I. First, Identify the Two Main Causes

Fog carryover: Fine droplets and foam generated by boiling are carried by steam into the condenser, resulting in condensate that exceeds permissible limits for salts, COD, and heavy metals.

Equipment leaks: Damage to heat exchange plates, welds, or seals allows the feed solution to enter the condenser side.

II. Operational Process Adjustments (Rapid Mitigation of Liquid Carryover)

Control the liquid level inside the reactor

If the liquid level is too high, there is insufficient space for gas-liquid separation, making it highly likely for boiling liquid to splash into the steam lines; maintain the equipment at the calibrated low-to-medium liquid level to reserve sufficient steam buffer space.

Reduce the circulation flow rate

Excessive circulation flow causes violent churning in the chamber, generating large amounts of water mist; appropriately lower the circulation pump frequency to ensure stable evaporation.

Strictly Control the Concentration Ratio

If the waste liquid is oversaturated with salts, it will continuously foam and cause crystallization and splashing. Once the set concentration is reached, promptly discharge the concentrated liquid; do not force further concentration.

Add Specialized Defoaming Agents

Painting waste, emulsions, and wastewater with high organic content are prone to foaming. Add a small amount of high-temperature-resistant defoaming agent to prevent foam from escaping with the steam.

Stabilize Vacuum and Evaporation Temperature

Fluctuating vacuum levels and drastic temperature swings can cause violent boiling. Maintain a stable, low-temperature evaporation range to minimize violent boiling.

III. Maintenance and Optimization of the Gas-Liquid Separation System (To Eliminate Steam Carryover)

Inspect the Gas-Liquid Separator

The most common issues involve loose, damaged, or clogged internal baffles, wire mesh packing, and demister screens. Replace corroded packing promptly and regularly flush out salt sludge.

Upgrade the Multi-Stage Separation Structure

In cases of severe liquid carryover, install a secondary wire mesh demister and cyclone separator to intercept microscopic liquid droplets.

Clear Liquid Accumulation from Steam Piping

Waste liquid accumulated at the bottom of pipes can flow back and contaminate the condensate. Install additional drain valves to periodically discharge residual liquid from the piping.

IV. Investigate Excessive Water Discharge Caused by Equipment Leaks

Pressure Test Heat Exchanger Plates / Coils

If condensate consistently and stably exceeds standards without obvious foam or liquid carryover, it is highly likely that the heat exchange plates have corroded and perforated; shut down the system and perform a hydrostatic test to locate leaks, then replace damaged plates immediately.

Replace Aged Sealing Gaskets

Corrosion and leakage in chamber and condenser flange seals can cause concentrated waste liquid to seep into the clean water side; regularly replace PTFE and silicone corrosion-resistant gaskets.

Inspect condenser welds and joints

Long-term corrosion of welds by high-salt media causes micro-leaks; perform weld repair and anti-corrosion treatment.

V. Upstream Pretreatment: Reducing Volatile and Entrained Contaminants at the Source

First, demulsify and remove oil from high-oil wastewater

Oil contamination forms stable foam; use upstream oil separation and flocculation filtration to remove floating oil.

Pre-treat high-hardness wastewater to remove hardness

Reduce foaming and splashing caused by salt crystallization.

Install degassing tanks for highly volatile organic waste liquids

Separate volatile organic compounds in advance to prevent COD levels from exceeding standards after organic vapors condense.

VI. Daily Maintenance and Preventive Measures

Flush the demister mesh weekly to remove adhered salt crystal sludge;

Avoid overloading the equipment to minimize boiling surges;

Monitor the conductivity of the condensate in real time; immediately shut down the unit and investigate if the value suddenly rises;

Periodically clean the chamber with acid and alkali to reduce localized violent boiling caused by scale buildup on the inner walls.