Gas/liquid separation technology

Sulzer Chemtech – separation technology

Your partner in separation and mixing technology

The highest level of Fast and reliable Comprehensive engineering

application know-how turnaround services and technology services
Our team provides expert knowledge We don’t shut-down, when you shut- We provide a full scope of associated
for more than 500 applications in 100 down. You can rely on Sulzer professionals, engineering and technology services to
processes, enabling us to optimize the expertise and procedures to get you back optimize or trouble-shoot your installation.
performance and your installation. and running in the shortest possible time.

Naphtha

Kero

Diesel

A broad range of innovative and high-performing products

More than 200 of our products cover a wide range of needs in the field of separation and mixing technology.

They have proven their performance in more than 100’000 columns, 50’000 gas/liquid or liquid/liquid
separators and 100’000 static mixers in operations worldwide.

MellapakPlus™ UFMPlus™ trays NeXRing™ SMV™ static mixer Dusec Plus™

packing One of the best The next High mixing efficiency coalescer
Often copied, high performance trays big thing in combined with large High performance
never equaled ever tested at FRI random packing turn-down processing liquid/liquid
capabilities coalescer

2
Gas/liquid separation technology

Product overview 5

Mist elimination 9

KnitMesh mist eliminators 12

Mellachevron 15

Axial cyclonic devices 18

Combined systems 19

Applications 21

Sulzer is a major player in the field of gas/liquid and liquid/ economic demands of offshore, onshore, remote and challenged
liquid separation technology, offering a full range of innovative gas processing. Compact Mass Transfer and Inline Separation
products and related services. Our commitment to development Technology (cMIST™), incorporating our patented compact HiPer
of technology, combined with application skills and consistent TwinLine™ Separator, can replace conventional TEG contactors and
fabrication standards ensures that a well-engineered solution is associated separators to meet pipeline dew point specifications. It
available for most separation problems. allows significant reductions in weight, footprint and cost. cMIST™
is an innovative dehydration system licensed from ExxonMobil to
Our expertise gained from thousands of successful installations in Sulzer.
a broad spectrum of applications ensures that the best possible
product is recommended for each individual duty. Enhanced liquid-liquid separation is provided by the Sulzer VIEC™
(Vessel Internal Electrostatic Coalescer), system that uses alternating
Our strategic alliance agreement with Shell Global Solutions high voltage electrical fields. With the ability to tolerate 100% water
International B.V. provides access to state of the art separation and 100% gas in a robust and stable process, the system is well-
technology, including the Shell VersiSwirl™ and Schoepentoeter™. suited for the separation of water dispersed in oil and the handling of
The oil and gas industry is increasingly pursuing compact and stable emulsions.
lower weight processing technology to meet the technological and

3
Sulzer vessel based separator portfolio

Typical materials*
Product
PP,
Stainless Alloy Alloy Alloy Alloy Alloy Alloy FEP, Glass
facts
Type of separator Copper on page
steels C22 C276 400 625 825 20 ETFE, fibers
PTFE

KnitMesh™
5
Mist Eliminator

KnitMesh V-MISTER™ 5

KnitMesh™ 9797
High Performance 5
Mist Eliminator
** ** ** **

Mellachevron™
6
Mist Eliminator
***

Shell VersiSwirl™ 6

Shell Swirltube Light™ 6

MKS Multi Cassette™

7
Mist Eliminator

Shell Schoepentoeter™
and Schoepentoeter Plus™ 7
Inlet Device

Treelnlet™
7
Device

HiPer™ Cyclone
8
Inlet Device

GITV
8
Vapor Horn

* other materials on request

** can contain PTFE multifilaments in addition to the metal wire
*** if not metallic then typically: PP, PP-TF, PVC, PVDF or FRP

4
Product overview

KnitMesh Mist Eliminator

Features and benefits

• Manufactured as a knitted wire mesh packing.
• Can be easily tailor-made to suit most vessel shapes and sizes.
• Cost effective and versatile solution for most mist elimination
applications

Key characteristics Key areas of application

• Relatively low capacity with K-values typically up to • Broad range of gas/liquid • Glycol dehydration
0.107 m/s (0.35 ft/s). separation problems • Inert gas scrubbers
• High efficiency separation down to droplet sizes of • Scrubbing systems and • MSF/MED desalination
2 to 3 µm. absorbers • Sulfuric acid absorbers
• Pressure drop typically less than 2.5 mbar. • Evaporators and dryers
• Designs available for installation in either horizontal or vertical • Steam drums
gas flow. • Knock-out pots

KnitMesh V-MISTER™

Features and benefits

• Manufactured as a knitted wire mesh packing. Support grids
fitted with special V-MISTER drainage channels to enhance
drainage characteristics.
• Can be easily tailor-made to suit most vessel shapes and sizes.
• Cost effective and versatile solution for most mist elimination
applications.

Key characteristics Key areas of application

• Enhanced capacity with K-values typically up to • Broad range of gas/liquid • Glycol dehydration
0.13 m/s (0.45 ft/s). separation problems • Inert gas scrubbers
• Limited to horizontal installation with vertical gas flow. • Scrubbing systems and • MSF/MED desalination
• High efficiency separation down to droplet sizes of absorbers • Sulfuric acid absorbers and
2 to 3 µm. • Evaporators dryers
• Pressure drop typically less than 2.5 mbar. • Steam drums
• Very effective for heavy liquid loadings/ irrigated systems. • Knock-out pots

KnitMesh™ 9797 High Performance Mist Eliminator

Features and benefits

• Manufactured as a knitted wire mesh packing.
• Can be easily tailor-made to suit most vessel shapes and sizes.
• Provides optimized designs to meet the challenges of specific
applications.

Key characteristics Key areas of application

• Optimally designed capacity with K-values typically up to • Broad range of gas/liquid • Optimized coalescing and
0.12 m/s (0.4 ft/s). separation problems de-entrainment in critical
• Optimized efficiency separation for selected applications down • Glycol contactors services such as dew-point or
to droplet sizes of 1.5 to 3 µm. • Amine contactors LT separators
• Pressure drop typically less than 2.5 mbar. • Steam drums • Compressor knock-out drums
• Designs available for installation in either horizontal or vertical
gas flow.

5
Mellachevron™ Mist Eliminator

Features and benefits

• Constructed from banks of parallel corrugated,
chevron profiles.
• High capacity designs provide compact separators -
ideal for gas processing applications.
• Lower capacity designs available for fouling service and heavy
liquid loadings.

Key characteristics Key areas of application

• High capacity systems available with K-values up to • Broad range of gas/liquid • Knock-out pots
0.45 m/s (1.47 ft/s) at the vane face inlet. separation problems • Glycol contactors
• Effective droplet separation down to ~20 µm. • Scrubbing systems and • Inert gas scrubbers
• Efficiency can be enhanced by combination with absorbers • MSF/MED desalination
KnitMesh pre-conditioners. • Evaporators • Sulfur condenser
• Generally for use at: - surface tension > 10 dynes/cm • Steam drums • Flue-gas desulfurization (FGD)
- operating pressure < 60 bar in hydrocarbon systems.
• Pressure drop is typically in the range 1 to 10 mbar.
• Designs available for installation in either horizontal or vertical
gas flow.

Shell VersiSwirl™

Features and benefits

• VersiSwirls arrayed in boxes or banks provide compact
separators and are ideal for gas processing at all pressures.
• Suitable for use in fouling or waxy services.

Key characteristics Key areas of application

• High capacity systems with vessel K-values of typically Gas processing applications;
0.15-0.3 m/s (0.5-1 ft/s) or higher for selected cases. • Inlet separators • Compressor suction drums
• Effective droplet separation down to ~10 µm. • Turbo-expander suction drums • Glycol contactors
• Efficiency can be enhanced by combination with KnitMesh or • Dew-point separators
Mellachevron pre-conditioners.
• Pressure drop is typically < 30 mbar.

Shell Swirltube Light™

Features and benefits

• Array of axial cyclones originated from the Shell ConSep™
Swirltube design.
• The device can be combined with a Sulzer Mellachevron or
KnitMesh pre-conditioner.
• The separation efficiency of the Shell Swirltube Light is in the
range of high performance vane packs or above.

Key characteristics Key areas of application

• High capacity systems with vessel K-values up to General gas processing applications and mist removal in
0.25 m/s (0.82 ft/s). mass transfer towers such as in the PEB neutralization column.
• The Shell Swirltube Light is suitable for higher operating
pressures, offers higher capacities than vane packs installed for
vertical gas flow and is therefore a useful complement to our
Mellachevron mist eliminators.

6
MKS Multi Cassette™ Mist Eliminator

Features and benefits

• The patented MKS Multi Cassette device combines axial
cyclonic and cross flow separation Technology to create a very
efficient and attractive mist eliminator.
• One or more MKS Multi Cassette candles are assembled on a
support plate acting as liquid collector with drain pipes.

Key characteristics Key areas of application

• High capacity device with vessel K-values of typically Gas processing applications;
0.1-0.3 m/s (0.33-1 ft/s) or higher for selected cases. • Inlet separators • Dew-point separators
• High efficiency separation down to droplet sizes of 8 to 10 μm. • Turbo-expander suction drums • Steam drums
• Efficiency can be enhanced by combination with KnitMesh • Compressor suction drums • Knock-out drums
pre-conditioner. • Glycol contactors • Discharge drums
• No limitation in operating pressure.
• Very suitable for glycol contactors (meets glycol losses
≤0.1 USgal/MMscf) and for systems with very low liquid
densities and surface tensions.

Shell Schoepentoeter™ and Schoepentoeter Plus™

Inlet Device

Features and benefits

• Constructed from banks of swept vanes.
• Designs available for operation in most gas/liquid flow regimes.
• The Schoepentoeter Plus is equipped with sophisticated
catching rims to minimize entrainment.

Key characteristics Key areas of application

• Generally designed at dynamic pressures < 8000 Pa, but can • The Schoepentoeter is the most commonly used vane inlet device
perform well at higher values. for introducing gas/liquid mixtures into columns.
• Is typically used for feeds having a gas volume fraction of • The Schoepentoeter Plus is an advanced feed inlet vane device
> 70 vol%. with considerably increased de-entrainment efficiency and first
• Suitable for installation in horizontal or vertical separators. choice for all demanding tasks such as in vacuum towers,
• Suitable for liquid slugs. crude distillation and hydrocracker main fractionators and
high pressure separators.

Treelnlet™ Device

Features and benefits

• By installing a Treelnlet and a high efficiency KnitMesh mist
eliminator, liquid carryover losses are reduced to virtually zero.

Key characteristics
• The Treelnlet provides a superior liquid pre-separation and gas
distribution and is normally effective up to dynamic pressures of
about 10’000 Pa.
Key areas of application
• The Sulzer Treelnlet is an axial flow vane gas inlet device for vertical
feed nozzles.
• Ideal for bulk liquid disengagement in a wide range of services and
applications.

7
HiPer™ Cyclone Inlet Device

Features and benefits

• The HiPer cyclone inlet device consists of an arrangement of
one or more cyclones symmetrically arranged off a common,
centrally located header box.
• The device can be installed in vertical or horizontal vessels.
• If required, special elements at the cyclone gas outlet will
improve the distribution to the downstream device.
Key areas of application
Key characteristics
The HiPer cyclone inlet device is applicable for high gas and liquid
• The HiPer cyclonic inlet device utilizes the momentum of the
handling capacities. Useful to suppress and break many types of
feed stream inlet in order to generate high g-forces.
process foams.
• Defoaming is achieved as gas bubbles are separated from the
liquid phase by the centripetal forces in the cyclone tubes.
Some typical applications include FWKO drums, flash drums,
• Gas is released from the top of the device and the bottom
test separators, 2 and 3-phase production separators.
opening of the cyclones is submerged below the liquid in the
separator in order to avoid a gas ‘blowout’.

GITV Vapor Horn

Features and benefits

• The gas distribution is performed by baffles according to a vane
gas inlet device.
• The device is suitable for vessel inner diameters larger than
4 m.

Key characteristics Key areas of application

• The tangential vane gas inlet device GITV can be used for The Sulzer Vapor Horn GITV is primarily used in fractionators where
very high vapor velocities in the feed pipe of F-Factors up to flashing feeds require high pre-separation of any free liquids.
120 Pa1/2.
• The feed flows radially around the vessel projecting and
collecting the liquid droplets on the inner wall of the vessel.

8
Mist elimination

Liquid entrainment in a process gas stream can be formed by If the gas is travelling too fast to allow the liquid droplets to settle out
either dynamic processes, such as contact between gas and liquid under gravity, they become suspended (or entrained) in the gas or
phases in a mass transfer operation, or thermal processes such vapor. In most cases, the entrainment must be removed to purify the
as condensation. For example, droplets can result from bubbles gas and prevent potential process or environmental contamination.
bursting or jetting at a gas/liquid interface - typically in distillation
columns, evaporators, bubble columns and flooded packed bed Sulzer mist eliminators provide an effective solution to liquid
scrubbers. Where there is a high relative velocity between gas and entrainment problems in many types of equipment including:
liquid, droplets can be sheared from the wet surfaces. This type of • scrubbing, absorption, stripping or distillation columns
problem is likely to occur in venturi scrubbers, two-phase flow in • evaporators
pipes and packings. • falling film condensers
• knock-out vessels
Droplets can also be formed by thermodynamic changes in a • 3 phase separators
system. For example, vapor condenses when saturated gases • desalination plants
are cooled in condensers and heat exchangers and, although • refrigeration plants
most of the liquid will remain on the heat transfer surfaces, the gas • gas dehydration plants
can become supersaturated in places causing droplet formation. • compression systems
This type of condensation mist can occur during heat exchange
processes, the sudden release of pressure or by mixing hot and
cold gas streams. Similar mists can result from gas phase reactions
which yield a liquid product. Typical applications suffering from mist
contamination include sulfuric, phosphoric and nitric acid plants.

Rain
Drop Drizzle Mist Fog

Entrainment
from water
cooling & spray
cooling towers

Spray produced by bubble

bursting at a liquid vapor interface

Entrainment from evaporators, Typical

distillation & absorption process
applications
Condensate Condensate from
from intercoolers on
gas coolers compression plant

Condensate from high

pressure compression plant

Knock out drums & collectors fitted mesh mist eliminators

Knitted mesh mist eliminators

Vane mist eliminators

Types and
operating
Cyclonic devices range of
equipment

Baffles, Fiber bed

louver separators mist eliminators

500 200 100 50 20 10 5 2 1 0.5
Droplet diameter (microns)

9
Mist elimination

Several types of mist eliminators are available for the separation Each mechanism is critically dependent on the droplet size
of entrained liquid. To choose the appropriate equipment, the four distribution for a given application. For example, in gas drying
basic mechanisms of droplet capture should be considered. applications using glycol contactors, droplet size distributions are
often in the range of 5-25 µm and high separation efficiency is
• Diffusional Deposition is only effective in the separation of very critical. In these circumstances, direct and inertial interception are the
finely dispersed aerosols with droplets typically smaller than 1µm - most appropriate mechanisms and separation is best achieved by
that are small enough to be affected by Brownian Motion. impingement of droplets on the wires and fibers of high performance
• Direct Interception assumes that a droplet of a given diameter and mesh mist eliminators.
negligible mass follows the stream line around the ‘target’ wire or
fiber and is separated as it touches the target or collection fiber. Diffusional deposition is an important mechanism in the design of
• Inertial Interception considers the droplet mass and predicts how fiber bed mist eliminators (candle filters) used for removal of sub-
momentum will make it deviate from the gas stream. micron droplet dispersions found in applications such as acid mists.
• Gravitational Deposition works on the principle that large, slow
moving droplets may separate from a gas stream under gravity.
This is restricted to large droplet sizes and low superficial gas
velocities – making separator dimensions both unreasonably large
and uneconomical.

Assuming that gravity separation can

be disregarded as an effective option,
Inertial interception the remaining mechanisms provide the
Droplets
design basis for Sulzer mist elimination
equipment:

• Sulzer Mellachevron™
– inertial interception
Diffusion • Shell VersiSwirl™ and Swirltube Light™

– inertial interception
• Sulzer KnitMesh™
– inertial/direct interception
• Sulzer MKS Multi Cassette™
– inertial/direct interception

Flow streamlines
Direct interception

Gravity

10
Mist elimination
Gravity Baffles/ Vane packs – Vane packs – Axial cyclone Knitted Candles/
separators/ louvers simple vanes with drainage separators mesh mist fiber beds
knockout channels eliminators
drums
Direct
Separation Gravitational Inertial Inertial Inertial Inertial Inertial/direct interception/
mechanism deposition interception interception interception interception interception diffusional
deposition
Gas handling
Low High High High Very high Moderate Low
capacity
30 %
Turndown capacity Very high 30 % 30 %-50 % 30 %-50 % Higher with 25 % Very high
preconditioner
Low except Low except High down High down High down Very high down Very high at
Efficiency for large for large to approx. to approx. to approx. to sub-micron
droplet sizes droplet sizes 25 µm 25 µm 10 µm 2-5 µm droplet sizes
Liquid load capacity Very high Very high Moderate High High Moderate Low
Solids
Very high Very high Moderate Low Moderate-high Low Very low
handling capability
Prone to fouling Prone to fouling
Suitable for high Suitable for high Unsuitable
Liquid Suitable for high Suitable for high with high liquid with high liquid
viscosities/ viscosities/ for high liquid
viscosity viscosity viscosity viscosities/ viscosities/
waxes waxes viscosities
waxes waxes
Pressure
Very low Very low Low Low Moderate Low High
drop

Table A: Summary of relative performance characteristics for mist elimination

Design advice
v = K· √ ρ ρ- ρ
l
v
v

Comprehensive performance information is available v = maximum superficial gas velocity Derating factors are often applied
on a wide range of standard designs, enabling Sulzer ρl = liquid density to allow a safety margin for
engineering staff to tailor the mist eliminator design to ρv = gas density exceptional conditions such as
suit most applications. K = a constant which is specific to the liquid slugs and gas surges, and
separation equipment and is a function the K-value can be optimized to
For best performance, it is important to achieve of process parameters such as: suit specific process conditions,
uniform gas flow distribution and maximum effective • Liquid loading and challenging physical
area, and recommendation can be given on the most • Gas and liquid viscosity properties such as low surface
appropriate positioning, in terms of disengagement • Gas pressure tension systems. The selection
distances from vessel inlet, outlet and other vessel • Surface tension of K-value is therefore critical
internals. and we recommend that designs
should be checked by our
engineering team.

Sizing
Equipment type K-Value ft/s
For equipment based on direct and/or inertial
m/s
interception, gas stream velocity affects all three
principles involved in separation (impingement, Gravity *) 0.07 0.23

coalescence and drainage). Flooding, or re- Sulzer Mellachevron – simple profiles 0.13 – 0.17 0.42 – 0.56
entrainment of liquid, can occur if the flow of gas Sulzer Mellachevron –
0.15 – 0.45 0.49 – 1.46
prevents drainage, and the effective area of the mist high capacity profiles with drainage channels
eliminator is therefore established by determining an Sulzer KnitMesh mist eliminator 0.08 – 0.12 0.26 – 0.4
appropriate superficial velocity for the equipment.
Sulzer KnitMesh V-MISTER 0.08 – 0.13 0.26 – 0.43
The overall performance of the mist eliminator is then
Sulzer MKS Multi Cassette *) 0.10 – 0.30 0.33 – 1
a balance between efficiency and pressure drop.
Shell VersiSwirl *) 0.15 – 0.30 0.5 – 1

*) refers to the vessel K-Value

11
KnitMesh mist eliminators

Sulzer KnitMesh™ Gas outlet

wire mesh mist eliminators

Sulzer KnitMesh mist eliminators have an Sulzer KnitMesh™
excellent track record as a low cost, highly mist eliminator

versatile and efficient method of removing Liquid drains counter-

current to gas flow
liquid entrainment from gas streams. They
are produced as a bed of knitted mesh Gas outlet
which presents a tortuous path and large Schoepentoeter Sulzer KnitMesh™
Gas inlet mist eliminator
surface area to the droplets entrained in
the gas stream. Separation is achieved
by impingement on, and capture by, the Gas inlet

filaments of the mesh where the droplets

coalesce and drain.

Installation can be made in a variety of

Liquid drains perpendicular
ways but gas flow is usually either vertically Liquid outlet
to direction of gas flow Liquid outlet
upwards, with the liquid draining counter-
current to gas flow, or horizontal, with the
liquid draining in a direction perpendicular supports such as beams and rings within Standard designs are available for routine
to the gas flow. the vessel. Sectional installation allows applications, providing excellent separation
ease of handling and access through vessel efficiency down to droplet sizes as small as
Each mist eliminator is tailor-made to suit manways. 2 µm, and with a pressure drop typically less
the dimensions of the vessel or housing into than 2.5 mbar. A selection of standard styles
which it will be installed. Most KnitMesh Accessories such as tie wire, bolting, is described in Table B. Alternatively, we can
wire mesh mist eliminators are supplied clamps and support beams can be supplied provide optimized designs to suit specific
complete with rigid support grids, which where necessary. duties using sophisticated design tools.
allow direct installation onto appropriate

Metal Designs

Material Type Free Density Specific surface area Application

number volume
(lb/ft³) (kg/m³) (ft²/ft³) (m²/m³)
Metal 9001 97.5% 12 192 196 643 Very high efficiency, very clean service
9033 97.5% 12 192 110 350 Heavy duty
9032 97.75% 10.5 170 93 305 For general use
9030 98% 9 144 79 258 Standard general purpose media
9030-L2 98% 9 144 147 482 High efficiency for fine entrainment
9059 98.5% 7 107 109 358 Fine entrainment
9036 98.75% 6 96 52 172 High velocity, dirty service
4530 98.75% 6 96 52 172 High velocity, clean service
4540 99% 5 80 44 145 Minimum pressure drop, dirty service

Plastic and other materials

Material Type Free Density Specific surface area Application

number volume
(lb/ft³) (kg/m³) (ft²/ft³) (m²/m³)
Glass Wool 9036 93% 12 195 450 1500 Coalescer-very fine mists
9048 95% 8.25 135 300 1000 Coalescer fine mists
Polypropylene 9008 95% 2.75 45.5 320 1050 High performance-acid mists
9030 93% 4.5 74 250 820 Acid mists and marine engine intakes with
9036 95% 2.75 44.5 150 495 minimum pressure drop
9048 97% 2 41 110 360
Multifilament 9033 94% 19 305 340 1115 Fine mist conditions where stainless steel
(glass wool/ 9030 95% 13.5 215 250 820 can be allowed and minimum
stainless steel) 9036 96% 9 145 160 525 pressure drop is important.
FEP 9048 94% 8 128 250 820 Highly corrosive conditions
ETFE 9048 95% 5.25 85 220 725 Highly corrosive conditions

Table B: Standard Sulzer KnitMesh mist eliminator types

12
KnitMesh mist eliminators

Sulzer KnitMesh V-MISTER™

The Sulzer KnitMesh V-MISTER provides
high performance wherever liquid
entrainment must be removed from
a vertically flowing gas stream. Mist
eliminators with Sulzer KnitMesh V-MISTER
technology employ the mechanism of a
Von Karman Roll around a bluff body (see
Fig. 1a) to obtain high vapor and liquid
handling capacity. A vortex develops in Figure 1a Figure 1b
a low pressure zone downstream of the
channel that has been attached to the
bottom of the mesh pad. Collected droplets
deposit in the trough and form a flowing
liquid stream there. Contrast this with the
standard mesh pad (see Fig. 1b) where
a two phase ‘fluidized’ zone of gas and
liquid develops in the bottom third to half
of the pad and from which large coalesced
droplets must ultimately drain counter-
current to the ascending stream. The high
capacity channels of the Sulzer KnitMesh
V-MISTER shield the collected liquid and
then drain it in steady streams from two
sides of the mist eliminator at the column
wall, where gas velocity is so low that re-
entrainment is limited (see Fig. 2). Figure 2

This simple enhancement to a standard Velocity (ft/s)

mesh pad improves mist elimination 8.2 10 12 14 16.4
8
because the higher velocities increase the Flood
droplets‘ inertial impaction with the wires 7
Flood
Pressure drop (mbar)

or filaments. Summarized the V-MISTER

6
collecting channels provide an increased
liquid capacity of up to 300 % and a higher 5
gas throughput of up to 20 %. Conventional Pad V-MISTER Pad
4

3
Liquid load: 1.1 m3/m2 hr
2
2.5 3 3.5 4 4.5 5
Velocity (m/s)

The unique Sulzer KnitMesh XCOAT™ mist eliminator:

the perfect solution for corrosive services
Sulzer has developed a completely new KnitMesh mist eliminator for corrosive services.
The Sulzer KnitMesh XCOAT is based on a metal wire which is coated with 100% pure
PFA. This new mesh material is unique and available exclusively through Sulzer.

Sulzer KnitMesh XCOAT mist eliminators are characterized by a high deformation,

corrosion and temperature resistance, and are therefore ideal for applications which
have to deal with acids such as sulfuric acid.

The advantage of longer service time of the Sulzer KnitMesh XCOAT mist eliminator
compared to common wire mesh pads using Teflon filaments or higher alloyed and Sulzer KnitMesh XCOAT mist eliminator for
acid-resistant steel wires has been demonstrated in several industrial applications. a sulfuric acid drying column

13
KnitMesh mist eliminators

High performance Sulzer KnitMesh™

9797 mist eliminators
The Sulzer KnitMesh 9797 Mist Eliminator technology provides D1
means of optimizing designs to meet the challenges of specific
D4
applications. D3

Unlike ‘industry standard’ mist eliminator design methods, which

D5 D2
predict performance using bulk density and filament diameter of
the separation media, the 9797 modeling techniques consider
the characteristics of individual mesh layers as a mathematical
model so that the entire process within the separator (capture,
coalescence and drainage) can be predicted on a layer by layer
basis. This enables Sulzer to produce unique structures where
the free volume and mesh free area can be varied through the
depth of the pad, giving the best balance of mist eliminator
characteristics, such as liquid hold-up and efficiency, from inlet Liquid drains
to outlet. Additionally, separation efficiency can be predicted in towards
terms of liquid entrainment concentration providing meaningful, adjacent pore
measurable information on separator performance; a considerable
improvement on droplet size efficiency predictions which are
extremely difficult to verify in practice.

Fig. 3 illustrates one layer of mesh within the mist eliminator and
stages of separation considered by the performance model:
• D1 avoids capture and moves in to the next layer of mesh.
• D2 is captured by the mesh.
• D3 and D4 coalesce to form a bigger droplet or film.
• D5 drains from the mesh surface. Fig. 3: The stages of droplet separation on a wire mesh.

An extensive range of mesh styles have been analyzed for a variety Existing applications for Sulzer KnitMesh 9797 Mist Eliminators
of process systems ranging from air/water to more challenging include:
hydrocarbon conditions. The performance of the mist eliminator is • glycol contactors – minimization of TEG entrainment from natural
established by calculating the cumulative effect of combined mesh gas dehydration columns (see p 21).
layers and their characteristics. The model allows a high degree • gas sweetening – installation in amine absorbers
of optimization so that layer specifications can be varied to meet • dew-point separators – 9797 designs have helped reduce water
specific process challenges. For example, high free volume/low liquid and hydrocarbon dew-points in natural gas processing (see p 23).
hold-up may be an important feature of the inlet region of the mist • rotary screw compressors – reduction of entrainment of synthetic
eliminator with a gradual increase in separation efficiency towards oil from compressor system knock-out drums
the outlet. • steam drums – guaranteed steam dryness can be achieved using
Sulzer KnitMesh 9797 mist eliminators

i=N Fig. 4 represents a bed with N layers of mesh.

i = n+1 By assuming that:

V0 is the volume of droplets entering Layer 1
Direction of Gas Flow

i=n
VN is the volume of droplets leaving layer N
i = n-1 Ei is the individual layer efficiency,

then the overall efficiency of the mist eliminator

can be expressed as:
i=2 i=N

Fig. 4
i=1
VN = V0 ∏ (1 – Ei  )
i=1

14
Mellachevron

Sulzer Mellachevron™
mist eliminators
Sulzer Mellachevron vane mist eliminators are
high capacity inertial separators constructed as
banks of parallel, chevron profiles which cause
the gas to change direction several times from
inlet to outlet. Momentum forces entrained liquid
droplets to impinge on the vane surfaces where
they form a liquid film and drain.

The Sulzer Mellachevron range is divided into a

number of categories depending on direction of
gas flow and the complexity of the vane profile.

Simple Sulzer Mellachevron profiles separate

liquid by impingement, coalescence and
Sulzer Mellachevrons are available in various profiles and materials such as
drainage on the vane surface with no
stainless steels, alloys or plastics.
disengagement of the liquid from the gas stream.
They are particularly suitable for applications with Gas
a significant risk of fouling due to solid particles
or high viscosity liquids in the feed but have
relatively low gas handling capacity.

More sophisticated designs provide special Complex Mellachevron profiles require

separation channels to allow disengagement of housings which ensure that the vanes are
liquid and drainage from the vane surface. This assembled accurately and provide a liquid
increases the capacity of the separator and gas sump for drainage of liquid into the vessel
load factors of up to 0.45 m/s are possible. This or column.
makes them an excellent choice when equipment
size is critical, for example, in offshore applications
or for de-bottlenecking existing equipment. Simple Mellachevron profile with
countercurrent drainage of liquid
from vane surface.

Drainage slots on vane

surface allow liquid to Removable spacer channel to Liquid drain channel
allow installation of the vanes integrated in beam
disengage from gas stream
Jacking bolts

Liquid drains in special

channels separated from
the gas flow

Liquid collects at bottom of

drainage channels and moves
laterally to Mellachevron hous-
ing where it is collected in a
sump and drained through
downcomer pipes Liquid drain
channel
integrated in
vane housing

15
Mellachevron

Mellachevron designs are available for installation in either vertical or Typical housing arrangement for cross-flow Mellachevron. Sectional
horizontal gas flow. When gas flow is horizontal, the liquid film on the installation allows installation and removal through manway and vane
surface of the vane drains vertically downwards into a liquid sump. profiles can be dismantled individually for cleaning if necessary.
Complex Mellachevron profiles are used with hooks or drainage
channels which help to disengage the liquid from the gas stream and Liquid is collected in the sump and drained through the downcomer
prevent re-entrainment from the downstream face. pipe connection.

Gas

Liquid drains down vane surface to a sump.

Horizontal gas flow arrangement.

Mellachevron – Mellachevron –
simple vanes complex profiles with drainage channels

Type C – profile Z - profile C or Z - profile Complex profile - Z-profile with Z-profile with
with large vane integral drainage drainage hooks large vane spacing
spacing channel

Profile

Flow Direction Vertical Vertical Vertical Vertical or horizontal Horizontal Horizontal

Housing and Housing and Housing and
Installation No housing No housing No housing drainage system drainage system drainage system
required. required. required.
Gas handling
capacity 0.17 m/s 0.14 m/s 0.14 – 0.17 m/s 0.17 – 0.45 m/s 0.35 m/s 0.35 m/s
(K-values)
Turndown capa-
≈ 30 - 50 % ≈ 30 - 50 % ≈ 30 - 50 % ≈ 30 - 50 % ≈ 30 - 50 % ≈ 30 - 50 %
bility
Medium Low – Medium High Medium Low – Medium
Medium – High
Efficiency down to down to down to ≈ 10 – down to ≈ 25 – down to ≈ 35 –
down to ≈ 25 µ
≈ 30 – 40 µ ≈ 30 – 50 µ 15 µ 30 µ 40 µ
Liquid load
Moderate Moderate High Moderate to High High Very High
capacity
Solids handling
Moderate to High Moderate High Low Low Low to Moderate
capability
Very suitable for Prone to fouling with Prone to fouling
Suitable for high Suitable for high Suitable for high
Liquid viscosity high viscosities/ high viscosities/ with viscosities/
viscosities/waxes viscosities/waxes viscosities/waxes
waxes waxes waxes
As for C and Z pro- Debottlenecking, As for C and Z
Desalination,
Typical Vacuum, general files but high fouling/ off-shore, clean ser- Horizontal scrub- profiles but high
general use,
applications use, fouling service low pressure drop vices, gas & steam bers fouling / low pres-
fouling service
services processing sure drop services

Pressure drop Very low Low Very low Moderate Low Low

Table C: Sulzer Mellachevron mist eliminator styles

16
Mellachevron

Sulzer Mellachevrons can be installed H45D and V35D high performance vane
in a variety of vessel configurations and packs provide significant advantages
as arrangement of multiple vane boxes over conventional vane mist eliminators,
to provide optimum flow and drainage including:
characteristics within the space available. • reduced pressure drop at high gas load
Typical box and vessel arrangements are factors
illustrated below in Fig. 5a and 5b. • improved liquid drainage and gas
streamlining based on hollow blade
The sophisticated vane profile with integral concept
drainage channels of our Mellachevron • up to 40 % higher gas load capacity

Double Box Four Box V-bank

with KnitMesh pre-conditioner
Fig. 5a

1. Vertical flow
1
2. Cross flow – horizontal vessel
1
3. Cross flow – two-stage separator
4. V-bank
5. Cross flow – in-line separator

3
5

2
4

Fig. 5b

17
Axial cyclonic devices

Shell VersiSwirl™
Shell VersiSwirl axial cyclone represents an evolution of the long
established SMS, SVS, SMSM and SMMSM family of separators.
In comparison with the previous generations of technologies, Shell
VersiSwirl gives a step-change in performance in terms of efficiency
and capacity allowing for either smaller vessel or greater capacity.
The numerous technological improvements incorporated in the Shell
VersiSwirl include a new aerodynamic swirler, optimized secondary
gas handling and liquid film drainage. In the Shell VersiSwirl, liquid is
separated from the gas stream by impact of liquid droplets on axial
cyclone tube wall which are then drained via slits into a collection
chamber. The droplets are forced to the wall by centrifugal forces
induced by the gas vortex generated by the swirler.
Primary
For the most demanding duties, the Shell VersiSwirl can be gas outlet

combined with other technologies which provide an Edge over Secondary gas
its already impressive performance. For non-critical duties, a outlets with
Shell Schoepentoeter™ is used as standard, but in challenging decreased gas
throughput
applications, a Schoepentoeter Plus™ will greatly reduce
Top plate
entrainment from the inlet zone.

Improved
secondary gas
management
Improved
separation part

Liquids

Advanced swirl part

Bottom plate

A swirler creates a strong rotation in the cyclone tube.

Liquid droplets are forced to the wall.
Shell Swirltube Light™
The Shell Swirltube Light is available as an attractive alternative to
vane packs for high capacity bulk separation. The Swirltube Light is
based on the sophisticated de-entrainment device used in the Shell
ConSep™ Tray.

Recommended use:
• comparable efficiency but higher capacity compared to vane
packs
• operation possible at higher pressures/ lower surface tensions
than vane packs
• compact design makes it suitable for offshore industry or in
general for high pressure conditions
• for debottlenecking of existing separators
• for high turndowns with pre-conditioner (up to factor 10)
• application for slightly fouling service and may be used where
complex vanes or wire mesh mist eliminators may become
plugged

18
Combined systems

Selection of the appropriate primary separator is key to the system’s Shell VersiSwirl/Drainable KnitMesh, SLR + Schoepentoeter Plus:
overall performance, whether the intention is to optimize the droplet extra drainage capacity reduces the overall load in the vessel
size reaching the Shell VersiSwirl or reduce liquid from the internals internals where critical guaranteed performance is a must.
and prevent re-entrainment. Shell VersiSwirl gives high performance for demanding applications
and when combined with optimized technologies from Sulzer’s
New combinations portfolio a tailored solution can be provided to meet the needs of the
• Shell VersiSwirl/Schoepentoeter Plus: customer. For example, Shell VersiSwirl followed by a Sulzer MKS
optimized inlet device performance Multi Cassette deck to meet extra high separation efficiencies.
• Shell VersiSwirl/V-MISTER:
improved performance over the widest range of operation

Secondary KnitMesh Secondary KnitMesh

VersiSwirl Deck VersiSwirl Deck VersiSwirl Deck

Primary KnitMesh Primary KnitMesh 2nd Primary KnitMesh

or Mellachevron 1st Primary KnitMesh

Schoepentoeter or Schoepentoeter or Schoepentoeter or

Schoepentoeter Plus Schoepentoeter Plus Schoepentoeter Plus

Shell SMS™ Shell SMSM™ Shell SMMSM™

Shell SVS™

Shell VersiSwirl is also available for horizontal gas flow. The

cyclone deck is installed vertically and is therefore ideally Two HiPer Perforated Baffle Plates,
suited for using in the gas cap area of 3-phase separators second one with Mellachevron Pre-conditioner
such as in slug catchers, production separators, etc.
The Shell VersiSwirl is characterized by allowing high gas VersiSwirl Deck installed in
throughputs at high efficiency, rather insensitive against gas Gas Oulet Box
and liquid surges, and high fouling resistance.
HiPer Feed Inlet Device

19
Combined systems

Combined systems
Increasing gas capacities and higher performance requirements The liquid dispersion re-entrained from the mesh mist eliminator has
in mass transfer equipment are challenging the capabilities of a larger mean diameter (see Fig. 6) and is suitable for subsequent
conventional mist eliminator equipment. separation by secondary, high capacity equipment.

To solve this, Sulzer offers combined systems which optimize By analysis of the inlet fluid conditions, Sulzer can design optimized
the benefits of individual types of equipment and improve overall mesh structures to provide the best possible outlet conditions for the
performance. downstream separator.

For example, KnitMesh mist eliminators can be used in combination Additional benefits of combined systems include:
with Sulzer Mellachevron vane packs or Shell VersiSwirl to produce • The ability to design the equipment to provide very high turndown
very high separation efficiencies at high gas loadings. By using the capabilities.
KnitMesh mist eliminator as a pre-conditioner for the Mellachevron, • At low gas velocities, where high capacity separators tend to be
it is operated above its normal re-entrainment or flooding point and ineffective, the mesh pre-conditioners behave as conventional
consequently liquid is stripped away from the downstream surface. mist eliminators.

Gas with fine mist Mist free gas

Frequency
KnitMesh as primary Coalesced
preconditioner large droplets
operates beyond efficiently
flooding point removed by
0 10 20 30 40 50
Mellachevron Drop size (µm)
Fig. 6
Coalesced large Separated
droplets fed liquid drains
to secondary
Mellachevron mist
eliminator

Provisional gap, if required

High capacity separators with Sulzer Mellachevron™

Vertical flow Separator In-line separator Two-stage separator

Gas inlet Gas outlet Gas outlet

Mellachevron Mellachevron Mellachevron
KnitMesh
KnitMesh mist eliminator Pre-condi- mist eliminator
Pre-conditioner tioner
KnitMesh
Pre-condi-
Downcomer tioner
pipe Schoepen-
Downcomer toeter
pipe
Downcomer
pipe
High capacity
packing
MellapakPlus Liquid sump Liquid sump

Liquid outlet Liquid outlet

20
Applications

Natural gas dehydration with TEG

Old fashioned State of the art High capacity The ultimate

Bubble Cap trays Mellapak™ and KnitMesh™ MellapakPlus™, MellaGlycol™ cMIST™ Compact Mass Transfer and
and KnitMesh™ mist eliminators and our high capacity Inline Separation Technology,
mist eliminators incl. the sophisticated mist eliminators such incorporating our patented compact
KnitMesh 9797 type as MKS Multi Cassette™. HiPer TwinLine™ Separator

TEG TEG
TEG

NG
NG NG

Characteristics Characteristics Characteristics Characteristics

~ 1.8 F-Factor (√ Pa) ~ 2.9 F-Factor up to ~ 5 F-Factor n/a

167% column diameter 131% column diameter 100% column diameter 21% column diameter

100% weight of column 73% weight of column 51% weight of column 35% weight of column

Dry gas outlet

Using Sulzer’s sophisticated KnitMesh 9797
technology in glycol contactors Sulzer KnitMesh
9797 Glycol contactor
mist eliminator
The first application for Sulzer KnitMesh 9797 mist eliminators Lean TEG Manway
was for installation on an offshore platform in the North Sea. The Sulzer MellaTech
Liquid distributor
requirement was to control and reduce the glycol entrainment (as
liquid drops) in the gas prior to compression and export. In off-
shore facilities the implications of entrainment from the dehydration Sulzer Mellapak/
columns are not only on the value of the glycol lost (and re-supply MellaGlycol/
MellapakPlus
from shore), but also the consequences of admitting the excess
glycol into the gas export pipeline. Not withstanding possible
operational problems for the pipeline, the increased separation load Chimney tray Rich TEG
at the shore terminal to separate gas condensate and glycol, and Sulzer KnitMesh
9798 Scrubber section
disposal of the glycol phase, are significant costs. The ‘industry mist eliminator Manway
standard’ figure defining the maximum entrainment of 0.1 US gallons Wet gas inlet
per MMSCF gas was therefore challenged and had to be improved
Schoepentoeter
upon. The mist eliminator supplied with this application was shown
to significantly reduce the free glycol loss in the exit to < 0.05 US
gallons per MMSCF gas, a figure verified after measurement of total
glycol loss from the dehydration unit. Liquid outlet

21
Applications
Vapor is free of mist
Using Sulzer’s MKS 4 Cassettes
equipped with
Multi Cassette™ technology in structured
eliminators were installed in the contactor wire demisting
glycol contactors packing
top section. The application has shown to
The first application for Sulzer MKS meet measured glycol losses of < 0.1US
Collector tray
Multi Cassette mist eliminators was for gallons per MMSCF gas.
installation in Glycol Contactors in Russia.
The contactors were revamped from trays The patented Sulzer MKS Multi Cassette
to Sulzer MellapakPlus and were operated mist eliminator combines the useful
at very high gas loading factors. In order to centrifugal forces in cyclones with the high Swirl tube
keep the glycol loss low at this high column separation efficiency of wire mesh packings
Swirling
gas throughput the MKS Multi Cassette mist to give a new superior demisting device. elements
Drain pipe

Vapor carries mist

Glycol dehydration process using Shell SMSM internals in the

feed inlet scrubber and MKS Multi Cassette in the glycol contactor
Highly efficient liquid scrubbing from the gas feed to glycol contactors is needed
in order to avoid bottlenecks in the dehydration system caused by hydrocarbon
carry over which can lead to foaming and excessive overall glycol losses. Sulzer’s
mist elimination products such as Sulzer KnitMesh, Sulzer MKS Multi Cassette and
Shell Separators meet for these high process demands.

Sulzer MKS Multi Cassette at top of

glycol contactor

Glycol
contactor

Glycol
regenerator
Feed Inlet
Scrubber Flash drum

Condensate treatment unit Glycol regeneration unit

Application of Sulzer’s liquid/liquid • Sulzer DC Coalescer™ Application of Sulzer’s mass transfer
separator products such as: • Sulzer Dusec™ and Dusec Plus™ products in the glycol regeneration
• Sulzer Mellaplate™ plate pack • Sulzer Static Mixers facility.

22
Applications
Low Temperature Separation (LTS) Process
The performance of the gas separators in LTS Processes is crucial in order to meet the
hydrocarbon and water dew point specifications. The dew point separator is especially
essential for the overall performance of the plant. Even small amounts of entrained liquids
will rapidly appear as increased dew point in the sales gas. To obtain the best from Compressor
the LTS Process, the high performance Shell VersiSwirl SMMSM or Sulzer MKS Multi suction drum
Cassette or the combination of both is used in the Dew Point Control Separator and in
the Separators upstream of it. To compression

Inlet separator Exp. suction drum Dew point control separator

Compressor
From slug
Expander
Catcher

JT valve

Glycol injection

Molecular sieve dehydration process

The effect of a high performing Feed Inlet Separator on the deactivation rate of the molecular
sieves is substantial. The water absorption capacity deteriorates badly over time as the co-
adsorbed hydrocarbons accumulate in the molecular sieve. Sulzer recommends the use of a
drum with Schoepentoeter and a high efficiency KnitMesh mist eliminator or the Shell VersiSwirl
SMSM or the Sulzer MKS Multi Cassette when high capacity and effciency are required.

Dried gas
Compressor Mol sieve driers to LNG unit
suction drum

KnitMesh
separator

Compressor

Feed inlet separator

Flash gas to
fuel gas system

Water/HC

23
Applications

Mist eliminators in Sulzer KnitMesh

desalination processes mist eliminators
Desalination by multi-stage flash evaporation Sulzer KnitMesh mist eliminators are ideally Most installations are designed using a
or multiple effect distillation unit is by far suited to most desalination applications. conventional K-value of 0.107 m/s but
the most widely used method of generating In multi-stage flash evaporators the mist Sulzer has developed the novel high
fresh water from brine or sea water in eliminators are installed directly above the capacity type 4540NS KnitMesh mist
the world. It is extremely reliable and can flash chambers. Water vapor rises vertically eliminator which can operate at up to 20%
produce high purity water from almost upwards through the mist eliminator and higher K-values, providing the opportunity
all forms of feed. The process involves passes into the condenser tube bundle. Any for either reduced equipment size or an
evaporating water from a brine solution and entrained liquid droplets are captured on increase in capacity. Major projects have
condensing the vapor as fresh water. the wires where they coalesce and drain, been successfully commissioned using the
counter-current to the vapor flow, back Sulzer KnitMesh 4540NS mist eliminators in
However, the performance of any flash into the flash chambers. The separation Oman, Algeria and the UAE.
evaporator can deteriorate if liquid mechanism is similar to this in multiple effect
entrainment is carried over from the flash distillation systems.
chambers into the condenser tube bundles. Sulzer Mellachevron
This is a very likely occurrence in view of The combination of high free volume and mist eliminators
the high velocities and volumetric flowrates specific surface area mean that excellent
experienced in these plants, and can lead to efficiencies can be achieved for droplets as Precipitation of salts and scale on the wires
problems such as: small as 5 µm while presenting minimum of KnitMesh mist eliminators can be a
• Reduced water purity pressure drop. problem in some plants, particularly in the
• Scaling of condenser tube bundle and first two or three effects of the evaporation.
downstream equipment such as boilers In these circumstances, the Mellachevron
• Corrosion of downstream equipment High capacity designs Type V20Z has been used to overcome the
problem. This simple vane profile provides
Sulzer Mist Eliminators are designed to To achieve the required capacity, the high separation efficiency performance for
reduce these problems and are installed in evaporators are often very large and the droplets larger than 30 µm, and its ability to
most desalination systems. mist eliminators usually cover a large withstand heavy scaling applications makes
effective free area above the flash chambers. it an ideal alternative to the KnitMesh mist
Our experience in desalination has helped The total area required is determined by eliminators when fouling is of concern. Its
us develop a range of equipment to calculation of the mist eliminator capacity robust construction makes it easy to clean,
meet the specific process needs of our and is a very important part of the plant and the Mellachevron V20Z also has a
customers, and great care is taken to design. Clearly, any opportunity to reduce relatively low pressure drop compared to the
ensure that the optimum design is offered the capital cost of the evaporators is very more complex Mellachevron designs with
for any particular duty. The main factors to attractive and the capacity of the mist drainage hooks and channels – an important
consider in desalination applications are: elimination equipment is of vital importance factor when designing for large volumetric
• Efficiency in this calculation. flowrates at low pressure.
• Pressure drop
• Fouling characteristics and the tendency
to scale
• Materials of construction
Steam Vent ejector

Feed
pump

KnitMesh or Mellachevron
Condensate mist eliminator Brine Product
pump pump pump

24
Comprehensive engineering services markets

Development and technology

Sulzer makes every effort to support our customers and continuously
improve our design tools. Engineers in the R&D lab develop new and
improved products, analyze and optimize processes.

We maintain close relationships to universities and independent

research organizations to support these efforts.

Engineering and manufacturing

Sulzer has a long-standing manufacturing tradition. Sulzer owns
dedicated factories in many regions to produce mixers, columns,
reactors, and heat exchangers.

For certain sizes and certain countries, we work with well-known

and proven subcontractors who are bound by Sulzer manufacturing
policies and quality standards.

Capabilities
Manufacturing according to PED 97/23/EC, ASME VIII Div.1, and
ASME B31.3/U-Stamp, Gost (TR), China Stamp, Norsok, or NACE

Design codes acc. to AD2000, EN 13445, ASME Broad selection of

material for construction available

Non-destructive testing (LPT, X-ray, pressure testing up to 500 bar,

PMI, MT, UT etc. acc. EN and ASME)

Designing with SolidWorks

Strength calculations, FEM analysis, nozzle loads etc.

Certification for ISO 9001, ISO 14001 and ISO 18001

Experienced project management team

CFD Analysis
CFD calculations done in advance of fabrication can support the
decision to go for a particular technology, and can save on the
time required for commissioning and testing later. Sulzer uses CFD
technology both for the modeling of existing and the development of
new products.

25
www.sulzer.com

E10508 en 1.2022, Copyright © Sulzer Ltd 2022

This brochure is a general presentation. It does not provide
any warranty or guarantee of any kind. Please, contact us
for a description of the warranties and guarantees offered
with our products. Directions for use and safety will be
given separately. All information herein is subject to change
without notice.