Central Florida Case Study

Accelerated Evaporation Pond Closure Project - Zellwood, FL

COMPANY PROFILE

OVERVIEW

Evaporation King LLC is a U.S. Florida and Colorado based designer, manufacturer, and global distributor of a proprietary line of evaporation equipment for the Mining, Energy, Food & Beverage, Bio & Pharma, Textile, and Waste Management industries. EK produces various models for high and lower-volume applications and distributes them through an international network of independent dealers, strategic partners, and distributors.

Kevin King started Evaporation King in April 2021 after pioneering two other rotary atomizer technologies. Kevin has sold and commissioned over 90 systems globally to Fortune 1000 companies.

GLADIATOR ENHANCED EVAPORATION SYSTEM

The Gladiator Evaporative System stands out as the most efficient and cost-effective solution for managing processed or excess water. By utilizing cutting-edge technology, the Gladiator system accelerates the evaporation of wastewater by atomizing it into droplets with the best spectra in the industry. This innovative evaporation technology from EK ensures that pure water is returned to the natural hydrologic cycle.

One of the main challenges with natural evaporation is the need for a large water surface area. Evaporation ponds have been used for centuries, but their performance varies depending on local climate conditions. In dry conditions, evaporation ponds perform well, but during rainy periods and colder temperatures, their efficiency decreases.

Recognizing the need for a new approach to global wastewater disposal, EK engineered and designed the most effective evaporative technology available. Our engineered design can handle the most demanding water conditions in industries such as energy, mining, food and beverage, oil and gas, domestic wastewater, and landfills.

The Gladiator System operates by mechanically breaking down water into small droplets and dispersing them into the surrounding air. These fractured water droplets can quickly transition from liquid to vapor (Figure 1), cooling the air and maximizing the evaporation process.

Competitive evaporators generate droplets by pressurizing the water discharge, resulting in larger droplets that hinder diffusion and vaporization. These larger droplets simply fall back into the pond. In contrast, the Gladiator system achieves high efficiency by breaking the water into significantly smaller droplets that rapidly vaporize. In fact, EK's average droplet spectra range from 20 to 80 microns, as shown in Figure 2.

EK's atomizer technology is manufactured using state-of-the-art materials, making it resistant to chemicals and requiring minimal maintenance for thousands of trouble-free operating hours. It eliminates the risk of clogged nozzles, wear issues, and high maintenance requirements, ensuring smooth and efficient operation.

Figure 1: Project Site Liquid to Vapor Cooling Effect

Figure 2: EK Micron Spectra

EXECUTIVE SUMMARY

Our Confidential client in Central FL chose Evaporation King’s two Gladiator 80 systems to comply with the Florida Department of Environmental Protection (FDEP) Abandonment Plan for their two evaporation ponds. By utilizing two Gladiator 80 systems with a throughput of 160 gallons per minute (GPM) and operating around the clock, Evaporation King's cutting-edge evaporators boosted the natural evaporation process by 85 times, all while meeting the FDEP-approved abandonment plan. The project was completed within our clients’ expected timeframe of approximately 90 days. The Gladiator 80 systems from Evaporation King replaced outdated mechanical evaporators, which were ineffective in meeting the requirements of the abandonment plan.

BACKGROUND

The client managed the Facility's industrial wastewater using a non-discharging, closed-loop recycle system (System) under Department Industrial Wastewater Facility Permit, valid until September 30, 2026. During Facility operations, the System efficiently collected and recycled all process water generated and utilized on-site. The industrial wastewater was directed to one of the two recycle basins (lined reclaimed water ponds), sized and permitted according to storage and reuse requirements.

 ABANDONMENT PLAN

“Continue using evaporators - The Permit includes the following paragraph in the Wastewater Treatment description: “The facility has implemented an Emergency Water Minimization Plan (EWMP) based on a Consent Order issued December 3, 2020. The facility will use strategically placed evaporators operated under specific conditions. The evaporation mist shall be contained to the ponds and not discharge to the ground surface.”

“The EWMP “triggers” no longer apply because client discontinued growing and processing operations and the associated industrial wastewater- generating activities in February 2024, but using evaporators to reduce the volume and ultimately nearly empty the two lined ponds is an effective activity that continues. The volume of water in both lined ponds has decreased since the operations have ceased and evaporation has continued. The estimated current pond volumes are presented.”

“Empty and render inoperable the north pond – client proposes to first empty and render the north pond inoperable for storing or treating wastewater. Rendering the north pond inoperable will reduce the surface area that is exposed to rain. This will help reduce the potential volume that could be added to the System for management.”

“To accomplish this step, client will concurrently reduce the water depth in both ponds via evaporation. Client proposes to assess transferring water from the north pond to the south pond, considering the south pond volume availability and weather conditions. Client will consider transferring water from the north pond when the south pond water surface elevation is approximately 136.0 feet, which is 5.5 feet below the north pond emergency discharge weir elevation (El 141.5) and 2 feet below the maximum design water surface elevation of 138.0 feet as shown on the pond construction drawings included with this AP. To quantify the volume and support this step, a volume calculation for the south pond between elevation 136.0 and 138.0 feet results in approximately 485,000 gallons. The transfer of water from the north pond to the south pond will be repeated as determined prudent based on the south pond volume availability and weather conditions.”

“Both ponds are sloped to drain. When water has been removed from the north pond and the liner has been rinsed, client will puncture the liner to render the north pond inoperable for storing or treating wastewater.”

WATER QUALITY

The water quality in the ponds comprises the byproducts from previous composting operations, which undergo a pre-treatment process before being transferred to the evaporation ponds. Figure 3 illustrates the water sample report submitted to FDEP, while Figure 4 displays images of the wastewater taken from the evaporation pond just before treatment.

Figure 3: Water Analysis

Figure 4: Wastewater from Evaporation Ponds

INITIAL POND LEVELS UPON INSTALLATION

The installation of the two Gladiator 80 systems commenced on April 5th, 2024. Throughout the installation process, Evaporation King conducted meticulous monitoring of both pond levels, documenting an elevation range of approximately 138.0 feet to 138.5 feet. For a visual representation, please refer to Figure 5.

Figure 6 illustrates the variations in elevation compared to the initial construction plans.

Figure 6: Pond Elevations

DOWNTIME FOR UPGRADES

Both Gladiator 80 systems underwent upgrades and were temporarily offline for maintenance for 12 days in April, starting on the 16th.

INITIAL POND VOLUMES UPON INSTALLATION

The initial volume of the South Pond at 138.5 feet elevation was approximately 1,456,997 gallons (Figure 7) which uses CAD. For this study, EK uses the average gallons from Appendix A totaling 1,557,129 gallons. The South Pond was successfully closed off on July 20, 2024.

Figure 7: Volumes South Pond

The initial volume of the North Pond at an elevation of 138.5 feet was approximately 2,558,942 gallons (Figure 8) which uses CAD. For this study, EK uses the average gallons from Appendix A totaling 2,689,051 gallons. The closure of the North Pond was successfully completed on June 20, 2024.

Figure 8: Volumes North Pond

The combined initial volume of the ponds, not including rainfall, totals approximately 4,246,180 gallons.

OPERATIONAL TIMEFRAMES

Both Gladiator 80 systems ran continuously for 24 hours a day over a period of 98 days.

TOTAL THROUGHPUT

The combined flow rate of the two Gladiator 80 systems is 160 gallons per minute (GPM). Over a span of 98 days, the total flow rate amounts to 22,579,200 gallons.

RAINFALL DURING OPERATION

Rainfall measurements over a 64-day period in the North Pond totaled 7.12 inches or 327,269 gallons, while the South Pond received 16.65 inches or 397,601 gallons of rainfall over a 98-day period.

NATURAL EVAPORATION (ET)

The North Pond experienced an evapotranspiration rate of 8.7 inches over a 64-day period, resulting in a loss of 324,834 gallons. Similarly, the South Pond had an evapotranspiration rate of 12.29 inches over a 98-day period, leading to a loss of 244,049 gallons. See Appendix A.

EVAPORATION CALCULATIONS

After calculating the total volume of water in the ponds, including rainfall, we found it to be 4,971,050 gallons. By subtracting the evapotranspiration (ET) of 568,883 gallons, we are left with 4,402,167 gallons. Dividing this by the total throughput of 22,579,200 gallons reveals a 19.5% evaporation efficiency over a 24-hour period.

Taking into account that evaporation mainly occurs during daylight hours, with an average of 10 hours of sunlight in Zellwood, Florida, we can determine that the total volume of water evaporated (4,402,167 gallons) divided by the total throughput for 10-hour days amounts to 9,408,000 gallons. This signifies a 47% daily evaporation efficiency over 10-hour days.

ACCELERATED EVAPORATION VERSUS NATURAL ET

The comparison below (Figure 9) illustrates the significant increase in evaporation rates achieved by utilizing Evaporation King's two Gladiator 80 systems in comparison to natural evapotranspiration. It is clear that the Gladiator 80 systems greatly expedite the natural evaporation process by an impressive factor of 85.

Figure 9: Natural vs ET

WEATHER CONDITIONS DURING GLADIATOR OPERATIONS

For the purpose of this case study, Evaporation King utilized the closest weather station to the project site. The Apopka, FL FAWN weather station is approximately nine miles away from the project site. You can access the weather data at https://fawn.ifas.ufl.edu/data/reports/

MONTHLY WEATHER DATA

The average monthly humidity for the project site during operation averaged 75%.

MONTHLY WEATHER AVERAGES

APPENDIX A

Contact our team of accelerated evaporation specialists today to take your project to the next level. Whether you are looking to efficiently manage wastewater, reduce pond volumes, or enhance water quality, our experts are here to help. With our proven track record of success and cutting-edge technology, we can provide tailored solutions to meet your specific needs. Don't wait, reach out to us now and let us help you achieve your project goals with ease and efficiency.