Académique Documents
Professionnel Documents
Culture Documents
effect of long term operation on the performance of those seawater hybrid desalination
processes.
As for the execution of the project, to be referred to hereafter as Part I, it was started on
22/3/1997 and after seven weeks of system modification and dual media cleaning to
remove the residual Fe3+ (from its media), the nanofiltration (NF) operation, using one
module with two NF membrane elements, was started on 10/5/1997 followed by the
installation and operation of 5 NF modules (10 elements) on 2/6/1997. The NF-SWRO,
NF-MSF and NF-SWROreject-MSF pilot plants were first operated on 3/6/1997,
21/9/1997 and 10/2/1998, respectively. So far the NF pilot plant unit has been in
operation for more than 9700 hours, while the SWRO and MSF pilot plants were
operated on NF product as feed to the former and make-up for the latter for over 5000
and 2300 hours, respectively. The hybrid system NF-SWROreject-MSF was operated for
a total of 170 hours (further operation shall be conducted at a later date). Continuous
non-interrupted operation of the NF unit without shutdown was maintained from the
start of the project until now. The execution of the project proceeded at a fast pace
ahead of schedule and all tasks were completed on time. Results were presented in a
paper to IDA World Congress, Madrid 97 [1]. A series of lectures on the same topic
were presented at SWCC. A two parts paper was published in the International IDA
D&WR Quarterly Magazine, May & September issues, 1998, on request of the editor
[2]. Two additional papers were presented at EDS Conference, Amsterdam, 1998, and
both papers were published in Desalination 118 (1998) 35-61 and 123-129 (3, 4). One
paper was accepted for presentation at the WSTA 4th Gulf Water Conference, Bahrain,
Feb. 1999. Three paper abstracts were submitted to organizers of IDA conferences on
desalination, San Diego, 1999, and the process is now in a patent pending status in
USA, Saudi Arabia and the International Patent Cooperation Treaty (PCT) Countries.
In view of the positive results obtained in this part of the R&D investigation, it is
recommended to continue work in this new field of seawater desalination. Summary of
an eight part proposed R&D work is covered under Recommendation, Section 9, Page
(26) of this report.
INTRODUCTION
With an increase in world population and rise in their living standard, there is an
increase in demand for good quality water. To meet this rise in demand, water treatment
in all its forms, is also on the rise. This tends to be the case also for water desalination
which has raised within the last two decades by over twenty folds and by the end of
1995 it stood at 20,300,000 m3/d [6]. Most of this world capacity is made of seawater
desalination by the MSF process (48.15%) and to a lesser extent by the RO desalination
process (35.9%). This latter number represents all forms of RO desalination: seawater
RO (SWRO), Brackish water RO (BWRO), industrial and membrane softening
processes.
As the world leader and the major producer of desalinated water from the sea by both
the multi stage flash (MSF) and seawater reverse osmosis (SWRO) processes, SWCC
has a major interest in both the thermal and membrane technologies. SWCC has a keen
interest in solving the above three problems. For the last ten years, SWCC R&D Center
was engaged in finding solutions to those problems. First work dealt with studying the
existing SWCC SWRO plants by establishing their performance and identification of
major problems encountered in their operation [7]. This was followed by a meticulous,
systematic study of factors affecting the seawater feed pretreatment and investigation
of the various parameters affecting the conventional coagulation filtration process [8].
The
study led to the use of membranes in the pretreatment of seawater feed to SWRO plants
[9], first by using the ultrafiltration (UF) membrane process as a secondary pretreatment
to SWRO feed along with the evaluation of other microfiltration (MF) and
nanofiltration (NF) membranes for pretreatment of feed to SWRO plants. The UF
experiment proved the effectivity of this membrane process as a secondary
pretreatment. Like the MF membrane pretreatment, the UF membrane pretreatment
succeed only in the removal of turbidity and bacteria from the feed, but kept the ionic
composition of seawater the same. The NF membrane pretreatment, however, was
found to be successful in removal of turbidity, in significant removal of hardness and in
lowering of the seawater TDS [1-5]. With this pretreatment SWCC which introduced
during the late 1980s the new hybrid concept by the addition of the two 15 mgd Jeddah
SWRO plants to the existing MSF - Power facilities, introduced a new concept to
seawater desalination by combining the NF membrane process with one or more of the
conventional seawater desalination processes in one fully integrated process system. In this
process, the NF product constitutes the feed to SWRO plants or the make-up to thermal,
e.g., MSF, VC, ME, desalination plants. Alternatively, in a trihybrid system,
the reject from SWRO of the NF-SWRO unit is used as the make-up to the MSF unit. This
concept was evaluated on an NF-SWRO, an NF-MSF and an NF-SWROreject -MSF pilot
plant units using Gulf seawater. From the results obtained so far together with
preliminary technoeconomic and cost analysis performed on the system, the process
was found to merit further consideration and evaluation on a demonstration plant, which
is currently ongoing, and on commercial SWRO plants as well as its application to
thermal seawater desalination processes. The report describes the long-term operation
and results obtained so far on pilot plants scale (capacity 20 m3/d), using 4" x 40"
commercial NF membranes with this new concept of NF-seawater desalination
processes, which is now in a patent pending status.
2-SOME MAJOR PROBLEMS IN SEAWATERDESALINATION
&THERREMEDIES
As mentioned under Introduction, by comparison to other forms of water desalination,
seawater desalination is the most complicated, complex and expensive water
desalination process. The major cause for the high expense and process complexity is
the seawater itself which is characterized by having high degree of hardness due to
presence of Ca++, Mg++, SO4= and HCO3 ions at relatively high concentrations, high
TDS, varying degrees of turbidity, presence of micro particles, macro and
microorganisms at pH of about 8.2. For illustration, compositions of Gulf and normal
(ocean) seawater are given in Table 1. These extreme seawater characteristics give
rise to three major problems in seawater desalination, which are discussed along with
their remedies in the following sections.
exchange process [10]. This way higher water recovery and more importantly at a
reduced unit production cost could be achieved. In SWRO operation, acid and in some
cases SHMP or other antiscalants are normally added to prevent membrane or SWRO
plant scaling. Again, water recovery tends to be limited, e.g., for Gulf seawater to about
35% or less.
2.1.2 Problem 2: Impurities and marine organisms and their Effect on Seawater
Desalination
Another problem in seawater desalination is the impurities in seawater feed to the
desalination plants. Their presence in seawater feed could and many cases cause the
desalination system to foul. Thus, the presence of macroparticles and macroorganisms
(mussels, barnacles, algae) requires their removal from feed to both SWRO and thermal
desalination plants. In presence of bacteria in the feed, disinfection of the feed tends to
be a requirement also for both the SWRO and the thermal processes. Removal of
turbidity and fine particulates, measured as total suspended solids (TSS), from feed
destined to SWRO plants is an essential process but is not required for the thermal
processes. Although, as illustrated in this study, removal of particulates from the makeup to MSF plant reduces foaming and thereby eliminates the addition of antifoam
chemicals. Removal of Cl2 from feed to chlorine sensitive SWRO membrane is also a
must.
2.1.3 Problem 3: Seawater TDS and its Effect on Osmotic Pressure and SWRO
Desalination
A third problem in seawater desalination is the seawater feed high TDS.
This
constitutes a major problem to the SWRO process but not as much to the thermal
processes. However, an increase in seawater TDS is always accompanied by an increase
in hardness which as mentioned above in Section 2.1 constitutes a problem to thermal
desalination processes i.e., by limiting distillate recovery. Per se, the TDS without or
with very low concentration of hardness ions has a minimum effect on distillate
recovery in the thermal desalination process. This is demonstrated later in the text,
section 5.3 where high degree of distillate recovery was achieved from high TDS feed
from which a significant portion of the hardness ions up to 90% were removed.
Nevertheless, increased TDS hence elevated brine recycle salinity would influence
distillation processes. The increased brine recycle salinity would give rise to solution
specific gravity (SP) and boiling point elevation (BPE). These in turn could marginally
give rise and in the same order as they appeared above to pumping power plus heat
input and distillate production due to increases in required differential temperatures and
pressures between flash zones and condensing zones.
The feed osmotic pressure increases as the ionic molar concentration and, therefore,
TDS in seawater are increased. The feed osmotic pressure f in bar is calculated from
the following equation:
f = 8.308 x 0.9 (Tf + 273.15) Mi / 100.0195
(1)
where Tf is the feed temperature and Mi is the sum of ionic concentration in moles
while the factor 100.0195 is to convert kilo pascal to bar [11]. For example f (of feed)
is 31.08 compared to 27.03, 24.94 and 14.19 bars for Gulf, Mediterranean, Open Ocean
(normal) and Baltic seawater with TDS of 43800, 38,088, 35145 and 20,000 ppm,
respectively. The average decline in f is 0.70968 bar per 1000 ppm drop in seawater
TDS. The ratios of f value for seawater from Baltic sea to that from normal sea and to
f of Gulf seawater are: 0.4566: 0.8024: 1.0, respectively.
From the principles of SWRO, the applied pressure Pappl is necessarily used to overcome
the osmotic pressure and the remaining pressure is the net water driving pressure
through the membrane (Pnet). Thus, the net driving pressure can be represented simply
as:
Pnet = Pappl -
(2)
Where Pappl and are the differential applied and osmotic pressures across the
membrane, respectively. Both Pappl and are calculated from the following equation
[].
Pappl = Pf - (Pfb / 2) - Pp
(3)
= fb - p
(4)
(5)
where the subscripts f, b and p denote the feed, brine and product, respectively.
The fb in bar is given by the following equation:
fb = [0.2654 Cfb [T + 273.15] / [1000 - Cfb / 1000] [100.0195]
(6)
(7)
(8)
The product water quantity (Qp) or the rate of permeate passage through the membrane
is given by:
Qp = Kw (P - ) (A / ) Tc Mf = Kw Pnet (A / )Tc Mf
(9)
where
-
Tc and Mf are the correction factor effects for temperature and membrane
flux, respectively.
Qs = Ks (Cfb) (A/)
(10)
From Eqs. (2) And (5), the less is the osmotic pressure , the greater is the Pnet and the
greater is the amount of pressure available to drive the permeate water through the
membrane and the greater is the quantity of product. This is apparent in Eq. 9 as Qp and
Pnet are directly proportional.
pressure as shown later by Eq. 11. Unlike permeate flow, the salt passage through the
membrane (Qw) is independent of pressure and depends on the salt concentration
differential across the membrane. Therefore, raising the RO feed pressure increases
water flow and normally without increasing salt passage which leads to a decrease in
permeate TDS, i.e., it leads to salt dilution in permeate.
The effect of varying feed TDS on fb and Pnet in the SWRO process at an applied
pressure of 60 bars and final brine TDS of 66,615 ppm is shown in Figure 1. The
available useful pressure to drive the water though the membrane (Pnet) marked by the
shaded area increases as the feed TDS and therefore fb is decreased and vise-versa.
The fraction of the Pappl which equals to fb is considered to be a wasted energy
although it is necessary in the SWRO process. Since the permeate flow through the
membrane is directly proportional to the Pnet, therefore, any process that lowers the feed
TDS not only reduces the wasted energy but it increases the fresh water permeation (Qp)
through the membrane (Eq. 9) and decrease the permeate TDS.
2.2.1
The above problems in seawater desalination caused by the seawater properties and
measures used to alleviate them are summarized in Table 2 along with the quality
requirements of feed to SWRO plant and make-up feed to MSF plants when the feed is
taken from an open sea (surface) intake. In the past it was demonstrated that use of
beachwell can effectively remove turbidity and improve SWRO plant performance. The
This process,
however, does not remove the very fine particles with sizes of less than 1 to 2
micrometer.
2.2.2
For the removal from the feed of fine particles with sizes less than 1 micrometer,
microfiltration (MF), UF, NF and hyperfiltration/reverse osmosis membrane filtration
are employed. The MF is used for particle separation having sizes in the range of 2.0
down to about 0.08. The UF membrane process is suited for the separation of finer
particles having sizes in the range of 0.1 down to 0.02 and of molecular weight
(MW) in the range of 10,000 g/mole and above. On the other hand, the RO process,
which is based on the well-known RO desalination principle, deals with separation of
ionic size particles in the range of 0.001 or less, molecular weight 200 g/mole or less.
The NF Membrane falls in-between the RO and UF separation range, and is suited for
the separation of particle sizes in the range of 0.01 to 0.001, MW of 200 and above.
The rejection by NF, however, is based on three principles. The rejection of neutral
particles is done according to their sizes, as is the case with the MF and UF membranes.
Rejection of part of the ions and the very fine particles is done by the reverse osmosis
process. Like the RO membranes, the permeate flow through the NF membranes
increases, as illustrated in Section 5.1.2, as the Pnet is increased. Also, by a third
process, the ionic rejection of inorganic matter is achieved by their electrostatic
interaction with the negatively charged membrane
membrane repulses the anion increasing their rejection by the membrane. To maintain
electro-neutrality in the solution the cations are also rejected to the same degree as the
anion. For example, in certain membranes the rejection of sulfate ions is in the order of
80-90% or better with a similar rejection for the cations Mg++ and Ca++. This compares
to 10-60% rejection for the Na+ and Cl- ions. Thus, the degree of rejection by the NF
membrane is lesser for mono valent ions such as Cl- and Na+ than that for the divalent
SO4= and Ca++. The above ion selectivity allowed for the use of NF in the removal of
hardness from low salinity water. For this reason, the process is gaining acceptance as a
major water softening treatment replacing the conventional lime softening treatment.
This is most evident in the State of Florida where many of the ground waters in coastal
areas are classified as hard water. Presently the total NF plants capacity in Florida alone
is over 60 mgd and is on the rise [13]. In some of the plants both NF & RO (hybrid) are
included to allow for greater removal of dissolved salts. Moreover, use of NF serves in
the removal of hardness allowing for higher water recovery by the RO plant. Not only
the NF process removes hardness but also the product water quality was found to meet
or to exceed the drinking water standards.
Recently there is an increased interest in the application of NF membrane filtration in
brackish water and drinking water softening, removal of color, turbidy, removal of
dissolved organic which are precursors to disinfection by-products (THM) [14&15].
The water utilities justify the slightly higher cost of membrane softening over the lime
process by the superior water quality it produces especially when the feed has high color
and other impurities. To meet the various Drinking Water Acts in USA, UF and MF
membrane processes have been used also in the treatment of drinking water [16,17&18].
The NF has been used in other applications to treat salt solution and landfill Leachate
[19], demineralization of whey, removal of sulfate from seawater to be injected in offshore oil well reservoirs [20,21 &22] oil water separation [23], removal of natural
organic matter and precursors of disinfection by-products from a highly colored ground
water. Cross-flow microfiltration have been used in the treatment of industrial waste
water for the removal of toxic heavy metals and other suspended particles [24&25]. It
was also used to achieve 95% water recovery, which is essential in the treatment of
waste and industrial waters [26]. Use of NF filtration in treatment of various low
salinity waters is described in the literature.
All experimental work were done on a pilot plant scale. A schematic flow diagram of
the NF-SWRO pilot plant is given in Figure 2, while Figure 3 shows the integration
of the NF-SWRO with an MSF pilot plant distiller comprising 2 and 4 stages of heat
rejection and recovery, respectively. Moreover, this arrangement allows for utilization,
especially in winter season, of the seawater from MSF heat rejection section as feed to
the NF unit. The NF-SWRO pilot plant consists of seawater supply system, dual media
filter followed by fine sand filter, 5-micron cartridge filter, feed tank, the NF unit and
the SWRO unit. The SWRO and MSF pilot plant set-up excluding the NF unit were
described in earlier work [8&29]. The NF unit consists of the high-pressure pump and
NF modules each containing two membrane elements (size 4"x40") which were bought
about four years back. The arrangement of the modules is as shown in Figure 2 where
the feed is supplied to the first two modules arranged in parallel and the reject of each is
fed to its following module which is connected to it in series. Reject from the latter two
modules constitutes the feed for the final fifth module. The SWRO unit is made of a
high pressure pump followed by six SWRO modules, each contains one spiral wound
membrane element (size 2.5"x40"), all arranged in series as shown in the figure.
After its filtration without coagulation the filtrate was passed to the NF membrane under
pressure. This was followed by passing the product from the NF unit to the SWRO unit
where it is separated under pressure of 40 to 60 bar into product (permeate) and reject.
Alternatively, the NF permeate or SWRO reject can be fed to the MSF unit as shown in
the Figure 3.
During the entire experiment, no coagulant was added to the NF feed, which was
nonchlorinated seawater except in a very few occasions when the seawater, due to
intake maintenance, was received from intake to Al-Jubail MSF Phase-I plant. Chlorine
when present in the feed was removed prior to feed entry into the NF membranes.
During the first 2200 hours of NF pilot plant operation no acid was dosed in the feed.
Acid, however, was added to the feed, at the rate of about 25 ppm, to bring the feed pH
to 6.7 when the NF permeate recovery was raised above 50%. No antiscal or acid,
however, were added to the feed to SWRO or make-up to MSF pilot plants when they
were operated in the dual desalination system of NF-SWRO or NF-MSF or the trihybrid
5.1
NF- Trials
0.01m. So, how can this relatively large size bacteria (i.e. 1m) pass through such tiny
NF membrane of pore size less than 0.01m ?
across the SWRO membranes (P) remained steady and low in value at less than 1 bar,
during the entire NF-SWRO experiment indicating no biofouling.
Also the NF
membrane autopsy and analysis, after 12000 hours of operation, showed no biofouling.
The bacteria count on membrane surface was within the acceptable limit, i.e., CFU<103.
Changing the NF permeate sampling procedure, by taking the sample directly after it
flows from the NF product line instead of taking it at the end of the 3 m hose, near the
NF product tank, improved the situation. The CFU count in NF permeates dropped to
6.1 x 101 CFU as measured, for example, on 12.10.97 (Figure 6).
during October is also partially due to seasonal variation in bacteria number. Later
bacteria counts in NF permeate in the order of 1.5 x 101 to 5.2 x 102 CFU; tend to
support the latter date of 12.10.97 (see for example Figure 7).
Based on the above discussion, the CFU count still remained higher than expected, and
it can be argued that the bacteria count in NF membrane permeate should be much
lesser than what is shown in Figure 6 and 7. More elaborate NF permeates sampling
procedure need to be developed to elucidate this point.
5.1.1 Long Term NF Operation
Figure 8 shows the actual and normalized NF flow of feed, permeate and product
recovery, their conductivity and operating conditions which are plotted vs operation
time. At an applied feed pressure of about 20 bars he product conductivity remained
steady at about 41,000 s/cm, while product water recovery, depending on feed flow
and/or pressure, was about 40 to 45%. Increasing the NF applied pressure to 31 bars
resulted in further reduction of both conductivity to about 24,600s/cm and TDS to
about 16,400 ppm as shown in Table 3 and Figure 4. The normalized NF product
flow fluctuated around 13 l/min at the start of the operation; it then came down to about
11 l/min after 5000 hours of operation time. This is shown in Figure 8. The seawater
filtrate SDI was about 4.3, while the SDI of NF permeate was less than 1. During the
entire experiment, the differential pressure across the NF membrane (P) remained
steady at 15 psi ( 1bar).
Figure 9 illustrates the NF permeate flow versus operation time, for about 9700 hours
of operation. Figure 9a shows the operation conditions, while Figure 9b, c and d
shows the actual and normalized permeate flow for feed flow, temperature and pressure.
Data in Figure 9c are normalized only for temperature effect. Figure 9a shows that
during the cold seasons, operation hours 6000 to 9000 hours, adjustment of feed
pressure allowed for raising the product flow by off-setting the decline in permeate flow
due to the seasonal lowering of feed temperature. Full normalization of the data,
however, shows that a decline in flow occurred after the cleaning of the NF membranes
by a commercial phosphate - based type detergent, DMCA-14/BIZ, made by Cheyma
Inc., Monterial, Canada. Use of various cleaning and flushing procedures failed to
improve the permeate flow to its level prior to cleaning. Use of this detergent in NF
membrane cleaning should be avoided. However, after cleaning the NF permeate flow
remained nearly steady at its level before cleaning (Figure 9b). Prior to this cleaning the
membrane retention coefficient (MRC) calculated from Qt/Qi was about 80%, where Qt
and Qi are the quantity of permeate flow at time t = 5000 hour and initial time over the
first 100 hours.
5.1.2
The effect of feed applied pressure, flow and temperature at different operating
conditions on NF permeate flow, recovery and conductivity are shown by a family of
curves, one for each operating case, in Figures 10-13 Both permeate flow and recovery
are noticed to increase as either or both the feed applied pressure or temperature are
increased. On the average, this increase was about 6% and 3.4% for a rise in applied
pressure by 1 bar and for a rise in temperature by 1C, respectively. Increasing feed
flow had lesser effect on increasing permeate flow than that occurred when increasing
either feed applied pressure or temperature, but it is the recovery, which is markedly
increased with decrease in feed flow. For example, under same operating conditions of
applied pressure of 37.5 bars, the permeate recovery at the reduced feed flow rate of 20
l/min is 60% compared to only 43% when the feed flow rate was increased to 33 l/min
(Figure 10). On the other hand, permeate conductivity tends to decrease as the feed flow
rate or applied pressure or both are increased, while it tends to increase as the feed
temperature is increased (Figures 10, 12 and 13).
5.2
NF-SWRO Trials
During the early operation, from the start up to 2200 hours at the applied pressure of 60
kg/cm2 and feed temperature of 33 1 oC, the conductivity of the NF product, which
constituted the feed to the SWRO unit in the NF-SWRO hybrid system, was 41000
s/cm. The SWRO permeate flow and recovery ratio were maintained steady at 5 l/min
and about 50%, respectively. This is illustrated in Figure 14, which also shows the
SWRO permeate flow, product recovery and conductivity plotted versus operation time.
During the final phase of SWRO operation, because of a drop in NF permeate
conductivity to about 25000 s/cm, the same above SWRO permeate value and
recovery ratio were maintained at an applied pressure of only 40 bars instead of 60 bars
as shown in Figure 14. Operation at the normally applied pressure of 60 bars increased
both the permeate flow and permeate recovery each by about 40 and 25%, respectively,
Figure 14.
performance, which did not decline with operation time when operation was done at
same operating conditions.
The effect of applied pressure on SWRO permeate flow, recovery and conductivity are
illustrated in Figure 15, which for reasons of comparison shows also the same for the
conventional operation of same SWRO membranes under identical conditions but
without the NF pretreatment. Passage of the NF permeate to SWRO unit under pressure
gave satisfying results with P remaining steady and constant at 2 bars during the entire
operation. As shown in Figure 15, because of the low hardness of SWRO and TDS of
feed (see Table 3 for ions conc. at 31 bar) it is possible to obtain a recovery of up to
80% when the pressure is raised to about 70 bars. This high product recovery was
achieved with NF permeate compared to one half this value or less for normally
pretreated seawater feed. The product flow (Qp) and recovery ratio are also increased
directly with the applied pressure Figure 15. The SWRO permeate from the combined
NF-SWRO desalination system were much greater than those for the SWRO alone
when the two systems are operated at the same pressure and temperature. For example,
at 40 bars the permeate flow and recovery from the conventional SWRO are 1 l/min and
16.7%, respectively, as compared to a much higher flow and recovery ratio of 4.8 l/min
and 48% from the new process of NF-SWRO, i.e., for an increase of 480% in flow and
by 3 folds for permeate recovery. Even at the frequently employed pressure of 56 bars
(800 psi) the SWRO product flow and recovery for NF-SWRO: SWRO alone are in the
ratio of 2.43:1. Moreover, the quality of the permeate product from SWRO process is
4500 s/cm at an applied pressure 40 kg/cm2 and drops to 2300 s/cm at 60 kg/cm2 as
compared to less than 500 s/cm for SWRO permeate from the NF-SWRO process
obtained from the same membrane at the same pressure range. The SWRO membranes
used in this test, Figure 15, are old membranes and the NF pretreatment revives their
low performance.
5.3
NF-MSF Trials
In this trial NF permeate was used as make-up to MSF at a flow rate of 1.5 m3/hour
replacing normal seawater at low concentration of scale forming ions of alkaline and
non-alkaline types in the NF permeate to the MSF pilot unit as shown in Table 3,
while Table 4 shows for comparison these concentrations in the brine recycle stream
of the MSF operated with NF or SWRO reject from an NF-SWRO unit as make-up or
seawater as make-up (conventional MSF). Also, listed in Table 4 are pH and
conductivity values of the brine recycle streams. From this table, it can be seen that
scaling potential in the MSF system have been significantly reduced and it was safe to
operate the MSF plant with NF make-up for over 2320 hours, or with reject of SWRO
from the NF-SWRO unit for 270 hours at high temperature of 120 oC without addition
of antiscalant or antifoam chemicals. At the same operating conditions, the
concentration of the scale forming ions of Ca++, and SO4= of 168 and 410 ppm in the
NF-MSF case, Table 4, and 232 and 1020 in the SWRO reject make-up case, Table
4, are low when compared to 882, and 5830 ppm in the brine recycle stream of
conventional MSF. These observation, especially the drastic reduction in SO4=, Ca++
and Mg++, are encouraging to project MSF operation at higher TBT in the range of 120
o
C to 160 oC without inducing scaling [30] thus improving plant production and hence
water cost. Operation of MSF plants at higher temperature should increase the gain
output ratio (GOR) in Kgproduct/Kgsteam and the performance ratio (PR) in Kgproduct/1000
Kj, while decreasing the energy consumption in Kj/Kg product (Figure 16). Finally, the
MSF plant operation on NF make-up remained steady with operation time.
The result obtained so far from the NF-SWRO pilot plant were encouraging to consider
the application of the NF membrane process first in a demonstration NF-SWRO plant,
which is being done now, to be followed by its actual application to an existing
conventionally operated SWRO plant, which is now under consideration. For the
present report the performance of SWCC Jeddah SWRO plant with and without NF
unit was conceptually evaluated using the results obtained from the pilot plant studies
described above [1-3].
When NF feed pressure was set to 31 bar the hardness ion concentration in the NF
permeate, which constitutes the feed to SWRO plant was as shown in Table 3. At an
applied pressure of 40 bar and SWRO product recovery of 50%, the reject from the
SWRO contains low concentration of hardness ions of 96, 253, 410 and 42 ppm for
Ca++, Mg++, SO4= and HCO3-, respectively. The TDS of reject brine of 30,640 ppm in
the same Table 3 is also low when compared for example to the reject from Jeddah
SWRO plant of about 66,615 ppm at the applied pressure of about 60 to 65 bar
[31&32].
This suggests that higher recovery of more than 35% can be achieved from
flow diagram of the desalination part of Jeddah SWRO plant with and without NF unit.
Figure 17a represents the actual Jeddah SWRO plant feed, product and reject flows
along with the product water recovery percentage (%), the brine flow/modules and the
energy required for the desalination part alone.
equation [33]:
Energy (KWH/m3) = [Qf . Hf / 366 Qpe]
(11)
where:
-
Figure 17b, and c simulates the results of operation of Jeddah SWRO in a combined
NF-SWRO system utilizing the present SWRO desalination set-up as it is now (case b)
and with reject staging (case c), respectively. The Jeddah SWRO plant receives feed,
with TDS of 43,300 ppm from a conventional coagulation filtration unit at the rate of
6760 m3/hr and produces from 1480 modules at an applied pressure of about 60-65 bar
2370 m3/hr of fresh water for a product recovery of 35%. The total quantity of reject is
module/hour is 1.6 and 2.97 m3/hr, respectively. The energy requirement for the SWRO
desalination part alone is 6.14 kwh/m3 of product, assuming plant operation at 60 bars
and rises to 6.65 kwh/m3 at an operational pressure of 65 bar.
Each of the hollow fine fiber membrane modules used at Jeddah contains two SWRO
membrane elements arranged in series with brine staging where the feed is first passed
to the first set of elements (1st desalination step) and the remaining feed after extraction
of a fraction of it as product is passed as the SWRO reject to the second set of elements
constituting the 2nd desalination step which in turn extracts a second fraction of product
(Figure 17). The ratio of product quantities extracted by the first set of elements and the
second set of elements can be computed through Eq. 9 and the following ratio equation:
Qp 1st set
Kw ( Pappl fb)1 (A / ) Tc Mf
=
=
nd
Kw ( Pappl fb) 2 A / Tc Mf
Qp 2 set
( Pappl fb )1
Pnet 1
=
( Pappl fb ) 2 Pnet 2
(12)
where Pnet-1 and Pnet-2 are the net driving pressure force for all the first set and second
set of elements (1 and 2), respectively. Also as demonstrated in Figure 15, the product
flow (Qp) should increase as Pnet is increased.
To establish the value of Pnet-1 and Pnet-2 the recovery ratio for the first set of elements is
to be established.
estimated at 20% making the second set recovery equals 15% of the 6760 m3/hr feed for
a total system recovery of 35%. With this first approximation of recovery for the first
set of elements the water product recovery ratio of 1st set: 2nd set of elements is 0.5705:
0.4295 as compared to different ratio of Pnet-1 : Pnet-2 of 0.6175 : 0.3825. The Pnet values
are calculated from Eqs. 5 and 6. Regression analysis lead to the values shown in
Figure 13, where the product water ratio of 1st set: 2nd set of elements is 0.62: 0.38 or
in the ratio of 1:0.61 which is not only identical to the same ratio of Pnet-1 : Pnet-2 but also
the same, with some deviation, as the observed ratio values which were established
experimentally at our pilot plant by using the same SWRO membrane as used at Jeddah
SWRO desalination plant. The product recovery ratio of 1st set: 2nd set of elements
when compared to their feed is 21.75%: 17.01% and with product ratio of 1470: 900
m3/hr, respectively.
But the recovery (%) of each of 1st set: 2nd set of elements
compared to feed of 6760 m3/hr is 21.75%: 13.31% for a total product recovery of
35.059%.
The same data treatment used in case "a" for Jeddah SWRO was employed in
establishing the potential performance of Jeddah SWRO when combined with NF (NFSWRO), cases "b" and "c" in Figure 17. Again, the product flow, recovery and energy
were as shown in Figure 17b, and c.
desalination is assumed to occur in two steps. In case "b" of Figure 17, the first set of
elements, step 1, is assumed to treat the NF-product 27,300 ppm to yield reject with
comparable salinity (TDS) as that for the actual feed to Jeddah SWRO plant, which
constitutes the feed to the second stage elements. The second stage set of elements
allows for extraction of product from this feed to yield brine with TDS of 68258 ppm.
This arrangement yields 2724 m3/hr of product at a recovery of about 41% compared to
a product flow of 1282 m3/hr and recovery of 32% of the feed to the second step. The
overall recovery is 60%. But in this latter case the brine flow per module of 1.83 m3/hr
will be less than the minimum brine flow requirement of 2.0 m3/hr per module. This
could be tolerated since the hardness content of the SWRO reject is very low (Table 3).
However, SWRO feed has an SDI<1, and a recovery of 59 to 60% while maintaining
brine flow 2 m3/hr per element can be achieved either by increasing the seawater feed
flow and raising the Pappl by a few bars or by the use of a second stage SWRO in a brine
staging process with module ratio of 2 : 1 for first to second stage, Figure 13c. In this
latter arrangement, case "c" the NF-SWRO product recovery is 59%, while brine reject
per module is 5.62 m3/hr. The energy computed from Eq. 10 is 5.03 kwh/m3.
In all cases the operation with the combined NF-SWRO system is superior to operation
by SWRO system alone. For the three cases in Figure 17a SWRO alone, "b" and "c"
for the combined NF-SWRO system, the ratios of module requirements per 1000 m3/hr
product are 1 : 0.58 : 0.59; compared to water production ratio of 1 : 1.71 : 1.69; and to
product per element of 1.6; 2.74 : 2.63 m3/hr and to energy requirement ratio of 1.0 :
0.81 : 0.82, for "a", "b", & "c" cases, respectively. Moreover, A higher recovery than
60% is expected for SWRO permeate in NF-SWRO system (see Figure 15), which in
turn is expected to improve the yield, recovery and product water quality of Jeddah
SWRO plant when combined with an NF pretreatment.
The above results obtained with the NF pretreatment of seawater feed in the removal of
hardness, lowering of TDS, pH when added to the improvement of NF permeate as feed
to SWRO and the observed gain in SWRO product water recovery ratio are remarkable
ones and should allow for the overcoming of the three problems in seawater
desalination described earlier, Section 2, which are due to the composition of seawater
and what it contains such macro and micro particles and organisms. Moreover, because
of the high purity of product from the SWRO unit (TDS 200 ppm) the NF
pretreatment should make it quite easy to produce fresh water from the sea by the
SWRO process in one single stage SWRO, thus eliminating the second brackish RO
stage with savings in each of capital investment and O&M cost by over 10%. This is in
addition to increasing the plant output at least by 15% since the elimination of the
second stage allows for the recovery of all products from the first stage SWRO unit.
The above treatment of adding the NF to SWRO plant can be extended to NF addition
to MSF plants. Earlier work showed that operation of MSF plant at 135 oC and 150 oC
without scale formation was possible when the sulfate in the feed (Mediterranean sea)
was reduced, using ion exchange, from 2900 to 1200 ppm [10].
With the NF
pretreatment the sulfate ions in Gulf seawater is reduced from 3200 ppm to less than
206 ppm when using pressure to the NF feed of 18 bars and to only 72 ppm when using
a pressure of 21 bars. Further reduction in level of sulfate to less than above values is
expected from the NF treatment of seawater in other seas, e.g., Ocean, Mediterranean.
This should allow for the use of the NF permeate as make-up to MSF plant in a
combined NF product - MSF unit permitting the operation at TBT of 120 oC to 150 oC or
higher with an increased gain in distillate output. Furthermore, the sulfate content in
SWRO reject from the NF-SWRO pilot plant is less than 420 ppm and Ca++ less than
100 ppm when their concentration in the NF product is 230 and 52 ppm, respectively.
Lower values are expected when the Ca++ and SO4= levels in the NF product are less
than the above values. Again, this should allow for its use as make-up to MSF plant in
a hybrid NF-SWROreject/MSF system. This last desalination system arrangement should
allow, as already demonstrated in this study, for the recovery of up to 90% of the NF
product as potable fresh water, where 60 to 70% of the NF product is converted to
potable water by the SWRO unit and with the remaining 20 to 24% derived from the
conversion of 80% of the SWRO reject also into potable (distillate) water by the MSF
Unit. Work is in progress on further evaluation of the two concepts of NFproduct-MSF
and NF-SWROreject-MSF system by operation at TBT of 120 oC. Future work will
explore TBT elevation to as high as 160 oC in the MSF pilot plant at SWCC RDC, AlJubail. Results of work in progress as well as future work are to be described in
separate reports.
(13)
Where E is the electrical energy (kwh/m3) delivered by the various pumps. The letters f,
b, and p denote the feed, booster, and product, respectively, ENF and ESWRO are the
energy delivered by the high-pressure pump(s) to the desalination part of the NF and
SWRO units, respectively. The figure 8.35 kwh/m3 is the reported actual energy for the
total SWRO process including intake, pretreatment and post treatment steps in Jeddah
SWRO plant by [34], i.e., equals the sum of energies as given by Eq. 13. The energy
required for the desalination parts of the NF & SWRO process, i.e., ENF and ESWRO, in
Eq. 13 computed from Eq. 11 at recovery ratio of 60% for each process is 1.655 and
3.31 kwh/m3, respectively, for a total of 4.97 kwh/m3. This value compares to 6.14
kwh/m3 for the conventional SWRO process or in the ratio of the latter to the former
case of 1.0: 0.81. As established from Eq. 13 the total energy for the NF-SWRO
process is 6.28 kwh/m3 and the total energy ratio of ESWRO: ENF-SWRO is 8.35: 6.28
kwh/m3 or in the ratio of 1.0: 0.75. Thus the non-desalination part of the total process
energy in Eq. 13, i.e., Ef + Eb1 + Eb2 + Ep + Eothers, for the conventional ESWRO : ENFSWRO is 2.21: 1.32 kwh/m3 or 1.0: 0.597 and product ratio for ESWRO: ESWRO is /.32 :
2.21 kwh /m3 or 0.584 : 1.0 which explains the reduction in energy of the NF-SWRO to
that of the conventional SWRO process (see Eq. 11). The reduction in energy for the
NF-SWRO as compared to conventional SWRO is due to the expected increase in plant
productivity.
Operation of the combined NF-SWRO requires the following modifications: (1) the
addition of NF unit to the existing SWRO plant and (2) an increase in feed quantity by
introducing additional feed line with its necessary electrical, mechanical and civil
works. The latter works were computed from actual prices at about 18% of total
contract value for the Jeddah-2 SWRO plant and Yanbu plant and at about 25% for the
Jeddah-1 SWRO plant. As for the cost of the NF unit it was estimated from a quotation
for its desalination part alone (high pressure pump, NF modules, pipe and control)
without other auxiliary equipment.
Table 5 lists the cost in SR/m3 product for six cases: Jeddah-1, Jeddah-2 and Yanbu
SWRO plants with and without NF pretreatment unit for two energy prices. In case "a"
the cost of power was set at SR 0.05/ kwh as was done in reference [34] and in case "b"
the power cost was increased to SR 0.375 ($0.1)/ kwh. The annual fixed charge rate
was assumed at 10% per year of the installed cost. The interest on investment is zero.
This case is assumed to equal plant depreciation over 20 years with 7% annual interest.
In all cases, the cost of product from the NF-SWRO plants was lower than that when the
conventional SWRO plant is operated alone without the NF pretreatment. A drop in
cost of product by about 28% can be realized when the plant is operated with NF
pretreatment. The product water ratio of SWRO: NF-SWRO is 18,685,080: 31,977,504
m3/yr or 1: 1.71. The product cost SR/m3 is in the ratio of 1: 0.72 for SWRO: NF-
SWRO for Jeddah-2 and Yanbu SWRO plants. More details of the results are shown in
Table 5. The techno-economic results are in conformity with results of the simulated
model in that the operation of the SWRO plants with NF unit is superior to SWRO plant
operation alone without the NF pretreatment.
1.
2.
3.
4.
With this new NF SWRO process addition of a second stage (brackish RO) is
not required.
5.
6.
With this new NF source of make-up to the MSF process it becomes feasible to
operate at TBT above 120 oC due to its low potential of non-alkaline scaling.
Gulf Seawater,
Al-Jubail
Normal
Seawater
13440
483
508
1618
0.004
0.008
1
3
10780
388
408
1297
--1
--
24090
3384
176
--83
1
0.09
19360
2702
143
-66
1.3
--
62800
8.1
7
2.1
20
43800
-8.1
6.6
2
-35146
Cataions (ppm)
Sodium, Na+
Potassium, K+
Calcium, Ca2+ *
Magnesium, Mg2+ *
Copper, Cu2+
Iron, Fe3+
Stronsium, Sr2+
Boron, B3+
Anions (ppm)
Chloride, ClSulfate, SO4= *
Bircarbonate, HCO3- *
Carbonate, CO3=
Bromide, BrFlurried, FSilica, SiO2
Other Parameters
Conductivity (S)
H
Dissloved Oxygen (ppm)
CO2 (ppm)
Total Suspended Solids (ppm)
Total Dissolved Solids (ppm)
*
Thermal
High
Degree
of Requires
++
++
Hardness (Ca , Mg , Removal or
SO42-, HCO3-)
Inhibition of precipitation
by addition of antiscalant,
and by
Operation
at
correct
conditions
Requires:
Removal or
Inhibition of precipitation by
adding antiscalant
Operation at correct conditions
High TDS
Table 3. Chemical Composition and Physical Properties of Seawater, NF Filtrate, and NF and SWRO rejects at
Different NF Feed pressure
Element / Parameter
Seawater
NF Filtrate (5 modules)*
SWRO
Reject
Ion Con.
31
Ion. Conc.
Ion Conc.
Rejection (%)
Ion Con.
Rejection (%)
Ion. Con.
Rejected %
NF Feed Pressure (Bar)
18
18
22
22
31
31
A. Hardness
Ca++ (ppm)
481
92
80.9
50
89.6
52
89.2
1608
192
88%
96
94.0
143
91.1
Mg++ (ppm)
Total Hardness (ppm)
7800
1014
87
520
93.3
720
90.8
SO4-- (ppm)
3200
206
93.3
72
97.8
230
92.8
HCO3- (ppm)
128
46
63.3
30
76.6
24
81.3
B. Other Ions
22780
16,692
26.7
12320
46.3
9640
57.7
Cl- (ppm)
Na+ (ppm)
(12860)
(9426)
26.7
(6904)
46.3
(5442)
57.7
C. Total Dissolved Solids
TDS (ppm)
44046
27,720
37.3
20230
54.1
16400
62.8
pH
8.2
7.85
7.92
6.38
60,000
40,470
31100
24600
Conductivity (s/cm)
Module arrangement 2:2:1 , each module contains 2 NF elements, arrangement equals two parallel lines each having 5 elements in series.
NF Reject
Ion Con.
31
701
96
253
1280
414
42
2200
10800
4950
133
19570
29350
30,640
7.08
43300
63640
7.46
68600
Table 4. Operation and Performance Parameters of NF-MSF and NF-SWROreject-MSF Desalination Hybrid Systems Vs
Conventional Seawater MSF Desalination System (Operation of MSF unit with NF product or SWRO Reject from NFSWRO unit was done without addition to make-up of antiscalant or antifoam)
Trials
A. NF-MSF
With acid
Without acid**
B. NF-SWROreject-MSF ***
Without acid
C. Seawater MSF
TBT
(oC)
Ca++
(ppm)
120
120
160
168
390
410
120
232
1020
Performance Parameters
Make-up
Product
(m3/hr)
(m3/hr)
Conductivity
(
s/cm)
pH
26
65
59000
62000
8.19
8.63
1.5
1.5
0.97
0.97
65
65
72
87400
8.50
1.5
0.97
65
Table 5. Cost (SR) of Product Water from SWRO Plants with and Without NF Pretreatment
(a). Cost of Power SR. 0.05 KWH
Cost Component
Annual fixed charge rate
Jeddah -1
SWRO
16,545,566
Jeddah -2
SWRO
36,293,785
Yanbu
Jeddah -1
SWRO
NF-SWRO
37,938,113
Jeddah-2 NFSWRO
Yanbu NFSWRO
16,545,566
36,293,785
37,938,113
Cost of NF unit
5,158,188
5,158,188
5,158,188
4,376,353
4,376,353
4,376,353
Chemicals
9,32,940
9,32,940
9,32,940
574,500
574,500
574,500
Electrical
7,798,599
7,798,599
7,798,599
9,278,700
9,278,700
9,278,700
Spare parts
2,249,100
2,249,100
2,249,100
2,500,000
2,500,000
2,500,000
Membrane replacement
2,330,835
2,330,835
2,330,835
3,000,000
3,000,000
3,000,000
316,800
316,800
316,800
400,000
400,000
400,000
O&M - labor
3,500,000
3,500,000
3,500,000
3,600,000
3,600,000
3,600,000
33,673,840
53,422,659
55,066,387
45,433,307
65,181,526
66,825,854
1.786
2.833
2.92
1.421
2.038
2.089
0.791
0.719
0.716
Yanbu NFSWRO
Jeddah -1
SWRO
Jeddah -2
SWRO
Yanbu
Jeddah -1
SWRO
NF-SWRO
Jeddah-2 NFSWRO
25,875,241
45,623,460
47,267,788
36,154,607
55,902,826
57,547,154
Energy cost
58,551,881
58,551,881
58,551,881
69,664,480
69,664,480
69,664,480
Total cost
84,427,122
104,175,341
105,819,669
105,819,087
125,567,306
127,211,634
4.478
5.525
5.612
3.309
3.928
3.978
0.739
0.711
0.709
18,685,080
18,685,080
18,685,080
31,977,504
31,977,504
31,977,504
Cost (SR/m )
Ratio
3
80
Pappl
70
60
Pnet= Pappl-
50
40
30
20
10
0
20000
25000
30000
35000
40000
45000
TDS (PPM)
NF SECTION
Fine Sand
Seawater
TO MSF
MSF
Pump
CF
FEED
TANK
NF REJECT
PERMEATE
RO
FEED
HPP
MSF
SWRO SECTION
SWRO REJECT TO MSF
Media
Seawater
N F U n it
Pump
PRODUCT
CF
N F R E JE C T
FEED
TANK
S e a w a te r f r o m M S F H e a t R e je c tio n S e c tio n
S W R O U n it
B r in e h e a te r
FEED TANK
SW
BOOSTER PUMP
D
B.R
H. RJ
4 H .R .C S ta g e s
MSF UNIT
PERMEATE
A/A
SWRO UNIT
B.B
HIGH PRESSURE
PUMP
R e je c t to M S F
7800
8000
Seawater
NF Filtrate (AV )
7000
Concentration (PPM)
6000
5000
3200
4000
3000
1608
1014
2000
481
206
192
92
1000
128
128
Ca++
Mg++
SO4--
HCO3--
Total Hardness
Fig4Effect of New Process on Removal of Hardness Ions (Ca++, Mg++, SO4--, HCO3--) From Gulf Seawater (Using 5 Modules, 10
NF Elements)
100
93
88
86
81
90
80
63
60
50
37
40
32
27
27
30
20
TDS
Na+
Cl-
Total Hardness
HCO3--
SO4--
Mg++
Conductivity
10
Ca++
Rejection %
70
CFU
BDMF
ADMF
AMCF
NFP
thousand
26 / 07/ 97
12 / 10 / 97
Fig 6 Bacterial Count Colony Forming Unit /ml (CFU) from Different Sampling Points in NF Pilot Plant at 0 hr.
Mon
MAY
JUN
JUL
AUG
S EP
OCT
NO V
DEC
B DMF
1.0E+3
2.6E+3
2.9E+3
1.2E+4
1.7 E+4
1.1 E+2
1.2E+3
2.7E+3
ADMF
AMC F
2 .8E+3 2.8E+3
2.4 E+3
2.1E+3
8.5E+3 1.4 E+3
7.9E+3
7.9E+3
3.2E+3
7.2E+3
1.9E+2
6.0E+1
9 .5E+1
1.0 E+2
9.5E+1
7.5E+1
2.00E+04
NFB
6.2 E+ 3
4 .3E+3
2.4E+3
1 .06 E+4
1.9E+3
6.0E+2
8.5E+2
1.2 E+3
NFP
6.2E+1
2.1E+2
2.1 E+2
3 .1E+2
1.5E+2
3 .0E+1
7.1 E+1
5.7E+1
CFU
1.50E+04
MA Y
JUN.
1.00E+04
JUL.
A UG.
5.01E+03
SEPT.
OCT.
BDMF
AMCF
NFB
DEC
NFP
Nov
ADMF
1.00E+01
Fig 7 M onthly AVG Bacteria Count in Colony Forming Unit /ml (CFU) from Different Sampling Points in NF Pilot Plant
at 0 hrs (BDM F& ADM F are Before and After Dual M edia Filter respectively, AM CF is After M icron Cartridge Filter, ,
NFB& NFP are Nanofiltration Brine and Permeate)
40
Fl C)
o 0
Fe30
Te
edw(m
20
l/
p(
mi
10
feed flow
0
200
400
0
30
Fl25
o 20
w15
(l/10
i5
0
0
600
pressure (bar)
800
1000
1200
800
1000
1200
1000
1200
Cleaning
200
30
25
Fl
o 20
w15
(l/10
i5
0
0
30
temperature(oC)
400
600
y = 19.383x-
Cleaning
200
400
600
800
25
Fl
o 20
y = 39.456x-
w15
(l/10
i
5
0
200
400
600
800
1000
1200
20
50
P net = [P f - (
P fb/2) - P p] - [
fb - p]
16
45
Recovery
40
14
Flow (l/min.)
Flow
12
y = 1.0519x
R 2 = 0.9989
35
30
10
25
20
15
Recovery (%)
18
y = 3.5199x
R 2 = 0.9987
10
P f = P appl. (bar)
20.7
24.1
27.6
34.5
31.0
37.9
0
0.0
2.0
4.0
6.0
8.0
10.0
P net (bar)
12.0
14.0
16.0
18.0
80
100
120
140
160
SW R O unit
a.Jeddah SW R O (A ctual)
Qf
1470
67603/H
m
43300ppm
Cf =
4390 m 3/h
66678 ppm
SW R O unit
2774
b.N F -Jeddah SW R O
QF
NF
1282
43300 ppm
2704 m 3/h
C F = 27300 ppm
C f = 67300 ppm
SWRO
3.33
SWRO
3986 m 3/h
46300 m 3/h
SW R O unit
3057
Q F = 6760 m
112663/H
m
43300 ppm
NF
C f = 67300 ppm
68250 ppm
SWRO
Cf =
4056 m 3/h
112663/H
m
Cf =
Qf
Q F = 6760 m 3/h
933
3990 m 3/h
3/h
C F = 27300 ppm
SW R O
SW R O
SW R O
1st Stage
2nd Stage
2771 m 3/h
66600 ppm
IDA
EDS Conference
Desalination
Water Science and Technology Association
IDA World
Congress
IDA World
Congress
Desalination
ASTM Desalination,
Desalination,
Desalination
Desalination
Desalination
Desalination
Water Supply
Aqua,
Desalination
Desalination
Filtration and Separation
Journal of
Membrane Science,
Journal of Membrane Science
Desalination,
IDA World
Congress
World Congress
IDA
World Congress
Desalination
NWSIA
National Desalination and Water Reuse Conference,