Our answers to your frequently asked questions

Question 1

For which industries is the BAT Wastewater Directive for Industry relevant?

Accepted Answer

The BAT Wastewater Directive affects numerous industrial sectors in which relevant quantities of wastewater are produced. These include, in particular, metalworking/processing (e.g., CNC machining, surface treatment), automotive manufacturing, aerospace, surface technology, energy supply, the chemical industry, food and beverage production, mechanical/plant engineering, the manufacture of electronic and optical devices, electromobility/battery production, healthcare, and the recycling industry.In all these areas, wastewater treatment based on BAT recommendations can help to reuse water multiple times in the production process and improve discharge values. MKR Metzger offers modular solutions for this purpose, such as evaporators, filtration systems, and foreign oil separators, which can be individually adapted to the industry.

Question 2

What types of wastewater are atmospheric evaporators suitable for?

Accepted Answer

Atmospheric evaporators are suitable for many types of industrial process wastewater, such as that generated by parts cleaning, cooling lubricants, surface treatment, electroplating, paint pretreatment, die-casting, metalworking, the automotive industry, the aerospace industry, waste management and recycling, and industrial laundries. Their exact suitability depends on the medium, the constituents and the process requirements.

Question 3

FOR WHICH APPLICATIONS AND INDUSTRIES IS ZLD PARTICULARLY SUITABLE?

Accepted Answer

ZLD is particularly suitable for water-intensive processes, e.g. in metalworking, chemicals, pharmaceuticals, energy production, surface technology and in the field of waste disposal and recycling.

Question 4

IS ZLD ALWAYS ECONOMICLY SENSIBLE?

Accepted Answer

Whether ZLD is economically viable depends on factors such as wastewater volume, composition, fresh water and disposal costs, as well as legal requirements. An individual assessment is therefore crucial.

Question 5

Can the distillate be reused?

Accepted Answer

Depending on its quality, intended use and process requirements, the distillate can be reused or further treated. Whether it can be returned to the production process or discharged depends on its specific constituents, the required water quality and local regulatory limits.

Question 6

Can evaporation systems be integrated into existing processes?

Accepted Answer

Yes. MKR evaporators and compatible peripheral modules can be integrated, both electrically and mechanically, into new or existing plant designs. The modular design enables flexible system solutions that can be tailored to the medium, flow rate, space constraints and desired quality specifications.

Question 7

Are evaporators suitable for 24/7 operation and high utilization?

Accepted Answer

evaporators can operate 24/7 because many systems are designed for continuous industrial use and are controlled automatically. They deliver stable performance even with fluctuating material flows and require little maintenance. This makes them easy to integrate into existing plant structures.

Question 8

WHY IS ZERO LIQUID DISCHARGE (ZLD) GAINS INCREASING IMPORTANCE?

Accepted Answer

ZLD is gaining importance due to increasing environmental regulations, growing water scarcity, and higher costs for wastewater discharge and disposal. Companies are increasingly relying on closed-loop water systems to conserve resources and remain economically viable in the long term.

Question 9

Why is wastewater treatment so important in the electronics and semiconductor industry?

Accepted Answer

Wastewater Semiconductor industry Often heavily polluted   Etching , Electroplating -, Cleaning - and Rinsing processes and must not be discharged untreated. Even the smallest amounts of pollutants can harm the environment and sewage treatment plants. Appropriate Treatment is therefore crucial for safety and purity requirements.

Question 10

Why is wastewater treatment by evaporation particularly safe?

Accepted Answer

Evaporation is a safe way to treat wastewater because critical ingredients remain in the concentrate and the distillate   is significantly purified. The separation is physical and delivers reproducible distillate quality . This allows even complex wastewater streams to be treated reliably.

Question 11

Why is an evaporator in the hardening shop economical and resource-efficient?

Accepted Answer

Evaporator Hardening plant Economical because the amount of wastewater is greatly reduced depending on the application, and disposal and operating costs are reduced. Distillate and often salt can be reused, which saves resources. Fully automatic and Energy efficiency reduce operating and maintenance costs.

Question 12

Why is wastewater analysis so important for plant design?

Accepted Answer

A wastewater analysis for plant design is the basis for selecting the appropriate process technology and modules . This is the only way to ensure that the plant is correctly designed in terms of composition, quantities, and fluctuations. This ensures stable results and safe operation in the long term.

Question 13

Why is BAT-compliant wastewater technology important?

Accepted Answer

Wastewater technology that complies with BAT offers companies several advantages: it helps them comply with emission and discharge limits, conserves resources through recycling, and can significantly reduce operating costs. In addition, it is based on the latest technology, which makes sense in the long term with regard to future legal changes.At MKR Metzger, processes such as ultrafiltration, evaporator systems, and oil separation are combined in such a way that both water quality and energy efficiency are optimized. This results in solutions that meet technical requirements while placing environmental considerations at the forefront.

Question 14

Why are evaporators useful for waste disposal companies?

Accepted Answer

Evaporators for Disposal are useful because they can treat different wastewater streams in a stable and legally compliant manner. This facilitates the processing of changing waste streams and supports compliance with relevant regulations. At the same time, processes become more efficient and easier to standardize.

Question 15

Why should you treat cooling lubricant emulsions internally in production?

Accepted Answer

Processing KSS emulsion on site significantly reduces wastewater volume and disposal costs, especially in machining production . At the same time, distillate can be used as process water , reducing the need for fresh water. This improves the ecological balance and maintains process reliability.

Question 16

What does BAT mean in relation to wastewater?

Accepted Answer

BAT stands for “Best Available Technology” and refers to technologies and processes that represent the current state of the art in environmental protection. In the field of BAT wastewater, this includes systems and processes that enable particularly efficient, resource-saving, and environmentally friendly treatment of industrial wastewater. These processes are defined and described in the EU's BREF documents (Best Available Techniques Reference Documents).By following the BAT recommendations, companies can improve their wastewater quality and more easily comply with environmental regulations. Examples of such processes include modern evaporator systems or filtration technology from MKR Metzger, which are designed for high efficiency and durability.

Question 17

WHAT DOES ZLD MEAN IN CONNECTION WITH INDUSTRIAL WASTEWATER?

Accepted Answer

ZLD describes a concept in which industrial wastewater is completely treated and reused. No liquid wastewater is discharged – only concentrated or solid residues are disposed of.

Question 18

What is the difference between atmospheric evaporation and vacuum evaporation?

Accepted Answer

Atmospheric evaporators operate at normal pressure and do not require an additional vacuum system. This makes the technology robust, low-maintenance and well-suited to industrial wastewater containing oils, emulsions or of varying composition.

Question 19

What is the difference between distillate and concentrate?

Accepted Answer

The distillate is the water recovered from the evaporation process. The concentrate contains the concentrated constituents of the wastewater, such as oils, salts, solids or process chemicals. The aim is to recover as much water as possible and to reduce the residual volume for disposal or further treatment.

Question 20

What is an atmospheric evaporator?

Accepted Answer

An atmospheric evaporator is a system for the thermal treatment of industrial wastewater at normal pressure. The wastewater is heated so that the water evaporates and is subsequently recovered as a distillate. Substances such as oils, salts, solids and other impurities remain largely in the concentrate.

Question 21

Which types of wastewater from paint pretreatment can be treated?

Accepted Answer

Wastewater Pre-treatment for painting includes degreasing baths (alkaline, neutral, acidic), Rinsing water from iron and Zinc phosphating as well as media from pickling, Nanoceramics   or chrome-free conversion. Water containing blasting media and residues from wetting agents and corrosion inhibitors are also typical. Evaporators can treat these Process water safely and economically.

Question 22

What types of wastewater can an ET evaporator safely treat?

Accepted Answer

An evaporator ET wastewater system can typically treat cooling lubricants , washing and cleaning water , oil-containing emulsions and   heavy metal and salt-containing water . Many special media from industry and production are also possible. A suitable configuration based on media analysis is required.

Question 23

Which etching wastewater and electroplating rinse water can be treated?

Accepted Answer

Etching wastewater treatment typically involves rinse water from etching and electroplating processes as well as acidic or alkaline pickling and active baths. Media containing hydrofluoric acid and hydrochloric acid as well as wastewater containing heavy metals or organic residues are also possible. A suitable design ensures stable results.

Question 24

Which areas of automotive production benefit from evaporation technology?

Accepted Answer

Treating automotive wastewater is particularly relevant in foundries and die casting, engine and transmission manufacturing, press shops, and testing and washing facilities. Paint pretreatment, electronics manufacturing, electroplating, and hardening shops also benefit from complex process water. Evaporation technology delivers stable results and supports standard-compliant treatment.

Question 25

What operational reliability does the ET evaporator series offer in the hardening shop?

Accepted Answer

ET evaporator hardening systems are designed for continuous industrial use and remain stable even when wastewater composition fluctuates. Automated control and robust components ensure consistently high distillate quality and reliable compliance with discharge regulations. Wastewater reduction plus salt recovery further increase process reliability.

Question 26

Which biogas wastewater can be treated with evaporators?

Accepted Answer

Biogas wastewater treatment includes, for example, wastewater from digestate processing, fermenter cleaning, gas scrubbing, and exhaust air purification. Liquid residues containing organic and nitrogenous compounds are also typical. Evaporators help wherever direct discharge is not permitted.

Question 27

Which types of MRO wastewater can be cleaned with evaporators?

Accepted Answer

Wastewater from parts cleaning, oily wastewater, and used cooling lubricants are among the types of wastewater suitable for MRO wastewater treatment. Water containing heavy metals or salts from electroplating or hardening plants, as well as media from crack testing, can also be treated. The key factor is to ensure that the system is designed to suit the specific composition of the wastewater.

Question 28

Which oil-containing wastewater from production can be treated?

Accepted Answer

Treating oily wastewater is typical for cooling lubricant emulsions, industrial washing and cleaning water, die casting emulsions, and floor mopping wastewater. Other contaminated media from manufacturing are also possible. The key is to adapt correctly to the composition and quantity.

Question 29

Which pharmaceutical, cosmetic, and chemical wastewater is suitable for evaporators?

Accepted Answer

Pharmaceutical wastewater treatment is particularly relevant for plant and container cleaning, synthesis rinse water, and wash water from exhaust air purification. Media containing hormonal, antibiotic, or cytostatic residues can also be treated. Evaporation is useful when direct discharge is not permitted.

Question 30

Which cleaning media can be treated with MKR UC ultrafiltration?

Accepted Answer

Ultrafiltration wash water is suitable for common aqueous cleaning processes, especially in metalworking, pre- and intermediate cleaning, and fine cleaning prior to coating or painting. UC systems reliably separate emulsions, fats, oils, and particles. This provides a high-quality cleaning medium for the process.

Question 31

Question 32

Question 33

What technologies does MKR Metzger use for BAT-compliant treatment?

Accepted Answer

Depending on the industry and type of wastewater, MKR Metzger combines various processes to implement wastewater technology that complies withBAT. These include:Evaporator systems – energy-optimized separation of water and pollutantsFiltration – separation of fine particles, oils, and emulsionsForeign oil separators – efficient oil-water separationPre- and post-treatment stages (e.g., activated carbon, ion exchange) for particularly high water qualityThese modular systems can be used individually or combined to form a complete solution in order to adapt wastewater treatment to the state of the art.

Question 34

What pre-treatment is advisable before vaporization?

Accepted Answer

Pre-treatment of wastewater can include pH adjustment , filtration and oil separation , depending on the medium, also a light phase separator. These steps stabilize operation and relieve the evaporator . This increases availability and reduces maintenance costs.

Question 35

What are the benefits of MKR atmospheric evaporators?

Accepted Answer

MKR’s atmospheric evaporators enable a significant reduction in waste volumes, the recovery of process water and the robust treatment of complex industrial wastewater. Further benefits include fully automated operation, a modular design, easy integration into existing processes and energy-efficient plant operation through heat recovery.

Question 36

What are the advantages of evaporators over conventional wastewater treatment?

Accepted Answer

Evaporators offer the advantage of reliably separating water and pollutants such as oils , emulsions , surfactants, metals or organic residues. The result is clear distillate , which can often be used internally, while at the same time significantly reducing wastewater. Robust construction and low maintenance requirements make this technology suitable for continuous operation .

Question 37

What are the advantages of on-site wastewater treatment compared to external disposal?

Accepted Answer

Wastewater treatment in operation reduces external disposal routes and makes costs more predictable. In addition, treated water can often be reused as process water . This saves resources and improves the overall balance.

Question 38

What are the advantages of ultrafiltration in bypass mode in daily operation?

Accepted Answer

Ultrafiltration Bypass means continuous washing water purification without interfering with the production process. This stabilizes cleaning processes , improves component quality and reduces chemical and water consumption. Compact, robust design makes the systems suitable for continuous industrial operation.

Question 39

How complex are the operation and maintenance of an evaporator system?

Accepted Answer

evaporators are low-maintenance systems that operate largely automatically and require little operator intervention. Robust components and appropriate pretreatment ensure high system availability. Integration is tailored to the individual infrastructure and wastewater streams.

Question 40

How do evaporators reliably achieve discharge limits?

Accepted Answer

evaporators achieve discharge limits through clear separation: critical substances remain in the concentrate , while the distillate is significantly cleaner. This effectively reduces organic and chemical pollution. This supports legal and operational requirements.

Question 41

How does process water treatment work in paint shops with evaporators?

Accepted Answer

Process water treatment Paint shop is usually carried out via pH adjustment , Filtration and Pre-separation from Oil , Particles and Sludge , followed by atmospheric evaporator . Optionally, discharge monitoring , reverse osmosis or ion exchangers can be added. This allows the level of chemical cleaning and the desired water quality to be adjusted.

Question 42

How does an evaporator work in everyday wastewater treatment?

Accepted Answer

Evaporators How they work involves separating water and other ingredients through evaporation and condensation . The distillate is typically clear and oil-free and can be used, for example, to prepare new cooling lubricants or for parts cleaning . This reduces running costs and means that media changes are required less frequently.

Question 43

How does an evaporator system for industrial wastewater work?

Accepted Answer

During evaporation, contaminated process water is thermally separated into two streams: distillate and concentrate. The distillate contains the recovered water. The concentrated substances accumulate in the concentrate. This allows the volume of wastewater requiring disposal to be significantly reduced, depending on the application.

Question 44

How can the process integration of an evaporator system be successfully implemented in production?

Accepted Answer

evaporator system Process integration is achieved through individual design based on wastewater flow, volume flow, and fluctuations. Infrastructure, usable heat sources, and the desired recovery rate are also taken into account. This ensures that the solution fits neatly into the processes from a technical perspective and operates efficiently.

Question 45

How can discharge limits for nickel, zinc, and copper be maintained despite fluctuations?

Accepted Answer

Initial values Nickel Zinc Copper remain stable because heavy metals and complexing agents remain in the concentrate evaporation . The distillate is virtually free of critical components, largely independent of feed concentrations and electrolyte residues. This increases safety even during short-term official inspections .

Question 46

How does the ET evaporator series help with legal wastewater requirements?

Accepted Answer

's ET series supports legal requirements for wastewater with stable, traceable process control and guideline-oriented design. The technology helps to reliably achieve discharge values and simplify compliance. This is particularly important with changing wastewater flows.

Question 47

How are evaporators integrated into production lines in the automotive industry?

Accepted Answer

Wastewater Automotive industry Solutions are individually designed for infrastructure, wastewater flows, and recovery rates. Modular design enables connection to washing systems , test benches or production cells. Automation and stable performance help with changing loads.

Question 48

How can I determine whether my technology meets BAT requirements?

Accepted Answer

In order to determine whether your plant meets the BAT requirements for industry, an analysis of the current status is usually necessary. This includes reviewing the processes used, energy efficiency, wastewater quality, and the auxiliary materials used. A comparison with the current BREF documents shows whether there is a need for modernization.MKR Metzger offers individual consultations and practical tests for this purpose—existing plants can often be upgraded to the state of the art by retrofitting and combining technologies such as vacuum evaporation and filtration.

Question 49

How can hardening salt be recovered from wastewater?

Accepted Answer

It is possible to recover hard salt because spent salt can be concentrated in a targeted manner through evaporation . With appropriate process control, it is possible to recover pure salt, so that salt is available again in a usable quality. This reduces the need for additional dosing and operating costs.

Question 50

How can process water be treated in the aviation industry?

Accepted Answer

Process water in the aviation industry can be treated very reliably with atmospheric evaporators . Oil , Heavy metals , Salts and Chemicals are separated, producing a purified distillate that can be reused depending on the application. This makes it easier to comply with environmental regulations and improves resource efficiency in MRO operations.

Question 51

How can wastewater in the paint shop be significantly reduced?

Accepted Answer

Reducing wastewater Paint shop is achieved through evaporation , because the volume of wastewater is greatly reduced depending on the application and distillate is available for recycling. This stabilizes process water quality and can make paint results more consistent. In addition, disposal costs, chemical use, and operating costs are reduced.

Question 52

How can a pretreatment system be retrofitted without major modifications?

Accepted Answer

Pre-treatment   Retrofitting systems often works with compact, modular systems that are tailored to the space and process parameters. The chemicals used and the desired recovery rate are important. This allows the system to be integrated into existing lines and operated reliably in continuous operation.

Question 53

How can wastewater disposal costs be reduced in MRO operations?

Accepted Answer

Wastewater disposal costs can be reduced if process water is treated internally and less needs to be disposed of externally. The distillate can often be reused, which further reduces fresh water costs. At the same time, independence from disposal companies increases.

Question 54

How can electroplating wastewater costs be reduced with evaporators?

Accepted Answer

Electroplating Wastewater costs can be reduced because evaporators do not require precipitants or complex chemical-physical processes. Automated control reduces operating costs, and wastewater reduction minimizes disposal costs . Distillate can often be reused, which further improves cost-effectiveness.

Question 55

How can strict discharge limits for wastewater be reliably complied with?

Accepted Answer

In order to comply with discharge limits in wastewater, even low concentrations of heavy metals and acids or alkalis must be reliably reduced. Evaporation technology delivers consistent results through stable process control . This often means that fewer additional external steps are required.

Question 56

How modular can a wastewater treatment plant be adapted to different media?

Accepted Answer

A modular wastewater treatment plant can be configured to combine pH adjustment , filtration , oil separation and post-treatment . This allows the plant to be specifically tailored to acidic, alkaline, or oily media. This increases process stability and reduces operational disruptions.

Question 57

How does wastewater treatment improve the environmental balance in MRO operations?

Accepted Answer

To improve the environmental balance of in MRO operations , internal wastewater treatment reduces the amount of wastewater and lowers fresh water consumption through distillate use . At the same time, disposal transports and associated emissions are reduced. This makes processes more sustainable and easier to plan.

Question 58

How does an evaporator improve operational safety and environmental performance?

Accepted Answer

Wastewater Evaporator Operational reliability is increased thanks to high process stability and constant discharge values despite fluctuations. Residues are highly concentrated, making them easier to dispose of or treat further. At the same time, the volume of wastewater is significantly reduced and Distillate can be reused, which improves the environmental balance and reduces costs.

Question 59

How is a system correctly designed for medium and volume flow?

Accepted Answer

Properly designing a system means taking media analysis, volume flow, load peaks, and fluctuations into account. Process engineering, modules , and performance parameters are determined on this basis. The result is a solution that operates stably and delivers consistent quality over the long term.

Question 60

How is UC ultrafiltration connected to an existing washing system?

Accepted Answer

Retrofitting ultrafiltration is usually straightforward because the UC system is connected in bypass to existing aqueous cleaning systems . The design is based on bath size, degree of contamination, and desired cleaning level. This results in an energy-efficient solution without major modifications and with consistently high component cleanliness.

Question 61

How is an evaporator system designed for continuous operation?

Accepted Answer

A evaporator system continuous operation is designed on the basis of laboratory tests, media analysis, and operational data. This is used to determine the pretreatment, performance parameters, and monitoring . This ensures that the system remains stable even with load fluctuations.