Summary
The Ecologix EvapoDry is a submerged combustion evaporator that uses a low-temperature burner (180°F-186°F) directly immersed in the wastewater to achieve efficient evaporation while preventing vaporization of heavy metals and minimizing organic breakdown. With "zero-fouling" design, energy savings up to 25%, and robust construction, the EvapoDry provides reliable volume reduction for industrial wastewater where traditional methods fall short.
Ready to Reduce Disposal Costs?
The EvapoDry ED-1000 can process up to 1,000 gallons per hour of the most challenging industrial waste
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Introduction
Industrial facilities often face high disposal costs and regulatory limits for wastewater containing dissolved solids, heavy metals, oils, and other contaminants. Thermal evaporation offers a proven method to dramatically reduce wastewater volume, but many systems suffer from fouling, high energy use, or unintended contaminant release. The Ecologix EvapoDry Wastewater Evaporators overcome these limitations through innovative submerged combustion technology.
How the EvapoDry Works
The EvapoDry operates on the principle of submerged combustion evaporation:
- Wastewater is held in a conical-bottom evaporation tank. The tank and wetted materials chosen depend on the corrosive characteristics of the wastewater.
- A partial vacuum is maintained in the evaporation tank to lower the boiling point of the liquid inside.
- A burner (with typical fuel source as natural gas, propane, or butane) is submerged directly in the liquid.
- Combustion gases bubble through the wastewater, transferring heat efficiently and causing evaporation at 180°F-186°F.
- Pure water vapor is released while concentrated solids remain in the tank for periodic removal.
- Exhaust gases are minimal and treated to meet air quality standards.
This direct heat transfer method eliminates the need for electric heating coils that commonly foul in other systems [1].
Key Features of the Submerged Combustion Design
- Low Operating Temperature: 180°F-186°F prevents vaporization of heavy metals and thermal degradation of most organics.
- Flexible Fuel Source: Capable of using a wide array of fuels including landfill gas and flare gas.
- Zero-Fouling Technology: Direct bubble contact helps prevent scale buildup on tank and other heated surfaces.
- High Thermal Efficiency: Up to 25% energy savings compared to serpentine tube or hot plate evaporators.
- Corrosion-Resistant Construction: Available with optional corrosion packages for aggressive chemistries.
- Automatic Operation: Includes oil skimmer, sludge auger, auto-fill, and controls for hands-off performance.
- Scalable Models: Capacities from small units to high-volume systems (e.g., ED-1000 at 1,000 GPH).
Advantages Over Traditional Evaporators
| Factor | EvapoDry Submerged Combustion | Traditional Electric / Tube Evaporators |
|---|---|---|
| Fouling / Scaling | Virtually none ("zero-fouling") | Common; requires frequent cleaning |
| Energy Efficiency | High (up to 25% savings) | Lower due to heat transfer losses |
| Heavy Metals Vaporization | Eliminated (low temp) | Possible at higher temperatures |
| Organic Breakdown | Minimal | Higher risk |
| Maintenance | Low | High (coil/tube cleaning) |
| Operating Cost | Lower long-term | Higher due to energy and downtime |
These advantages make the EvapoDry particularly effective for challenging streams and/or remote operation [2].
Applications and Industries Served
- Machining and metalworking (coolants, wash water with metals)
- Food and beverage processing (high-organic rinse water)
- Landfill leachate volume reduction
- Mining and metals recovery wastewater
- Oil & gas produced water
- Manufacturing rinse and process effluents
The system excels where wastewater has high concentrations of dissolved solids (TDS), FOG, or dissolved metals that would foul or vaporize in other evaporators.
Challenges Addressed
- High energy consumption in evaporation
- Frequent downtime from fouling and cleaning
- Regulatory concerns over airborne heavy metals
- High disposal costs for untreated wastewater
- Handling variable or corrosive streams
Solutions and Recommendations
- Conduct a wastewater analysis to confirm suitability.
- Select the appropriate model based on evaporation rate needs.
- Integrate with pre-treatment (e.g., DAF or clarifiers) for optimal performance.
- Request a site evaluation and quote from Ecologix Environmental Systems at Evaporator Request Form.
- Consider energy audits to quantify long-term savings.
Conclusion
The Ecologix EvapoDry Wastewater Evaporators deliver reliable, low-maintenance, and cost-effective volume reduction for industrial wastewater. By leveraging submerged combustion at low temperatures, the system avoids common pitfalls of fouling, high energy use, and contaminant release. Facilities seeking to lower disposal costs and simplify wastewater management should consider this advanced technology.
Ready to Reduce Disposal Costs?
The EvapoDry ED-1000 can process up to 1,000 gallons per hour of the most challenging industrial waste
Contact UsGlossary
- Submerged Combustion: Direct firing of a burner beneath the liquid surface for heat transfer.
- Zero-Fouling: Design that prevents scale or buildup on heat transfer surfaces.
- GPH: Gallons per hour, a measure of evaporation capacity.
Frequently Asked Questions (FAQ)
Q: What temperature does the EvapoDry operate at?
A: Approximately 180°F to 186°F, low enough to avoid vaporizing heavy metals.
Q: How does it prevent fouling?
A: Direct bubble contact from submerged combustion eliminates traditional heat exchanger surfaces that scale.
Q: Is the EvapoDry suitable for corrosive wastewater?
A: Yes, with optional corrosion-resistant packages.
Q: What fuels can it use?
A: Natural gas (including landfill and oil well flare gas), propane, butane, and potentially others.
Bibliography
- American Petroleum Institute. “Design and Operation of Oil-Water Separators,” API Publication 421, 1990.
- [1] Ecologix Environmental Systems, "EvapoDry Wastewater Evaporators
- [2] Ecologix Environmental Systems, "The Heat is On: Why Submerged Combustion Evaporators Are Outperforming Electric
Related Products
EvapoDry Wastewater Evaporators
The EvapoDry employs a submerged, low temperature burner to evaporate solutions at approximately 180° F - 186° F, eliminating the vaporization of heavy metals and the organic breakdown of most solids.