Surface Combustion with Thermal Evaporation

Surface combustion technology solves traditional heat exchanger failures common with other designs.

Two common burner heat exchanger combinations are tubular double pass and vertical water tube construction. Both are immersed inside an evaporation tank with clearances on the sides and bottom. A third design is the bottom heated tank, which applies a frying pan approach to heat wastewater for evaporation.

These designs are subject to application specific conditions that impact performance and life expectancy of the heat exchanger. For example:

Application Condition Impact to Heat Exchanger:
Coolants with Floating Oils Suspended solids that precipitate. Hot spots on heat transfer surface causing metal deformation/failure.
Plating rinse water Salts generation on heat transfer surface. Corrosion and heat transfer insulation causing molecular failure.
Printing painting as well as Die Casting lubricants Oily or inky deposits on thermal transfer surface. Often baked on causing heat transfer insulation and metal deformation failure.

The WASTEWATER EVAPORATORS design considers the broad spectrum of applications and the harsh conditions that exist with wastewater contaminants. The result is a heat exchanger and burner combination that provides performance, longevity and low NOX, CO emissions.

WASTEWATER EVAPORATORSThe WASTEWATER EVAPORATORS design utilizes a surface combustion technology in which premixed gas and air burns on a permeable medium surface layer. Depending on the intensity, the combustion can occur in two modes - radiant (red flame) or convection (blue flame).

Radiant combustion occurs inside a permeable medium made of very thin metal fibers. This medium heats to incandescence and releases the energy input as thermal radiation. The flame is reddish orange color. Blue flame is more intense and hovers above the surface releasing energy through convection.

Surface combustion technology benefits include:

  • Long lasting metal fiber medium.
  • Extremely low emissions of NOx, CO and unburned fuel components.
  • No risk of heat exchanger metal impingement or high heat stress.

Surface combustion technology eliminates the traditional flame associated with tubular and some vertical water tube designs because combustion is contained within the fiber media. There is no risk of heat exchanger metal impingement or high heat stresses that will ultimately cause fatigue and failure.

By contrast, the double pass tubular design has flame and combustion gasses drawn by an induced draft blower through the heat exchanger. This design has sweep elbows and 90 degree pipe turns the burner flame contacts . This risks thermal damage to these welded areas which is compounded with application solids and grim buildup.

This also holds true for vertical water tube heat exchangers with traditional burner flame designs. If solids accumulate on the heat exchangers flat top or if the vertical water tubes were not kept clean of oily residues thermal damage will likely occur.

The Surface Combustion Technology utilized by WASTEWATER EVAPORATORS design insures no risk of thermal damage to the heat exchanger.

The WASTEWATER EVAPORATORS design combines the superior benefits of Surface Combustion Heat-ExcangerTechnology with the high efficiency of the vertical water tube heat exchanger. It incorporates a large heat transfer surface with internal flue gas passages engineered to maximize the thermal radiation of the combustion media.

The top of the heat exchange is sloped to prevent solids from accumulating. The vertical water tubes are easily accessible from the top of the tank for periodic inspection and cleaning.

All heat exchangers are not created equal. The WASTEWATER EVAPORATORS design combines innovation with high quality thus producing a robust solution to problematic evaporator applications.

For more information on product specifications or the surface combustion technology that makes our evaporators unique, contact one of our sales engineers today.




Specializing in evaporation and wastewater evaporators
for all water disposal requirements


2006 Wastewater Evaporators

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