Surfactants and anti-foam chemicals can change droplet size, surface tension, wetting, coalescence, liquid holdup, and drainage. A chemical formulation change can therefore alter mist eliminator performance even when gas flow, separator geometry, and total liquid flow remain unchanged.

Mist eliminator supports in FRP scrubbers require different mechanical design from steel towers because of stiffness, creep, thermal expansion, attachment methods, and local stress. Wet operating load, support spacing, hold-down design, material compatibility, and segmentation should be reviewed together.

High vessel liquid level can increase mist eliminator loading by reducing disengagement space, causing direct splash, restricting drainage, and intensifying foaming effects. Carryover correlated with level excursions should be investigated before modifying the demister.

Mist eliminators for HCl wet scrubbers should be selected from actual gas flow, temperature, HCl and liquid chemistry, droplet characteristics, liquid loading, fouling risk, pressure-drop allowance, vessel material, and support arrangement. Material compatibility alone does not determine the correct separator.

A visible scrubber stack plume does not automatically indicate mist eliminator failure. Water-vapor condensation, fine aerosol, chemical particle formation, and true liquid carryover can all produce visible emissions and require different solutions.