In numerous industrial production processes, horizontal mist eliminators play a crucial role. The key structural parameters—such as blade shape, spacing, and arrangement angle—in their structural design directly determine both the airflow permeability and the droplet interception capability of the mist elimination process.

　　First, the blade shape is one of the key factors influencing the mist removal efficiency. Common blade shapes include zigzag, arc-shaped, and wavy designs. Zigzag blades feature high rigidity and stability, enabling them to withstand significant airflow impacts and making them particularly well-suited for conditions with high dust concentrations and fast airflow velocities. For example, in the flue gas mist removal systems of some large-scale thermal power plants, horizontal mist eliminators equipped with zigzag blades can effectively resist the impact of high-speed airflow and maintain structural stability. During the mist removal process, the special zigzag structure on the blade surface causes mist droplets, under the influence of inertia, to collide with the blade surface and then flow along the blade toward the collection trough. According to actual tests, under specific operating conditions, zigzag blades can achieve a mist interception efficiency of over 80% for mist droplets with medium-sized particles or larger, thereby effectively ensuring the normal operation of downstream equipment.

　　Curved blades feature a smoother airflow passage, which reduces airflow resistance and enhances air permeability. In applications where airflow resistance is particularly critical—such as in fine chemical processes within the chemical industry—the horizontal mist eliminators equipped with curved blades perform exceptionally well. Thanks to their unique curved design, airflow can pass through the blades more smoothly, minimizing turbulence and vortices caused by airflow obstruction. This not only lowers the system’s operational energy consumption but also improves the stability of mist removal. In terms of droplet interception, curved blades leverage the centrifugal force of the airflow, causing mist droplets to gradually accumulate on the curved surface and form a liquid film, which eventually flows along the blade into the collection device. In practical applications, these blades demonstrate excellent interception performance even for smaller-sized mist droplets, achieving an overall mist removal efficiency of around 70%.

　　Wavy blades combine the characteristics of both stepped and curved blades, offering both a degree of rigidity and excellent airflow permeability. In some complex industrial environments—such as flue gas treatment systems in the metallurgical industry—horizontal mist eliminators equipped with wavy blades have been widely adopted. The unique wavy structure increases the blade surface area, enhancing the probability of contact between mist droplets and the blades, thereby improving the droplet interception efficiency. At the same time, the wavy design creates a certain degree of turbulence between the blades, which facilitates the separation and capture of mist droplets. Practical verification has shown that, under specific conditions in metallurgical flue gas treatment, wavy blades exhibit relatively balanced interception performance for mist droplets of various particle sizes, with an overall mist elimination efficiency consistently maintained above 75%.

　　The blade spacing is also one of the key parameters affecting the mist-removal efficiency. A smaller blade spacing can increase the probability of collision between mist droplets and blades, thereby enhancing the mist-droplet interception capability. However, it also increases airflow resistance and reduces air permeability. Conversely, a larger blade spacing reduces the mist-droplet interception capability but facilitates smoother airflow. For example, in applications with high requirements for mist-removal efficiency—such as waste gas treatment systems in the pharmaceutical industry—the blade spacing is typically designed to be relatively small, generally ranging from 20 to 30 millimeters, to ensure effective interception of fine mist droplets. On the other hand, in applications where air permeability is more critical—such as the mist-removal stage in ventilation systems—the blade spacing may be appropriately increased to between 40 and 50 millimeters, thus reducing system resistance to airflow.

　　The arrangement angle also significantly influences the demisting performance. A properly chosen arrangement angle can create a flow distribution pattern as the gas stream passes through the demister, thereby enhancing the separation efficiency of mist droplets. Generally, the blade arrangement angle for horizontal demisters typically ranges from 30° to 60°. When the arrangement angle is relatively small, the gas flow velocity over the blade surface is higher, and the inertial effect on the mist droplets is relatively weak, which is not conducive to droplet interception. On the other hand, when the arrangement angle is larger, although the inertial effect on the mist droplets is enhanced, the resistance to gas flow also increases dramatically, potentially leading to a rise in system energy consumption. For instance, in certain industrial flue gas treatment systems, after numerous experiments and optimizations, it was determined that an optimal blade arrangement angle of around 45° strikes a balance: it ensures good droplet interception capability while keeping the system's operational energy consumption within a reasonable range.

　　In summary, the key structural parameters of a horizontal mist eliminator—such as blade shape, spacing, and arrangement angle—directly determine the eliminator’s mist-removal performance by influencing both airflow passage and droplet interception capability. In practical applications, it is essential to rationally select and optimize these structural parameters according to different operating conditions and specific requirements in order to achieve optimal mist-removal performance.