New insights into the structural integrity of glass fibre mist eliminators

Mist eliminators are critical components in gas purification systems, effectively removing entrained aerosols and fine particulates. The performance of these eliminators is highly dependent on the physical properties of the coalescing media, particularly the type and quality of glass fibres used. This study brings advancement in scientific insights of industrial glass fiber system by establishing a clear structure performance relationship for glass fiber materials used in mist eliminators. A combination of advanced characterization techniques (ICP-OES, SEM, BET surface area, permeability test, XRD, acid resistance test) was employed to assess structural, textural, and functional properties of various conventional and alternative glass fibre materials. The pore size distribution and permeability testing studies demonstrated that larger fiber diameters and wider pore distributions compromise packing density and mist capture efficiency, whereas controlled pore size and uniform distribution enhances droplet–fiber interaction, coalescence, and pressure stability. The results reveal that among the alternate fibres studied, GF-A exhibited properties most comparable to the reference conventional glass fibre, including high acid resistance, uniform fibre diameter, appropriate surface area, and optimal gas flow characteristics. While GF-C, though chemically stable, was eliminated due to oversized pores and poor coalescence performance. Accordingly, this work provides a validated framework for selecting coalescing materials in industrial gas purification systems, ensuring long-term catalyst protection and operational reliability. • A systematic methodology was developed for evaluating glass fibre materials used in mist eliminators. • Fibre samples were characterized using acid stability testing, SEM, ICP-OES, BET surface area analysis, fibre diameter measurement, XRD, pore size distribution, and nitrogen flow (permeability) testing. • Nitrogen flow and mean pore diameter analysis provided insights into filtration efficiency and gas permeability of the fibres. • Select alternative fibres exhibited comparable physico-chemical properties to conventional glass fibres, including pore structure and flow characteristics. • Acid resistance, fibre diameter, elemental composition, surface area, and pore size distribution of alternative fibres met industrial performance standards.