Demister Pads and Wire Mesh Products
Browse our demisters pads and wire mesh solutions for
a wide variety of liquid-gas separation applications.
Air Gap Spacers & Cushion Pipes
‘Air gap’ or ‘twin wall’ pipes are often used for the manufacture of downpipes. Insulation is provided by the air gap between inner and outer pipes, reducing heat loss from the exhaust gas prior to the catalytic converter. This results in improved light-off times.
Demister Asia wire mesh spacer rings and cushion pipes are situated between the inner and outer pipe. This acts as a bearing surface, maintaining a constant gap through changes in thermal expansion whilst absorbing and reducing vibration.
All of these are from the same reliable maker of Knitwire based in UK.
Anti Vibration Mesh
A knitted wire component can be produced in any size, shape, and density to enable riveting or spot welding, keeping assembly and fastening costs to a minimum.
Typical applications for this range of products are:
- heat shields
- turbo and engine mounts
- down-pipes
- manifolds
Most applications where vibrations cause radiated sound can be cured with the addition of a wire mesh ring, pad, rope or mat.
Body Armour
With UK Partners, we have knitted one of the most light-weight Body Vest. Designed to be stab-proof, this light-weight Body Vest is also bullet-proof up to basic KR1 standards, as well to a Magnum 45.
Please send us your specifications as well as your application for your body armour, and we will get in touch with you.
Compressed Components
An endless array of size, shape and configuration of components can be produced from knitted mesh.
Compressed knitted mesh components can be adapted and used for numerous applications:
- anti-vibration
- engine mounts
- high temperature seals
- RFI/EMC gaskets
- filtration
- engine breathers
- catalytic converter seals
- mist elimination
- heat dissipation
- expansion joint media
With a vast choice of material type, grade, tensility, filament size and compressed density available, we can offer a wide range of solutions to any predicament.
Compressed knitted mesh components are supplied to various industries:
- computers
- telecommunications
- electronics
- automotive
- chemical and petrochemical
- water purification
- domestic appliances
Knitted mesh can be compressed in a custom-made tool or extruded through a die to form continuous lengths of rope in almost any shape or size.
Demister Asia Products have the added advantage of its own engineering facilities. Fully capable of manufacturing tools, the facilities utilize a wide range of materials and techniques, from mild steel for low volume and one-off jobs to fully hardened automated tooling for mass production items like demister pads.
Components and tooling can be custom-made to customer drawings and specifications or advice can be given on solutions and concepts for new projects.
Conventional Trays
Conventional trays are also available from ZEHUA, our supplier, in different designs for various uses.
Demisters
What is a Demister?
DEMISTERs are essential in many process operations for the removal of entrained material in vapour flow. DemisterASIA’s Demisters and mist eliminators provide a wide range of solutions suitable for any application.
The principle of a Demister operation is based on having a large number of obstacles intercepting entrained droplets in a vapour flow. These obstacles must provide minimum drop in pressure over the removal system.
How a Demister Works:
Mist eliminators/ Demisters are fabricated from knitted materials with interlocking asymmetrical loops of metal or plastic with typical diameters of 0.1 – 0.3mm. By careful choice of wire diameter, DemisterASIA has produced demisters with extremely high free volumes (typically 98 – 99%) along with very high removal efficiency and low pressure drop.
Along with wire diameter and mesh density, another important parameter in design and operation of a demisters is the vapour velocity. This can be controlled by careful selection of the eliminator area. Optimal area will depend on operating temperature, pressure and pressure drop. Under normal operating conditions more than 99% removal efficiency can be achieved with a pressure drop of less than 250 Pascals.
Different Types Of Demisters:
DEMISTERs can come in different forms and designs, a general guideline as follows:
| Standard DEMISTER Types | Surface Area m²/m³ | Free Volume % | Density kg/m³ | Typical Applications |
| Type 1 | 1650 | 95 | 450 | Very high efficiency |
| Type 2 | 1300 | 95.5 | 350 | High efficiency |
| Type 3 | 600 | 97.5 | 195 | Very high efficiency & clean service |
| Type 4 | 400 | 97.5 | 195 | Heavy duty |
| Type 5 | 350 | 97.75 | 170 | Heavy duty |
| Type 6 | 300 | 98 | 145 | General purpose |
| Type 7 | 250 | 98.5 | 125 | High velocity |
| Type 8 | 200 | 98.75 | 100 | High velocity, dirty service |
| Type 9 | 200 | 98.75 | 100 | High velocity, clean service |
| Type 10 | 150 | 99 | 75 | Dirty service, least pressure drop |
| Type 11 | 445 | 98 | 145 | High efficiency, fine entrainment |
| Type 12 | 400 | 98.5 | 120 | Fine entrainment |
| Type 13 | 1200 | 93 | 600 | High efficiency, fine entrainment |
Stock Materials commonly used:
Stainless Steel: Grades 302, 304, 316, 316L, 321, 309, 310S
Super Alloys: Inconel 601, Incoloy DS, Hastaloy, Carpenter 20
Fibrous Filament: ‘E’ Glass, ‘S’ Glass, ‘A’ Glass, Basalt, Ceramic, Silica, Kevlar
Others: Aluminium, Monel, Copper, and Brass, Mild Steel (plain and galvanised), Polypropylene, Polyethylene
Why Demisters from DemisterASIA?
Elimination of DA demisters are dependent on droplet sizes:
5 – 9 micron 99%
>10 micron 99.5%
Most of the weight of entrained mist tends to be associated with the larger mist particles (larger than 5 – 10μm) thus providing greater than 99.99% weight removal.
All Demisters from Demister Asia are custom-made to your specification. The units can be broken up into smaller parts for easy installation in tight spaces. Individual drawings are also provided and documented for each of the Demister units upon confirmation.
Our units are known among our customers for good durability. We also have a good track record of negligible annual production errors for the past few years*.
While there are many manufacturers of wire mesh products in Asia, the manufacturing of a Demister requires complex calculations for even the simplest application. Demister Asia is one of the few providers in the Asian and Middle East market whom provides proper performance data for all the units we manufacture.
At Demister Asia, we are experienced in projects from desalination plants to FPSOs. You can be sure to get the best quality and durability for your units with us.
Most importantly, with our Demisters manufactured in reliable factories around the world, we are also one of the most cost effective compared to many “Asia-based” factories. We can thus provide reliable solutions to our loyal customers at satisfactory prices every year.
Distributors
Only the best internals for packed towers.
Developed and optimized in ZEHUA’s test facilities, the tower internals are assuredly of the highest possible quality.
These liquid and vapour distributors vary in design for the optimal match to your requirements.
Liquid Distributor
Trough Distributor (Type TTD-1)
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Trough Distributor (Type TTD-2)
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Pipe Distributor (Type PTD)
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Spray Distributor (Type SPD)
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Orifice Pan Distributor
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Weir-Risdr Pan Distributor (Type WPD)
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Vapour Distributor
Vapour Distributor (Type VD-1)
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Vapour Distributor (Type VDT)
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Vane Type Distributor (Type VNT)
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EDV High Performance Tray
A solution with higher capacity and efficiency, lower pressure drop and better flexibility.
EDV® High Performance Tray is superior to conventional trays in many aspects, including:
- Easy installation
- More than 40% increase in capacity
- Up to 20% increase in efficiency
- Up to 50% improvement in flexibility
- Minimum modification
The EDV® High Performance Tray is available in different designs to cater to your needs.
EMI/RFI Shielding with Mesh
Demister Asia knitted mesh products provide very effective and affordable solutions to radio frequency interference (RFI) shielding.
All electronic equipment sensitive to electromagnetic interference (EMI) must be shielded from external interference sources. Any equipment which produces electromagnetic radiation must also be isolated to prevent any degradation to the performance of surrounding electrical and electronic equipment.
Demister Asia wire mesh provides a perfect solution for many applications, especially where it is necessary to bridge gaps and leakage points in electronic enclosures.
Strips and cores can be produced in many different cross-sectional forms with or without ‘fins’ for mounting into extrusions. The outer layer(s) of wire mesh provide an excellent shielding whilst the elastomer or mesh core provides a high level of resiliency.
Compressed gaskets can be produced from knitted wire mesh for ideal grounding or shielding around shafts.
Cable wrap mesh is supplied in a continuous, flattened stocking with two-ply tape for shielding around cables and loom assemblies. By overlapping the wraps, 4 layers of mesh will provide an excellent shield.
Any commercially available wire can be used although the most popular materials are monel and stainless steel, followed by tinned copper-clad steel and aluminium. Tinned copper-clad steel provides a very good magnetic corrosion resistance whereas monel offers very good shielding performance and corrosion resistance. Monel has a high tensile strength and is most commonly used in aluminium enclosures.
End Protection Seals
Compressed knitted wire mesh seals can be incorporated into the design and manufacture of most catalytic converters and diesel particulate filter assemblies. Seals can be made to suit existing production or new developments.
Seals are positioned around the monolith wherever turbulent, hot exhaust gas can come in contact with the expanding support mat.
A specialty of CSS (and a patented concept) is designing and manufacturing seals for close coupled converters where operating temperatures exceed 1000 °C. These typically include high purity, man-made fiber in addition to high nickel stainless steel. This greatly improves insulation properties, operating temperature, and sealing properties.
The seals can be catered to the requirements of any size, any shape and any canning technology. The majority of the seals have a round, oval or square cross section, although they can be profiled with a small lip to provide added protection against chipping of the monolith edges.
Depending on the application, knitted mesh end seals have densities between 0.8 and 3g/cm3 and are typically manufactured from 0.15 to 0.3mm diameter, fully annealed wire.
Fasteners
Wide range of fasteners with various designs for your different needs.
Guaranteed to be of the highest possible quality for securing your equipment and tower internals.
Flex Assemblies & Load Supports
Flex Assemblies
Standard braiding is typically used on the outer surface of flex assemblies, protecting from abrasion and reducing noise emissions. Conventional braiding is more expensive in comparison to knitted mesh.
CSS produces a knitted wire mesh sleeve, which can either substitute or compliment the braided mesh, enabling a reduction in the coverage and cost of braid. The mesh sleeve, if placed beneath the braid, also further reduces any problems associated with vibration.
Load Supports
Knitted wire mesh rings can be found inside a majority of load support assemblies. The mesh ring acts as a bearing between the moving parts, absorbs thermal expansion and helps prevent the assembly from over stretching.
The mesh rings that CSS manufactures for load supports are made in an endless configuration. This eliminates any possibilities of the mesh unwinding in operation completely.
The most common wire sizes used for load support mesh rings are between Ø0.2mm and Ø0.35mm with densities from 2.5 to 3.5g/cm3. In this application the wire mesh ring has to be robust enough not to deteriorate, yet not so rigid as to cause damage to the final assembly.
Flex Assemblies & Load Supports
Flexible couplings
During assembly line testing of engines, high scrap rates are encountered from permanent distortion of manifold flanges. A solution was needed.
CSS designed and produced a low-cost, disposable seal, which was easily located and mounted in the existing assembly between the two mating flanges. Manufactured from 304 stainless steel and flexible graphite, the necessary clamping torque was reduced by 50%, eliminating all distortion to the flanges.
The same system is easily adapted for use on OEM and after-market applications where leakage through distortion of flanges may occur.
Spring-loaded ball joints
CSS manufactures a range of high density seals for spring-loaded ball joints. Knitted wire mesh, combined with flexible graphite is typically used in low heat applications whilst a higher grade of stainless steel wire combined with mica may be used for moderate temperatures.
At CSS, we believe that we have designed and produced the quietest, most robust and most versatile seal for this application. Manufactured from 310S stainless steel and a high fibre yarn, this development eliminates squeaking and provides virtually leak-free sealing at temperatures of 1000°C.
Framed Filters
A wide range of knitted mesh elements are produced for industrial filter and demister applications. Industrial cooking canopies are among the most common application.
Framed elements, commonly known as ‘grease filters’, are installed above cooking ranges to eliminate entrained grease and fat from being drawn into the extraction ducts. This is necessary to reduce the risk of fire hazards and also to provide essential protection to expensive motors and blowers.
Knitted wire mesh filters provide a functional design with optimum performance, offering low resistance with maximum efficiency of up to 98%. A mesh pad is designed with specific thickness, density and wire size to optimize separation efficiency and flow capacity for expected process conditions.
Wire mesh filters are easily cleaned with steam or hot soapy water to prolong the service life.
Framed filters are usually constructed from multiple layers of aluminium, galvanized or stainless steel crimped knitted mesh, enclosed in a channel frame with either expanded metal or welded metal fascias both at the front and back. Handles can be added to the frames to aid removal for cleaning and replacement. There are many stock sizes available in the range of materials; however, custom-made sizes are also easily catered for.
Further details and technical information regarding Framed Filters can be provided upon request.
Joined-End Protection Seal Assembly
From the makers of demister pads from Demister Asia comes a new, equally ingenious design: one-piece twin seal assembly providing the flexibility to utilize one set of pressings for a variety of different brick lengths.
Once the converter is assembled, the tubular connecting mesh will maintain the position of the two edge protection seals, even where the size or profile of the ‘can’ offers no alternative means of keeping the seal in place.
The system’s ease of assembly with unique technical and financial benefits make it ideal for use in any canning technology. We assure quality for you and your customers.
Knitted Wire Mesh Rolls
Demister Asia produces high quality and versatile knitted mesh and demister pads from a vast range of materials, offering a high degree of creativity and expertise.
Our skilled design and development team strives to ensure that the correct characteristics and specification are chosen for each individual application. Customers are welcome to specify the diameter of wire (0.08 to 0.5mm), the number of strands and the shape and size of the stitch.
The majority of the material we use is 100% recyclable.
From a vast range of raw materials we can advise on the best possible choice to ensure optimum performance and life expectancy in almost any demisters pads we produce.
Stock materials commonly used:
- Stainless Steel: Grades 302, 304, 316L, 321, 309, 310S
- Super Alloys: Inconel 601, Incoloy DS, Hastaloy, Carpenter 20
- Fibrous Filament: ‘E’ Glass, ‘S’ Glass, ‘A’ Glass, Basalt, Ceramic, Silica, Kevlar
- Others: Aluminium, Copper, and Brass, Mild Steel (plain and galvanised), Polypropylene, Polyethylene, and any other continuous filament material supplied as a wire or yarn
Knitted Wire Mesh Rope & Air Breather Pads
Knitted wire mesh rope
Demister Asia wire mesh rope was traditionally used for manufacturing catalyst end seals before the introduction of endless compressed seals. Rope is inexpensive and can be produced in any size, section, profile, density and length, therefore tooling costs are minimal and rarely charged for.
Rope is frequently used in the production of very low volume work that does not warrant the cost of press tooling. Development engineers can often use knitted wire mesh rope in prototype builds during the development of new catalytic converter systems as a very cheap alternative to pressed seals.
Different permutations of knitted rope can be made from semi-hollow to heavy duty high-density stainless steel or high grade nickel alloy rope to over knitted fine ‘A’ glass, ‘E’ glass, ceramic or other man made fiber.
Air breather pads
Demister Asia wire mesh pads are produced as filters and breather pads for use in:
- engine oil fume re-circulation
- air conditioning systems
- slag filters
- diffusers for airbag applications
Mist Eliminator
What is a Mist Eliminator?
Mist Eliminators, also known as demisters, are essential in many process operations for the removal of entrained material in vapour flows. DemisterASIA’s Mist Eliminator pads provide a wide range of solutions suitable for any application.
The Mist Eliminator works by having a large number of obstacles intercept entrained droplets in a vapour flow. This large number of obstacles must provide minimum drop in pressure over the removal system.
Mist Eliminator pads are constructed from knitted materials with interlocking asymmetrical loops of metal or plastic with typical diameters being 0.1 – 0.3mm. By careful choice of wire diameter, DemisterASIA has produced demisters with extremely high free volumes (typically 98 – 99%) along with very high removal efficiency and low pressure drop.
How a Mist Eliminator Works:
Elimination of vapours by DemisterASIA Mist Eliminator is dependent on droplet size:
5 – 9 micron 99%
>10 micron 99.5%
Most of the weight of entrained mist tends to be associated with the larger mist particles (larger than 5 – 10μm) thus providing greater that 99.99% weight removal.
Stock Materials commonly used:
- Stainless Steel: Grades 302, 304, 316, 316L, 321, 309, 310S
- Super Alloys: Inconel 601, Incoloy DS, Hastaloy, Carpenter 20
- Fibrous Filament: ‘E’ Glass, ‘S’ Glass, ‘A’ Glass, Basalt, Ceramic, Silica, Kevlar
- Others: Aluminium, Monel, Copper, and Brass, Mild Steel (plain and galvanised), Polypropylene, Polyethylene
Why use Demister Asias Mist Eliminators:
Our products are known among our customers for good durability. We have also a good track record of negligible annual production errors for the past years*.
With Demister Asias excellent experience, you can be sure to get the best quality and durability for your Demister Asias Mist Eliminators.
Our satisfied clients include:
- Desalination Plants (Saudia Arabia/ UAE)
- Marine/oil & gas- FPSOs (Worldwide)
- Marine/oil & gas- Scrubber Units (Worldwide)
- Food/ Chocolate Factory (Singapore)
- Public Utility plant (Singapore)
See also:
- Demister
- Wire Mesh Rolls
Monolith Support Wraps
CSS Knitted Support wraps can be manufactured to varying specifications, each offering a range of different holding forces, typically between 6 and 24 KGF/cm2 in an assembled gap of 2 to 6 mm.
The wire mesh system is compressed in assembly and will maintain the required holding force throughout changes in thermal expansion.
These designs offer assembly times which are 1/3 those of conventional systems.
Variations include:
- wire mesh only
- wire mesh with integral strip of intumescent mat
- wire mesh with a form of insulating fiber material.
A comprehensive range of products is available, from low-cost, stainless steel support wrap to competitively-priced insulating component of fiber and nickel alloys capable of service temperatures in excess of 1000 °C.
Random Packings
A new generation of high-performance random packings.
Bringing to you a better combination of capacity and efficiency.
Ranging from metal to plastic to ceramic and available in a wide variety of designs, you can surely find the packings you need.
Separation Rings
In a ‘twin brick’ converter assembly, a device is needed to maintain a constant gap between the front and rear monoliths.
Conventionally, this involves a pressed metal (usually inconel) clip, which has a tendency to creep with thermal expansion and lift away from its seating position on the edges of the monolith. This allows turbulent gas to travel underneath the clip causing erosion and degradation of the expanding mat.
Separation rings made from flexible knitted wire mesh can overcome all of the above problems. A knitted component does not expand and lift the intumescent mat, nor does it ‘chip’ the edges of the ceramic monolith. Easy to assemble and cost-effective, it can be up to 75% less than a pressed inconel clip.
To further improve the thermal and sealing properties, knitted man-made fibers can be incorporated into the body of the component.
Silencer & Muffler packing
From the same makers of DemisterASIA demister pads, we present:
Wire wool sleeves
Traditionally, perforated tubes are wrapped with stainless steel wool to protect the vulnerable fibrous absorption material pack. As an alternative, CSS can supply a one-piece, flat packed needled tube that is very easily placed over the perforated pipe. The density of the pack is much more evenly distributed than wrapping loose wool, and because the pack is needled together, it is less likely to migrate in operation.
‘Acousta-fil’™
‘Acousta-fil’ is a textile product with outstanding thermal and acoustic insulating properties. It has been designed to expand on initial contact with heat and fills voids to a predetermined density. ‘Acousta-fil’ is produced from a continuous filament, either ‘E’ glass, ‘S’ glass or silica depending on temperature and chemical requirements.
Structured Packings
Well-designed structured packings that allow for maximum air flow.
Bringing to you greater efficiency and efficacy.
Available in a wide range of designs and materials, each with different properties that cater to various specifications or requirements you may have.
Tower Internals
Liquid Collector
Liquid Collector (Type CTC-1)
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Chimney Tray Collector (Type CTC-2)
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Packing Support & Hold down Grid
Grid Type Support GTS (Type GTS)For structured packings |
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Hump Type Support HTS (Type HTS)
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Hold Down Grid HDG (Type HDG)
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