Patent ID: 8083827

Claim:
A method for making a mist collector pad comprising: (a) forming a first zone of the mist collector pad by stacking one or more layers of a knitted wire mesh tube that has been (i) flattened and (ii) crimped twice; (b) forming a second zone of the mist collector pad by stacking one or more layers of a knitted wire mesh tube that has been (i) flattened and (ii) crimped once; (c) forming a third zone of the mist collector pad by stacking one or more layers of a knitted wire mesh tube that has been (i) flattened and (ii) crimped twice; and (d) securing the first, second, and third zones in a grid which is used to install the mist collector pad in a process gas stream so that during use of the mist collector pad, the first zone is upstream of the second zone and the second zone is upstream of the third zone; wherein: (I) the density of the second zone is greater than the density of the first zone; (II) the density of the second zone is greater than the density of the third zone; and (III) the wire meshes of the first, second, and third zones are selected so that during use of the mist collector pad, liquid droplets in a process gas stream land on the wire meshes, coalesce on the meshes, and then run off from the meshes due to gravity.