Verdantas Flow Labs was engaged by a confidential industrial client to investigate and resolve stack liquid discharge (SLD) issues observed on two exhaust stacks at a large manufacturing facility in the Midwest. The stacks, which serve separate process lines, were experiencing visible liquid discharge shortly after commissioning. Neither stack was originally equipped with liquid collection systems, and the client sought a long-term solution to mitigate the issue.

To address the issue, our team began with a site visit to assess the source of stack liquid discharge. Observations revealed that liquid was entering the exhaust fans from upstream ductwork, prompting an expansion of the study to include the full path from mist separators to fan inlets. We developed five physical flow models representing key duct and stack sections to simulate gas-liquid interactions under operating conditions. These models helped us pinpoint areas of re-entrainment, pooling, and upward liquid motion, particularly around elbows, junctions, and structural supports.

Using these insights, we designed and validated custom liquid collection and drainage systems tailored to each stack and duct section. We also modeled condensation to estimate liquid loads and provided clear recommendations and installation drawings to guide implementation.

The final solution offered a practical, cost-effective approach to mitigating SLD while improving the long-term reliability of the facility's exhaust systems.