Micro bubble flotation systems in DAF units typically fail due to 12 common issues, from clogged saturators (reducing bubble generation by 40-60%) to improper chemical dosing (causing 30-50% lower TSS removal). Industrial fixes include pressure adjustments (optimal 4-6 bar for 30-50 μm bubbles), pH control (6.5-7.5 for protein skimmers), and automated skimming calibration. This guide provides diagnostic steps, root causes, and compliance-safe solutions for each problem, backed by EPA 2024 benchmarks and Zhongsheng Environmental field data from 200+ DAF installations.
Why Micro Bubble Flotation Fails in Industrial DAF Systems
Micro bubble flotation failures in industrial DAF systems can lead to significant financial penalties, with a food processing plant, for instance, facing EPA fines upwards of $50,000 for recurring TSS violations in 2023 due to an underperforming DAF unit. A common scenario involves a large-scale dairy processing facility experiencing inconsistent effluent quality, despite its DAF system operating, resulting in frequent exceedances of total suspended solids (TSS) and biochemical oxygen demand (BOD) discharge limits. These issues often stem from subtle yet critical microbubble generation or attachment problems, which, if left unaddressed, lead to severe compliance breaches and operational inefficiencies.
The primary compliance consequences stemming from microbubble issues include: TSS and BOD exceedances, leading to regulatory fines and potential facility shutdowns; increased chemical overuse as operators attempt to compensate for poor flotation, driving up operational costs; and higher sludge disposal costs due to inefficient solids separation and increased sludge volume. Effective diagnosis requires understanding the core failure modes. These typically fall into three categories: inadequate bubble generation (too few, too large, or no bubbles), compromised bubble-particle attachment (particles don't adhere to bubbles), and inefficient skimming/removal (flocculated solids aren't effectively removed from the water surface).
A quick diagnostic framework can help pinpoint the general problem area: if bubbles are completely absent or visibly too large, the issue likely lies with the saturator or air injection system. Conversely, if bubbles are present but no discernible flotation layer forms, chemical dosing or wastewater characteristics are often the culprits affecting bubble-particle attachment. If a flotation layer forms but the effluent still contains excessive solids, then skimming or post-DAF bubble removal might be inadequate.
Building on this framework, the most immediate and impactful failure is often the complete absence of microbubble generation.
Diagnosing No Microbubble Generation: Step-by-Step Fixes
Insufficient microbubble generation, often manifesting as a complete absence of bubbles, accounts for approximately 40-60% of DAF operational failures, directly impacting TSS removal efficiency. The absence of fine bubbles means no mechanism exists for lifting suspended solids, leading to immediate DAF bypass or severe effluent quality degradation.
- Step 1: Verify Air Compressor Pressure. The air compressor must consistently supply air at 4-6 bar (58-87 psi) to the saturator to produce microbubbles in the optimal 30-50 μm range (per 911Metallurgist data). Check the pressure gauge on the compressor and the saturator inlet. If pressure is below 4 bar, the compressor may be failing, undersized, or experiencing leaks.
- Step 2: Check Saturator for Clogging. The saturator vessel is where air dissolves into the recycle water under pressure. Over time, especially in hard water areas or with high concentrations of dissolved solids, scale or fouling can occur on internal surfaces or the air diffuser, reducing air dissolution efficiency. Visually inspect the saturator internals if possible (during a scheduled shutdown) or monitor differential pressure across the saturator. A significant pressure drop indicates clogging.
- Step 3: Test Air Injection Nozzles. The pressurized recycle water, supersaturated with air, is released through pressure reduction valves or nozzles into the DAF tank, where microbubbles form. To test, collect a 100 mL sample of the DAF influent (after the nozzles) in a graduated cylinder and observe bubble formation with a stopwatch. Optimal systems should show a rapid, dense cloud of fine bubbles (30-50 μm) that rise evenly. A lack of bubbles or presence of large, erratic bubbles indicates nozzle wear, blockage, or incorrect pressure.
- Step 4: Measure Recycle Flow Rate. The recycle flow rate, typically 10-30% of the influent flow (per Zhongsheng DAF manual), is critical for providing enough dissolved air. Use flow meters to verify the actual recycle rate. A reduced flow rate directly impacts the volume of dissolved air available for bubble generation.
No Microbubble Generation: Fix Checklist
Based on the diagnosis, implement the following industrial-grade fixes:
- If compressor pressure <4 bar: Replace or repair the air compressor. Ensure regular maintenance, including air filter changes and oil checks, to prevent future pressure drops.
- If saturator fouled/clogged: Perform an acid wash. Isolate the saturator, drain it, and circulate a dilute acid solution (e.g., 5-10% phosphoric or citric acid) for 4-8 hours. Rinse thoroughly with clean water and neutralize any remaining acid before returning to service. This procedure typically takes 2-4 hours of downtime.
- If air injection nozzles are faulty: Clean or replace the nozzles/pressure reduction valves. Ensure proper sizing and material compatibility for your wastewater. Zhongsheng Environmental's ZSQ series DAF systems for industrial microbubble flotation feature robust nozzle designs engineered for consistent bubble generation.
- If recycle flow rate is low: Check recycle pump performance, valve positions, and piping for blockages. Adjust pump speed or valve openings to achieve the optimal 10-30% recycle ratio.
| Symptom | Root Cause | Diagnostic Step | Industrial Fix |
|---|---|---|---|
| No bubbles / Large bubbles | Low compressor pressure | Check compressor/saturator gauge | Compressor repair/replacement |
| Reduced bubble density | Saturator fouling/clogging | Monitor saturator ΔP, visual check | Acid wash saturator |
| Erratic/uneven bubbles | Worn/blocked nozzles | Visual inspection, 100mL test | Clean/replace nozzles |
| Insufficient dissolved air | Low recycle flow rate | Verify flow meter readings | Adjust recycle pump/valves |
Once adequate bubble generation is confirmed, the next common challenge arises when bubbles are present but fail to effectively remove solids.
Bubbles Present but No Flotation: Attachment Failure Causes & Solutions
When microbubbles are visibly present but effective flotation is absent, the root cause lies in the failure of efficient bubble-particle attachment, a critical step determining DAF performance. This often means particles are not sufficiently charged, agglomerated, or hydrophobic enough to adhere to the rising air bubbles, resulting in poor TSS removal despite adequate bubble generation.
The efficiency of bubble-particle attachment relies on three primary mechanisms: collision (physical contact between bubble and particle), adhesion (the ability of the particle to stick to the bubble surface), and stability (the strength of the bubble-particle aggregate against shear forces). Adhesion, in particular, is influenced by surface chemistry; for example, studies on microplastic flotation highlight how surface charge and hydrophobicity dictate attachment behavior. Particles that are too small (<0.006mm) or too large (>0.1mm) often float poorly, as very fine particles lack sufficient mass for effective collision, while very coarse particles are too heavy to be lifted by microbubbles (per 911Metallurgist and Top 5 research).
Common chemical dosing issues significantly impede attachment:
- Coagulant Overdose/Underdose: Insufficient coagulant (e.g., PAC, ferric chloride) results in poorly destabilized particles that cannot form flocs, leading to fine, non-settleable particles. Overdosing can lead to restabilization of particles (re-charging them), or create weak flocs that break easily in the DAF, causing bubble breakage and reduced flotation.
- pH Drift: Most industrial wastewater applications, especially those involving protein or oil/grease removal, require an optimal pH range of 6.5-7.5 for effective coagulation and flocculation. Deviations outside this range can significantly alter particle surface charges and chemical efficacy.
- Surfactant Interference: High concentrations of surfactants (soaps, detergents) in the wastewater can compete with particles for the bubble surface, reducing attachment efficiency. They can also stabilize bubbles, leading to excessive foaming rather than effective flotation.
Attachment Failure: Diagnostic & Solution Table
To diagnose and resolve attachment failures, a systematic approach is necessary:
| Symptom | Probable Cause | Industrial Fix |
|---|---|---|
| Fine particles in effluent | Coagulant underdose / Insufficient mixing | Increase PAC dosage by 20% / Optimize rapid mix speed to 100-200 RPM |
| Large, weak flocs that break | Coagulant overdose / Excessive mixing | Reduce PAC dosage by 10% / Reduce slow mix speed to 10-30 RPM |
| No floc formation, cloudy water | Incorrect pH / Ineffective coagulant | Adjust pH to 6.5-7.5 using acid/base / Try different coagulant (e.g., ferric sulfate) |
| Excessive stable foam, poor flotation | Surfactant interference / Polymer overdose | Pre-treatment for surfactants / Reduce polymer dosage by 5-15% |
| High effluent turbidity despite bubbles | Particle size mismatch / Inadequate flocculation | Optimize chemical dosing via jar test / Consider pre-filtration for very fine particles |
The jar test procedure is indispensable for optimizing chemical dosing. Collect representative wastewater samples, add varying doses of coagulant and flocculant, and observe floc formation, settling/flotation speed, and supernatant clarity. Typically, a rapid mix (100-200 RPM for 1-2 minutes) is followed by a slow mix (10-30 RPM for 10-15 minutes) to promote floc growth, then a settling/flotation period. Visual criteria for optimal dosing include rapid formation of dense, easily floatable flocs, and clear supernatant. For precise control, consider PLC-controlled chemical dosing systems for optimizing microbubble attachment that can adjust dosages in real-time based on influent characteristics.
Even when flotation is successful, another common problem can arise: the presence of excessive microbubbles in the treated effluent.
Excessive Microbubbles in Effluent: Causes and Industrial Removal Methods
Persistent microbubbles in the DAF effluent, often leading to post-treatment turbidity issues and even interference with subsequent treatment steps, can indicate supersaturation or inefficient removal mechanisms, and are a common concern in industrial operations. This issue is frequently raised in operator forums, such as the Facebook group query regarding the removal of bubbles from flotation must to enable filtration.
Bubbles can persist in the effluent due to several reasons: supersaturation, where the dissolved air concentration in the recycle water is too high for the operating pressure, leading to excess air remaining dissolved and then releasing in the effluent; improper skimming, where the skimmer's speed or design fails to capture the entire flotation layer, allowing bubbles and floc to escape; or chemical carryover, particularly from certain defoamers or surfactants that stabilize bubbles rather than breaking them.
Industrial facilities employ several methods to address excessive microbubbles in the effluent:
- Degassing Tanks: These are simple, open-top tanks positioned after the DAF. By providing additional retention time (typically 5-15 minutes), they allow residual microbubbles to naturally rise to the surface and dissipate. Efficiency ranges from 80-90% for typical industrial DAF effluent, and they are relatively low-cost in terms of CAPEX but require a significant footprint.
- Vacuum Degassing: For applications requiring extremely low residual bubble content, vacuum degassing units apply a negative pressure to the effluent stream, rapidly drawing out dissolved gases and microbubbles. This method offers up to 95% removal efficiency but comes with high CAPEX and OPEX due to energy consumption for the vacuum pump.
- Chemical Defoamers: Specific anti-foaming agents can be dosed into the DAF effluent or a dedicated degassing tank to chemically break down stable microbubbles. Dosing rates typically range from 1-5 ppm, depending on the defoamer type and wastewater characteristics. Compatibility with downstream processes and potential for secondary pollution must be evaluated carefully.
Microbubble Removal Methods: Cost and Efficiency Comparison
| Method | CAPEX (Relative) | OPEX (Relative) | Removal Efficiency |
|---|---|---|---|
| Degassing Tanks | Low | Very Low (minor pumping) | 80-90% |
| Vacuum Degassing | High | High (energy for vacuum) | >95% |
| Chemical Defoamers | Very Low (dosing pump) | Medium (chemical cost) | 70-90% (variable) |
To prevent bubble carryover into the effluent, several operational adjustments can be made: optimize skimmer speed by calibrating it to the solids loading rate (e.g., 0.5-2 m/min for typical DAFs); adjust the recycle ratio downwards if the influent solids load is consistently low, reducing the amount of dissolved air introduced; and install baffles within the DAF tank to create quiescent zones where bubbles can rise and consolidate before the effluent weir.
Beyond simply removing excess bubbles, achieving the correct microbubble size and distribution is equally critical for maximizing DAF efficiency.
Optimizing Microbubble Size and Distribution for Maximum Efficiency
Achieving the optimal microbubble size and distribution is paramount for maximizing DAF efficiency, directly influencing collision probability and particle removal rates. The effectiveness of a DAF system hinges on generating a sufficient quantity of appropriately sized bubbles that can efficiently collide with and attach to flocculated particles.
The relationship between bubble size (Db) and collision probability (Pc) is critical; as highlighted by 911Metallurgist's principles, decreasing Db generally increases Pc for a given particle size, leading to more effective flotation. Smaller bubbles offer a larger collective surface area per unit volume of air, increasing the likelihood of contact with fine particles. However, bubbles that are too small may lack sufficient buoyancy to lift heavier flocs.
Target bubble sizes vary based on the primary contaminants: 30-50 μm is generally optimal for efficient TSS removal in most industrial wastewaters, while 10-30 μm bubbles are more effective for removing fine oil and grease particles (citing EPA DAF guidelines). Measuring bubble size accurately is crucial for optimization. This can be done via microscopy (a lab-based method involving capturing samples and analyzing bubble images) or more advanced laser diffraction (an online, real-time method that provides continuous data but involves higher capital cost).
Five key parameters significantly affect microbubble size and distribution:
- Saturator Pressure: Higher pressure generally leads to smaller, more numerous bubbles upon depressurization.
- Nozzle Design: The geometry and orifice size of the air injection nozzles or pressure reduction valves directly influence bubble formation.
- Water Temperature: Colder water can dissolve more air, potentially leading to smaller bubbles upon release, but also affects viscosity.
- Salinity: Increased salinity (higher ionic strength) tends to reduce bubble size due to changes in surface tension.
- Chemical Additives: Certain surfactants or polyelectrolytes can influence bubble stability and size.
Microbubble Optimization Table
| Wastewater Type | Target Contaminant | Optimal Bubble Size (μm) | Saturator Pressure (bar) | Recycle Ratio (%) |
|---|---|---|---|---|
| Food Processing | TSS, FOG | 35-45 | 4.5-5.5 | 15-25 |
| Oil & Gas (Produced Water) | Oil, Suspended Solids | 25-35 | 5.0-6.0 | 20-30 |
| Pulp & Paper | Fibers, Lignin, TSS | 40-50 | 4.0-5.0 | 10-20 |
| Textile Dyeing | Color, TSS | 30-40 | 4.5-5.5 | 15-25 |
While optimizing bubble characteristics is vital, chemical dosing remains another fundamental lever for improving microbubble flotation performance.
Chemical Dosing Strategies to Improve Microbubble Flotation Performance
Precise chemical dosing is fundamental to enhancing microbubble flotation performance, facilitating robust floc formation and improving bubble-particle attachment efficiency. The correct selection and application of chemicals can significantly boost the removal of suspended solids, oils, and other contaminants, while improper dosing can lead to system failures and compliance issues.
Four common categories of chemicals are used in DAF systems:
- Coagulants: Such as polyaluminum chloride (PAC) or ferric chloride, destabilize negatively charged particles, allowing them to aggregate. Typical dosing ranges for PAC are 20-100 mg/L, while ferric chloride might be 10-50 mg/L, depending on influent characteristics.
- Flocculants: Anionic or cationic polymers, which bind destabilized particles together to form larger, more robust flocs that are easier to float. Anionic polymers are often dosed at 0.5-5 mg/L.
- pH Adjusters: Acids (e.g., sulfuric acid) or bases (e.g., caustic soda) are used to maintain the optimal pH range, typically 6.5-7.5 for most industrial applications, which is crucial for coagulant effectiveness and particle surface charge.
- Surfactants/Defoamers: While some surfactants can interfere, specific defoamers are used to control excessive stable foam, ensuring that bubbles are primarily used for flotation rather than surface accumulation.
To avoid overdosing and ensure optimal performance, several strategies are employed: routine jar tests provide a visual assessment of floc formation and settling/flotation characteristics; zeta potential measurements quantify particle surface charge, guiding coagulant dose to achieve optimal charge neutralization; and real-time monitoring using turbidity meters or streaming current detectors can provide immediate feedback for automated dosing systems. For instance, maintaining the zeta potential close to zero often indicates optimal coagulation.
Chemical compatibility is also critical. For example, avoid mixing cationic polymers with anionic surfactants, as this can lead to undesirable precipitation and reduced effectiveness of both chemicals. Automated chemical dosing systems, such as Zhongsheng Environmental's automatic chemical dosing systems, offer precise control and can prevent these issues.
Chemical Dosing Troubleshooting Table
| Chemical Issue | Symptom | Fix/Adjustment |
|---|---|---|
| Coagulant Underdose | Fine, dispersed particles; cloudy effluent | Increase coagulant dose by 10-20% |
| Coagulant Overdose | Small, re-stabilized particles; increased sludge volume | Decrease coagulant dose by 5-10%; check zeta potential |
| Flocculant Underdose | Small, weak flocs; poor flotation blanket | Increase polymer dose by 0.5-1 mg/L |
| Flocculant Overdose | Large, stringy flocs; floc breakage; high polymer cost | Decrease polymer dose by 0.5-1 mg/L; reduce mixing intensity |
| Incorrect pH | Poor floc formation; chemical inefficiency | Adjust pH to optimal range (e.g., 6.5-7.5) |
| Floc breakage | Small flocs in effluent; high turbidity | Reduce mixing speed in flocculation tank; optimize polymer type |
Ultimately, the effectiveness of all these operational and chemical strategies directly impacts a facility's ability to meet stringent compliance and discharge limits.
How Microbubble Issues Affect Compliance and Discharge Limits
Microbubble flotation issues directly translate into regulatory non-compliance, leading to exceedances of discharge limits for key parameters like TSS, BOD, and oil/grease, with significant financial and reputational repercussions. For industrial facilities, maintaining a DAF system in optimal condition is not merely an operational goal but a regulatory imperative, as non-compliance can result in substantial fines and operational restrictions under frameworks like the EPA's 2024 industrial discharge limits.
Three key compliance parameters are most affected by microbubble flotation problems:
- Total Suspended Solids (TSS): The most direct impact. Inefficient bubble generation or attachment means suspended solids are not effectively floated and removed, leading to high TSS concentrations in the effluent.
- Biochemical Oxygen Demand (BOD): High TSS often correlates with high BOD, as suspended organic matter contributes to oxygen demand. Poor DAF performance, therefore, can cause significant BOD exceedances.
- Oil and Grease (O&G): DAF systems are highly effective at removing free and emulsified oils. Microbubble issues, especially inadequate bubble size or attachment, can severely compromise O&G removal, leading to violations.
Compliance Impact Matrix for Microbubble Failures
| Microbubble Problem | Typical TSS Increase (%) | Typical BOD Increase (%) | Typical Oil/Grease Increase (%) |
|---|---|---|---|
| No Microbubbles Generated | +80% | +50% | +90% |
| Poor Bubble-Particle Attachment | +40% | +30% | +60% |
| Excessive Microbubbles in Effluent | +20% | +15% | +25% |
| Suboptimal Bubble Size/Distribution | +30% | +20% | +40% |
To mitigate compliance risks, it is essential to document fixes for regulators. This includes maintaining detailed logbooks of DAF operational parameters, chemical dosages, maintenance activities, and effluent quality data. SCADA (Supervisory Control and Data Acquisition) systems provide invaluable real-time and historical data for demonstrating compliance and troubleshooting. Additionally, third-party testing can provide independent verification of DAF performance.
Consistent DAF performance data can also be leveraged to negotiate permit limits. For instance, if a facility consistently achieves 95% TSS removal with its DAF, this robust performance data can be presented to regulatory bodies to support requests for higher influent limits or more favorable discharge conditions, demonstrating proactive environmental stewardship. For specific regional standards, refer to guides such as India's CPCB Wastewater Discharge Standards or Wastewater Discharge Standards Australia.
Understanding the compliance implications naturally leads to a crucial next step: evaluating the cost-effectiveness and return on investment for various microbubble flotation fixes.
Cost Analysis of Microbubble Flotation Fixes: ROI and Downtime Comparison
Implementing microbubble flotation fixes requires a strategic evaluation of capital expenditure (CAPEX), operational expenditure (OPEX), and potential downtime, balanced against the return on investment (ROI) from avoided fines and improved efficiency. A clear decision framework helps management approve necessary repairs and upgrades, ensuring long-term compliance and cost-effectiveness.
Fixes can range from simple operational adjustments to significant equipment overhauls. Understanding the financial implications of each is critical:
Cost and ROI Comparison of DAF Fixes
| Fix | Typical CAPEX | Typical OPEX (per m³) | Typical Downtime | Estimated ROI Period |
|---|---|---|---|---|
| Saturator Acid Wash | $500 (chemicals) | $0.01 - $0.05 | 2-4 hours | 1-3 months (avoided fines/efficiency) |
| Nozzle/Valve Replacement | $100 - $1,000 | Negligible | 1-2 hours | 3-6 months |
| Recycle Pump Repair/Replace | $1,000 - $5,000 | $0.05 - $0.15 | 4-8 hours | 6-12 months |
| Automated Dosing System | $5,000 - $15,000 | Reduced chemical cost | 1-2 days (installation) | 6-18 months (chemical savings, compliance) |
| Air Compressor Upgrade | $3,000 - $10,000 | $0.02 - $0.10 | 4-12 hours | 12-24 months (efficiency, reliability) |
The comparison between short-term vs. long-term fixes is crucial. Chemical adjustments or minor operational tweaks are low-cost and offer immediate, albeit sometimes temporary, improvements. For instance, a quick chemical adjustment might cost minimal OPEX but provides immediate compliance. In contrast, a saturator replacement (high CAPEX, but with a 5-10 year lifespan) offers a durable solution, potentially reducing long-term OPEX due to increased efficiency and fewer compliance issues.
To calculate ROI, quantify avoided costs (e.g., TSS fine avoidance of $10,000/year) against the fix cost (e.g., a $2,000 repair). This scenario yields a quick 2.4-month payback period. Beyond fines, consider savings from reduced chemical consumption, lower sludge disposal volumes, and decreased energy usage. Minimizing downtime is also a key consideration; maintaining a spare parts inventory for critical components, implementing predictive maintenance based on sensor data, and even designing systems with parallel trains for redundancy can significantly reduce operational interruptions and associated costs.
Frequently Asked Questions
Operators and engineers frequently encounter specific challenges in microbubble flotation systems; addressing these common questions can expedite troubleshooting and maintain optimal performance.
Why do microbubbles persist in my DAF effluent?
Persistent microbubbles in DAF effluent typically occur due to supersaturation of dissolved air, where the water is unable to hold all the dissolved air at atmospheric pressure, causing it to release in the effluent. Improper skimmer operation, which fails to capture the entire flotation layer, or the presence of surfactants that stabilize bubbles can also exacerbate this. Quick Fix: Adjust recycle pump pressure or flow rate downwards slightly, optimize skimmer speed, or consider adding a small degassing tank.
How can you get rid of bubbles formed during flotation to be able to filter the flotation must?
To remove bubbles from flotation must for subsequent filtration, several industrial methods are effective. Degassing tanks provide retention time for natural bubble dissipation, achieving 80-90% removal. Vacuum degassing offers higher efficiency (>95%) for critical applications but at a higher energy cost. Chemical defoamers can be dosed at 1-5 ppm to destabilize and break down persistent bubbles, though compatibility with downstream processes is essential. Quick Fix: Install a small degassing tank or dose a compatible chemical defoamer before filtration.
What are the key steps for micro bubble flotation troubleshooting?
Effective micro bubble flotation troubleshooting involves a systematic approach: 1) Verify air compressor pressure and recycle flow to ensure adequate bubble generation. 2) Inspect the saturator and nozzles for clogs or wear. 3) Assess chemical dosing (coagulant, flocculant, pH) using jar tests and real-time monitoring to confirm proper particle destabilization and floc formation. 4) Evaluate skimmer speed and DAF hydraulics to ensure efficient solids removal and prevent bubble carryover. Quick Fix: Start by checking the air pressure and chemical feed pumps, as these are common failure points.
How does water quality affect micro bubble flotation efficiency?
Water quality significantly impacts micro bubble flotation efficiency. Parameters like pH, temperature, salinity, and the presence of dissolved organic matter or surfactants can alter bubble size, stability, and particle surface charges, thus affecting bubble-particle attachment. For instance, high levels of surfactants can stabilize bubbles, leading to excessive foaming rather than effective flotation, while extreme pH values can render coagulants ineffective. Quick Fix: Monitor and control pH to the optimal range (e.g., 6.5-7.5) and conduct jar tests to adapt chemical dosing to varying influent water quality.
If bubbles are too large, what should I check first?
If microbubbles in your DAF system appear too large, the first component to check is the saturator pressure and the air injection nozzles. Insufficient pressure (below 4 bar) in the saturator or worn/clogged nozzles can lead to the formation of larger bubbles rather than the desired fine microbubbles (30-50 μm). Large bubbles have less surface area per unit volume and a reduced collision probability with fine particles. Quick Fix: Reduce saturator pressure to 4 bar or inspect and clean/replace air injection nozzles.
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