Optimize operating parameters to match actual working conditions

Accurate control of vacuum degree and temperature: The energy consumption of low-temperature evaporators is positively correlated with vacuum degree and heating temperature. If the vacuum degree is too high and the heating temperature exceeds the actual demand, it will cause energy waste. Parameters need to be adjusted according to the boiling point and concentration of the wastewater being treated. For example, when treating high salt wastewater, the vacuum degree can be controlled within a reasonable range while ensuring the evaporation effect, to avoid blindly pursuing "lower temperature".

Adjust the feed load: avoid overloading operation, as excessive feed volume can lead to a decrease in evaporator heat transfer efficiency and a surge in energy consumption; It is also necessary to prevent low load idling, as the proportion of equipment heat loss during idling is high. It is recommended to use frequency conversion control to adjust the feed pump speed according to the amount of wastewater generated, in order to achieve the matching of load and energy consumption.

Strengthen equipment maintenance and restore heat transfer efficiency

Timely cleaning of scaling on the heat exchange surface: Calcium, magnesium ions, suspended solids, and other substances in wastewater can easily form scale or dirt on the surface of the heat exchange tube, leading to a significant decrease in heat transfer coefficient and requiring more energy consumption to maintain evaporation. Chemical cleaning (such as citric acid or hydrochloric acid pickling) or physical cleaning (such as high-pressure water flushing or mechanical scaling) can be used regularly to remove scale, and the cleaning cycle is set according to the water quality (usually once every 1-3 months).

Check the sealing and insulation performance: Poor sealing of the vacuum system can lead to a decrease in vacuum degree, and the equipment needs to be continuously vacuumed to maintain working conditions, increasing the energy consumption of the vacuum pump; Damage to the insulation layer of the evaporator cylinder and pipeline can cause significant heat loss. Regularly check whether the vacuum seals (such as sealing rings and flange gaskets) are aging and replace them in a timely manner; Repair the damaged insulation layer using efficient insulation materials such as rock wool and polyurethane to reduce heat loss.

Upgrade equipment configuration to reduce energy consumption

Replace high-efficiency energy-saving components: Replace traditional circulation pumps and vacuum pumps with frequency conversion energy-saving models, which can automatically adjust the speed according to working conditions and reduce no-load energy consumption; Replace the heating tube with titanium alloy or high-efficiency threaded tube to improve heat transfer efficiency and reduce heating time.

Installation of waste heat recovery device: The secondary steam and condensate generated by the evaporator carry a large amount of waste heat, which can be recovered through a heat exchanger for preheating feed wastewater or heating the plant area. For example, using the latent heat of secondary steam to preheat low-temperature feed can reduce the heat load of the heating system and reduce energy consumption by 15% -30%.

Optimize pretreatment process to reduce evaporation difficulty

Pre treatment to remove impurities and high boiling point substances: Suspended solids, colloids, and high boiling point organic matter in wastewater can increase the heat transfer resistance of the evaporator and may also accelerate scaling. Impurities can be removed through pretreatment processes such as flocculation sedimentation, filtration, and activated carbon adsorption, reducing wastewater viscosity and improving the heat transfer efficiency of the evaporator, thereby reducing energy consumption.

Quality based treatment of high concentration wastewater: If the inflow concentration fluctuates greatly, the high concentration wastewater directly entering the evaporator will increase the evaporation load. Batch evaporation or dilution adjustment can be used to control the concentration of wastewater within the optimal treatment range of the equipment, avoiding energy consumption increase caused by high concentration.