Pulsating gas flow can cause mist eliminator movement, wire wear, vane vibration, joint loosening, unstable drainage, and temporary re-entrainment. Steady-state average velocity alone may not describe the real operating stress.

Startup and shutdown can expose mist eliminators to liquid slugs, condensation, temporary flooding, thermal movement, vibration, and unstable mist loading. These transient conditions should be included in design review and operating procedures.

Foaming can create finer droplets, increase liquid loading, destabilize pressure drop, and accelerate fouling. A mist eliminator selected for normal operation may therefore behave very differently during foam events.

PP and PVDF mist eliminators require mechanical review as well as chemical compatibility review. Lower stiffness, thermal expansion, and long-term creep can cause sagging, vane-spacing changes, compression, and bypass if support and restraint are not designed correctly.

Differential-pressure monitoring can reveal mist eliminator fouling and hydraulic changes, but incorrect pressure tap location, nearby internals, turbulence, blocked impulse lines, or condensation can distort the reading. Instrument layout should be reviewed before diagnosing the separator.