(distributors for 201/m2/h have been successfully applied e.g. distillation of glycerine)
flexibility: standard turn down ratio 1:3 (higher ranges of loading
e.g. 1:10 and more are possible using multi-stage distributors)
design know-how for viscous liquids
diameters range from 70 mm to 12 m and more
the same design principle applies to diameters from
200 mm to >12m
liquid feed by pre-distribution system can be adapted to
most applications
contamination is reduced because our designs are
resistant to dirt and sedimentable impurities
Can be adjusted easily with standard fitters tools
Fits solidly against the column wall
Installation and inspection can be made through manholes
for columns from DN 800; smaller columns can be accessed
through shell flanges.
Liquid distributor type R for
assembly through shell flanges
11
LIQUID DISTRIBUTOR TYPE S

SOLUTIONS FOR EXTREMELY SMALL SPRINKLING DENSITIES
The patented liquid distributor Type S

is suitable for extremely small sprinkling
densities. The special design enables a
high density of drip points so that the
packing surface is completely wetted
even with small amounts of liquid.
The Channel-style Type S
liquid distributor
The basic design of the Montz channel-type liquid distributor

Type S is the tried and trusted Montz modular system. The
standard drain tubes have additional drainage sleeves so that
the liquid flows from each tube and is split into a number of
small individual flows. The design enables drip point densities
of at least 100 per m2 for even small amounts of liquid.
Solutions for the

toughest applications
Channel-style Type S
Special applications
n liquid distributor for lowest volumetric flows (smallest
n non-corrosive materials such as tantalum, zirconium and
Because of the great demands made by liquid distribution

on structured packings, Montz has gained a reputation as
a specialist in this field. Special designs tailored to even
extreme requirements are standard for us.
flows to date around 20 l/m2/h)

n liquid outlet through drain tubes similar to Type R
n each drain tube has drainage sleeves with lateral
slots and seven or more drip fingers at its lower
end to split the liquid flow into corresponding
partial flows
titanium are usually standard

n liquid distributor Type S to sprinkle tube bundle
reactors filled with catalyst
n distribution of high-viscosity liquids, for example
1300 mPas
Operating ranges:
The Montz Type S liquid distributor with short drip fingers
n 1-stage: approximately 1:3

n 2-stage: approximately 1:10
(higher ranges upon request)

n number of drip points 100 to
1,000 per m2
n throughputs 0.02 to approximately
70 m3/m2/h
n insensitive to sedimentable dirt particles
Detailed view of
the Type S
12
Montz liquid distributor Type S for use in a

partition column
A Montz Type S liquid distributor made of aluminum, DN2400 designed

for 100 l/m2/h up to 750 l/m2/h
Note the drip pattern of this Type S

specially designed liquid distributor
The Montz Type S liquid distributor can be specially designed for the
lowest liquid sprinkling densities
13
PERFORMANCE CHARTS
OVERVIEW OF PERFORMANCE AND PRESSURE DROP
The following charts will give you an idea of the

efficiency of Montz packings. Details are given on the
separation efficiency and pressure drop of the main
types of packings. Liquid loads B in m3/m2/h.
MONTZ-PAK TYPE A3-500

SEPARATION EFFICIENCY
Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5
MONTZ-PAK TYPE A3-500M

Pressure drop in mbar/m
Nth/meter
7
6
5
4
3
2
1
0
0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
Pressure drop in system air/water for

Montz-Pak A3-500M (B in m3/m2h)
Pressure drop in system chloro-/ethylbenzene for

Montz-Pak A3-500M and A3-500
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Separation efficiency in system chloro-/ethylbenzene for

Montz-Pak A3-500M
0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
MONTZ-PAK TYPE A3-750

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5
MONTZ-PAK TYPE B1-100

dP in mbar/meter
Nth/meter
F-factor in Pa0.5
14
PRESSURE DROP
F-factor in Pa0.5
0
1
F-Factor in Pa0.5

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5
15
PERFORMANCE CHARTS
MONTZ-PAK TYPE B1-250M

Pressure drop in system cyclohexane/n-heptane
for Montz-Pak B1-250M
Nth/meter
7
6
5
4
3
2
1
0
0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
10
9
8
7
6
5
4
3
2
1
0
Pressure drop in system air/water

for Montz-Pak B1-250M (B in m3/m2h)
Separation efficiency in system cyclohexane/n-heptane

0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
10
9
8
7
6
5
4
3
2
1
0
0
1
F-Factor in Pa0.5
B = 100
B = 50
B = 20 B = 10
B=2

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5
MONTZ-PAK TYPE B1-350M

Separation efficiency in system cyclohexane/n-heptane
Pressure drop in system cyclohexane/n-heptane

Nth/meter
7
6
5
4
3
2
1
0
16
0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
10
9
8
7
6
5
4
3
2
1
0
B = 100

for Montz-Pak B1-350M (B in m3/m2h)
0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
10
9
8
7
6
5
4
3
2
1
0
0
1
F-Factor in Pa0.5
B = 50 B = 20 B = 10
B=2
MONTZ-PAK TYPE B1-350MN

Pressure drop in system chloro-/ethylbenzene
for Montz-Pak B1-350MN
Nth/meter
7
6
5
4
3
2
1
0
0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
10
9
8
7
6
5
4
3
2
1
0

for Montz-Pak B1-350MN (B in m3/m2h)
10
9
8
7
6
5
4
3
2
1
0
B = 20
B = 10
B=5B=2
Separation efficiency in system chloro-/ethylbenzene

0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
0
1
F-Factor in Pa0.5
MONTZ-PAK TYPE B1-500MN

Pressure drop in system chloro-/ethylbenzene
Nth/meter
7
6
5
4
3
2
1
0
0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
10
9
8
7
6
5
4
3
2
1
0

for Montz-Pak B1-500MN (B in m3/m2h)
Separation efficiency in system chloro-/ethylbenzene

0
0.5
1
F-Factor in Pa0.5
1.5
2.5
3.5
10
9
8
7
6
5
4
3
2
1
0
B=20
0
1
F-Factor in Pa0.5
B=10 B=5 B=2
MONTZ-PAK TYPE BSH-250

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5
17
PERFORMANCE CHARTS

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5

Nth/meter
dP in mbar/meter
PRESSURE DROP
F-factor in Pa0.5
F-factor in Pa0.5

dP in mbar/meter
Nth/meter
F-factor in Pa0.5
18
PRESSURE DROP
F-factor in Pa0.5
MONTZ QUALITY
PRECISE MEASURING FOR QUALITY ASSURANCE
It is our corporate practice to assure the optimum quality

and efficiency of our products which is why we have two
state-of-the-art flexible test plants (an air-water test
plant and a liquid distributor test plant). It is here that
all products are carefully tested and checked often in the
presence of our customers.
Air-water test equipment
Our air-water test equipment is used for fluiddynamic tests of column internals in accordance with
the specific requirements of our customers .
We offer the following:
n test columns of a diameter of 100 to 2500 mm
are available
n tests of the minimum and maximum load limit
of mass-transfer trays, structured packings or
separator internals
n determination of all essential data by means
of precise measuring instruments: mass flow,
pressure drop entrainment, etc.
Liquid distributor test equipment
This helps assure the top quality of

Montz products.
We can fulfill nearly any requirement:
n test rigs with diameters of 8000
mm and 2000 mm
n test set-up with the suspension
and leveling elements used in the
column
n flow rates exceeding 2000 m3/h
n measuring the quality of
distribution and of the operating
ranges
n quality control with regard to
workmanship and dimensional accuracy
A Montz channel-style Type S DN 3000

liquid distributor on the test rig
19
Services
Complete service to improve the capacity of

existing columns
The capacities of existing tray and random packing columns
can be considerably improved by revamping with AMACS or
Montz structured or random packings.
We can help you improve the column efficiency
higher throughput
improved product qualities
lower pressure drop
energy savings
Our affiliates can help you with revamping services
planning
supervision and teams
dismounting of existing internals
delivery
AMACS is the exclusive U.S. manufacturer/distributor

for Julius Montz GmbH
14211 Industry Street, Houston, TX 77053
Phone: 713-434-0934 Fax: 713-433-6201
E-mail: amacs@amacs.com
24/7 SERVICE CALL:
800-231-0077
www.amacs.com
Julius Montz GmbH

Hofstrabe 82 D-40723 Hilden
Fax: (02103) 89477
E-Mail: bkaibel@montz.de
www.montz.de
AMACS Wedge Wire Screen

For The Water Well Industry
Continuous V
slot opening
for high intake
efficiency
Non-clogging
construction
Large filtration
area
Ease of back
wash and well
completion
Additional inlet
area reduces
inlet velocity
Wide variety
of construction
strength and
open area ratio
Unlimited slot
size design
AMACS Wedge Wire Screens provide reliable

ltration for a wide range of well completions
and work over operations. Screens are constructed of a series of parallel V shaped wire
welded on perpendicular support rods. The
result is a smooth plug resistant screen surface
that is structurally sound.
for a broad range of well completion applications in the ground water industry.
We engineer our products to optimize strength,

precision, and exibility in the eld. They are
built to provide specic end-user solutions
AMACS can provide sieve analysis, sand

size and slot size recommendations based
on well formation samples.
AMACS Wedge Wire Screens are available

in various shapes and sizes of wedge wire
and support rods to meet a wide range of
customer requirements.
1-800 231 0077

www.amacs.com
Wedge Wire Screen Products
wedge Wire Screen Products
For a wide range of industrial and process applications AMACS manufactures a complete line of Wedge Wire
industrial screens. The Wedge Wire screen products are constructed of a series of parallel V resistance welded
cold drawn wire, cold wound welded on perpendicular support rods. The result is a smooth plug resistant
screen surface that is very structurally sound. AMACS Wedge Wire industrial screens provide superior
performance in numerous process industries including chemical, petrochemical,
Advantages
wedge wire screens
and water treatment.
when compared to other types of screening include:
The wedge tapered opening becomes progressively wider increasing dewatering

Non plugging, unlike mesh there are only two contact points to retain particles
Slot sizes ranging from .002 to 1
Durable and capable of carrying heavier loads without support structures
One piece construction
Flexibility in forming fabricating and shaping
Wide range of materials
Low maintenance easy to clean
Tolerance ranging from + .002 /- .001 to +/.005
OUR ENGINEERING GROUP
Our experienced
provides the following custom
support services:
process analysis, troubleshooting and recommendation
design to your performance criteria or
redesigns and retr
cost
technical support
quality assurance
to improve performance and
PROFILE and SUPPORT CONFIGURATIONS

AMACS manufactures wedge wire screens and
screen products to accommodate a wide range of
requirements. D
rent construction methods can be
employed to address ow direction and strength of the

product. Standard AMACS screen products feature
external circumferential wedge wire for outside to inside
ow. Internal circumferential wedge wires can face the
support rods for inside to outside applications. Support
structures can be included for additional strength.
Screens can be built parallel or perpendicular to the ow.
AMACS WEDGE WIRE SCREEN PRODUCTS

Catalyst Bed Supports
Hub and Header Laterals
Support grids provide superior media retention characteristics
Hub Laterals can be designed for disc head vessels enabling
in vessels of all types. They feature durable construction,
the system to collect completely to the bottom of the vessel.
precise open area, and are virtually non-clogging. For larger
Header Laterals design are also available for
vessel diameters AMACS support grids are manufactured
vessel distributor or collector applications. Systems can be
in sections to accommodate installation through man ways.
designed to accommodate side, center, top or bottom inlet
Complete operating systems including inlet basket or distrib-
piping. Integral backwash systems can be designed for any
utor lateral, support grid and outlet basket with backwash
hub and header lateral for fast
systems can be designed for
Connections of the laterals can be
and
operations.
and
bottom
cleaning.
or threaded. All
liquid or solid retention in
systems are designed for
a wide range of applications
Nozzles, Strainers
including exchangers, clay
AMACS Wedge wire screen retention nozzles are manufac-
and sand
tured in accordance to customer ow requirements in almost
towers and power plants with water systems.
any alloy. They can be designed for

systems to permit more
ration or treatment
use of the treatment media.
Because of their non-clogging design wedge wire nozzles

are
in a wide range of water treatment and other
industrial applications. Common applications include under

drain media retention elements or ow distributors in demineralizers and water softeners in pressure and gravity sand
s. Nozzles can also be used as collectors at the bottom
of the vessels by installing a number of nozzles uniformly
across a tray plate. The combination of high open area and
a non-plugging slot design
makes this nozzle/collector
application popular.
ration applications, carbon
Our experienced engineering group designs

each system to provide even distribution
or collection and to avoid ow/pressure
concentrations.
Sieve Bend and Flat Screens

eens
Wedge wire screens are particularly
ticularly well matched to the
requirements of high capacity
rration.
ation. These sc
screens are
e
self-cleaning, durable and reusable.

(curve
eusable. The SSieve
eusabl
ieve Bend (cu
(cur
rve
direction
dir
rection
screen) with wedge wire perpendicular to the ow di
allows water to drop through screen to be collected as wastewater while the angle and ow allow the solids or branches
anches to
slide over. The product is
in wastewater treatments,
dewatering systems and other applications as well. Flat

screen panels are used in a similar application as sieve bend
and in shakers for sewage separation systems.
Inlet and O
Outlet
utlet B
Baskets
askets
AMACS inlet and outlet baskets are designed to meet
open area, designated temper
temperature,
rature, and
Resin Trap Screens

AMACS Resin Traps are placed in a housing, inline with the
ow to capture expensive media from traveling downstream.
rential
ential pressu
pressure
essure
s. Combination inlet basket

baske
et or distr
distributor
r ibutor
ls syste
stems
laterals and outlet basket or collector laterals
systems
e
can be designed and manufactured to meet customer
We can design the traps to capture media particles of any
performance requirements or
size. With the continuous open slot, the traps provide
(reverse ow) systems can also be designed to automatically
open area to let process ow move smoothly.

Our engineering group can provide a complete system
including the housing design.
clean the screen products.
s. Backwash
Numerous custom
ration application
For a myriad of standard or inverted ow
ration requirements AMACS separation specialists
can assist you in designing a wide variety wedge wire screen and other separations products.
For applications that require very
particulate removal AMACS also manufactures a wide range
of mist eliminators tower internals, and other components critical to
mass transfer and
separation. For complete details visit www.amacs.com
SPECIFICATIONS
V-WIRE
WIDTH
.047
.058
.060
. 0 9 0
.069
.118
. 0 9 0
HEIGHT . 0 8 8
.085
.100
.140
.170
.185
. 1 05
SUPPORT
ROD
WIDTH
.090 F
HEIGHT
.140 H
Round
Round
Round
.098 dia.
.125 dia.
.177 dia.
NOTE: Other wires and rods available upon request.
Other AMACS Products

When it comes to
mass transfer, separations and
WEDGE WIRE INDUSTRIAL SCREENS

for a wide range chemical processes including
catalyst support beds, misc. filtration and much more.
pollution control, come to AMACS Process Tower Internals.

With a full range of separation products, we
individual
components or turnkey systems built to your

and/or performance requirements.
from knitted mesh pads to vane mist eliminators

and candle filters for submicron mist removal.
We also manufacture our patented MistFixTM
insertion mist eliminator for applications where
vessel access is prohibitive.
RANDOM PACKINGS

STRUCTURED PACKING
AMACS provides a choice of three types of

structured packing.
Vane type Mist Eliminator


Insertion Mist Eliminator

LIQUID REDISTRIBUTORS
INLET DISTRIBUTORS
for effective collection and redistribution of

liquids. AMACS offers variable options to
meet a variety of performance requirements.


TRAYS
for gas/liquid contacting in distillation,

sieve, bubble cap & special designs
TURNKEY POLLUTION
CONTROL PACKAGES

14211 Industry Street Houston TX.77053 Ph: (713) 434 0934 Fax: (713) 433 6201 amacs@am
acs.c om
www.amacs.com
AMACS Hub & Header Laterals
AMACS Hub laterals are designed for disc head vessels enabling the
system to collect completely to the bottom of the vessel. Header laterals
designs are available for flat bottom collector applications. Distributor systems
can be designed to accommodate side or center inlet piping.
Integral backwash systems can be designed for any hub and header lateral
for fast effective and efficient cleaning. Connections of the laterals can be
flanged or threaded. All systems are designed for effective liquid or solid
retention in a wide range of applications including exchangers, clay and
sand filtration applications, carbon towers and power plants with water systems.
Wedge Wire Screens
Applications:
Ion Exchange
Clay and Sand filtration applications
Activated Carbon Towers
Chemical Catalytic exchangers
Industrial Softeners and
Demineralizes
Our experienced engineering group designs each system to provide even

distribution or collection, and to avoid flow / pressure concentrations.

Provides uniform, effective distribution
and collection
High open area, non clogging surface
Profile Wire
Available in a variety of designs to

accommodate side, center, top or
bottom inlet piping.
Slot opening
fixed or variable
Slot opening
Support rod
Integral backwash systems available

for fast effective and efficient cleaning.
Slot sizes .002 to 1

Tolerance from +.002/ - .001 to .005
304ss, 316ss, hastelloy, inconel and other specialty alloys
1-800-231-0077
www.amacs.com
AMACS Woven Gauze Structured Packing
AMACS Woven Structured Packing is excellent for applications

that require a large number of theoretical stages, lower pressure
drop and small overall packed bed heights.
The packing is manufactured from specially woven wire gauze that is
pressed into smooth plates, uniformly perforated, corrugated and
stacked with corrugations in alternate directions.
Structured Packing
Applications:
Pharmaceuticals
Fine chemicals
Flavors and fragrances
Electronic chemicals
This construction promotes intimate gas/liquid contact. AMACS

AWSP packing is well suited for applications that require high
separation efficiency and minimal hold-up.
Woven structured Packing is available in a wide range of metal and
alloy materials.
The performance of can be

summarized below:
HETP
Pressure drop
Liquid flow
Capacity factor
5 to 8
0.1 W.C. per theoretical stage
0.05 to 5 gpm/square foot
0.1 to 0.25 ft./sec
1-800-231-0077
www.amacs.com
Compressor Suction Drums:

I think Ive got liquid carryover.
What can I do about it?
Usually 1980s mist eliminator technology
Cooler
Stage 2
Stage 1
Knockout
drums
Figure 2. Typical
Figure 1. Typical compressor
compressor
ate mist eliminator elements in correct congur

,s taking
into account many factors. In multistage compressor installas, the proper knockout drum design is seldom the same for
all stages. To maintain good performance, the design of each
drum should be reviewed whenever there are signicant
changes in the process, such as increases or decreases in
throughput, shifts in composition of the gas or mist droplets,
alterations of upstream equipment, or revisions of operating
mist eliminator elements
and control procedures. In
should be visually inspec ted occasionally (especially after
major process upsets) to make sure they are intact and free of
excessive solid deposits.
A thorough understanding of the relevant consider
will help you avoid common suction-drum pitfalls - and some
not-so-common ones - that could severely damage your compressors due to liquid carryover. For detailed explanations of
mist eliminator selection sizing, and vessel design for a wide
range of applications, see Amacs literature such as AMACS
Mesh & Vane Mist Eliminators brochure . This paper provides
infor
that applies specically to compressor inlet knockout drums.
drums
T HAPPENS in petrochemical plants, reneries, and anywhere else that the gas approaching a comp ressor is wet.
Traces of aqueous or organic liquid escape the inlet knockout drum - often intermittently - and silently damage the compressor. Telltale signs include pitting corrosion, salt deposit s,
and diluted lubricants.
Instead of trying to repair symptoms, look for the root
cause, which usually involves the mist eliminator in the knockout drum (Figu res 1 and 2). Problems may include improper
mist eliminator specications, overloading, uneven velocity
proles, incorrect installations , high liquid viscosity, waxy
deposit s, liquid slug s, foaming, and several other possibilities .
The trouble may even be that no mist eliminator was provided in the rst place - or perhaps no knockout drum at all.
But wherever free liquid drops out in a suction drum, it generates some mist that can damage the compressor unless it is
removed by a mist eliminator. Even in cases where the feed gas
never has any free liquid, there are often ne mist droplets that
coalesce into large drops on the walls of the inlet pipe or inside
the compressor. For all but the driest gas, a compressor should
be protected by an inlet mist eliminator. New high-capacity,
high-eciency mist eliminator technologies pay o the rst
you avoid a shutdown.
For optimum separation performance, compressor knockout drums must be properly designed and sized with appropri1
Designing for droplet size distr
with higher velocity, ner mesh strands, closer packing of mesh

(greater density), closer spacing of vanes, and greater thickness
of the mist eliminator element.
There are many dierent types of mist eliminator elements,

and the variety has greatly increased through the years. Not
understanding the liquid source in the upstream process can
cause you to select the wrong type of mist eliminator, or to keep
a given type when process changes make it inappropriate.
Understanding the process allows you to design for the
most ecient mist
Most important,
should
not be made
the droplet size dist
is dened, in
terms of the propo
of droplets of each size. Assuming an
incorrect droplet size dist
can mean that you have
designed for a less ecient mist eliminator, and liquid carryover
may occur.
Mesh pad fouling

In some cases, liquid carryover to the compressor is caused
by fouling of a mesh-type mist eliminator, on account of the
r
of gas ow and extra holdup of liquid in the
pad. Vane-type mist eliminators are
choice for fouling
s Due to the
wide open spaces between
blades, vanes are much less likely to plug. If the fouling deposit
can be readily dissolved by a suitable solvent, as might be the
case with viscous oils or waxes or certain caked solids, consider
installing a spray system as shown in Figure 3 to clean the vanes
on-line whenever necessary. Adding a high-eciency mesh
mist eliminator downstream of the vane unit (also shown in
Figure 3) can help make up for the inherently lower droplet capture eciency of the vanes.
Table 1. Diameter range of mist and other droplets

Par
Type
Size range (microns)
----------------------------------------------------------------------------------------Large organic molecule s
Up to 0.004 m
Smoke
0.0045 to 1.0 m
C
fog
0.1 to 30 m
Atmosphe ric clouds and fog
4 to 50 m
Generated by gas
nozzle
1 to 500 m
Atmospheric mist
50 to 100 m
Atmospheric drizzle
10 to 400 m
Generated by boiling liquid
20 to 1,000 m
Generated by 2-phase ow in pipes
10 to 2,000 m
Atmosphe ric raindrops
400 to 4,000 m
Mist-free gas
MESH PAD
VANE UNIT
Table 2. Droplet sizes (water in air) typically captured with

99.9% eciency by mist eliminator elements of various types
Element type
---------------------------------------------Fiber candles or panels
Mesh with co-knit yarn
0.006-inch
mesh
0.011-inch
mesh
Amistco double-pocket vane
vane arrays
C
Gas
with
mist
Size range (microns)

---------------------------------------------0.1 and larger
2.0 m and larger
5.0 m and larger
10 m and larger
10 m and larger
15 m and larger
Figure 3.
See Tables 1 and 2 for some points of reference and rough

guidelines in this respect. Be aware that the capture eciency of
a given mist eliminator element does not depend only on
droplet size. It is also inuenced by gas velocity through the element and mist load in terms of liquid ow rate per unit of crossarea. Then there are variables such as density and viscosity that depend on temperature, pressure, and liquid and gas
All else being equal, eciency generally goes up
Thin ooded
layer across
pad
capturing mist
and draining
light liquid load
dry zone,
ooded zone,
agitated by
rising gas
Typical mist eliminators for reference:

vane unit (above)
larger mesh pad (below)
spray system to remove deposits
Liquid slugs and high liquid loading

In som
s, liquid slugs occasionally come in with
the gas feed. These surges can temporarily overwhelm the slugcatching capability of the inlet knockout drum and ood a meshtype mist eliminator, causing liquid carryover. (See Figure 4.)
Large
re-entrained
droplets begin
to escape pad
higher in
pad
is ooded
and
agitated
Higher velocity and load:

re-entrainment begins
Figure 4. Envisioning mesh pad performance deg
as liquid and gas loads increase (ve

2
Most captured
mist is blown
away as
re-entrainment
liquid
drains
below
Excessive velocity and load:

ooding, full re-entrainment
Breaking inlet foam

If liquid in the gas approaching the compressor knockout
drum is subject to foaming, it can readily ood a mesh pad and
in severe cases even a vane unit. The end result is massive liquid carryover from the vessel and damage to the compressor. A
vortex-tube cyclone device (Figure 5) can break up foam in the
incoming feed.
Dealing with high liquid viscosity

There are applications in which high viscosity impedes liquid drainage so severely that a mesh pad would ood at prohibitively low velocities and liquid loading. In these applications, a
vane unit is the better choice. For high eciencies, consider
AMACS multi-pocket vane , s which handle high-viscosity
liquids with an eciency of 99.9% for 8-micron and larger
droplets.
Mist eliminator spacing in the vessel

Figure 5. Cyclone device to break inlet foam
An often overlooked but very important aspect of suction

drum design that can lead to liquid carryover is proper spacing
in the vessel. Figure 6 illustrates guidelines for sucient distance between the mist eliminator and the gas inlet and outlet.
If spacing is too close, the gas will pass though only part of
the mist eliminator. This causes localized high velocities with
When liquid slugs or generally high liquid loading are

expected, it is recommended to use a vane-type mist eliminator
upstream of the mesh pad as shown before in Figure 3. Vanes can
generally handle up to 10 times more liquid load than mesh pads.
Figure 6. Generally accepted spacing guidelines to maintain even velocity prole

drums with axial ow
and avoid entrainment in compressor
3
liquid re-entrainment and low

with poor eciency as
shown in Figure 7.
In an
drum where the mist eliminator is too close to the gas outlet, there may not be enough room
to lower the mist eliminator. The
then might be a
properly designed ow distr
device located above the
mist eliminator to create a more uniform velocity prole.
When a knockout drums throughput has grown to exceed

its capacity, there are generally two
1. Replace the vessel with a larger one to allow a mist eliminator with greater cr
area, thus reducing the
velocity.
2. Replace the mist eliminator in the
vessel with
one using the latest technology to maintain eciency
with higher throughput.
O
2 is generally much more
and
does not require pr
down
e. In a tr
ver
cylindrical vessel, the tr
horizontal or
is no
longer the only
Compressor knockout drums can be
retr
for capacity increases using any of the following
techniques:
1. Ver
mist eliminator elements with horizontal ow (K
= 0.42 for mesh pads, K = 0.65 for vane units)
2. Properly engineered baing for even velocity proles
with close spacing
3. Horizontal mesh pads with drainage layers or
zones that can increase capacity by 10 to 12% (K = 0.40)
4. Amistco Double-Pocket Vanes that can double the capacity of a
vane unit (K = 0.8 to 1.1)
5. Mesh-vane
that can increase eciency
and capacity by 10% to 25% (K = 0.5 to 0.65)
6. Mesh agglomerator followed by Double-Pocket Vanes for
highest eciency (99.9% of 2-micron droplets) and greatest capacity increase
7. Two-bank or four-bank congur
that allow mist
eliminator elements of greater cr
areas
Figure 8 illustrates several of these
horizontal
ow through ver
mist eliminator elements, use of mesh
pads to agglomerate ne mist into large droplets that are
removed by vane units, and a double-bank congura on.
Amistcos design specialists can help apply such advanced
means of
the eciency and capacity of
knockout drums to create o
al
for par cular
s.
Figure 7. Example of mist eliminator performance

due to uneven velocity prole
degr
Overcoming pressure-drop constraints

Processes that operate under vacuum or very low pressure
immediately upstream of the compressor can be very tricky for
drum design, because the pressure drop across the mist
eliminator must be kept low. However, generally speaking, the
lower the pressure-drop character
of a mist eliminator
type, the lower its eciency in removing mist. Liquid carryover
from the
drum may be a result of
a low-eciency mist eliminator for the sake of low pressure drop.
When high eciency is not required, a vane unit or lowdensity mesh pad may be recommended to achieve low pressure
drop. To gain higher eciency without much cost in terms
of pressure drop, a possible
is a dual-density mesh
pad. In such a pad, the downstream layer has higher density
than the upstream layer. The result is higher separ
eciency
with only slight increase in pressure drop.
For highest efficiency:

AMACS Multi-Pocket
Vane unit
Throughput exceeding design capacity

In designing compressor knockout drums, like other gasliquid separator vessels,
mist eliminators are generally selected and sized with a margin of about 10% above the
design throughput. Flow rates beyond the upper oper
limit may allow liquid carryover due to high
that
cause re-entrainment from the mist eliminator element.
More specically, mist eliminators are typically sized for
cr
area to achieve a design velocity according to
the Souders-Brown vapor load factor K:
K = V G / ( L G )/ G
VG = Gas velocity (volume ow divided by cr
= Liquid density
L
G = Gas density
C
horizontal mesh pads are tr
sized
for a K factor of 0.35 feet per second, which corresponds to a
velocity of 10 feet per second in the reference case of water and
air at room
s.
Figure 8. Typical retrot of a compressor

drum that
more than doubles its capacity over that of the original
horizontal mesh pad
4
Retrot without recertifying for ASME code

Retrotting an existing vessel for any of the foregoing suggested remedies has one drawback: it often requires welding
new support rings, beams, clips and other structures to the vessel wall. Most vessels are ASME code certied. Thus, after welding to the vessel wall, the welded area must be heat-treated, and
the vessel must be recertied. It is generally desirable to avoid
this cumbersome procedure. AMACS oers expansion rings
that are made in sections that can be passed through a manway.
(See Figure 9.)
The rings are then bolted together and wedged against the
vessel wall without welding. The unique double expansion
design ensures that the installed ring does not move during
operation. Once the rings are installed - either in vertical or
horizontal vessels - beams can be bolted to the rings and complete housings can be built up inside the vessel.
Low
efficiency
Reentrain
MESH PAD
Re-entrainment
Figure 10. Typical results of poor flow distribution from the

inlet to a compressor knockout drum
surge valve. Thus, a mesh-type mist eliminator can be
subjected to forces not seen in normal operation. This can dislodge the pad sections, leading to compressor damage from liquid carryover or even from fragments of the pad.
Figure 9. AMACS expansion rings for retrotting

knockout drum internals without welding
Using inlet diusers to relieve carryover
Plan view of inlet diuser
Inlet design is one of the most commonly neglected

aspects of a compressor knockout drum design, thus often the
cause of poor performance. In the example shown in Figure 10;
a half-pipe inlet deector projecting into the vessel reduces the
gas ow area of that position, with the following results:
1. Gas jets to the back wall of the vessel.
2. Without enough space to diuse the jet, gas utilizes only
part of the mist eliminator. Due to uneven velocity prole, liquid carryover occurs as in Figure 7.
3. The gas jet agitates the accumulated liquid below, generating droplets.
4. Turbulence spoils normal gravity settling of larger liquid
droplets below the mist eliminator. Additional liquid
load increases the likelihood of ooding the mist eliminator.
A properly selected inlet diuser added to an existing
knockout drum (Figure 11) provides more eective separation
of liquid coming in with the gas and distributes the gas evenly
throughout the vessel diameter before the gas moves upwards.
Damage by sudden pressure changes

Carefully review the transient pressures that occur at the
knockout drum and mist eliminator during all phases of operations. The suction drum could see a sudden surge of ow in
either direction due to compressor recycle or opening an anti-
Figure 11. Use of an inlet diuser to alleviate

poor distribution of inlet ow
5
Pads and vanes can also be damaged by freezing liquids in

cold climates. In natural gas production and pipelining,
hydrate formation is known to destroy mesh pads and vanes.
To cope with any of these scenarios, as shown in Figu re 12,
any or all of the following remedies can be applied to mist eliminator elements:
1. Reinforce with heavy-duty material.
2. Fasten with bolts instead of traditional tie wires, or provide an upper suppo rt ring in addition to the lower one.
4. Provide a pressure relief door in the case of mesh.
Fertilizer plant capacity boost & amine loss cut

A 4-train fertilizer plant needed more ammonia gas processing capacity in one of the trains to increase production
capacit y. The bottleneck was the overhead knockout drum in
two of four carbon dioxide absorber towers in that train. Those
vessels also served as suction drums for the comp ressors that
followed. In addition, it was desired to r educe excessive loss of
valuable amine in the form of mist escaping the knockout
drums.
On reviewing the absorber process conditions it
was discovered that the available space in one of the drums was
very tight, we were able to solve this problem by retrotting both
drums with a double-bank system as in Figu re 8. In each bank,
a mesh agglomerator is followed by an AMACS Multi- Pocket
Vane unit. The result was a 30% capac ity increase. In addition,
the rate of amine loss fell to 0.05 gallon per million standard
cubic feet, which corresponds to savings on the order of $75,000
per year. Another benet was elimination of a cause of pitting
corrosion in the comp ressors.
Gas production & condensate recovery increase
Dual support
rings
Through bolts
Relief door
Figure 12. Protecting mesh pads from pressure damage
Comp ressor knockout drum cases
A large oil and gas company wanted to revamp several

dozen of their 30-year-old two-phase eld separ ators (sizes 2 to
5 feet OD). The purpose was to increase capacity and improve
recovery of condensate. As in the preceding case, the separators were also suction drums for comp ressors.
As part of a joint venture with a local fabrication shop, we
moved the units fr om the eld removed the old internals,
enlarged the inlet and outlet nozzles, and retrotted the
vessels with Multi-Pocket Vane units. The separators were ASMEcode recertied painted, and reinstalled in the eld with new
instrumentation. This rejuvenation saved the company thousands of dollars per unit as compa red to purchasing new separators. Gas capacity increased by up to 50%, and condensate
recovery went up by many thousands of barrels per year.
HESE CASES are typical of many applications where

our separation technology has made a big dierence.
Similar results can be achieved for a wide variety of compressor knockout drums in r eneries, gas plants, oil and gas
exploration and production, and petrochemical plants.
Ethylene plant debottleneck

A large ethylene producer needed to debottleneck its sixstage comp ressor train to increase throughout. This project
needed to be accomplished with minimal cost and down time.
Using conventional mist eliminators - mesh pads or horizontal-ow vanes - the knockout drum before each comp ressor
stage would have to be enlarged. For instance, the drum at the
inlet to the rst stage, eight feet in diameter, would be replaced
by a 14-foot vessel.
After thoroughly reviewing the process conditions and
internal geometry of each knockout drum. We then customi zed
each existing drum with double-pocket v anes and mesh
agglomerators arranged as in Figu re 8, using on e, two, or four
banks as required. To ensure proper gas distribution, we added
inlet diusers as in Figu re 11 and ow distribution plates on the
downstream side of the vane units. The result was 35%
increased capacity while achieving an eciency of 99.9% of 1micron and larger mist droplets.
14211 Industry Street Houston, Texas 77053

P hone 281-331-5956 Fax 281-585-1780
amacs@amacs.com www.amistco.com
24-hour Emergency Service: 800-839-6374
AMACS has endeavored to assure that all information in this publication is accurate. However, nothing herein is intended as a guarantee or warranty.
AMACS strictly prohibits publication, distribution,

or dissemination of this paper or any part of it, or
conversion of this digital version into any other
format, without prior written permission of Amacs
AMACS
We need a mist eliminator

in that knockout drum!
Can we add one without
overhauling the vessel?
TS A SURPRISINGLY COMMON problem in refineries,

petrochemical plants, gas plants, and similar facilities. A
vertical knockout drum, such as the one shown in Figure 1,
removes free liquid from a certain gas stream. In many such
vessels, a mist eliminator is provided to remove fine droplets of
liquid suspended in the gas. The conventional arrangement is
a mesh pad located immediately below the gas exit as in Figure
2. However, at the time the plant was built, that precaution was
not considered necessary in this particular knockout drum.
Now mist is carrying over and causing trouble downstream.
The conventional solution is simply to add a mist eliminator as shown in the diagram. That would be feasible if the drum
Figure 2. Knockout drum with conventional mesh-type

mist eliminator, manway, and body
had a manway for worker entrance or a full body flange at the
top, both shown in Figure 2. However, this particular vessel was
not provided with either of those features. Thus, adding a conventional mist eliminator would require cutting the vessel
open, at considerable cost in terms of dollars and down time.
Figure 1. Typical vertical knockout drum

1
A potential solution: the MistFix

mist eliminator
However, there is another solution that works in many
cases such as this. It is a patented type of mist eliminator manufactured by AMACS Process Tower Internals called MistFix
(U. S. patent number 5,985,004). As seen in Figure 3, a MistFix
unit is a hollow cylinder of the same sort of knitted mesh that
conventional mesh pads are made of. It is designed to be
inserted in a vertical flanged gas exit nozzle, being secured by a
base ring that fits between the flanges. Rigidity is provided by a
cylindrical frame around which the mesh is wrapped (not
shown in the diagram), and the bottom end is closed by a plate.
MistFix units are widely applicable for exit nozzles with inside
diameter no less than about 6 inches, provided that the length
necessary to achieve an efficient gas velocity range is no greater
than about 54 inches. By use of special high-efficiency highdensity mesh styles, the radial thickness of the mesh can be as
low as two inches - sometimes even less.
Figure 3. MistFix
Figure 4. Gas ows through the mesh of a MistFix unit

mesh
horizontally, as it does through a vertical
pad in some knockout drums such as this one.
A MistFix mist eliminator functions in the same manner as

a mesh pad mounted vertically, such as in the knockout drum
shown in Figure 4. Gas flows horizontally through the mesh,
and captured liquid drains downward. In a MistFix unit as in
Figure 3, mist-free gas emerges from the mesh into the central
cavity and ows upward into the gas exit pipe.
The MistFix unit is sized to closely inside the exit nozzle.
Its length depends on the case at hand. The longer the mesh
cylinder, the greater the cross-sectional area of the mesh for gas
ow, and the lower the gas velocity for a given volumetric
throughput. The length of the mesh cylinder is selected so that
the velocity through the mesh is within an optimum range for
the application.
MistFix units can be advantageous for retrofitting even
large vessels that have manways. This method avoids the usual
down time and expense for installing a conventional mist eliminator. There is no need to purge and ventilate the vessel, build
a
inside, weld supports for the mist eliminator, and
recertify the vessel to ASME code.
Vessels with special linings for corrosion resistance but no

mist eliminators are especially appropriate candidates for
retrofit with MistFix units. If increased throughput causes mist
and the need for a mist eliminator, it is difficult to attach a support ring without penetrating the lining. Even slight damage to
the lining can lead to corrosion and possible failure of the vessel.
A MistFix unit may be the only viable alternative.
Even for new construction, MistFix mist eliminators are
preferred over conventional alternatives in some cases. One
instance is applications requiring frequent replacement
because of fouling or corrosion. Another is those in which
entering the vessel for inspection and replacement would be
burdensome because down time cannot be tolerated, or the
process material is exceptionally hazardous, etc.
Despite the advances that have been made in the technology, there is still as much art as science in the design and specification of mesh and vane mist eliminators. For all but the
most experienced users, proper application depends on consultation with the manufacturers engineers. This is especially so
the case of MistFix mist eliminators.
This paper provides some background for those discussions with AMACS engineers. Included are some general
guidelines for applying MistFix mist eliminators
, particularly in
retrofits The information is not intended to enable users to
design and specify these devices without assistance.
Applying general mist eliminator

design to a MistFix unit
Although MistFix mist eliminators are cylindrical, they are
designed and specified for an application by the same methods
as conventional flat mesh and vane units. The overall general
procedure is as follows:
1. Estimate the size distribution of mist droplets.
in terms of the
2. Specify the required separation
percent of mist to be removed.
3. Considering droplet size, mist load, liquid characteristics,
and the characteristics of various mesh types in terms of
droplet capture efficiency, corrosion resistance
, mist load
capacity, and wettability by the mist liquid, tentatively
2
choose a mesh style and material and the radial thickness

of the cylindrical mesh pad to achieve the required separation at optimum gas velocity.
4. Choose a design value for the vapor load factor K that is
appropriate for the foregoing assumptions, and calculate
the optimum design velocity through the mesh using the
Souders-Brown equation (explained next).
5. Based on the optimum velocity, the expected volumetric
throughput, and the assumed diameter of the MistFix
unit, calculate the necessary cross-sectional area for gas
ow through the mesh and thus the length of the unit
(also explained below).
6. Estimate separation efficiency and pressure drop within
the required turndown range.
7. If the estimated results are not acceptable, repeat steps 3
through 6 with a different mesh style, material, or thickness, or with a different diameter of the MistFix unit if
that option is available.
8. Check for conformance with internal gas ow guidelines
and for height available for the MistFix unit inside the
vessel, and revise as necessary.
For explanations of those methods as applied to a broad
range of devices, see Amacs literature such as AMACS Mesh & Vane
Mist Eliminators.
Regarding Step 3 above, a very wide variety of mesh types
are available for conventional pads and MistFix units. Standard
wire diameters are 0.011 inch and 0.006 inch. Standard alloys
are 304 and 316 SS, but others such as Inconel and Hastelloy are
often supplied for certain corrosive services
. Plastic monofilaments include polypropylene and Teflon Yarns co-knit with
metal or plastic mesh for capturing very fine mist droplets are
commonly provided in Dacron, glass fiber polypropylene, and
Teflon. It may be that the optimum mesh selection is a combination of different types. For instance, an outer layer of fine,
dense mesh or co-knit yarn may serve to coalesce very small
mist droplets, forming larger entrained droplets that are in turn
captured by an inner layer of coarser bare mesh.
Efficiency and pressure-drop estimations (Step 6 above)
are beyond the scope of this paper, typically requiring consultation by Amacs engineers. The full spectrum of efficiencies can
be provided by a MistFix unit, from a general-purpose efficiency
of 99% of 10-micron and larger droplets to a high efficiency of
99.9% of 2-micron and larger droplets. Typically the pressure
drop across a MistFix device is 2 to 4 inches of water column.
Step 4 above is conducted for a MistFix unit in the same
way as for a conventional flat mist eliminator. These devices are
sized for cross-sectional area to achieve a design velocity
according to the Souders-Brown vapor load factor K:
The Souders-Brown equation allows experimental data

taken with air and water on a certain mist eliminator to be generalized to the same type of device with gases and liquids having generally similar characteristics but different densities.
Once a design value of the vapor load factor K is established for
a mist eliminator type, the design velocity can be calculated for
various combinations of gases and liquids.
The appropriate design value of K for a MistFix unit
depends on a number of factors that are beyond the scope of
this paper. As a first approximation in most cases, however, one
can use the figure that is commonly recommended for vertical
flat mesh pads: 0.42 feet per second. This K factor corresponds
to a velocity of 12 feet per second in the reference case of water
and air at room conditions.
It is assumed that the mist load is less than 0.1% volumetric, which is equivalent to 0.5 gpm per square foot at 10 feet per
second. Greater mist loads require special considerations.
It is also assumed that the pressure in the vessel is between
atmospheric and about 85 psig. The K value should be de-rated
by 0.1 (24%) for each 100 psi increase above atmospheric pressure.
Sizing a MistFix unit

Applying the design velocity to size a MistFix unit (Step 5
above) is a bit more tricky than with a conventional flat mesh
pad. In a flat pad, the velocity is the sameth roughout the padat least ideally to a first approximation. That velocity is simply
the volumetric flow rate divided by the cross-sectional area of
the pad, which is the same throughout the thickness of the pad.
However, in the cylindrical mesh pad of a MistFix unit, the
cross-sectional area through which the gas enters the mesh at
the outer surface is larger than the area of the inner surface.
(See Figure 5.) Thus, the velocity increases as the gas flows radially inward.
The design velocity is the value of the superficial or average

gas velocity through the mesh (volumetric ow rate divided by
cross-sectional area) that is optimal for the particular liquid and
gas involved. It is intended to lie about 10% below the upper
end of the operating velocity range. That upper end is the point
at which increasing gas velocity begins to cause excessive reentrainment of captured liquid from the mesh. The lower end
of the operating range, in turn, is the point at which decreasing
gas velocity begins to cause unacceptably poor droplet capture
y.
Figure 5. A special consideration in selecting a MistFix unit:

higher velocity at the inner surface than at the outer
3
Figure 6. S
Depending on the judgment of the designer , the design
velocity may be established at the inner or outer surface or anywhere in between. The most conservative and cautious
approach is to set the inner-surface velocity at the design value,
to make sure re-entrainment is avoided. Velocities farther out
toward the outer surface will be progressively lower.
Figure 6 depicts the application of Steps 4 and 5 above to a
typical simplified design case. A knockout drum with design
throughput of 3,600 actual cubic feet per minute has an 18-inch
gas exit nozzle. A MistFix unit is to be inserted in the nozzle,
and the proper length is to be determined. The pressure is less
than 85 psig. The owing materials are hydrocarbon vapor and
liquid with densities of 0.31 and 45.2 pounds per cubic foot.
Using a design K factor of 0.42 as discussed before
, the
design velocity turns out to be 4.91 feet per second. The crosssectional area required to achieve that velocity is 12.2 square
feet. For this MistFix unit, the length to achieve that design
velocity at the outer surface is 31.1 inches. By comparison, if a
conventional round horizontal mesh pad were used, that
design cross-section would correspond to a diameter of 47.3
inches.
sizing example
the unit, and avoiding strong turbulence and fluid shear around
and below the MistFix unit. Consultation by Amacs engineers is
especially important in this area.
To prevent uneven flow through the mesh, the bottom end
of the device should be well clear of the inlet stream - more
than about half a vessel radius above the top of the inlet nozzle.
In many cases, undesirable turbulence can be diminished by a
properly selected inlet feed device. If a manway is not available for
installing such a device, it may be possible to use a diffuser
designed for insertion through the inlet nozzle as shown in
Figure 7. To control flow inequality along the length of the
MistFix unit, variation in thickness or density of the mesh may
be incorporated.
Height and ow considerations

in the vessel
Special considerations for MistFix units are also involved in
Step 8 above, regarding available vessel height and internal flow
guidelines. The length of a MistFix device is of course constrained by the vertical space inside the vessel as well as the typical 54-inch maximum. The length limit is to allow good
drainage of captured liquid, without excessive flooding in the
lower end of the MistFix unit. Four and a half feet is a generally appropriate maximum for typical wire mesh, low-viscosity
liquid, and a typical light mist load of about 0.1% volumetric.
The length limit must be shortened for high viscosity, heavy
mist loads, and high-density mesh.
Flow guidelines in turn, encompass two considerations:
maintaining an even velocity profile throughout the length of
Figure 7. Use of an inlet feed device to help maintain even flow

through a MistFix unit when it extends near the
inlet nozzle of the knockout drum
4
In-line chamber for small

gas exit nozzles
If the existing gas exit nozzle on the knockout drum is too
small for inserting a MistFix unit, an in-line chamber can sometimes be provided for the device directly above the knockout
drum as shown in Figure 8. This expedient comes into play
when the exit nozzle diameter is smaller than the minimum 6
inches, or when the MistFix unit must be bigger than the nozzle
to provide enough ow area within the available vessel height.
these devices have been operating very successfully for several

years. The plant keeps spare MistFix units in inventory and can
easily change a fouled MistFix in a few hours.
y capacity increase and

downtime reduction
A medium-size Midwestern
ry needed to increase the
capacity of three knockout drums by 10%. At the same time,
management was looking for ways to reduce the periodic down
time of the vessels for replacing the horizontal mesh pads. The
drums had an outside diameter of 60 inches and a height of 108
inches. For each vessel, the gas flow rate was 8,000 ACFM. The
gas was fuel gas with a density of 0.15 lb/ft .3 The mist consisted of oil with a density of 50 lb/ft 3, the liquid load being less
than 0.1%. The exit nozzles were 16 inches in diameter.
One of the knockout drums was chosen for retrofit with a
MistFix unit on a trial basis. The design was for a diameter of 16
inches, a length of 48 inches, Monel for the mesh, and 316 SS for
the frame. The device has been operating successfully for 16
months. Because of this positive experience, the refinery is considering MistFix units for the other two separators as well as additional applications in the plant.
Specialty chemicals plant with lined vessels

A specialty chemicals plant had increased its capacity over
the years and was operating without mist eliminator pads in
any of its vessels. Now frequent liquid carryover in several
places required corrective action. Unfortunately, most of the
vessels involved were lined for corrosion resistance. Adding a
mesh pad would require welding a support ring to the vessel
wall, entailing considerable expense to restore the lining.
A 36 inch long MistFix unit was designed for one of the
vapor-liquid separators with 42-inch outside diameter and 108inch height. The diameter of the gas outlet nozzle was 10 inches. The gas flow rate was 3,000 ACFM, and the gas density was
0.007 lb/ft 3. To resist corrosion, the mesh was made of Ni-200
and Teflon Using a MistFix unit in the gas outlet avoided damaging the vessel lining. As a result of success in that retrofit the
plant has ordered additional MistFix units for other lined vessels
Figure 8. Mounting a Mist-Fix unit in a chamber

above the knockout drum
In the special circumstances where this
ation is
feasible, it provides all
that a MistFix mist eliminator brings when inserted in a knockout drum. C
mesh pads and vane units can also be mounted in this fashion.
However, in such cases, the chamber must be considerably larger than for an equivalent MistFix unit. Each application of this
type is unique and requires consultation of Amistco engineers.
Case Histories
Chemical
plant reduces cleaning cycle
A Midwester
production plant had to shut down two
identical vertical gas-liquid separators four times a year to
replace the horizontal mesh pads due to fouling
s.
Each shutdown lasted two days because of the time required for
reach the
mesh pad. The plant was operating near maximum capacity, so
any down time dir
the companys bottom line.
The separators were 36 inches in diameter and 84 inches
high. The incoming stream consisted of
gas with a density of 0.25 lb/ft 3 and a throughput of 3,600 actual cubic feet per
minute. The feed contained less than 0.1% water with droplets
greater than 10 microns in size, and also traces
s. The
gas outlet nozzle had an inside diameter of 12 inches.
Based on the process conditions, a 12- inch MistFix unit
with a length of 30 inches for each separator, using 316 SS mesh.
14211 Industry Street, Houston, TX. 77053

Phone 713-434-0934 t Fax 713-433-6201
amacs@amacs.com t www.amacs.com
24-hour Emergency Service: 800-231-0077
MistFix is a trademark of AMACS Process Tower Internals. AMACS has endeavored to assure that all information in this publication is accu ar te. However, nothing herein is intended as a guarantee or warranty.
High Performance Structured Packing
can solve a wide

AMACS is the only North American licensee for Julius Montz GmbH
sheet metal structured packing. The special features of Montz
packings allow for variable geometric dimensions and the choice
of different surface structures. This flexibility can solve nearly any
fractionation problem.
The Montz-Pak Type M and MN are further developments of the
tried and trusted Montz structured packing types B1, A3 and BSH.
The patented crimp geometry creates two packing types that meet
the demands of high separation efficiency and throughput
exceptionally well.
The new MN-type series gives 30% more separation efficiency s
along with higher throughput capacity when compared to
f
standard packing crimps. Higher purities, small column heights
and simple tower debottlenecking are now possible.
A
The Type-M series allows throughput increases of 30% compared
to columns equipped with standard packing types due to the
reduced pressure drop. This packing type only offers the same
efficiency as standard packing types
Both packing types are patented in the USA and Europe. Layer
height depends upon crimp shape which prevents liquid hold-up
at the lower end of the packing layer at high gas loads.
Type M and Type MN packing are ideal for new columns or
tower revamps. Revamps from standard packed columns to the
new high performance packing types consistently deliver
outstanding performances.
Sheet Metal Packing
Applications
vacuum columns
normal and high pressure columns
absorption
gas drying/glycol columns
revamps
Characteristics Type M
capacity advantage of 30%
low pressure drop
liquid loads from 0.2 to > 250
m3/m2/h
reduced liquid hold-up
Characteristics Type MN
higher capacity
lower pressure drop
highest separation efficiency
Materials
Carbon-steel, stainless, Hastelloy,
monel, other materials are available
on request
1-800-231-0077
www.amacs.com
Are Dollar$ $lipping Through Your
Mist Eliminator?
Save Thousands in TEG Recovery
For your next turn around or new gas
dehydration process think about cutting
your losses before you start.
$40,000
$35,000
$30,000
$25,000
$20,000
$15,000
$10,000
$5,000
$0
$31,098
Loss with Typical
Mist Eliminator
$27,988
Savings with
High Capacity
Mist Eliminator
Based on the cost of glycol

at $8.52 per gallon.
With AMACS High Eciency mist eliminators

you can signicantly improve your glycol
recovery and gas purity during your
dehydration process. Not only do you cut
your carry over glycol losses, you also
protect your downstream equipment from
possible corrosion or mechanical damage.
High Efficiency Demisting Design

Unlike conventional mist eliminator mesh constructions,
the high eciency mist eliminator is specically designed
to remove the ner droplets generated during high temperature applications which normally bypass standard mist
eliminator designs. The high eciency pad is co-knitted
with multi-lament Dacron or hydrophobic Teon onto a
metal wire mesh or substrate such as 304SS. The result is a
much more ecient demisting process (as much as ten times).
Tell Us About Your Process

AMACS high eciency mist eliminators are designed specically to meet the particulars of your process requirements.
Experienced separations engineers are available at any time
to assist you in the sizing and selection of your high eciency
mist eliminator. Remember, when you need it right, and you
need it right now, call AMACS.
4000
2500
2000
1500
1000
500
0
Glycol Loss for Typical

mist eliminator
3000
Glycol Loss with

AMACS High Efficiency
3500
24 HR. EMERGENCY SERVICE

1-800-716 -1179
Phone: (281) 716-1900
Fax: (713) 433-6201
14211 Industry Street Houston, Texas 77053 Phone: (281) 716-1900 FAX: (281) 433-6201 www.amacs.com
AMACS
tower trays
AMACS Process Tower Internals is a worldwide
Trays and hardware are all part of AMACS
supplier of phase contacting and separation
commitment to providing customers with a
equipment, components and packaged systems.
full range of tower components and internals.
This equipment is used in a full range of process
All tray product designs have been proven
and pollution control applications. AMACS o
many mesh and vane t ype mist eliminators that
products can also be manufactured to custom
ctively remove droplets down to less than a

micron in size. AMACS also supplies a variety of
AMACS separation specialists are on hand to
random, structured and grid style packing, pack-
assist customers in the design, sizing and
ing supports and column internal hardware. For
selection of components and hardware.
liquid/liquid separations, AMACS manufactures

and cylind rical coalescers.
2
tower trays
materials of
construction
hex nut
manway lock clamps
manway lock studs
manway (active)
(active)
tray
AMACS offers trays in a wide
manway clamps
variety of materials including all

steels and most alloy materials.
For availability of special alloys,
hex nut
seal plate
tray
(active)
outlet weir
downcomer truss
please consult with your

AMACS separation specialist.
hex nut
standard tray
component assembly
tray
(inlet panel)
tray support ring

hex-head bolt
standard washer
hex nut
frictional washer
tray
(inlet panel)
tray support ring
bottom tray clamp
hex-head bolt
hex nut
frictional washer
downcomer panel
downcomer bolting bar
bottom tray clamp
hex-head bolt
hex-head bolt
manway lock clamp
downcomer bolting bar
manway stud
seal plate
frictional washer
bottom tray clamp
tray type selection

When selecting between AMACS
In addition to the list of perform-
sieve, valve, bubblecap, dualflow
ance factors, you should also take
and baffle type trays it is important
into account fouling and other
that all performance considerations

are taken into account including:
characteristics specific to the
Pressure drop
Turndown
Capacity
Efficiency
balance the various tray types and
process. The key, of course, is to

other tower components so that
the process is optimized, safe and
reliable over the long haul.

sieve or
perforated trays
valve trays
Sieve trays are made from flat
AMACS valve trays have better
perforated plate which allows the

passage of vapor through the liquid.
turndown and slightly higher

efficiency than sieve trays. AMACS
T hey are the most economical tray
offers different valve selections
option when low turndown is
including fixed valves, floating
required. They have better
valves and combination valves.
anti-fouling characteristics and
Valve trays cost more than sieve
lower pressure drop than valve
trays, but are more economical
or bubble cap trays. Perforations
than bubble cap trays.
are typically 1/2 diameter, but

AMACS can provide designs with
smaller hole size.
tower trays
AMACS valve types
bubble cap trays

Bubble cap trays are best suited for
applications with low liquid ows
and/or high turndown ratios. In
terms of capacity, however, they
are slightly lower than valve or
sieve trays. They are also the most
one piece valve
expensive tray option.
This is the most commonly used valve. This design features

integral legs for tray decks up to 1/4 thickness. Anti-stick dimples
are standard. Other options include heavy/light valve combination,
h designs and non-rotating tabs in the tray deck.
slotted
bubble cap
3 piece valve
This valve consists of a light weight or
cross bar with

e plate, a valve, and
welded stud
a restraining cage. This design is recommended for higher

turndowns.
swaged riser
extruded tray
deck opening
fixed valve
This valve is integral with the tray deck. This is the preferred
option for fouling conditions. However, it provides lower
turndown and less efficiency than floating valves
one piece rectangular valve

AMACS offers rectangular valves, caged valves, and also
venturi type openings to provide lower pressure drop.

dual flow trays
baffle trays
high strength trays
Dual flow trays are sieve trays that
Because of their open design baffle
For applications with potentially
do not have downcomers. The
trays are used in applications
damaging uplift surges, AMACS
term dual flow comes from the
requiring high capacity, fouling
can equip trays with special heavy-
counter current flow of the vapor
resistance and low pressure drop.
duty features. These include special
and liquid through the perforations.
Vapor-liquid contacting takes
fasteners, increased tray thickness
Typical perforation sizes range
place when the vapor passes
or additional support beams.
between 1/2 and 1 in diameter.
through a curtain of liquid falling
Dual flow trays best suit systems
between trays, or through rivulets

of liquid flowing through tray deck
criteria, design adjustments can be
perforations. Tray decks may be
ters such as corrosion, temperature,
level or slightly inclined and
vibration and pressure surges.
typically occupy 40-60% of the
Contact your AMACS specialist for
tower cross-sectional area. Disk
design assistance.
containing a moderate to high

solids content or polymerizable
compounds. High open area dual
flow trays have a higher capacity
and lower pressure drop than
comparably spaced fractionation
trays. However, their primary drawback is their narrow operating range.
and donut trays have circular

baffles and are a popular variant
of this deign.
Most often, they are efficient when
Baffle trays are well suited to heat
used in smaller tower diameters.
transfer applications including
Dual ow trays are also sensitive to
heavy oil refining and petrochemical
levelness and may be subject to
oil refining and petrochemical oil
gross liquid and vapor ow parti-
transfer services with high solids or
tioning through the deck if not level.
petroleum coke content.
donut tray
disk tray
made to take into account parame-
tower trays
additional tray
design options
For special customer requirements
Splash Baffles-For low liquid rate
and/or performance, AMACS

Process Tower Internals offers
services, Splash Baffles serve to
numerous tray performance-
on the trays. They can be used in
enhancing features. Some of the
place of, or in conjunction with,
most common features offered by
picket fence weirs. Splash Baffles

are located adjacent and parallel to
AMACS include:
maximize the liquid retention time
the outlet weir. They clear the tray

Cartridge TraysSuitable for small
deck and outlet by 1/2 to 1 forcing
diameter body flanges. Can provide
the exiting liquid to flow under the
up to 5 trays per cartridge. Different

sealing options are available.
baffle before it flows over the top of

the outlet weir.
Anti-Jump Downcomer Baffles- To
Swept-Back WeirsTo reduce the
prevent liquids flowing across the
effective liquid height on the tray
tray from jumping over the downcomer onto the opposing flow path.
by lowering the volume of liquid
Anti-Jump Downcomer Baffles are
outlet weir. This option should be
standard for multi-pass trays with
considered for high liquid flow rates.
center and off-center downcomers.
Swept-Back Weirs are used on side
Picket-Fence WeirsThese are

used to decrease the effective weir
height. This is for low liquid flows,
and using this option will
per unit length flowing over the
downcomers. They can also be used

to balance weir loads between side
and off-center downcomers in
multi-pass tray designs.
increase the effective liquid height
Sloped Downcomers with Recessed
and prevent blowing.
Inlet SumpsSuitable for heavy

liquid loads that could otherwise
cause downcomer flooding.
cartridge tray bundle
Call our
24 hour number
1-800-231-0077
AMACS stocks an extensive

variety of tray hardwa re.
Other AMACS Products

When it comes to effective mass transfer, separations and pollution control,
come to AMACS Process Tower Internals. With a full range of separation
products, we offer individual components or turnkey systems built to your
specifications and/or performance requirements.
from knitted mesh pads to vane mist eliminators.

We also manufacture our patented Mist Fix
insertion mist eliminator for applications where
vessel access is prohibitive.
RANDOM PACKINGS
STRUCTURED PACKING

AMACS provides a variety of

structured packing types.

INSERTION MISTFIX MIST ELIMINATOR
LIQUID REDISTRIBUTORS
INLET DISTRIBUTORS
for effective collection and redistribution of

liquids. AMACS offers variable options to
meet a variety of performance requirements.


TRAYS
for gas/liquid contacting in distillation,

sieve, bubble cap & special designs
TURNKEY POLLUTION
CONTROL PACKAGES

14211 Industry Street, Houston, TX Ph: 713-434-0934 Fax: 713-433-6201
e-mail: amacs@amacs.com www.amacs.com

AMACS DeMister Randing Packing

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

AMACS DeMister Randing Packing

Încărcat de

Drepturi de autor:

Formate disponibile

BROCHURES

Corrugated Grid Packing

Amine Still Column Revamp

Mesh & Vane Mist Eliminators

Pall Ring Packing

Knockout Drum Revamp

Liquid Liquid Coalescers

Metal Raschig Ring Packing

Structured & Random Packing

Carbon Raschig Ring Packing

Compressor Suction Drums

Saddle Ring Packing

Wedge Wire Products

Knitted Structured Packing

Mist Eliminator Installation Guide

Woven Gauze Structured Packing

AMACS Process Tower Internals

Toll Free USA & Canada: (800) 231-0077

Amacs Process Tower Internals

AMACSs liquid-liquid separation technology can solve a wide

f the North American

r ACS opened a factory

For more information please call:

The Engineered Mist Eliminator

14211 Industry Street Houston, TX 77053 TEL: 713-434-0934 FAX: 713-433-6201

History of ACS Industries, Inc. . . . . . . . . . . . .12

Plate-Pak and AccuFlow are trademarks of AMACS Process Tower

The Engineered Mist Eliminator

Mist elimination, or the removal of entrained liquid droplets from a vapor

Droplet Formation and Size Distributions

Entrained liquid does not consist of same-sized droplets, but as a broad

THE ENGINEERED MIST ELIMINATOR

equipment corrodes rapidly without the removal of this

ical evidence shows that the target size - important in

Hydraulic spray nozzles generate particles with diameters

THE ENGINEERED MIST ELIMINATOR

Consider a droplet approaching a mesh filament of

momentum, tend to move

Figure 7 illustrates typical

Mesh pad Style 4CA

Droplets ~20 m and greater are primarily collected

THE ENGINEERED MIST ELIMINATOR

eliminator becomes choked with liquid, a condition

It is worthwhile to discuss Fig. 8 and mist eliminator

Types of Mist Eliminator Mesh Styles & Materials

THE ENGINEERED MIST ELIMINATOR

As far back as the 1950's researchers (C. LeRoy

TABLE 1 Wire and Plastic Mesh Styles

CRIMPED WIRE MESH

CO-KNIT MESH WITH FIBERGLASS YARN

In summary, it is important to report mesh styles in

THE ENGINEERED MIST ELIMINATOR

To determine mist eliminator cross-sectional area (and

design gas velocity (ft/sec)

After selecting the appropriate Capacity Factor and

THE ENGINEERED MIST ELIMINATOR

S = Specific surface area of mesh ft2 / ft3

SO = Specific Surface Area x 1/ x Thickness (ft) x 0.67

With due consideration given to the mist eliminator

At high flow rates, primary removal of bulk liquids

THE ENGINEERED MIST ELIMINATOR

of liquids over the

Several factors must be considered when deciding on

THE ENGINEERED MIST ELIMINATOR