Shutdown inspection should document fouling patterns, edge sealing, segment joints, mesh condition, supports, drainage, corrosion, and vane geometry before cleaning. Comparing these findings with pressure-drop and carryover history can reveal the true cause of mist eliminator problems.

Corrosion can reduce wire strength and collection surface, damage vane geometry, weaken supports, create bypass, and alter pressure drop. Mist eliminator corrosion should therefore be evaluated as both a mechanical and hydraulic performance issue.

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.