CONQINPHI 5TPH Triple Effect Evaporator for Silica Wastewater Treatment — Indonesia Project Case

H1: How CONQINPHI Delivered a 5-Ton-Per-Hour Triple Effect Evaporator for White Carbon Black Wastewater Recovery

White carbon black wastewater treatment remains one of the most technically demanding challenges in the silica manufacturing sector. High salinity, elevated COD levels, and corrosive chemical residues make conventional evaporation systems unreliable for long-term industrial operation. In this case study, we examine how CONQINPHI designed, manufactured, and commissioned a triple effect evaporator capable of processing 5 tons per hour of concentrated silica effluent for a major producer in Indonesia.

The project required a system that could operate continuously at 7200+ annual hours while maintaining thermal efficiency above 85% and achieving zero liquid discharge (ZLD) compliance under local environmental regulations. CONQINPHI’s engineering team in Qingdao Jiaozhou collaborated with the client’s process engineers for eight weeks before finalizing the thermal and mechanical design. This article details the technical specifications, on-site performance, and why Southeast Asian, Russian, and Latin American silica manufacturers increasingly specify CONQINPHI evaporation systems for their white carbon black wastewater treatment lines.

H2: Project Background and Technical Requirements

H3: Client Profile and Wastewater Characteristics

Their white carbon black wastewater treatment stream originated from three production lines:

• Flow rate: 4.8–5.2 t/h (design basis: 5.0 t/h)

• Inlet TDS: 85,000–120,000 mg/L (primarily Na₂SO₄ and trace silicic acid)

• COD: 3,200–4,800 mg/L

• pH: 9.5–11.2

• Temperature: 55–65°C

• Corrosive elements: Chloride content up to 800 ppm

The client had previously operated a single-effect forced circulation evaporator. Steam consumption exceeded 1.15 kg per kg of water evaporated, and scaling on heating tubes required chemical cleaning every 72 hours. Downtime was costing approximately $18,000 per month in lost production and maintenance labor.

H3: Why a Triple Effect Evaporator Was Specified

After analyzing steam economy, CAPEX, and operational reliability, CONQINPHI proposed a triple effect evaporator with falling film configuration in Effect 1 and forced circulation in Effects 2 and 3. This hybrid approach addressed two critical constraints:

1. Falling film in Effect 1 handles the high-temperature, low-concentration feed efficiently, minimizing scaling risk during the initial concentration phase.

2. Forced circulation in Effects 2 and 3 manages the high-viscosity, high-solids brine that characterizes late-stage white carbon black wastewater treatment.

The theoretical steam economy of a triple effect evaporator is approximately 0.35 kg steam per kg water evaporated — a 70% reduction compared to the client’s existing single-effect unit. Over a ten-year operational life, this translates to steam cost savings exceeding $2.4 million at current Indonesian industrial gas prices.

H2: CONQINPHI Engineering and Manufacturing Execution

H3: Thermal Design and Material Selection

CONQINPHI’s Process Engineering Division in Qingdao Jiaozhou performed rigorous heat transfer calculations using MDP software. Key design parameters included:

Material selection was critical due to the chloride-induced stress corrosion cracking risk in white carbon black wastewater treatment applications. CONQINPHI specified:

• Effect 1 heating tubes: S2205 duplex stainless steel (ASTM A789)

• Effects 2 & 3 heating tubes: S2507 super duplex for high-chloride zones

• Flash vessels and separators: 316L stainless steel with 3 mm corrosion allowance

• Pumps and recirculation lines: CD4MCu duplex cast stainless steel

H3: Manufacturing at CONQINPHI Production Bases

CONQINPHI GROUP operates dual manufacturing capabilities to ensure competitive lead times and quality control:

• Primary production base: Xinyang, Guangshan, Henan Province — 100,000 m² facility dedicated to large-scale evaporator and crystallizer fabrication, equipped with CNC plasma cutting, automatic submerged arc welding, and 50-ton overhead cranes.

• Secondary facility: Qingdao Jiaozhou, Shandong Province — 80,000 m² plant specializing in precision finishing, skid-mounted system integration, and pre-commissioning testing.

For this Indonesia project, the three flash vessels were fabricated in Xinyang and transported to Jiaozhou for heat exchanger tube insertion, piping integration, and hydrostatic testing. This dual-base workflow reduced the total manufacturing cycle to 14 weeks — four weeks faster than a single-facility approach.

CONQINPHI’s annual production capacity exceeds 180 evaporator units across all effect configurations, with triple effect evaporator systems representing approximately 40% of output. The company maintains raw material inventories of duplex stainless steel sufficient for 35 units, insulating clients from global supply chain volatility.

H2: On-Site Installation and Commissioning Results

H3: Modular Skid Delivery and Rapid Erection

The entire triple effect evaporator system was pre-piped and pre-wired on three structural skids in Jiaozhou. This modular approach reduced on-site installation time in Indonesia from an estimated six weeks to eleven days. CONQINPHI dispatched a four-person commissioning team including a senior process engineer, a welding inspector, an automation specialist, and a local project coordinator fluent in Bahasa Indonesia.

Key commissioning milestones:

• Hydrostatic test: 1.3× design pressure, zero leakage over 24 hours

• Vacuum leak test: System reached -0.092 MPaG within 15 minutes; leak rate <0.5 kPa/h

• Steam trial run: Achieved design evaporation rate of 5,080 kg/h at 0.48 MPaG steam pressure

• 72-hour continuous run: Average steam consumption 0.38 kg/kg water, within 8% of design prediction

H3: Performance Validation and Client Acceptance

After thirty days of commercial operation, the client’s engineering department issued a formal acceptance certificate. Measured performance versus guarantees:

The extended cleaning interval — from 72 hours on the old single-effect unit to 840 hours on the new triple effect evaporator — represented the most significant operational improvement. The client attributed this to CONQINPHI’s proprietary anti-scaling distribution system in Effect 1, which maintains uniform film thickness across all 312 heating tubes.

H2: Why Global Silica Producers Choose CONQINPHI

H3: OEM and ODM Capabilities for Diverse Market Requirements

CONQINPHI serves clients across Southeast Asia, Russia, Latin America, and the Middle East with both standardized and fully customized evaporation solutions. The company’s OEM/ODM framework allows regional partners to specify:

• Local electrical standards (IEC, GOST, NEMA, or custom)

• Pressure vessel codes (ASME, GB, EN, or GOST-R)

• Automation platforms (Siemens, Schneider, Yokogawa, or Mitsubishi)

• Skid dimensions optimized for regional shipping container constraints

For Russian and CIS markets, CONQINPHI provides full GOST-R certification packages including strength calculations, material certificates with 3.2 mill test reports, and Russian-language operation manuals. For Latin American clients, CONQINPHI offers Spanish and Portuguese documentation and has completed projects in Mexico, Brazil, and Colombia with local tax and customs documentation support.

H3: Export Experience and After-Sales Infrastructure

Since 2012, CONQINPHI has exported triple effect evaporator and multi-effect systems to 34 countries. Representative white carbon black wastewater treatment and similar high-salinity projects include:

• Thailand: 3.5 t/h MVR + triple effect hybrid for silica gel wastewater

• Russia: 8 t/h triple effect evaporator for sodium sulfate recovery (Tatarstan)

• Mexico: 2× 6 t/h triple effect systems for detergent intermediate effluent

• Vietnam: 4 t/h falling film evaporator for rubber chemical wastewater

CONQINPHI maintains spare parts inventories in Jakarta, Dubai, and São Paulo, with critical components (seals, gaskets, instrumentation) available for 48-hour dispatch to most markets. Remote diagnostic support is provided through a secure VPN-connected SCADA interface, enabling real-time troubleshooting without waiting for international travel.

H2: Technical Specifications Summary — 5TPH Triple Effect Evaporator

H2: Request a Customized Proposal for Your Silica Wastewater Project

If your facility generates concentrated effluent from white carbon black wastewater treatment or similar silica production processes, CONQINPHI can engineer a triple effect evaporator matched to your specific chemistry, capacity, and regulatory requirements.

CONQINPHI GROUP operates from Qingdao Jiaozhou, Shandong Province, with primary manufacturing in Xinyang, Guangshan, Henan Province. With dual production bases, and a proven export track record across Southeast Asia, Russia, and Latin America, we deliver evaporation systems that reduce operating costs and ensure environmental compliance.

Contact our technical sales team today to receive: - Free wastewater sample analysis and feasibility assessment - Customized heat and mass balance calculations - Preliminary P&ID and 3D layout proposal - Detailed CAPEX/OPEX comparison versus your current disposal method

CONQINPHI — Engineered Evaporation for Demanding Industrial Wastewaters.

About CONQINPHI GROUP 

CONQINPHI is a China-based manufacturer of industrial evaporation, crystallization, and drying systems. Headquartered in Qingdao Jiaozhou with a 100,000 m² production base in Xinyang Guangshan, the company specializes in triple effect evaporator technology for high-salinity and corrosive wastewater applications. CONQINPHI provides OEM/ODM services, holds ASME U-stamp certification, and exports to 34 countries including key markets in Southeast Asia, Russia, and Latin America.