Why this topic matters on the plant floor
Evaporation OPEX is often compared using only power or steam cost. That misses chemical dosing, manpower, cleaning, sludge handling, reject logistics, and downtime impact.
A useful calculator starts with flow and concentration: average KL/day, peak KL/day, TDS, COD/BOD, hardness, silica, oil and grease, and expected seasonal variation.
Energy inputs should be separated by equipment. Pumps, blowers, compressors, heaters, cooling systems, and auxiliaries have different operating hours and maintenance behavior.
Chemical and consumable costs should include antiscalant, pH correction, cleaning chemicals, filter media, cartridge filters, spares, and disposal of generated solids.
The final comparison should express cost per KL treated, cost per KL recovered, and annual compliance risk. A lower equipment price is not useful if it raises recurring cost every month.
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