MESHIUM

Engineering Tool

Demister Sizing Calculator

Souders-Brown first-pass sizing: Vmax = K √((ρL − ρV) / ρV). Pick a K factor for your service, enter actual gas flow and densities.

Operating Conditions

K = 0.107 m/s (0.35 ft/s) — most common starting point for SS304/SS316L pads at near-atmospheric pressure.

Sizing Result

Max allowable velocity Vmax (Souders-Brown)
3.084m/s(10.12 ft/s)
Design velocity (75% of flooding)
2.313m/s
Required pad cross-section area
0.6m²
Equivalent pad diameter (round, vertical vessel)
0.874m(874 mm)
Get a Verified Sizing & Quote →

Send us these numbers plus temperature, pressure, medium and tower drawing — we return a checked design with material recommendation within 24 hours.

Engineering Disclaimer — Demister Sizing Calculator (Souders-Brown) (v1.0, updated 2026-07)

This tool provides preliminary estimates only, based on generalized correlations and typical service assumptions. Actual performance depends on operating conditions, fouling, turndown, mist load, and vessel internals. Results must be verified by a qualified process engineer before purchase or fabrication. Meshium accepts no liability for decisions made solely on this output.

References: GPSA Engineering Data Book (14th ed.), Perry’s Chemical Engineers’ Handbook (9th ed.), ASTM E2016-20.

Want a checked design? Send us your operating conditions — our engineers reply within 24 hours with a verified sizing and quotation.

How this calculation works

The Souders-Brown equation sets the maximum superficial vapor velocity a mesh pad can handle before liquid re-entrainment (flooding). The K factor bundles droplet drag and service experience: 0.107 m/s (0.35 ft/s) is the common starting point for knitted mesh pads near atmospheric pressure, derated for high pressure, vacuum or co-knit designs.

Designers usually run pads at 30–110% of Vmax, targeting ~75% for the best balance of efficiency and turndown. The required flow area then follows from your volumetric flow, and the pad diameter from simple geometry. Real vessels also need allowance for support rings, liquid drainage and inlet distribution — which is exactly what our engineering review covers.