Case Study | CONQINPHI 300 T/D Triple-Effect Evaporative Crystallization System for Mixed Wastewater from Rubber Additives Production

Project Snapshot

Background

The client is a chemical technology company producing a range of rubber additives, including accelerators, antioxidants, and processing aids. Their production lines generate 300 tons per day of mixed wastewater with complex characteristics: high salinity, fluctuating composition, significant organic content, and a tendency to foam and scale during concentration.

Treating such wastewater presents multiple challenges:

1. Variable feed composition – Different product lines discharge at different times, causing the salt composition and organic load to shift constantly.

2. Fouling and foaming risk – Organic residues and mixed salts make stable long-term evaporation difficult.

3. Discharge compliance – Local regulations require zero liquid discharge, with all water recycled and salts safely recovered.

The CONQINPHI Solution

After jar testing and full process simulation of the client’s actual wastewater samples, CONQINPHI delivered a 300 T/D triple-effect evaporative crystallization system engineered for complex mixed brines:

1. Triple-Effect Falling Film + Forced Circulation Configuration The dilute wastewater is pre-concentrated in three-effect falling film evaporators, where secondary vapor from each effect heats the next — delivering excellent steam economy compared to single-effect designs. The final concentration stage uses a forced circulation crystallizer with optimized flow velocity to suppress scaling and ensure continuous crystal discharge.

2. Intelligent Feed & Composition Management An equalization tank with online monitoring stabilizes feed composition before evaporation, allowing the system to adapt smoothly to production fluctuations and maintain stable operation around the clock.

3. Anti-Foaming & Defoaming System A dedicated foam control package, combining mechanical separation and chemical dosing, effectively manages foaming caused by residual organics — protecting the vapor path and ensuring clean, reliable condensate recovery.

4. Mother Liquor Recycle & Complete Crystallization Recycled mother liquor maximizes salt recovery, while a small bleed stream is returned to pretreatment, preventing organic accumulation and keeping the system in long-term stable balance.

5. Automatic CIP & PLC Control Fully automated clean-in-place sequences and PLC-based control with real-time monitoring of density, temperature, and level minimize manual workload and maximize system availability.

Results & Performance

✅ Stable full-capacity operation – The system reliably processes the full 300 T/D design load, adjusting automatically to daily production variations.

✅ Excellent steam economy – The triple-effect design with thermal vapor recompression delivers impressively low specific steam consumption, keeping operating costs well within the client’s budget.

✅ Zero liquid discharge achieved – All wastewater is converted into clean distilled water and dry mixed salts; no liquid effluent leaves the site, ensuring full regulatory compliance.

✅ High-quality recovered water – The condensate is clean and stable in quality, recycled to production and utility systems, significantly reducing the plant’s freshwater demand.

✅ Consistent salt discharge – The crystallizer produces uniform, well-formed crystals with easy dewatering, and the recovered salts are directed to compliant reuse or disposal channels according to their composition.

✅ Long run cycles, easy maintenance – The anti-fouling design and automatic cleaning deliver extended intervals between washes, minimizing downtime and maintenance effort.

Why CONQINPHI

CONQINPHI supported the project end-to-end: wastewater analysis, process development, equipment fabrication, installation supervision, commissioning, and operator training — a true single-source turnkey delivery with responsive long-term service.

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Facing complex, high-salinity wastewater from rubber additives, dyes, or fine chemical production? CONQINPHI specializes in evaporation and crystallization systems for the most challenging industrial effluents. Contact us for a free wastewater assessment and process proposal.