Uneven Flow Distribution
Some Plates Overloaded, Others Starved
When flow is not shared evenly across all plates, part of the pack is hydraulically overloaded and carries over solids while the rest is under-used — cutting effective capacity.
Understanding the Problem
The inlet distribution system exists to feed every plate channel equally. Poor design, partial blockage or asymmetric piping concentrates flow, so the effective surface loading rate is far higher than the average in the loaded zone.
Because the average loading looks acceptable, uneven distribution is often missed — yet it is one of the most common reasons a correctly sized unit under-performs.
Inspect the distributor, baffles and inlet geometry; dye or float testing quickly reveals the flow pattern.
Common Symptoms
- ›Carryover from one area only
- ›Visibly faster flow in some channels
- ›Capacity below nameplate
- ›Uneven sludge distribution
Causes & Corrective Actions
Cause
Poor inlet / distributor design
Corrective Action
Redesign inlet baffling for uniform feed across the pack.
Cause
Partial blockage of distributor
Corrective Action
Clean the distribution system; add upstream screening.
Cause
Asymmetric inlet piping
Corrective Action
Add flow-splitting baffles or a distribution channel.
Cause
Unlevel installation
Corrective Action
Check and correct level of the vessel and weirs.
Prevention
Related Pages
Still seeing the problem?
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