Battery-recycling acid scrubbers handling lead-containing particulate should be evaluated for wet sludge formation, lower-bed fouling, solids recirculation, distributor blockage, demister contamination, upstream particulate control, cleaning access, and controlled waste handling in addition to acid compatibility and gas removal.

Hot-dip galvanizing and flux-fume scrubbers should be evaluated for zinc/ammonium/chloride-containing aerosol or salt loading, gas cooling, recirculation concentration, distributor crystallization, packing fouling, demister deposits, and blowdown. Increasing packing efficiency alone does not control the accumulation of captured flux material.

For fertilizer or phosphoric-acid scrubbers handling fluoride species and phosphate-containing solids, evaluate gas chemistry, particulate load, wet deposit behavior, packing openness, distributor blockage, solids removal, demister fouling, and complete material compatibility. A chemically resistant packing can still fail hydraulically if reaction or process solids accumulate throughout the liquid loop.

Plastic packing and fabricated polymer internals can be chemically suitable for a scrubber while becoming more vulnerable to impact during very cold shutdown, storage, installation, or startup. Minimum design temperature, resin grade, handling method, thermal transition, support restraint, and fracture evidence should be reviewed separately from normal corrosion resistance.

When a saline scrubber evaporates significant water, dissolved salts can concentrate until crystals appear on packing, distributor outlets, demisters, and tower walls. Level control alone does not control salt inventory. Blowdown, conductivity, evaporation, shutdown drying, packing openness, and separator washability should be managed together.