Zero Liquid Discharge System Design & Integration

Zero Liquid Discharge (ZLD) is not a single piece of equipment—it is a fully integrated wastewater treatment system that must be engineered around site-specific water chemistry, flow variability, discharge requirements, and lifecycle cost.

UCC Environmental provides end-to-end ZLD system design and integration, serving as the engineering lead responsible for how each technology performs together as a complete system. Rather than promoting a single proprietary unit, we evaluate, specify, and integrate the right combination of technologies to achieve reliable ZLD performance.

Integrated ZLD System Components

A properly engineered ZLD system may include:

• Pretreatment systems to protect downstream thermal processes and manage fouling, scaling, and solids loading
• Evaporators to concentrate high-salinity wastewater streams
• Brine concentrators to reduce liquid volumes prior to final solids processing
• Crystallizers to convert concentrated brine into manageable solid salts
• Solids handling and dewatering systems for compliant disposal or beneficial reuse

Each component is selected and integrated based on influent chemistry, recovery targets, energy consumption, and long-term operating reliability.

Engineering-Led ZLD Integration

As the system integrator, UCC Environmental ensures that all ZLD components operate as a cohesive, optimized system—not as disconnected packages. Our role includes:

• Process modeling and system configuration
• Equipment specification and vendor coordination
• Integration with existing wastewater infrastructure
• Commissioning and performance validation
• Ongoing technical support and optimization

By taking an engineering-led approach, we help industrial facilities avoid vendor-locked designs, reduce operational risk, and achieve sustainable Zero Liquid Discharge wastewater treatment that performs over the life of the plant.

Why is Zero Liquid Discharge Important?

In April 2024, the U.S. EPA finalized the updated ELG rule requiring coal-fired powerplants to adopt a Zero Liquid Discharge approach for FGD wastewater, Bottom Ash Transport Water, and Combustion Residual Leachate (CRL). ZLD removes the discharge pathway entirely, eliminating future compliance risk and supporting long-term operational planning.

Why Choose UCC Zero Liquid Discharge (ZLD) Systems

Zero Liquid Discharge succeeds or fails at the system level. Facilities choose UCC Environmental because our ZLD systems are engineered to perform reliably across variable wastewater conditions, regulatory scrutiny, and long operating horizons.

Engineering-Led System Design

Our ZLD systems are designed by engineers who understand wastewater chemistry, thermal processes, and solids behavior—not just individual equipment performance. Each system is configured around influent variability, recovery targets, and long-term operating risk to avoid over- or under-designed solutions.

Technology-Agnostic Integration

We do not push a single proprietary unit. Instead, we evaluate and integrate evaporators, brine concentrators, crystallizers, pretreatment, and solids handling technologies from proven suppliers. This technology-agnostic approach allows us to select the right tools for each application while avoiding vendor-locked ZLD designs.

Reduced Lifecycle Cost and Risk

ZLD systems often fail due to scaling, fouling, corrosion, or solids mismanagement. Our designs prioritize pretreatment, materials selection, and process controls that reduce unplanned downtime, stabilize OPEX, and protect thermal assets over the life of the system.

Proven Regulatory Alignment

Our ZLD systems are engineered to support ELG compliance, no-discharge requirements, and site-specific permitting constraints. We design with regulatory review in mind, helping facilities demonstrate compliance confidence while maintaining operational flexibility.

Integration with Existing Plant Infrastructure

Most facilities cannot start from a blank sheet. We integrate ZLD systems into existing wastewater treatment, utilities, and solids handling infrastructure—minimizing disruption while improving overall water management performance.

Long-Term Technical Support

ZLD is not a “set it and forget it” solution. UCC Environmental provides ongoing technical support to help facilities adapt to changing influent conditions, production rates, and regulatory requirements—ensuring sustained ZLD performance over time.

How Zero Liquid Discharge Systems Work

A complete ZLD system integrates several treatment stages that convert wastewater into two outputs: recovered water and a stable solid byproduct. Typical components include:

Pre-Treatment

• Softening
• Clarification
• Media and membrane filtration

Concentration Technologies

• Reverse osmosis (RO)
• Brine concentrators
• Evaporation systems

Crystallization

• Converts concentrated brine into solid material
• Reduces long-term handling and disposal risk

Water Recovery & Reuse

• Treated water is recycled back into the facility
• Reduces freshwater draw and operating costs

ZLD Compliance Checklist

1. Water balance – Have you mapped all wastewater streams and recycle opportunities?
2. Permit review – Do your NPDES requirements or local conditions point toward ZLD?
3. Pilot study – Have you tested RO, evaporation, or crystallizer options at your site?
4. Residual management – Do you have a plan for handling and disposing of crystallized solids?
5. Energy/cost model – Have you modeled the CAPEX and OPEX impact of ZLD vs. advanced treatment?
6. TIMELINE – Do you have 24–36 months to design, permit, and install a full ZLD system?
7. Regulatory engagement – Have you discussed ZLD as a compliance option with your permitting authority?

Next Step: ZLD systems are complex — but with the right engineering partner, utilities can reduce risk and achieve long-term compliance.

Zero Liquid Discharge Frequently Asked Questions

Next Step: Request a Site Evaluation

ZLD projects require the right technical and compliance strategy. Our engineers can review your water balance, site constraints, and treatment options to determine if ZLD is the best fit.