Emirates Steel is a leading integrated steel manufacturer in the UAE, located in Abu Dhabi’s Industrial City. Established in 1998, Emirates Steel has grown to become a significant player in the global steel industry, producing a range of products including rebar, wire rods, heavy sections, and sheet piles. The company operates state-of-the-art facilities that include direct reduction plants, electric arc furnaces, and rolling mills, ensuring it can meet both regional and international market demands for high-quality steel products.

The client was facing issues with existing demister failure at the gas compressor aftercooler due to improper removal of mist in the upstream pressure vessels. To mitigate this issue, Emirates Steel was increasing the size of the demister which will theoretically improve the separation efficiency of the liquid from the gas stream. Prior to carrying out the implementation at the site, the client wants to carry out CFD Analysis to predict and validate the performance and its effectiveness in removing the wetness from the gas stream thereby assuring better process and mechanical integrity of the new demister.

Mechartes was entrusted with carrying out the CFD Analysis to simulate the gas flow inside the three pressure vessels, namely, Process Gas Quench Tower, Process Gas K.O Drum, and Process Gas Compressor Aftercooler.

Apart from gas flow simulation, the CFD model was able to simulate the droplet dispersion and evaporation inside the pressure vessel to predict the wetness of the gas stream at the outlet of each pressure vessel. Mechartes began the project with a survey of the vessels to gather initial inputs and conducted additional studies to verify the support and mechanical robustness of the new demister installation. Ultimately, the analysis provided process and design assurances to Emirates Steel, helping to mitigate existing demister failure issues and optimize operational efficiency.