Advanced Separation & ZLD Equipment Units
Factory-tested, skid-mounted and containerized membrane treatment modules built in Shanghai for extreme TDS reduction, pharmaceutical compliance, and oilfield flowback recovery.
OEM Purified Water System for Food & Beverage Production
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Wholesale Pharmaceutical Purified Water & WFI Generation Skid
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OEM Pharmaceutical Grade Purified Water & WFI Membrane System
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CE Certified Oilfield Fracturing Flowback Fluid ZLD Treatment System
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High Salinity Brine Concentration System - Osmosis Assisted Train
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ODM Two-Stage RO & Deep Disinfection System for Food & Beverage
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Fracturing Flowback Water Reuse Treatment Equipment for Oil & Gas
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Physical Water Degassing & Deoxygenation Membrane Equipment Skid
Inspect Engineering ScopeEngineering Zero Liquid Discharge: The Paradigm Shift in High-TDS Effluent Abatement
Zero Liquid Discharge (ZLD) represents the apex of modern chemical and environmental engineering. Beyond conventional wastewater management, ZLD is an advanced closed-loop thermodynamic and separation methodology designed to eradicate liquid effluent entirely, systematically producing purified reusable distillate while condensing all remaining dissolved contaminants into dry, transportable crystalline solids or saleable salt derivatives.
Shanghai Tongjie Environmental Protection Technology Co., Ltd. (established in 2010) stands as a National High-Tech Enterprise and Shanghai Specialized & Sophisticated Enterprise. Possessing Class II contracting qualifications in environmental engineering and mechanical-electrical installations, Tongjie bridges the gap between fundamental membrane science and turnkey EPC scalability. As environmental regulations—such as China's strict GB standards, the European Union's Industrial Emissions Directive (IED), and the US EPA Effluent Limitations Guidelines (ELG)—continue to tighten globally, high-load industrial facilities can no longer rely on discharge dilution or shallow disposal wells. Our engineering framework transforms liquid wastewater from an ongoing environmental liability into a predictable source of high-purity process water and mineral valorization.
1. Intensive Chemical Softening & Pre-Treatment
Membrane fouling and scaling are the primary failure modes of high-salinity ZLD operations. Tongjie deploys high-density chemical softening clarifiers coupled with ceramic microfiltration (MF) or tubular ultrafiltration (TUF) to eradicate polyvalent scaling precursors, ensuring silica (< 5 mg/L), total hardness (< 10 mg/L as CaCO3), and suspended solids are suppressed before high-pressure membrane concentration.
- Hardness Removal:Ca2+, Mg2+, Ba2+, Sr2+ > 99%
- Turbidity Threshold:SDI15 < 3.0 / Turbidity < 0.1 NTU
- TOC / COD Pre-Oxidation:Fenton / Advanced Catalytic O3
2. Ultra-High Pressure Membrane Concentration
Thermal evaporation is energy-intensive; therefore, pushing membrane volume reduction to the physical thermodynamic boundary is mandatory for operational expense (OPEX) control. We integrate high-pressure Disc Tube Reverse Osmosis (DTRO up to 160 bar), Spacer Tube RO (STRO), and Osmosis-Assisted Reverse Osmosis (OARO) to elevate brine concentration up to 120,000–180,000 mg/L TDS before sending concentrate to the thermal loops.
- Operating Pressures:Up to 16.0 MPa (160 bar)
- Module Design:Open-channel hydrodynamic discs
- Specific Power:< 4.5 kWh/m³ (Membrane Phase)
3. MVR Evaporation & Salt Fractional Crystallization
The core thermal finishing loop utilizes Mechanical Vapor Recompression (MVR) falling-film evaporators alongside forced-circulation crystallizers. By recycling secondary latent steam energy using high-efficiency centrifugal compressors, electrical input is minimized. Selective crystallization systems split sodium sulfate (Na2SO4) and sodium chloride (NaCl) into commercial, industrial-grade solid co-products.
- Steam Compression:MVR Centrifugal Compressor
- Thermal OPEX:20–28 kWh/ton evaporated water
- Salt Purity:Industrial grade > 98.5%
Localized Applications Across Demanding Global Sectors
ZLD process trains cannot be built as one-size-fits-all packages. Tongjie calibrates hydraulic flowsheets to the specific geochemical and chemical matrices of diverse industries worldwide.
Coal Chemical & Petrochemical Complexes
Coal gasification, coal-to-olefins (CTO), and refining effluents harbor complex combinations of high chemical oxygen demand (COD), refractory phenols, thiocyanates, ammonium, and extreme dissolved salts. Tongjie deploys pre-ozonation catalytic oxidation coupled with bio-membrane reactors (MBR) and high-recovery RO trains. The resulting concentrated brine is routed through MVR forced-circulation units, yielding dry cake salts while recycling 98% of clean water back into boiler feed makeup.
Oil & Gas Fracturing Flowback & Produced Water
Hydraulic shale fracturing produces flowback laden with hydrocarbons, emulsified oils, barium, strontium, and volatile organics. Installed widely across extreme settings in Western China, Kazakhstan, and the Middle East, our mobile, containerized DTRO units execute rapid unassisted de-oiling, precision tubular softening, and concentration. The permeate delivers suspended solids ≤ 1 mg/L and oil ≤ 5 mg/L, making it immediately viable for high-rate reinjection or zero-discharge agricultural recycling.
Lithium Battery Precursor & EV Hydrometallurgy
Ternary cathode material manufacturing (NCM/NCA) and battery recycling produce heavy sodium sulfate brines laden with nickel, cobalt, manganese, and fluoride. Tongjie integrates nanofiltration (NF) multi-stage selective ion fractionation with specialized DTRO systems. By isolating sulfates and purifying them via continuous crystallizers, battery gigafactories recover high-purity anhydrous sodium sulfate as a market commodity while conserving millions of liters of process freshwater daily.
Semiconductor & Electronics Pure Water Loops
Semiconductor wafer fabrication demands electronic-grade ultrapure water (resistivity up to 18.2 MΩ·cm, sub-ppb TOC) and produces aggressive fluorinated and copper-bearing rinse wastewater. Our integrated system combines primary RO/EDI polishing with an downstream ZLD recovery system that re-concentrates polishing reject brines. This enables cutting-edge fabrication facilities to reach up to a 95% total plant water utilization index.
Textile Dyeing, Printing & Chemical Parks
Textile wastewater features intense chromaticity, refractory organic complexes, surfactants, and saturated salt baths (NaCl and Na2SO4). By executing high-flux ceramic ultrafiltration, selective dye-adsorbing polymeric membranes, and thermal crystallizers, Tongjie enables centralized industrial textile parks to operate within tight river-basin discharge caps while recycling direct dye bath brines.
Flue Gas Desulfurization (FGD) in Power Utilities
Coal-fired and waste-to-energy power utilities face rigorous chlorine-induced corrosion in FGD blowdown streams. Tongjie delivers specialized chemical precipitation, lime-soda softening, and high-pressure disc-tube membrane units that concentrate chlorine-rich brines up to critical saturation. Spray drying or crystallization towers finish the slurry into non-hazardous gypsum and dry salts.
The Chinese Manufacturing Advantage: Precision, Scale & Cost Agility
Deploying a full-scale ZLD plant requires immense industrial coordination—from high-grade metallurgy (Titanium, Hastelloy, Duplex Stainless Steel) to automated PLC architectures. Tongjie harnesses China's mature manufacturing cluster to optimize total cost of ownership (TCO) without engineering compromises.
| Evaluation Parameter | Tongjie Engineered Solution (China) | Conventional Western EPC / OEMs | Standard Regional Suppliers |
|---|---|---|---|
| Pre-Fabrication & Modularity | 100% Factory skid-mounted & containerized; complete Shanghai FAT wet testing. | Field assembled with significant on-site mechanical and piping labor. | Loose components shipped; high installation unpredictability. |
| Metallurgical Specifications | Direct procurement: Titanium Gr. 2/12, 2507 Duplex, Hastelloy C-276. | Premium surcharge for exotic alloys; long subcontracting lead times. | Standard SS316 often utilized inappropriately for high chlorides. |
| Project Lead Time | 12–16 Weeks from P&ID sign-off to port dispatch. | 32–48 Weeks standard engineering and fabrication cycles. | 16–24 Weeks without full automation integration. |
| Capital Expenditure (CAPEX) | Optimized tier-1 industrial supply ecosystem (35–50% cost advantage). | High engineering overheads, corporate markup, and localized labor costs. | Low initial price, but excessive maintenance and retrofit expenses. |
| Digital Control & Automation | Siemens / Allen-Bradley PLC, remote cloud SCADA, edge-AI fault diagnostics. | Proprietary closed architectures requiring costly vendor license renewals. | Basic relay logic or limited semi-automated control cabinets. |
Vertically Integrated Shanghai Manufacturing Facility
Located on Waiqian Highway in Jiading District, Shanghai, Tongjie operates advanced automated robotic orbital welding stations, dynamic hydraulic test bays, and specialized membrane potting rooms. By keeping R&D, thermal simulation, pressure vessel fabrication, electrical assembly, and FAT (Factory Acceptance Testing) under one unified corporate roof, we eliminate intermediate supply chain delays. Every high-pressure pump, automated pneumatic valve, and DTRO module is calibrated under realistic hydrostatic loads prior to shipping to global destinations.
Technology Roadmap: Next-Generation Innovations in ZLD Engineering
The boundary of Zero Liquid Discharge is advancing from energy reduction to resource circularity. Here is how Tongjie is pioneering the next decade of water resource science.
AI-Powered Digital Twin Thermodynamics
We are incorporating neural network models into our MVR crystallizers. By monitoring boiling point elevation (BPE), viscosity changes, and ion activity coefficients in real-time, the system automatically adapts compressor speed and recirculating pump volume, eliminating unexpected crystallization fouling and reducing energy consumption by an additional 12%.
Bipolar Membrane Electrodialysis (BMED)
Moving beyond salt disposal, Tongjie's future-ready ZLD trains deploy BMED systems that convert high-purity sodium chloride and sodium sulfate brines back into industrial hydrochloric acid (HCl), sulfuric acid (H2SO4), and sodium hydroxide (NaOH). This circular chemical generation empowers industrial operators to close their in-house chemical loop on site.
Renewable-Powered Modular Desalination & ZLD
In water-stressed, off-grid regions such as the MENA territory and remote mining corridors in Australia and Chile, Tongjie is deploying containerized ZLD skids directly coupled with utility-scale photovoltaic (PV) and battery storage systems. Intelligent load-shifting software maintains membrane operation dynamically based on available renewable energy yield.
Built to Global Engineering & Safety Standards
Exporting complex industrial water machinery requires absolute alignment with regional electrical, mechanical, and environmental codes. Tongjie guarantees full compliance and turnkey documentation for overseas EPC contractors and plant operators.
CE Machinery & PED Directives
All pressure vessels, electrical switchgear, and rotating assemblies strictly adhere to the European Pressure Equipment Directive (PED 2014/68/EU) and Machinery Directive (2006/42/EC).
ASME Section VIII Certification
Pressure vessels, cartridge housings, and high-pressure reverse osmosis piping circuits are welded and non-destructively tested (NDT) in compliance with ASME Section VIII Division 1 guidelines.
ISO Quality Triad
Tongjie operates an audited management ecosystem holding ISO 9001 (Quality Management), ISO 14001 (Environmental Stewardship), and ISO 45001 (Occupational Health and Safety).
Remote SCADA & On-Site Support
Our secure cellular- and satellite-linked telemetry empowers our Shanghai senior process engineers to conduct remote debugging, parameter tuning, and 24/7 technical advisory for clients globally.
Frequently Asked Questions: Sizing, Execution & Maintenance
In-depth responses to the exact criteria evaluated by plant directors, procurement managers, and municipal water authorities before commissioning a ZLD installation.
What specific feed water data is required to calculate an accurate mass balance and proposal?
To produce an authoritative mass balance, process flow diagram (PFD), and accurate capital projection, our engineering team requires: comprehensive ion chromatography (Na+, K+, Ca2+, Mg2+, Ba2+, Sr2+, Cl-, SO42-, NO3-, HCO3-, CO32-), total dissolved solids (TDS), silica (both reactive and colloidal), chemical oxygen demand (COD), total organic carbon (TOC), oil and grease content, feed temperature variability, diurnal pH profiles, operating capacity per hour/day, available site steam or electrical infrastructure, and target cake dryness.
How does Tongjie mitigate severe scaling inside MVR falling-film evaporators?
Scaling control is achieved through three integrated barriers: First, thorough upstream chemical softening using lime, soda ash, and sodium hydroxide down to Ca2+/Mg2+ < 10 mg/L; second, dosage of advanced polymeric threshold antiscalants engineered specifically for high ionic strengths; and third, thermodynamic design: we utilize forced-circulation flash crystallizers at the high-concentration end to prevent crystallization directly on heat-transfer surfaces. An automated Clean-in-Place (CIP) loop with acid and chelant flushing is integrated into the PLC logic.
What makes DTRO superior to spiral-wound membranes in high-salinity ZLD operations?
Standard spiral-wound reverse osmosis elements employ tight feed spacer mesh channels (typically 28 to 34 mil) that trap suspended solids and provide nucleation points for biofouling and scaling crystals. In contrast, Disc Tube Reverse Osmosis (DTRO) features an open-channel hydrodynamic architecture where feed water traverses radial flow channels across open flat-sheet membrane discs. The high-shear velocity profile prevents boundary layer concentration polarization, allowing stable operation up to 160 bar and handling SDI levels exceeding 5 without clogging.
What is the typical Levelized Cost of Water (LCOW) and operational energy breakdown?
By heavily loading the membrane concentration phase to reach ~100,000 to 120,000 mg/L TDS, the membrane stage consumes only 3.5 to 5.0 kWh per cubic meter of treated water. The subsequent MVR evaporation phase consumes approximately 22 to 30 kWh per ton of water evaporated. Compared to pure thermal systems that consume 60 to 90 kWh/m³, our hybrid membrane-thermal architecture slashes net operational energy expenditure by up to 60%, delivering an industry-leading levelized treatment cost per cubic meter.
How does Tongjie support overseas commissioning and lifecycle field maintenance?
Every system is dispatched with standard pre-wired containerized or skid connections for plug-and-play installation. We provide dual commissioning options: sending senior process and automation field engineers directly to your global plant site for hands-on commissioning and operator certification, or executing fully remote guided commissioning via our cloud SCADA telemetry. Furthermore, we maintain a dedicated consignment warehouse in Shanghai to ensure expedited international courier delivery of replacement membrane elements, mechanical seals, and specialized valve kits.
High-Pressure Membrane, Demineralization & Desalination Inventory
Explore our specialized range of seawater desalination plants, high-purity microelectronics systems, and industrial demineralization units designed for severe conditions.
OEM Compact Reverse Osmosis Seawater Desalination System
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Membrane Deoxygenation & Degassing Equipment for High-Purity Feed
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Wholesale Compact Seawater Desalination System for Island & Marine Duty
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CE Certified Oilfield Flowback Re-Injection & Water Treatment Skid
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High-Pressure Membrane Concentration System (DTRO & STRO Units)
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Fracturing Flowback Fluid System for Closed-Loop Zero Discharge Reuse
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Electronic Ultra-Pure Water System for Semiconductors (18.2 MΩ·cm)
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