Pre processing: Remove impurities to ensure stable operation of equipment

Core purpose: To filter large particle impurities, floating oil, and suspended solids in wastewater, neutralize strong acids and alkalis, and avoid problems such as pipeline blockage, equipment corrosion, and scaling in subsequent evaporation processes. The pretreatment process is simple and can be easily implemented by small and medium-sized enterprises.

The wastewater first enters the raw water collection tank to temporarily store the industrial wastewater to be treated, balancing the inflow and water quality to avoid instantaneous water fluctuations affecting equipment operation;

By lifting the pump, the wastewater is transported to the pretreatment unit, which then passes through a precision filter (50-100 mesh) to filter out large particle impurities, and an oil separator/air flotation machine to remove floating oil and emulsified oil (for oily wastewater such as hardware and painting);

If the wastewater is of strong acid/strong alkali water quality, it will go through a pH neutralization tank and automatically add an acid-base regulator to adjust the pH value to a suitable range of 6-8. The matching mixing device will make the neutralization more uniform;

The pre treated standard wastewater enters the intermediate buffer tank and waits to enter the main evaporation system. The water inlet is automatically controlled by the liquid level sensor throughout the process, without the need for manual operation.

Core evaporation: Vacuum low-temperature boiling, achieving preliminary concentration of wastewater

Core objective: To use vacuum negative pressure to reduce the boiling point of water, allowing wastewater to boil and evaporate at a low temperature of 30-40 ℃, separating most of the water, and forming a high concentration concentrated solution from the remaining wastewater.

The pre treated wastewater in the buffer tank is fed into the evaporation tank (main chamber of evaporation) at a constant speed according to the set flow rate through a metering feed pump. The feed rate matches the evaporation efficiency to avoid the liquid level in the evaporation tank being too high/too low;

The vacuum system inside the evaporation tank continuously extracts air to maintain a negative pressure environment of -0.08~-0.095MPa inside the tank, reducing the boiling point of the wastewater to the low temperature range;

The heating components (heating tubes/heating plates) on the outside/inside of the evaporation tank continuously provide low-temperature thermal energy to heat the wastewater to the set boiling point. The wastewater quickly boils under negative pressure, producing a large amount of water vapor. The remaining wastewater in the tank is continuously concentrated due to water evaporation, forming a high salt/high COD concentrated solution.

Gas liquid separation: purifying water vapor and improving the quality of recycled clean water

Core objective: To separate tiny wastewater droplets and impurities carried in water vapor, avoid contaminating subsequent condensate water, ensure effluent quality meets standards, and reduce material loss.

The water vapor generated in the evaporation tank will first enter the gas-liquid separator, and through the dual effects of centrifugal separation and baffle filtration, the tiny concentrated droplets and suspended solids carried in the water vapor will be completely separated;

The separated concentrated liquid will flow back to the evaporation tank for further concentration, and the purified pure water vapor will enter the condensation system, which is the key to ensuring the reusability of the condensed water.

Condensation recovery: water vapor is converted into clean water, realizing the reuse of water resources

Core objective: To cool pure water vapor into liquid clear water, collect it and reuse it in the production line or discharge it in compliance with standards, and achieve the resource utilization of water resources.

The purified water vapor enters the condenser, and the cooling circulating water (or chiller) inside the condenser exchanges heat with the water vapor, allowing the water vapor to quickly cool and liquefy, forming liquid clear water (condensed water);

The condensate water flows into the condensate collection tank, which is equipped with water quality monitoring sensors (conductivity, pH) to monitor the water quality in real time. If the water quality meets the standard, it is transported to the production line in the factory area (such as cleaning, spraying) for reuse through the reuse water pump, or directly discharged to the municipal pipeline network;

If the water quality temporarily fails to meet the standard, it will automatically flow back to the raw water collection tank for reprocessing, avoiding the discharge/reuse of unqualified water. The real-time water quality data throughout the process will be displayed in the control cabinet, and an automatic alarm will be triggered for any abnormalities.

Bottom up of slag discharge: Drying/collection of concentrated liquid to reduce the amount of hazardous waste disposal

Core objective: To collect and dry the high concentration concentrated solution continuously concentrated in the evaporation tank, significantly reduce the volume, and outsource disposal to reduce the cost of hazardous waste treatment for enterprises.

The wastewater in the evaporation tank is continuously evaporated, and when the concentration of the concentrated solution reaches the set value (such as TDS ≥ 20000mg/L), the liquid level/concentration sensor will trigger the slag discharge command;

The concentrated solution is sent to the concentrated solution collection tank for temporary storage through the slag discharge pump, or directly sent to the drying machine (such as scraper drying, spray drying) for drying treatment to convert the liquid concentrated solution into solid dry slag;

Dry residue or concentrated liquid is regularly removed by professional hazardous waste disposal units. Compared to the original wastewater, the concentration reduction rate can reach 80% -95%, significantly reducing the amount and cost of hazardous waste disposal;

After the slag discharge is completed, the equipment will automatically start the online cleaning program, inject cleaning water (or specialized descaling agent) into the evaporation tank and pipeline, clean the scale and residual impurities, ensure the efficiency of the next operation, and the cleaning wastewater will flow back to the raw water collection tank for reprocessing.

Full process assistance: system linkage control to ensure stable and fully automatic operation of equipment

In the entire process, the PLC control cabinet serves as the "brain", collecting real-time parameters such as vacuum degree, temperature, liquid level, water quality, flow rate, etc., and automatically adjusting the operating status of the vacuum pump, heating components, and various pump valves;

At the same time, it is equipped with a cooling water circulation system (to ensure condensation effect), a non condensable gas discharge valve (to discharge harmful gases generated during evaporation and maintain vacuum degree), and a fault alarm system (to sound and light alarms and automatically stop the machine for protection in case of abnormal parameters), which can achieve one click start stop and unmanned operation throughout the process. Only regular inspections and simple maintenance by staff are needed for daily operation.

Core highlights of the process

Low temperature throughout the process: operating at 30-40 ℃ without high temperature scaling or coking issues, suitable for various types of difficult to degrade industrial wastewater;

Fully automated: No manual intervention is required from water intake to slag discharge, solving the pain point of insufficient operation and maintenance manpower for small and medium-sized enterprises;

Resource recycling: Condensed water can be directly reused, and the volume of concentrated liquid can be greatly reduced, balancing environmental protection and economic benefits;

Closed loop without secondary pollution: no high temperature exhaust gas, VOCs emissions, cleaning wastewater reflux treatment, in line with environmental compliance requirements.