Wet FGD scrubbers expose mist eliminators to slurry droplets, salts, chlorides, high gas volume, and repeated washing. Open vane or chevron geometry, effective wash coverage, drainage, corrosion resistance, gas distribution, and sustainable pressure drop are key design considerations.

Rectangular and non-circular mist eliminators require evaluation of local gas distribution, corners, structural blockage, modular joints, drainage, upstream elbows, and installation access. Average velocity based on width × height alone can hide severe local overload.

Mist carryover can rise at constant gas flow when higher liquid circulation increases spray entrainment, packed-bed holdup, demister wetness, and drainage demand. Gas velocity alone is therefore insufficient for diagnosing separator overload.

Caustic scrubber mist eliminators can foul because absorbed gases react with alkaline liquid to form dissolved salts that later concentrate or crystallize inside the separator. Material compatibility, salt chemistry, open geometry, drainage, washing, and DP monitoring should be evaluated together.

Marine and seawater scrubber mist eliminators must address chloride corrosion, salt crystallization, suspended solids, gas-load variation, vessel motion, support stability, wash systems, and restricted maintenance access. Long-term cleanability and mechanical stability are as important as initial droplet removal.