Numerical simulations of a demister vane with various geometries and operating conditions were performed to study the separation efficiency. The numerical solutions were carried out using commercial CFD code Fluent 6.1. A prediction model of the separation efficiency was obtained based on response surface methodology by means of the statistical software program Minitab V14. The results show that not only the vane spacing and flue gas velocity, but also vane height (including height of curve and upright region) and vane turning angles, play an important role in influencing the separation efficiency. Compared with some experimental and simulative conclusions, the results indicate that present prediction model can estimate the effects of different geometries and operation conditions on the separation efficiency, and can direct the optimum design of demisters. (C) 2007 Published by Elsevier B.V.