Thermal desalination demisters prevent salt-bearing brine droplets from contaminating distillate. Vacuum operation, high vapor volume, strict product purity, chloride corrosion, scaling, drainage, and bypass control make the application especially demanding.

Biogas and H₂S scrubber mist eliminators must account for variable gas flow, downstream sensitivity, water condensation, sulfur or salt fouling, chemical compatibility, and limited blower pressure. Mesh, vane, or staged separation should be selected from the real process duty.

Ammonia scrubbers can create ammonium salt solutions and fine reaction aerosol that foul mist eliminators through evaporation and crystallization. Separator geometry, wash strategy, chemistry, pressure-drop monitoring, and material selection should therefore be evaluated together.

Mist eliminator design margin should reflect gas-flow variation, liquid loading, fouling, maldistribution, data uncertainty, and operating cases rather than an arbitrary universal safety factor. Excessive oversizing can also create low-velocity performance and cost problems.

Mist eliminators in cold climates can suffer icing in mesh, vane passages, drains, and wash systems. Freezing can block gas area, prevent drainage, raise pressure drop, and damage components during freeze-thaw cycles, especially during shutdown.