1. Core influencing factors: Water quality characteristics (determining wear rate). Water quality complexity is the primary variable affecting consumable wear, directly impacting the service life of consumables and subsequently driving up or down replacement costs. Corrosivity: Wastewater containing chloride ions, strong acids and alkalis, and heavy metals (such as electroplating and chemical wastewater) can accelerate the corrosion and aging of seals (sealing rings, gaskets), valves, and pipeline inner walls. Ordinary rubber seals can only be used for 1-2 months in high chloride wastewater, while corrosion-resistant materials can only last for 3-6 months; if it is neutral low-corrosivity wastewater (such as food wastewater), the lifespan of seals can be extended to 6-12 months, with replacement frequency halved and costs significantly reduced.

Impurity content and scaling: High suspended solids and high hardness wastewater (such as landfill leachate and mine wastewater) are prone to clogging filter cartridges and wearing pump seals. At the same time, scaling can exacerbate the wear of pipeline valves, resulting in a shortened filter cartridge replacement cycle from 1-2 months to 1-2 weeks, and an increase in valve maintenance and replacement frequency by more than 40%. After pretreatment (filtration, softening), the lifespan of consumables can be significantly extended.

Special component impact: Materials containing organic solvents and heat-sensitive components (such as pharmaceutical and fine chemical wastewater) may dissolve or degrade some high molecular consumables (such as plastic seals), necessitating replacement with specialized solvent-resistant materials (such as fluororubber). However, the unit price of specialized consumables is 2-3 times higher than that of ordinary consumables, directly increasing the replacement cost.

II. Key Variables: Selection of Consumable Materials (Balancing Lifespan and Unit Price) The adaptability and quality of consumable materials determine the comprehensive cost of "replacement frequency × unit price". Deviations in selection can lead to cost imbalance: Material Adaptability: For corrosive wastewater, valves and pipeline fittings made of titanium alloy and Hastelloy materials are selected. Although they are expensive, their lifespan is 3-5 times that of ordinary 316L stainless steel. Seals made of fluororubber and polytetrafluoroethylene (PTFE) are more resistant to corrosion and wear than ordinary nitrile rubber, extending their lifespan by 2-3 times and resulting in lower long-term comprehensive costs.

Consumable quality level: Although the unit price of original genuine consumables is 10%-30% higher than that of non-genuine parts, their material purity and dimensional accuracy are superior, and their lifespan can be extended by more than 50%. Additionally, they can avoid equipment failures caused by consumable damage (such as downtime due to seal leaks), reducing hidden losses. Non-genuine parts may seem cheaper, but they may drive up the total cost due to frequent replacement.

III. Basic Factors: The cumulative wear and tear effect of equipment operation is directly determined by the operation duration and load rate, which directly affects the cumulative wear and tear of consumables. The higher the intensity, the shorter the replacement cycle: Operation duration: Equipment operating continuously for 24 hours has a wear and tear rate of consumables that is 2-3 times higher than equipment operating intermittently (8 hours per day). The replacement frequency of seals, vacuum pump oil, and filter cartridges increases accordingly, and the annual replacement cost can be more than twice that of equipment operating intermittently.

Operating load rate: When the equipment operates at over 70% of its rated load for an extended period, the pressure and friction intensity experienced by the pump body, valves, and seals remain stable, with uniform wear and tear. However, frequent overload operations (such as handling capacities exceeding the rated value) can exacerbate component wear, leading to a 30%-40% reduction in the lifespan of consumables and a corresponding increase in replacement costs.

IV. Controllable Factors: Maintaining Operational Standards (Reducing Abnormal Wear and Tear) Standardized operation and maintenance can prevent abnormal damage to consumables and extend their service life. Conversely, it will incur additional costs. Frequency of Routine Maintenance: Regular cleaning of filter elements, replacement of vacuum pump oil, and inspection of seal integrity can prevent excessive wear of consumables caused by impurity accumulation. If maintenance is neglected, clogged filter elements can lead to excessive pressure in the pump, accelerate seal damage, and increase replacement frequency.

Operational standardization: When starting and stopping equipment, follow established procedures (such as slowly adjusting pressure and temperature) to avoid instantaneous shocks that could damage valves and seals. Before adding materials, perform pre-treatment to remove large impurities, which can reduce wear on filter elements and pump bodies and lower replacement costs.

Timeliness of fault handling: Timely replacement of slightly damaged consumables (such as minor leakage of seals) can prevent damage from spreading to other components (such as pipeline corrosion and pump body wear), reducing the associated replacement costs. Delayed handling may lead to multiple component damages, doubling the replacement costs.

V. Auxiliary Factors: Equipment Technology Type (Differences in Consumable Types) Different types of low-temperature evaporators have different consumable types and wear and tear focuses, which directly affect the composition of replacement costs: MVR model: The core consumables are compressor seals, vacuum pump oil, and filter cartridges. Compressor seals have a high unit price (several thousand yuan per set) due to their high pressure resistance, but they have a long replacement cycle (1-2 years);

Common vacuum low-temperature evaporator: The consumables are mainly seals, filter elements, and valves, which have a lower unit price but require higher replacement frequency. The annual comprehensive cost is not significantly different from that of MVR models;

Scraper/falling film models: These models additionally involve scraper seals and distributor components, which are specialized consumables with high unit prices. Their replacement intervals are significantly influenced by material viscosity, resulting in more pronounced cost fluctuations.

The core of optimizing the cost of consumable replacement lies in "selecting the right material for the water quality + standardizing operation and maintenance to extend lifespan + balancing quality and unit price". Typically, this accounts for 10%-15% of the total operating cost of low-temperature evaporators, but can be reduced to below 8% after optimization.