Optimal design of hybrid RO/MSF desalination plants Part III: Sensitivity analysis

This is the last paper in a series of three parts entitled “Optimal design of hybrid RO/MSF desalination plants”. This research is concerned with exploring the feasibility of hybridization of multi-stage flash (MSF) and reverse osmosis (RO) technologies in order to improve the performance characteristics and process economics ofthe conventional MSF process. The research project involved an optimization study where the water cost perunit product is minimized subject to a number of constraints. In the first part, the design and cost models were presented, the optimization problem formulated and solutions for a number of cases were outlined. In the second part, results were presented and discussed. In this paper we discuss the sensitivity of water cost from the alternative plant designs to variations in some cost elements and operating conditions. In general, it is concluded that, for the same desalting capacity, hybrid RO/MSF plants can produce desalted water at a lower cost than brine recycle MSF plants, while hybrid plants are characterized, by lower specific capital costs and higher water recovery fractions. Reduction in steam cost allows MSF to compete more with hybrid RO/MSF plants. This result explains the advantage of coupling MSF plants and steam power plants where the exhaust steam from the back pressure turbine represents a relatively cheaper source of heat for the MSF process. Results showed that the RO technology exceeds all other designs over the whole range of energy, chemicals and membrane costs studied here. However, water cost of the RO process was the most sensitive to variations in membrane and electricity costs compared to other hybrid configurations.     

Implications of desalination for water resources in China — an economic perspective

China is a country with severe water shortages. Water is becoming scarcer due to population growth, industrialization and urbanization. Recent studies show that by the next 50 years water resources per capita will go down to around 1700 m³, which is the threshold of severe water scarcity. Especially in North China, water shortage has become a critical constraint factor for socioeconomic development in the long run. To solve or eliminate water shortage problems, seawater desalination draws more and more attention as an alternative water supply source. The objective of the study is to assess the potential of desalination as a viable alternate water source for China through analysis of the costs of desalination, the water demand and supply situation as well as water pricing practices in China. Based on the investment costs and estimated operation and maintenance costs, an economic appraisal for the costs of desalination for two main processes, MSF and RO, has been conducted. The study shows that there is a decline of unit cost of desalination over time and the average unit cost of the RO process was lower than that of the MSF process. A unit cost of 0.6 $/m³ for desalting brackish water and 1.0 $/m³ for seawater are suggested to be appropriate for the potential application of desalination in China. Future trends and challenges associated with water shortages and water prices are discussed, leading to conclusions and recommendations regarding the role of desalination as a feasible source of water for the future.     

Performance study of water desalination methods in Saudi Arabia

Saudi Arabia is an arid desert country without rivers or sweet water lakes, however, it does have vast amount of groundwater and seawater. In order to make these waters suitable for human consumption and industrial use, most of their salts must be removed by some means. The desalination methods most frequently used in the Kingdom are: Multistage flash (MSF) evaporation, reverse osmosis (RO), and electrodialysis (ED).During the last decade, we have witnessed a spectacular growth of desalination plants. This growth is expected to continue in the next decade. The present production capacity of all desalting plants in Saudi Arabia is estimated to be 750,000 m³/day; this figure will be most likely tripled in the next five years.This paper is a report on a performance study of the most significant desalination plants in the Kingdom. The plants, which include MSF and seawater and brackish water RO plants, were selected either because of their size or their importance to the desalination technology. The plants are briefly described and their performances are discussed.     

Nitrate removal with reverse osmosis in a rural area in South Africa

The nitrate-nitrogen concentration (>6 mg/l) and the salinity (>1000 mg/l TDS) of many borehole waters in rural areas in South Africa are too high for human consumption. Therefore, an urgent need for water denitrification and water desalination exists in these areas. Reverse osmosis (RO), electrodialysis (ED), ion-exchange (IX) and certain biological technologies can be very effectively applied for water denitrification. Each of these technologies, however, has its own advantages and disadvantages. Reverse osmosis technology, however, has been selected for this study because the technology is well known in South Africa and because it can be very effectively applied for water desalination. The objectives of this study were: (a) to transfer RO technology through process demonstration performance for water denitrification and water desalination to people living in rural areas; (b) to build capacity regarding the operation and maintenance of an RO application in a rural area; (c) to produce a preliminary operational and maintenance manual for the operation of an RO unit in a rural environment; (d) to train local operators to operate and maintain an RO plant in a rural environment; (e) to evaluate stock watering as brine disposal option; and (f) to determine the preliminary economics ofthe process. The following conclusions were drawn. It was demonstratedthatthe RO process could be very effectively applied for water denitrification and water desalination in a rural area. Nitrate-nitrogen was reduced from 42.5 mg/l in the RO feed to only 0.9 mg/l in the RO product water. The TDS of the RO feed was reduced from 1292 mg/l to 24 mg/l in the RO permeate. Therefore, an excellent quality water could be produced for potable purposes. The RO brine at approximately 50% water recovery should be suitable for stock watering if the conditions for stock watering are met in terms of nitrate-nitrogen concentration, TDS and other constituent concentrations. The capital cost for an approximately 50 m³/d output RO plant is approximately US $29,900. Preliminary cost estimates have shown that the operational cost for water denitrification is approximately US $0.50/m³. This cost, however, should be significantly reduced by optimisation of the chemical dosing and by blending borehole water with RO product water.     

Distillation vs. membrane filtration: overview of process evolutions in seawater desalination

The worldwide need for fresh water requires more and more plants for the treatment of non-conventional water sources. During the last decades, seawater has become an important source of fresh water in many arid regions. The traditional desalination processes [reverse osmosis (RO), multi stage flash (MSF), multi effect distillation (MED), electrodialysis (ED)] have evoluated to reliable and established processes; current research focuses on process improvements in view of a lower cost and a more environmentally friendly operation. This paper provides an overview of recent process improvements in seawater desalination using RO, MSF, MED and ED. Important topics that are discussed include the use of alternative energy sources (wind energy, solar energy, nuclear energy) for RO or distillation processes, and the impact of the different desalination process on the environment; the implementation of hybrid processes in seawater desalination; pretreatment of desalination plants by pressure driven membrane processes (microfiltration, ultrafiltration and nanofiltration) compared to chemical pretreatment; new materials to prevent corrosion in distillation processes; and the prevention of fouling in reverse osmosis units. These improvements contribute to the cost effectiveness of the desalination process, and ensure a sustainable production of drinking water on long terms in regions with limited reserves of fresh water.     

Integrating hybrid systems with existing thermal desalinationplants

In Gulf countries, most power plants are co-generation power desalting plants (CPDP) that generate electric energy and also produce fresh water through the desalination of seawater. This paper provides detailed technical and economical analyses to evaluate a new generation of dual purpose technology that includes the integration of reverse osmosis (RO) processes with existing thermal desalination processes and power generation (triple hybrid system) at Layyah plant, Sharjah, UAE. Hybridization of sweater reverse osmosis (SWRO) and the multi-stage flash (MSF) technology was considered to improve the performance of latter and reduce the cost of the produced water. Moreover, “idle” power in winter (seasonal surplus of unused power) was mainly utilized by RO to further reduce the cost of the hybrid system for six months of the year. Spinning reserve was also used to further reduce the cost of the proposed hybrid system. Integration ofthe three processes of MSF, MED, and RO desalination technologies could be made at different levels through which the resulting of water cost will depend on the selected configuration and the cost of materials of construction, equipment, membrane, energy, etc. Thus, the capital and annual operating costs were calculated for all potential alternatives for various plant capacities. It was found that for all plant capacities, integrated hybrid systems resulted in most cost effective solution. For example, at a capacity of 50 MIGD, the present worth of the cost was calculated to be 588.7, 443.2, and 380 million US$ for MSF, MED, and hybrid RO systems, respectively.     

Low temperature reject heat utilization for desalination; Economical and technical aspects

The economics of medium and large sized (1'000…10'000 m³/d) MSF/ME plants which utilize reject heat at temperatures between 50…90 °C is investigated.It is shown that for a cogeneration plant based on the Rankine cycle in combination with an evaporative desalination plant, there exists a steam condensation temperature (60…80 °C) below which the water production of the cogeneration plant is higher than the production of a power equivalent reverse osmosis plant. Power equivalent means, that the reverse osmosis plant would utilize the electricity otherwise lost when the same Rankine cycle is operated at higher condenser temperature. In spite of the higher investment costs for the evaporative plant, the specific water costs are lower than those for the power equivalent RO plant. Using a Rankine cycle for cogeneration, optimization of reject heat temperature levels is therefore crucial for obtaining economically favourable conditions.Further it is shown, that for todays and assumed future electricity rates and oil prices, the MSF/ME when powered by diesel reject heat produces cheaper water than RO or VC plants. It is necessary however, that the MSF/ME can cope with the inevitable load variations of the diesel power station. Our companys contribution in this field is briefly described.     

热膜耦合海水淡化系统的优化设计

采用混合节点和分配节点的概念,建立了多级闪蒸(MSF)和反渗透(RO)海水淡化集成系统的超结构模型,以年度总费用最小为目标,引入产水比的概念,并将该参数作为集成系统的一个优化变量,采用改进的遗传算法进行求解,获得了集成系统的最优结构及相应的操作条件。实例结果表明:集成海水淡化系统的淡水成本比独立运行的RO和MSF低,产水比为0.45时集成系统的费用最小,流程结构为MSF-RO。     

RO,MSF and VTE/VC Desalination: A comparative evaluation

For sea water conversion in single-purpose plants, reverse osmosis (RO) is shown to be more economical than multistage flash (MSF) desalination over a wide range of unit size and fuel cost. Attention is focussed on vertical tube evaporation/vapor compression (VTE/VC) a self-contained, low-energy consuming thermal process which is potentially competitive with RO.     

考虑不同水质输入的水电联产优化设计

结合已有的反渗透/多级闪蒸混产系统和发电-多级闪蒸联产系统,设计了一个新的包括热力发电系统、反渗透海水淡化系统和多级闪蒸海水淡化系统的水电联产超结构,对以不同盐度苦咸水、海水为原水的水电联产系统进行了优化设计,通过求解系统以年费用最小为目标函数的非线性数学模型,得到不同盐度下联产系统优化的生产结构. 结果表明,在低盐度(≤25000 mg/L)下采用冷凝式发电和一级反渗透产水,高盐度下采用抽汽冷凝式发电和热膜混合产水,可降低联产系统的年费用,获得较低成本的淡化水. 在本工作所定的生产规模下,优化联产方案的年费用可降低23%~36%.     

Economical study of a small-scale direct contact humidification-dehumidification desalination plant

Economical study of humidification-dehumidification desalination (HDD) pilot plant was made in order to estimate the economic benefits of the process in comparison with a small-scale reverse osmosis (RO) system. The energy recovery of the unit was investigated to be 75%. Some theoretical modifications were made to the HDD system in order to reduce the energy costs of the unit. Exact and clear economic analysis results were obtained using COMFAR ΙΙΙ software including fixed investment costs, production costs, internal rate of return on investment, operating costs, energy costs and some other economical parameters. Based on the energy prices in Iran, the total fresh water production cost was calculated to be $ 6.4/m³ that was nearly the same as produced by an imported RO plant. Finally some points were recommended whether to choose HDD or RO plant in different cases and capacities.     

Energy advantages of reverse osmosis in seawater desalination

The very rapid increase in energy costs during the past three years is causing a change in the preferred process technology for seawater desalination. The phase changes, evaporation, and condensation, required in the distillation processes make them more energy intensive than the ambient temperature liquid separation that occurs in the reverse osmosis (RO) process. This paper describes the RO process and how to calculate its energy consultation.The RO process requires only 5–7 KWh/m³ of product water compared to 15–16 KWh/m³ required by the most efficient distillation process. The productivity of a large dual purpose electricity/RO water plant is compared to the productivity of a commercially purchased state-of-the-art dual purpose electric/distillation water plant that is currently under construction. The RO potable water productivity is about 2X the distillate flow at the same fuel rate     

Analysis of water and power costs by various methods,based on Jeddah IV

The Jeddah IV Power and Desalination Plant is the biggest, dual-purpose plant in the world. Moreover, it is perhaps the first plant of this kind for which authentic cost and operational data are available. As such, it provides a reliable means of assessing the present status of desalination technology and its influence on the cost of power and water.The well-known theoretical methods of cost allocation are used in deriving the product cost from the Jeddah IV plant. The influence of local factors and contractual constraints is discussed. Extrapolations are made to determine the projected cost of water on similar plants but with different performance ratios. Recommendations are made on cost optimization and the most favourable combination for dual-purpose power/desalination plants based on steam turbines and MSF process.     

Computer code for optimizing MSF desalination plant

Egypt faces the prospect of population growth pressing on available agricultural land resources. A very large areas of coastal desert could be helpful in population density redistribution and of great economical interest, with the installation of a suitable water supply.Of the many desalination processes, the Multi-Stage Flash (MSF) desalination process is still the most developed and reliable technology for large scale conversion of sea water to fresh water.In this paper, a computer code was developed for optimizing a large scale MSF plant. This code can calculate the optimum design for the plant, and the minimum cost of product fresh water, as a function of both design and operating variables.Sample results obtained using this code for the Egyptian conditions are presented. The effect of energy and material costs, the chemical treatment type, and the feed water salinity on the optimum performance ratio and the minimum fresh water cost are drawn.     

Characterization of uncertainties in the operation and economics of the proposed seawater desalination plant in the Gaza Strip

In the Gaza Strip, the available freshwater sources are severely polluted and overused. Desalination of seawater through reverse osmosis (RO) has become the most realistic option to meet a rapidly growing water demand. It is estimated that the Gaza Strip will need to develop a seawater desalination capacity of about 120,000 m³/d by the year 2008, and an additional 30,000 m³/d by the year 2016 in order to maintain a fresh water balance in the coastal aquifer and to fulfill the water demand for different uses in a sustainable manner. Cost and reliability of a large RO facility are still subject to much uncertainty. The cost of seawater desalination by RO systems varies with facility size and lifetime, financing conditions, intake type and pre-treatment requirements, power requirements, recovery rate, chemicals cost, spare parts cost, and membrane replacement cost. The permeate salinity is a function of feed water temperature, recovery rate, and permeate flux. The quantity of water produced depends mainly on plant size, recovery rate, and operating load factor. Many of these parameters are subject to a great deal of uncertainty. The objective of this work is to develop a probabilistic model for the simulation of seawater reverse osmosis processes using a Bayesian belief network (BBN) approach. This model represents a new application of probabilistic modeling tools to a large-scale complex system. The model is used to: (1) characterize the different uncertainties involved in the RO process; (2) optimize the RO process reliability and cost; and (3) study how uncertainty in unit capital cost, unit operation and maintenance (O&M) cost, and permeate quality is related to different input variables. The model utilizes information from journal articles, books, expert opinions, and technical reports related to the study area, and can be used to support operators and decision makers in the design of RO systems and formulation of operational policies. The structure of the model is not specific to the Gaza Strip and can be easily populated with data from any large-scale RO plant in any part of the world.     

Hybrid systems in seawater desalination—practical design aspects, present status and development perspectives

Ever since seawater desalination has been applied on an industrial scale, and particular in the countries of the Arabian Gulf, the application of desalination processes in dual-purpose facilities—water and power—as a hybrid configuration has been discussed in many feasibility investigations and also planning concepts. It is above all the combination of reverse osmosis with thermal processes that has found increasing interest with the aim of ensuring, as economically as possible, uniform water supplies under the specific, greatly varying load conditions in the Gulf countries. Such design concepts for hybrid configurations encompass straightforward structures with a low degree of coupling between membrane and thermal desalination processes, but range up to very complex configurations with strong interconnections on both the water side and thermally, as well as with several desalination processes connected in series or in parallel. Classical hybrid concepts in which the permeate from an RO desalination component is mixed with distillate from thermal desalination have already been implemented in Saudi Arabian dual-purpose plants, like Jeddah and Yanbu-Medina. Although hybrid systems of greater complexity have been addressed in many design studies and publications, up to now none has been brought to fruition. Coming into consideration asthe design basis for determining the capacity shares of the various desalination processes operated in a hybrid configuration are: arrangement of thermal cycle of the power plant component; water/power ratio of the dual-purpose seawater desalination and power plant; provision of undiminished water production of the desalination plant as electricity generation varies; provision of a specified drinking water quality with regard to composition and salt content; combination of all these aspects. Also gaining in importance are concerns of environmental pollution and sustainable development when selecting seawater desalination and power plant configurations, as well as their optimization when considering desalination and electricity generation as a whole. In the practical design of hybrid membrane and thermal systems, aspects come to light, though, that restrict linking of the two systems and joint utilization of facilities, as conceived in studies and conceptual design investigations. This applies both for common utilization of intakes and the use of heated up cooling water from thermal processes as a feed stream for the RO part of the desalination process. Additionally, requirements of drinking water composition, particularly chloride content, TDS and compliance with a specific residual content of boron, influence specifically the design of the membrane process part and its share in the total desalination capacity. Such practical aspects have greatly influenced the design and configuration of the Fujairah hybrid plant for which, from a total desalination capacity of 100 MIGD (454,600 m³/d), the share of 37.5 MIGD (170,500 m³/d) makes its seawater RO plant the biggest currently being constructed anywhere in the world. From the findings of the engineering of this plant and the idea that, by increasing interconnection between the two processes on the water side, it is possible to advance a hybrid configuration of this type with regard to cost optimization in the membrane installation, but also by joint utilization of the intake equipment, perspectives result for applied research efforts over the near and long terms, for example: long-term behavior of membranes at elevated temperatures; tendency for biofouling in membrane process with common utilization of cooling water and brine; influences of such interconnections on the overall availability of the facility. But also for the operation and maintenance organization of such large facilities, consequences can be foreseen for the future development of hybrid plants, particularly for operation management and organisation of the interplay of the different power plant and desalination systems, monitoring of SWRO membrane replacement and cleaning, as well as controlling water quality.     

Rehabilitation of an uneconomic MSF plant in the Canary Islands,Spain

Rehabilitation of the MSF desalination plant Fuerteventura I, producing 2000 m³/d is described. It is planned to take advantage of the waste heat from Diesel engine units in operation nearby in order to produce water at a reasonable, economically feasible cost to the local Water Authority, Consorcio de Aguas de Fuerteventura.     

Long term experiments on sea water desalination at the Chigasaki Laboratory

The technology of producing fresh water from sea water by the reverse osmosis (RO) process has been developed since 1974 under the supervision of the Ministry of International Trade and Industry. Highly satisfactory and stable performances have been recorded for the two-stage desalination process using RO modules developed in Japan. Durability of the membranes under testing is expected to last more than three years. The quality of the product water can be kept below TDS 200 ppm that is suitable for potable consumption. Construction of a demonstration plant of 500 m³ /day using domestic modules is now being planned.     

Optimization of solar-powered reverse osmosis desalination pilot plant using response surface methodology

A solar thermal and photovoltaic-powered reverse osmosis (RO) desalination plant has been constructed and optimized for brackish water desalination. The central composite experimental design of orthogonal type and response surface methodology (RSM) have been used to develop predictive models for simulation and optimization of different responses such as the salt rejection coefficient, the specific permeate flux and the RO specific performance index that takes into consideration the salt rejection coefficient, the permeate flux, the energy consumption and the conversion factor. The considered input variables were the feed temperature, the feed flow-rate and the feed pressure. Analysis of variance (ANOVA) has been employed to test the significance of the RSM polynomial models. The optimum operating conditions have been determined using the step adjusting gradient method. An optimum RO specific performance index has been achieved experimentally under the obtained optimal conditions. The RO optimized plant guarantees a potable water production of 0.2 m³/day with energy consumption lower than 1.3 kWh/m³.