The Science Behind Smarter Evaporation

 Aquality's Convection-Enhanced Evaporation (CEE) technology is built on a peer-reviewed mathematical model and validated field performance — not theoretical projections. Co-founder and co-inventor Prakash Bhalekar is a named author on the foundational CEE research published in Desalination (2021) and Water Research (2022), giving Aquality a direct line from academic validation to commercial deployment. 

How It Works

CEE drives evaporation through vapor pressure differential — not heat. Produced water is distributed as thin films and forced airflow across those films carries moisture away continuously. Autonomous controls optimize airflow and inlet water temperature in real time, responding to ambient conditions to maintain consistent, model-aligned performance 24/7. The system runs at low pressure using corrosion-resistant, non-metallic materials — purpose-built for the punishing chemistry of high-TDS produced water.  

Why It Outperforms

Permian Basin Pilot Results

Permian Basin Pilot Results

 Published benchmarking puts CEE at approximately 4x lower cost per barrel evaporated than comparable commercial evaporators, with a footprint up to 7.5x smaller. Unlike thermal technologies such as MEE or MVC — which require high-grade heat and operate at 60–190°C — CEE runs at sub-boiling temperatures on grid power, solar, or waste heat. The Permian Basin's arid, low-humidity climate is among the most favorable operating environments CEE can have.

Pilot Highlights

  • 100 barrels/day of produced water evaporated

  • 1.5–2.5 kWh/bbl energy consumption

  • <20% variance between modeled and actual results

  • 0% overspray under all operating conditions

  • 400 ft² footprint for a 6-module array

  • 3–6 month deployment with autonomous operation

Advantages

Engineered Efficiency

  • Optimized airflow improves evaporation rates
  • Textured pans increase water residence time
  • Closed system enhances overall performance

Closed-System Safety

  • No overspray or drift
  • No airborne contaminants
  • Suitable for regulated environments

Low-Energy Operation

  • Runs on waste heat
  • Compatible with solar power
  • Lower energy use than MVR/MEE
Proven in the field(rev)

Proven in the Field

 Aquality's current Midland Basin pilot is validating 100 BPD evaporation in a 400 ft² footprint, targeting 1.5–2.5 kWh/bbl energy consumption with zero overspray — all autonomously operated. The commercial Gen10 configuration scales this to 10,000 BPD in under one acre, compared to over seven acres required by conventional evaporation pond infrastructure at equivalent throughput.  

Cross Industry Performance / Case Studies

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International Tire Manufacturer

  • Challenge: Achieve Zero Liquid Discharge (ZLD) for ~1,250 bbl/day of effluent with high oil/grease content.

  • Solution: CEE deployed as Evaporation as a Service, powered by waste heat from cooling towers and compressors.
  • Outcome: Full 1,250 bbl/day evaporation at ~3.2 kWh/bbl, with competitors costing 3× more.
  • Duration: 2 years of continuous operation.
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Hydraulic Components Manufacturer

  • Challenge: Replace diesel-powered MEE + dryers for ZLD on 60 bbl/day of plating-process reject.

  • Solution: CEE system using electric heat pump under an EaaS model.
  • Outcome: 90% reduction in both energy cost and CO₂ emissions.
  • Duration: 2 years of successful operation.
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Food Color Manufacturer

  • Challenge: Concentrate 100,000–160,000 mg/L brine without relying on natural-gas-fired steam vessels.

  • Solution: CEE system using waste heat to drive evaporation.
  • Outcome: 100% reduction in natural gas use; zero additional fuel required.
  • Duration: 3 years of continuous operation.

From Data to Deployment

Our pilot programs turn modeled performance into real-world results you can trust.