Desalination 394 (2016) 3043

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Desalination

journal homepage: www.elsevier.com/locate/desal

Global optimization of MSF seawater desalination processes

Chandra Sekhar Bandi, R. Uppaluri , Amit Kumar
Department of Chemical Engineering, Indian Institute of Technology Guwahati, North Guwahati, Assam 781039, India

H I G H L I G H T S

For MSF-BR and MSF-M processes, DE provided global optimal solutions.

Cost based MSF process ranking is MSF-BR > MSF-M > MSF-OT* (* refers solution with penalty).
For important MSF process parameters, obtained solutions improved by 2.31%, 3.9%, 2.92%, 20.24%, 3.53% and 5.2%.

a r t i c l e i n f o a b s t r a c t

Article history: This article addresses the global optimal design of multi-stage ash desalination processes. The mathematical for-
Received 2 February 2016 mulation accounts for non-linear programming (NLP) based process models that are supplemented with the
Received in revised form 5 March 2016 non-deterministic optimization algorithm. MSF-once through, -simple mixture (MSF-M) and -brine recycle
Accepted 6 April 2016
(MSF-BR) process congurations have been evaluated for their optimality. While freshwater production cost
Available online 12 May 2016
has been set as the objective function for minimization, mass, energy and enthalpy balances with relevant sup-
Keywords:
plementary equations constitute the equality constraints. Differential evolution algorithm (DE/rand/bin) was
Differential evolution algorithm adopted to evaluate the global optimal solutions. Further, obtained solutions have been compared with those
Global optimization obtained with MATLAB optimization toolbox solvers such as SQP and MS-SQP. The global optimal solution corre-
Seawater desalination sponds to a variable value set of [2794.4 m3/h, 1.0499, 7.62 m, 3.359 kW/m2 K, 3.297 kW/m2 K, 3.042 kW/m2 K
Multi stage ash (MSF) and 22] for decision variables [WM, RH, LT, UB, UR, Uj, NR] in the MSF-BR process to yield an optimal freshwater
MSF-BR production cost of 1.0785 $/m3. Compared to the literature, the obtained global solution from DE is 2.31% better.
MSF-OT Further, inequality constraint resolution has been excellent for DE but not other methods such as MS-SQP, SQP
MSF-M
and DE-SQP.
SQP
2016 Elsevier B.V. All rights reserved.
Modeling
Optimization

1. Introduction
Among several technologies viable for potable water production,
the desalination of sea and brackish water is an established technol-
ogy in several countries including the USA, Persian Gulf and
European countries [15,35]. Based on the working energy principle,
desalination processes are further classied primarily into two clas-
ses namely thermal processes that involve phase change due to addi-
tion of heat and membrane processes that involve pressure energy.
While thermal processes are primarily classied into multi-effect
evaporation (MEE), MSF and vapor-compression (VC) processes,
membrane processes are primarily classied into RO and electrodial-
ysis (ED) processes. Among various alternate technologies for sea
water desalination, MSF processes have the promising features of
Corresponding author.
E-mail address: ramgopalu@iitg.ernet.in (R. Uppaluri).
large scale operation and ability to deliver good quality potable
water (550 ppm total dissolved solids).
A typical MSF process involves brine heating followed with ash
distillation in multiple stages and subsequent heat recovery. Thereby,
a MSF process plant has three important sections namely brine heater,
heat rejection and heat recovery sections. Design variations in the
MSF process systems refer to either once through (OT) or simple
mixer (M) or brine recirculation (BR) process congurations to yield
MSF-OT or MSF-M or MSF-BR processes respectively. Among these,
while MSF-OT is the simplest in design, it is not as efcient as the
MSF-BR system.
The design of efcient MSF processes invariably requires simulation
and optimization studies. Several researchers have conducted simula-
tion studies to obtain insights upon the process performance of MSF
processes. These have been contributed by Mandil and Abdel Ghafour
[19], Helal et al. [2], Al-Mutaz and Soliman [14], Rossol et al. [26], Thom-
as et al. [29], Abdel-Jabbar et al. [28], Hawaidi and Mujtaba [6], and
Tayyebi and Alishiri [34]. Many of these literatures emphasized upon

http://dx.doi.org/10.1016/j.desal.2016.04.012
0011-9164/ 2016 Elsevier B.V. All rights reserved.
 C.S. Bandi et al. / Desalination 394 (2016) 3043
stage-to-stage calculations and deployed NewtonRaphson method or
tridiagonal matrix (TDM) formulations solved with Thomas algorithm
(TA) for evaluation of MSF process performance.
Further, optimization studies have also been conducted by several
researchers. These include MSF-OT processes [35,2123]; MSF-M pro-
cesses [20] and MSF-BR processes [1,35,6,7,8,9,16,18,24,25,31,32,33].
Considering the minimization of water production cost as objective
function, the literature refer to the deployment of either one of the fol-
lowing methods: genetic algorithm (GA) [24,32]; sequential quadratic
programming (SQP) method [22,23], deterministic optimization
methods built in gPROMS [6,25], generalized reduced gradient (GRG)
[1,35,20] and in DICOPT++ [22,23]. Further, MATLAB programming
environment has also been used in several engineering applications as
a competent modeling tool for simulation and optimization studies
[36,37,38,39].
A critical analysis of the available literatures in optimization studies
refers to the following. Firstly, earlier research works mostly addressed
either MSF-BR or MSF-M or MSF-OT processes for process optimization
based insights. Only [35] addressed MSF-OT and MSF-BR process opti-
mization but not the MSF-M process. The authors adopted GRG optimi-
zation method which is a local optimization tool. It is well known that
GRG might provide local solutions whose quality could not be judged
in conjunction with the global optimality. Further, GRG is well known
to be non-rigorous and fails to solve problems with larger number of in-
equality constraints, as the method needs the satisfaction of all inequal-
ity constraints in each iteration. While SQP method foregoes such
limitation, the SQP also could not provide insights upon the quality of
generated optimal solutions. On the other hand, non-deterministic
models such as GA were only investigated for the MSF-BR but not
MSF-OT and MSF-M processes. Thus, it is apparent that global optimiza-
tion methods have not been applied till date for the comparative assess-
ment of MSF-BR, MSF-M and MSF-OT processes.
Secondly, a critical issue with respect to alternate optimization
methods such as GRG, SQP, and GA, is with respect to the satisfaction
of inequality constraints. The traditional approach to couple a penalty
function with cost function may or may not yield feasible solutions
using GRG and SQP methods, given the fact that these algorithms may
require additional ne tuning of optimization algorithm parameters
such as maximum number of iterations, maximum function evalua-
tions, and penalty parameters, to obtain feasible solutions. Thus, it
might be the case that an engineer may have to spend a signicant
amount of time in ne tuning these parameters for the deterministic op-
timization methods. On the other hand, such insights may not be appli-
cable for the non-deterministic optimization methods due to random
nature of solution search. Therefore, an important issue that also
needs to be addressed is the ability to fetch feasible solutions with sim-
ilar penalty function parameters for both deterministic and non-
deterministic optimization methods.
A third and essential insight is to visualize upon the sensitivity of
process and operating parameters using global optimization ap-
proaches. While such sensitivity analysis might be possible with local
optimization methods, they may not provide the most stringent sensi-
tivity analysis. Therefore, the sensitivity analysis conducted with non-
deterministic methods needs to be judged with that conducted with de-
terministic methods.
In summary, this work addresses three major objectives. The rst ob-
jective refers to comparative assessment of MSF-M, MSF-OT and MSF-BR
processes using non-deterministic optimization. The second objective re-
fers to the evaluation of inequality constraint resolution ability for both
deterministic and non-deterministic methods. The nal objective is to
conduct sensitivity analysis of all MSF processes in the light of global
and local optimization. Differential evolution (DE) has been chosen as
the global optimization tool as it has not been studied for MSF process op-
timization despite being proven effective for other engineering optimiza-
tion problems. Thereby, suitable benchmarks are expected to be set for
the engineering optimization of MSF processes.
31
2. Process congurations
A schematic representation of the MSF-OT, MSF-M and MSF-BR pro-
cess congurations is presented in Fig. 1(a)(c). Among these processes,
while MSF-OT limits the temperature of the last stage to 3040 C for
winter and summer operations, the ashing operation on several ash
stages requires vacuum pressure conditions to achieve operating tem-
peratures below 100 C. As indicated in the gure, the common features
of these process congurations are briey summarized as follows:
The feed seawater (WMF) at temperature TSea, is de-aerated and
chemically treated before being introduced into the condenser/pre-
heater tubes of the last ashing stage in the heat recovery section.
The preheated feed seawater at temperature T2 enters the brine
heater tubes, where the heating steam (WS) is condensed on the
outside surface of the tubes. Eventually, the seawater reaches the
maximum design temperature value also known as the top brine
temperature (T3).
The feed seawater nally enters the ashing stages, where a small
amount of fresh water vapor is generated by brine ashing in each
stage. In each stage, the ashed off vapor condenses on the outside
surface of the condenser tubes, where the feed seawater (WMF)
ows inside the tubes from the cold to the hot side of the plant.
Thereby, the heat recovery process enables an increase in the feed
seawater temperature. The condensed fresh water vapor outside
the condenser tubes accumulates across the stages and forms the
distillate product stream (WMD).
Fig. 1(b) illustrates that the MSF-M process essentially consists of a
brine heater, heat recovery section and brine recycle mixing tank.
Hence, the MSF-M process conguration facilitates a brine recycle
stream to reduce fresh seawater requirements and associated chemical
pretreatment costs. This is achieved by mixing part of the blowdown
brine stream (WMR) with the feed stream (WMSC), thereby generating
a mixed stream (WMF) with higher salinity than that of the fresh seawa-
ter (set as 70,000 ppm for the upper bound according to El-Dessouky
et al. [11].
It can be further observed in Fig. 1(c) that the MSF-BR desalination
plant has heat rejection, recovery section and brine heater section. The
nal reject stream from the heat recovery section is being split into
two streams which serve as cooling seawater stream (WMCW) and
makeup stream (WM). The makeup stream is further chemically treated
and mixed in the brine pool of the last ashing stage in the heat rejec-
tion section. The mixed stream is sent to blowdown splitter S2 from
which the brine recycle stream (WMR) is introduced into the condenser
tubes of the last stage in the heat recovery section. The stream after ab-
sorbing the latent heat of condensation from ashing vapor in several
stages leaves the last stage and enters the brine heater, where its tem-
perature is enhanced to saturation temperature (i.e., top brine temper-
ature) at the prevalent system pressure.
3. Methodology
Process optimization of alternate MSF congurations has been
targeted by coding a competent simulation model that is supplemented
with a non-deterministic optimization algorithm. For comparison pur-
poses, deterministic optimization algorithms have also been considered
to evaluate upon the efcacy of the non-deterministic optimization al-
gorithm. The following sub-sections summarize the simulation and op-
timization models.
3.1. Simulation model
The simulation models for MSF-OT and MSF-BR processes were
adopted from Helal et al. [3]. For the MSF-M process, the simulation
32 C.S. Bandi et al. / Desalination 394 (2016) 3043

model was taken from Abduljawad and Ezzeghni [20]. Other than these d) The specic heat capacity of brine solution is a weak function of salt
literatures, a comprehensive account of the models for MSF processes is concentration.
not apparent elsewhere in other literature. e) Distillate product is salt free; non-condensable gases have negligible
The process simulation model accounts for the mass and energy bal- effect on the heat transfer process.
ance equations applied for each stage including the brine heater, recov- f) Effect of the boiling point rise and non-equilibrium losses on the stage
ery and rejection sections. The process models are non-linear in nature energy balances is negligible.
and consist only algebraic expressions. Further details of the process g) The average specic heat capacity of brine solution is equal to that of
models can be obtained from the cited literature and this section briey the distillate.
outlines various important features of the same. As outlined in the liter- h) The boiling point rise at the exit from the last recovery for MSF is neg-
atures, the following assumptions are usually applicable for the process ligible.
models on a theoretical basis [3,10]: i) Heat loss is negligible.

a) Temperature proles of all streams owing within the plant are linear.
b) Each section has a constant value for heat transfer coefcient, heat
transfer area, boiling point rise and specic heat capacity (CP) of
brine solution.
c) The latent heat of vaporization of water () is constant, and indepen-
dent of temperature.
The non-linear system of algebraic equations involving mass and en-
ergy balances has been deduced by carrying out overall mass balances
across blowdown splitter, rejected sea water splitter (for the MSF-BR
process), salt balances across mixer, energy balances across brine heater
and condenser, enthalpy balances on the heat recovery section, heat

Fig. 1. Schematic of (a) once-through MSF (MSF-OT), (b) brine-mixing MSF (MSF-M), and (c) brine recycle MSF (MSF-BR) seawater desalination processes.
 C.S. Bandi et al. / Desalination 394 (2016) 3043
Fig. 1 (continued).
rejection section (MSF-BR process), brine heater, mixers and ashing
brine. Supplementary expressions for the process model include ex-
pressions for distillate product temperature (equilibrium correlation),
overall heat transfer coefcients in various process sections, inside
lm resistance, average tube side brine temperature and thermal resis-
tance. The thermal resistance is accounted as a function of steam-side
condensing lm, steam-side fouling, tube metal and brine side fouling
resistance components.
Table 1(a) summarizes various parametric and design specications
required for the process simulation model for cross ow type MSF pro-
cesses. Table 1(b) presents the process cost parameter data, which is
adopted from Helal et al. [3]. For various process models, the indepen-
dent simulation model variables that need to be specied are (WMF, LT,
UB, UR and NR) for MSF-OT; (LT , UB , UR , WMSC , CMSMF and NR) for MSF-
M and (WM , LT , UB , UR , NR , RH and Uj) for the MSF-BR process. Hence-
forth, these variables are treated as independent (decision) variables
during process optimization.
3.2. Optimization model
The MSF process simulation model consisting of non-linear set of al-
gebraic equations is formulated as a non-linear programming (NLP) op-
timization model dened as:
Min OF
Subjected to
f x 0
gx0
33
where refers to the objective function dened as the sum of annual-
ized freshwater production cost and associated penalties. The process
simulation model is specied as f(x) = 0 for a specic MSF processes
and g(x) refers to the set of inequality constraints.
The total annualized freshwater production cost function is evaluat-
ed using relevant expressions for direct capital less intake investment
(CDCLIC), intake-outfall cost (CIC) (evaluated as a sum of costs of electro-
chemical equipment, civil work, electro chlorination, brine disposal cost
and annual plant intake-outfall), direct capital investment cost (CDCC),
indirect capital investment (CICC) and operating and maintenance cost
(COMC) (evaluated as a sum of costs of steam, chemical treatment,
power, labor and spares costs). Relevant expressions have been adopted
from Helal et al. [3]. Thereby, the objective function for MSF is modied
and expressed as:
 

$
C IC C DCLIC C ICC C OMC
y
MSF  3 penalty of gx: 1
m
WY
y
Inequality constraints refer to lower bound and upper bound speci-
cations for makeup ow rate for MSF-BR (WM), feed ow rate for MSF-
OT (WMF) and MSF-M (WMSC), tube length (LT), number of recovery
stages (NR), heat transfer coefcients in various sections, brine loading,
brine velocities in various sections, rejected brine concentration values
(CMBD, Clast) and absolute values of various heat transfer coefcients.
The inequality constraint parameters and values have been presented
in Table 2(ab). The penalty function has been evaluated using large
34 C.S. Bandi et al. / Desalination 394 (2016) 3043

Table 1 Table 2
(a) Parametric and design specications data for cross ow type MSF processes. (b) A (a) Summary of lower and upper bound values for the optimal design of MSF processes.
summary of MSF process cost parameter data. (b) A summary of inequality constraint parameters for MSF optimization model.

(a) (a)

Variable Unit MSF-OT MSF-M MSF-BR MSF-BR MSF-OT MSF-M

Variable Unit
a 0.88 0.88 0.88 Lower Upper Lower Upper Lower Upper
CMF ppm 42,000 42,000 42,000
WM m3/h 2000 3000
CPR kJ/kgK 4.18513 4.18513 4.18513
WMF m3/h 5500 10,000
Cpj kJ/kgK 4.17658 4.17658 4.17658
WMSC m3/h 5500 10,500
Cp kJ/kgK 4.18513 4.18513 4.18513
RH 0.8 2
ID m 0.02199 0.02199 0.02199
LT m 7 10 7 15 7 15
OD m 0.024069 0.024069 0.024069
NR 18 30 15 50 15 50
Nj 3
UB kW/m2 K 2.7 3.7 2.7 3.7 2.7 3.7
T1 C 34
Uj kW/m2 K 2.7 3.7
T3 C 110 110 110
UR kW/m2 K 2.7 3.7 2.7 3.7 2.7 3.7
T6 C 28
TD C 30 30 30
(b)
TS C 114 114 114
TSea C 25 25 25 Constraints Unit Lower Upper
WMD m3/h 1122 1122 1122
Brine loading m3/h m width 900 1200
R C 1.4 1.4 1.4
VB m/s 0.9144 1.8288
j C 1.78
Vj m/s 0.9144 1.8288
J/kg 2346.3 2346.3 2346.3
VR m/s 0.9144 1.8288
B kg/m3 1060 1060 1060
CMBD or Clast ppm 80,000
W kg/m3 1000 1000 1000
ABS(1 UBcal / UB) 0.001
ABS(1 Ujcal / Uj) 0.001
(b)
ABS(1 URcal / UR) 0.001
Unit Value

Current work capacities

MSF plant section m3/d 26,928 parametric settings that were dened for the initialization, propagation
Reference capacities and ow rates
and termination strategies of various optimization methods for the MSF
Ref. feed rate for intake calculation m3/d 1000 optimization problem. Further, it shall be noted that for several methods
Ref. blowdown rate for outfall calculations m3/d 750 including SQP, MS-SQP and DE-SQP, initial vector values (independent
MSF plant cost data
variables) had to be dened for MSF-OT, MSF-BR and MSF-M processes.
Capital recovery factor 0.0963 Table 3(b) summarizes the initial vector values set for the optimization
Parameter in xed capital cost term 5500 studies. All simulations were conducted in MATLAB programming envi-
3
Chemicals $/m prod 0.024 ronment. SQP has been implemented from MATLAB optimization tool-
Energy (pumping) $/m3 prod 0.03
box [27,36].
Spares $/m3 prod 0.082
Labor $/m3 prod 0.1
4. Model validation

positive penalty parameters that are set to realize the satisfaction of all
inequality constraints.
3.3. Optimization algorithm
Differential evolution (DE) algorithm has been applied for the non-
deterministic optimization of NLP process models. Introduced by Storn
and Price [30], the DE optimization algorithm is a stochastic population
based direct search optimization method that essentially involves the
generation of new candidate solutions by combining the parent individ-
ual and several other individuals of the same population. This is facilitat-
ed by adding the weighted difference between any two population
vectors to a third population vector [13]. Further, the parent vector is re-
placed with the mutant vector only when the mutant vector provides a
better tness value [17]. Thus, DE is an effective, fast, simple, robust, and
inherently parallel technique that has few control parameters and
needs less effort to tune and adopt optimization parameters. The DE
has been applied as a sequence of mutation, cross-over and selection
operations for all populations. The maximum number of permitted gen-
erations has been set as the termination criteria.
The efcacy of the DE algorithm has been evaluated by comparing
the results obtained from sequential quadratic programming (SQP)
method with and without multi-start (MS) approach. Further, hybrid
optimization approach involving the combination of both DE and SQP
was also considered. For this case, the solution generated from DE is
being provided as an initial guess value for the SQP method. Thus, the
optimization methodology involves the application of either one of
DE, SQP, MS-SQP and DE-SQP methods. Table 3(a) summarizes the
Model validation precisely refers to the validation of developed code
for simulation and optimization models. Since appropriate data has
been available only for the MSF-BR system, the simulation model code
validation has been carried out using the data provided by Helal et al.
[3]. Based on the input simulation variable data set of [2790 m3/h
(2,790,000 kg/h), 1.0129, 18, 3.26 kW/m2 K, 3.443 kW/m2 K,
2.864 kW/m2 K, 7.62 m] for [WM, RH, NR, UB, UR, Uj, and LT], the obtained
results of dependent variables are [101.7 C, 32.41 C, 70,178 ppm,
135.5 m3/h (135,446 kg/h), 3662.8 m2, 2515.5 m2, 3355.4 m2,
9040 m3/h (9,040,000 kg/h)] for variables [T2, TBD, CMBD, WS, AB, AR, Aj,
and WMF] respectively. Precisely, the same values have been reported
in the literature [3] and hence the model code validation is inferred to
be successful.
The DE algorithm code has been tested for standard optimization
model test function such as Rosenbrock Banana Function. For the algo-
rithm parameters [F, CR, NG, and NP] specied as [0.8, 0.8, 100 and
100], the DE provided optimal solution of [1.000, 1.000] with a standard
deviation of 106. The obtained optimal solution is in complete agree-
ment with that available as the global optimal solution for Rosenbrook
(Banana) function [12]. Hence, the DE algorithm is inferred to be effec-
tive for the optimization of alternate MSF process congurations.
5. Results and discussions
5.1. Efcacy of the DE algorithm
Fig. 2 depicts the comparative performance of various optimization
methods to obtain optimal solutions for the MSF-M, MSF-OT and MSF-
 C.S. Bandi et al. / Desalination 394 (2016) 3043 35

Table 3 using various methods is presented in Tables 4, 5 and 6 respectively.

(a) Parameters for various optimization techniques. (b) Initial independent variable set In these methods, optimization methods with asterisk indicate the exis-
data for MSF processes and alternative optimization methods.
tence of penalties in the nal solutions obtained and hence these solu-
(a) tions cannot be recommended as appropriate design solutions for the
Parameter DE SQP MS-SQP DE-SQP respective MSF process congurations. For several cases, UB inequality
constraint could not be resolved without penalty.
NP/no. of starting points 350 400 500 500
NG max/function evaluations 1000 700 1000 1000 Further, the literature data for MSF-BR has also been presented in
DE-step-size, F 0.9 0.9 Table 4 to reect upon the comparative optimality of obtained variable
CR 0.9 0.9 values with those presented in the literature. As outlined in Table 4, in
Termination criteria NG max (DE) or 106 (SQP) comparison with the available literature data for the MSF-BR process,
(b)
the optimal solution obtained with DE refers to marginal combinations
of higher feed ow rate (2794.4 but not 2790.0 m3/h), higher specic
Optimization MSF-BR MSF-M MSF-OT
heat ratio (1.0499 but not 1.0001), lower tube length (7.62 m but not
method [WM, RH, NR, UB, UR, Uj, [WMSC, NR, UB, UR, LT] [WMF, NR, UB, UR,
LT] LT] 7.92 m), higher overall heat transfer coefcient in brine heater section
(3.359 kW/m2 K but not 3.260 kW/m2 K), lower overall heat transfer
SQP [2449, 1.02, 19, [6168, 21, 3.4599, [9543, 26,
3.5124, 3.1937, 3.5266, 7.4, 99.21, 3.4517, 3.6275,
coefcient in recovery section (3.297 kW/m2 K but not 3.443 kW/
2.9223, 8.51] 69,944] 8.12] m2 K), higher overall heat transfer coefcient in brine heater
[2767, 1.17, 18, [6014, 23, 3.1432, [9561, 28, (3.042 kW/m2 K but not 2.864 kW/m2 K), higher number of recovery
3.1673, 3.4619, 3.5221, 8.12, 103.23, 3.5454, stages (22 but not 18), lower steam ow rate (130.365 m3/h but not
3.4454, 8.21] 69,021] 3.5514.7.65]
135.446 m3/h), lower feed ow rate, cooling water and cost. It is further
[6546, 22, 3.3565, [9756, 27,
[2439, 1.16,21, 3.3351, interesting to note that the optimal concentration of rejected stream
3.4526, 8.85, 101.45, 3.4624,
3.2680, 3.5171, 7.12]
69,584] 3.6454.7.69] leaving the heat rejection section is precisely the same for this case
[2566, 1.03, 23, 3. [6059, 25, 3.2452, [9628, 26, and literature data. Compared to the literature reported optimal
3513, 3.4259, 3.4411, 7.85, 102.56, 3.3515, 3.5554,
cost of 1.104 $/m3 , the DE generated solutions for the MSF-BR
3.6637.7.51] 69,885] 7.18]
MS-SQP [2787, 1.07, 21, [6356, 25, 3.5232, [9643, 28,
process to be 2.31% lower (1.0785 $/m3), MSF-M process to be
3.4673, 3.4119, 3.6221, 8.25, 101.23, 3.3217, 3.3275, 7.85% higher (1.198 $/m3) and MSF-OT process to be 9.88% higher
3.4454, 7.61] 69,981] 7.98] (1.2251 $/m3).
DE-SQP [2790, 1.05, 22, [5857, 25, 3.7, 3.6719, [9500, 23, No relevant data was available in the same literature to compare the
3.3624, 3.3003, 9.74, 101.48,70,772] 3.4108, 3.7398,
solutions obtained for the MSF-M and MSF-OT process congurations. It
3.0448, 7.62] 8.62]
can be observed that marginal improvement in solutions can be obtain-
ed for the MSF-BR plant conguration in comparison with the literature
BR plant congurations. It has been evaluated that the optimal fresh using the DE algorithm. For the MSF-BR process congurations, solu-
water production cost using DE, SQP, MS-SQP and DE-SQP methods tions with penalty were obtained using the DE-SQP method. For the
are 1.2251, 1.2856, 1.2785 and 1.2534 $/m3 for MSF-OT, 1.198, 1.2445, MSF-M process model, only DE provided solutions without penalty. Fur-
1.22 and 1.2135 $/m3 for MSF-M and 1.0785, 1.1, 1.0852 and 1.0843 ther, all optimization methods can be observed to provide solutions
for MSF-BR respectively. Hence, it can be concluded that the DE provides with penalty for the MSF-OT congurations. This conveys the efcacy
the lowest fresh water production cost for MSF-BR. Based on the obtain- of the DE algorithm to obtain solutions without penalty (feasible solu-
ed results, the optimal cost based ranking is MSF-BR b MSF-M b MSF- tions) for both MSF-BR and MSF-M congurations. Hence, it is impor-
OT*. For the MSF-BR plant, the efcacy of various methods for the opti- tant to envisage that DE has potential to obtain high quality solutions
mization is in the order of DE N SQP N MS-SQP* N DE-SQP*. The solution even for the MSF-M process. The best set of optimal decision variable
with asterisk (*) corresponds to solution with penalty (and hence values are [WM, RH, LT, UB, UR, Uj and NR] for [2794.4 m3/h, 1.0499,
infeasible solution). An infeasible solution for the DE-SQP is due to 7.62 m, 3.359 kW/m2 K, 3.297 kW/m2 K, 3.042 kW/m2 K and 22].
rounding of solutions generated from DE, which were then supplied to For the MSF-BR, the optimal variable values corresponded to pro-
SQP as initial guess. duction cost, thermal performance, specic heat transfer area and
A summary of the important independent and dependent variable plant recovery of 1.0785 $/m3, 8.61, 0.009 m2/h/kg and 0.1287 respec-
values obtained after optimization of MSF-BR, MSF-M and MSF-OT tively. These corresponded to an improvement of about 2.31, 3.90,
2.92 and 20.24% with respect to those reported in the literature [3]
(1.104 $/m3, 8.283, 0.008487 m2/h/kg and 0.107 respectively). For the
same case, the optimal feed ow rate and cooling water ow rate
were evaluated as 8720 m3/h and 5930 m3/h respectively, which corre-
spond to a reduction of about 3.53% and 5.2% with respect to the best
known optimal values in the literature (9040 m3/h and 6250 m3/h
respectively). These results indicate marginal improvement in the
optimal solutions obtained and thereby convey the competence
and efcacy of the DE algorithm for desalination process design
and analysis.

5.2. Optimality of other dependent variables

Based on thermodynamics, heat transfer and process economics

Fig. 2. Bar chart depicting the performance of optimization methods for MSF desalination
processes.
based insights, several dependent variables have been dened to indi-
cate upon the optimality of various MSF processes. These refer to specif-
ic heat transfer area, specic feed ow rate, specic cooling water rate
and overall plant recovery. Denitions and formulae to evaluate the
same are presented as follows:
36 C.S. Bandi et al. / Desalination 394 (2016) 3043

Table 4
Optimal independent and dependent variable values for the MSF-BR process and alternate optimization methods.

Variable Unit DE SQP MS-SQP* DE-SQP* Literature [3]

Independent variables WM m3/h 2794.4 2809.8 2617.8 2784.4 2790.0

RH 1.0499 1.0001 1.0339 1.0149 1.0129
LT m 7.62 7.92 7.98 7.61 7.62
UB kW/m2 K 3.359 3.362 3.7 3.254 3.260
UR kW/m2 K 3.297 3.161 3.294 3.436 3.443
Uj kW/m2 K 3.042 3.114 3.687 2.858 2.864
NR 22 19 20 18 18
Dependent variables T2 C 102.00 102.03 102.03 101.50 101.70
TBD C 32.35 32.38 32.34 32.34 32.41
CMBD ppm 70,178 67,092 67,093 70,038 70,178
WS m3/h 130.365 139.860 129.900 135.175 135.446
AB m2 3470.5 3165.7 3304.4 3655.47 3662.8
AR m2 3297.1 3137.9 2588.7 2510.47 2515.5
Aj m2 3044.7 2992.8 2868.4 3348.69 3355.4
WMF m3/h 8721.0 8732.6 8856.5 9021.9 9040.0
WMCW m3/h 5926.6 6257.5 6238.8 6237.5 6250.0
WMBD m3/h 1672.4 1353.1 1495.8 1662.4 1668.0
AT m2 85140.8 74902.1 63683.6 58799.61 59008.8
Cost $/m3 1.0785 1.1000 1.0852 1.0843 1.104

The specic heat transfer area is dened as the ratio of total heat The overall plant recovery is dened as the percentage of total sea-
transfer area to the total amount of fresh water produced i.e. water intake that gets converted to the fresh water i.e.

Overall plant recovery 5

Specific heat transfer area
total heat transfer area A total amount of fresh water produced W MD
: 2  100  100:
total amount of fresh water produced W MD total seawater intake fed to plant W MF

Along with thermal performance, Table 7 summarizes the optimal

The specic ow rate is expressed as the ratio of total seawater fed to
plant to the total amount of fresh water produced i.e.
Specific feed flow rate
total seawater intake fed to plant W MF
: these dependent variables, the DE approach used in this work provided
total amount of fresh water produced W MD
The specic cooling water ow rate is dened as the ratio of total
cooling water ow rate of the plant to the total amount of fresh water
produced i.e.
dependent variable values for various MSF processes. The thermal per-
formance values of MSF-OT, MSF-M, MSF-BR and MSF-BR literature
data are evaluated to be 10.3457, 7.5918, 8.6066 and 8.2837 respective-
3 ly. Fresh water production cost is lowest for MSF-BR plant (1.0785 $/
m3) and the corresponding water recovery is highest (12.28). For
better results than those reported in literature [3] using the Newton
Raphson method (1.10 $/m3 and 10.7 respectively). The specic feed
ow rate value is also the lowest for MSF-BR case (7.77) and this indi-
cates lower processing cost involved with the feed pre-treatment plant.
5.3. Contributions of various cost functions

Specific cooling water flow rate Fig. 3(a), (b), (c) and (d) presents the pie charts that depict the per-
total cooling water flow rate of plant W MCW centage cost contributions of ICM, DCLIC, ICC, FCC and OMC to the total
: 4
total amount of fresh water produced W MD cost for MSF processes. For the literature data, the pie chart depicting

Table 5
Optimal independent and dependent variable values for the MSF-M process and optimization methods.

Variable Unit DE SQP* MS-SQP* DE-SQP*

Independent variables WMSC m3/h 5852.7 5475.1 5617.8 5784.4

NR 26 22 22 22
LT m 8.32 9.99 8.15 9.98
UB kW/m2 K 3.699 3.626 3.7 3.625
UR kW/m2 K 3.671 3.665 3.499 3.664
T2 C 101.48 100.28 101.42 100.23
CMF ppm 70,772 56,342 75,829 56,314
Dependent variables TBD C 36.52 37.18 36.57 37.16
CMBD ppm 70,803 56,399 75,905 56,370
WS m3/h 147.790 171.429 148.434 171.343
AB m2 3661.3 3907.2 3496.5 3905.2
AR m2 1964.7 1992.9 2700.0 1991.9
WMF m3/h 9727.1 9745.3 9755.3 9740.4
WMBD m3/h 8605.1 8623.3 8633.3 8618.5
AT m2 54743.5 47751.0 62896.5 47705.2
Cost $/m3 1.198 1.2445 1.22 1.2135
 C.S. Bandi et al. / Desalination 394 (2016) 3043 37

Table 6
Optimal independent and dependent variable values for the MSF-OT process and optimization methods.

Variable Unit DE* SQP* MS-SQP* DE-SQP*

Independent variables WMF m3/h 10043.2 10061.9 10072.1 10056.9

LT m 10.18 8.0 11.8 11.79
UB kW/m2 K 3.7 3.410 3.70 3.691
UR kW/m2 K 3.456 3.468 3.498 3.495
NR 23 21 21 21
Dependent variables T2 C 101.48 103.6 103.6 103.51
TBD C 31.4 31.39 31.4 31.37
CMBD ppm 48,035 47,624 47,623 47584.9
WS m3/h 153.450 153.490 158.450 157.363
AB m2 3053.3 3094.4 3285.1 3249.8
AR m2 3530 4397.0 3596.9 3594.0
WMBD m3/h 1672.4 1353.1 1495.8 1662.4
AT m2 84243.3 95431.4 78820.0 78663.9
Cost $/m3 1.2251 1.2856 1.2785 1.2534

the cost contributions of these components is presented in Fig. 3(d).
From Fig. 3(c) and (d), for the MSF-BR process conguration, it can be
observed that DCLIC is 2% lower for the DE based optimal solution in
comparison with that reported in the literature. For the same case, the
DE based optimal solution indicated the DCLIC, ICC, OMC and optimal
water production cost to be 5.44, 0.70, 22.40 M$/y and 1.0785 $/m3 re-
spectively. Compared to the literature data [3], these values correspond
to a reduction of 12.71, 7.29, 3.22 and 2.31% respectively. Further, with
respect to the literature data, it can be also analyzed that the areas of
heat rejection and brine heater sections are respectively marginally
lower and marginally higher for the heat recovery section for the
MSF-BR process conguration.
5.4. Optimality of DE algorithm parameters
The effect of DE algorithm parameters (F and CR) on the solution
quality was investigated. According to Storn and Price [30], among F
and CR, DE is much more sensitive to F. For optimal DE algorithm perfor-
mance, they further suggested that F, CR and NP can be set as F [0, 2],
CR [0, 1] and NP = 10 D, where D is dimensionally of the problem.
Typically, F and CR are specied as 0.9 and 0.8 respectively for engineer-
ing optimization problems. Thereby, algorithm optimality is critically
investigated for the optimality of NG and NP. Signicant tradeoffs
exist for the optimality of NG and NP. A very low value of NG and NP
may terminate the algorithm before it could reach the global optimal
and a very high value of NG and NP may take signicantly a long time
to achieve all solutions very close to the global optimal solution. Solu-
tion clustering phenomena are typically addressed as the criteria to
set optimal values of NP and NG. In this work, NP is varied from 25 to
340 and NG is varied from 50 to 2000 for the optimization of MSF
processes.
Fig. 4 panels (a) and (b) respectively summarize the variation of
total optimal objective function value (including penalty) and total
penalty function value with population size (NP = 35 to 340) and gen-
eration size. As shown, signicant penalties existed for lower combina-
tions of NG and NP for the MSF-BR process. Solutions without penalty
have been achieved using a critical specication of NG and NP, over
Table 7
Optimality of thermodynamic, heat transfer and cost function variable values for MSF de-
salination processes.
Performance model TPR sA, m2/(kg/h) sF sWCW
MSF-OT* 10.34 0.005867 8.95
MSF-M 7.59 0.005014 8.66
MSF-BR 8.61 0.008745 7.77 5.28
MSF-BR literature [3] 8.28 0.008497 8.06 5.57
and above which solutions were found to exclusively cluster around
the global optimal domain. For all cases of NP, a critical value of NG =
200 has been evaluated to be relevant to yield optimal solutions without
penalty. Further, above an NG value of 800, almost all solutions
remained fairly constant, thus indicating that the solutions generated
are very close to the global optimal domain. Further, for few cases of
NP and generation size where few best solutions were obtained, addi-
tional investigations were carried out to evaluate upon the solution
quality in the context of the global optimal domain. For this purpose,
standard deviations were evaluated for the obtained solutions. The
standard deviation of the solutions obtained for a population and gener-
ation size of 270 and 800 respectively is 105 for the best 100 solutions.
For this case, the lowest optimal solution of 1.0785 $/m3 has been ob-
tained. However, for the case of the population and generation size of
100 and 500 respectively, a standard deviation of 103 was obtained
for the best 100 solutions. The achievement of lower standard deviation
for lower combinations of NG and NP in comparison with the higher
combinations of NG and NP is expected, given the fact that higher NG
and NP combinations facilitate better search of the solution space. A
similar explanation could be provided for the results indicated in
Fig. 4(c)(f) for MSF-M and MSF-OT processes. Thus, the optimal DE al-
gorithm parameter combinations for MSF-BR refer to F, CR, NG and NP
values of 0.9, 0.8, 800 and 270 respectively.
For the MSF-OT process conguration, Fig. 4 panels (c) and
(d) respectively depict the variation of optimal total objection function
value and optimal total penalty value with NP and generation size. The
obtained trends are similar to those obtained for MSF-BR case and the
solutions converged to optimal value for all populations (NPs) for a gen-
eration size of 800. The results reported for the MSF-OT system refer to
the existence of penalties for few constraints and the reported values
indicate solutions with lowest penalties. A careful analysis of the opti-
mization results for MSF-OT indicated that brine velocity constraint
was the violated beyond the specied upper bound value (6 ft/s). Even-
tually, with higher brine velocity, the inequality constraint presented as
abs1 UUBcal 0:001 did not get satised, as UBcal is a function of brine
B
density, which is in turn a function of brine velocity. The penalties for
the MSF-OT have been successfully eliminated by targeting the follow-
ing alterations in the parametric and design specications:
a) The brine velocity is xed as 6 ft/s for heat recovery section and the
inequality constraint has been specied to have a constraint param-
eter value of 102 but not 103. For such a scenario, the minimal
fresh production cost has been evaluated using the DE algorithm as
OPR 1.1249 $/m3.
11.17 b) The brine velocity is xed as 6 ft/s and the brine heater width is re-
11.78 duced to 30 ft from 35 ft. No additional changes have been carried
12.87 out for the abovementioned inequality constraint specication. For
10.70
such a scenario, solutions without penalty were obtained for the
38 C.S. Bandi et al. / Desalination 394 (2016) 3043
Fig. 3. Pie-charts representing the cost contributions of various cost functions to optimal freshwater production cost; (a) MSF-OT, (b) MSF-M, (c) MSF-BR and (d) MSF-BR literature
data [3].
MSF-OT system to indicate the optimal fresh water production cost
of 1.1154 $/m3.
Fig. 4 panels (e) and (f) respectively illustrate the variation of total
optimal objective function value (inclusive of penalties) and total opti-
mal penalty function values for various cases of NP and generation
values. The obtained trends are similar to those presented for MSF-BR
case. Also, it can be observed that for MSF-M, solutions without penalty
(feasible solutions) have been obtained using the DE algorithm. The
MSF-OT conguration provided infeasible solutions among the three
different process congurations. Using DE, the optimal water produc-
tion cost for the MSF-M process is 1.1980 $/m3 respectively.
5.5. Sensitivity analysis
5.5.1. Effect of feed concentration
Sensitivity analysis involves the evaluation the optimal freshwater
production cost critical dependence on with various operating parame-
ters of the MSF process. Typically, feed concentration is varied from
20,00050,000 ppm for MSF processes [3]. Varying feed concentration
in this range, the optimal freshwater production cost was evaluated
using DE for MSF processes. Fig. 5(a) summarizes the results obtained
for the feed concentration effect on optimal fresh water production
cost. It can be observed that the optimal water production cost in-
creased from 1.2125 to 1.2455, from 1.1876 to 1.2132, from 1.0656 to
1.1051 and from 1.09 to 1.13 $/m3 respectively for MSF-OT, MSF-M,
MSF-BR and MSF-BR literature processes. From a variation in feed con-
centration 20,000 ppm to 40,000 ppm, the optimal water production
cost varied from 1.0656 to 1.0708 for the MSF-BR process which afrms
that the cost remained fairly constant. From 40,00050,000 ppm varia-
tion in feed concentration, water product cost increased linearly from
1.0708 to 1.1051 for the MSF-BR process. The slope of the graph is
about 3.433 10 6. The insensitivity of the water production cost
with feed concentration up to 40,000 ppm is due to the insignicant ef-
fect of feed concentration in inuencing the product ow rates, concen-
trations and temperature. This might not be the case for reverse osmosis
process where feed concentration will have a signicant effect on the
water production cost. Above 40,000 ppm, the feed concentration can
be observed to have a signicant effect on the water production cost.
The DE based optimal cost proles lowered by 2.232.65% than
those reported in the literature for the variation in feed seawater con-
centration. In comparison with the literature data, it can be observed
that the lowest cost trends have been obtained for the MSF-BR process.
This once again conrms the efcacy of DE to obtain high quality solu-
tions for MSF process optimization.
5.5.2. Thermal performance
The thermal performance is dened as the ratio of total amount of
fresh water produced to total steam intake of the MSF process:
Thermal performance 6
total amount of fresh water produced W MD
:
total steam intake fed to plant W MS
In general, the thermal performance ratio varies from 6 to 12 for the
MSF desalination system and below 1 for the single stage ash desalina-
tion system [10]. Similarly, the top brine temperature (TBT) is varied
from 90 to 100 C for a variation in total number and thermodynamic
loss range of 1829 and 0.52 C [10].
The variation of thermal performance with TBT for MSF processes is
presented in Fig. 5(b). For a variation in TBT from 90 to 110 C, the ther-
mal performance ratio varied from 6.66 to 7.31, from 6.75 to 7.59, from
7.26 to 8.61 and from 7.02 to 8.28 for MSF-OT, MSF-M, MSF-BR and
MSF-BR literature data. It can be observed that the thermal performance
is marginally sensitive with TBT for MSF-OT and MSF-M processes but
not MSF-BR. Further, it can be observed that the thermal performance
 C.S. Bandi et al. / Desalination 394 (2016) 3043 39

Fig. 4. Effect of DE algorithm parameters (NG and NP) on the solution optimality for various MSF processes (a) total optimal objective function value for MSF-BR, (b) total penalty
function value for MSF-BR, (c) total optimal objective function value for MSF-M, (d) total penalty function value for MSF-M, (e) total optimal objective function value for MSF-OT and
(f) total penalty function value for MSF-OT.

increased linearly with increasing TBT and the corresponding slope
values are 3.2 102, 4.0 102, 6.7 102, and 6.4 102 respec-
tively for the said process sequence. Also, in comparison with the liter-
ature data, it is apparent from the gure that the highest thermal
performance values were obtained for the MSF-BR process using the
DE algorithm. The thermal performance of the MSF system has been
varied from 6 to 9, where the DE based optimal costs have been evalu-
ated to be 3.423.99% lower than those reported in the literature.
5.5.3. Chemical cost multiplier
Typically, cost multipliers are varied from 0.25 to 2 for MSF desalina-
tion processes [3]. Fig. 5(c) presents the variation of optimal water
40 C.S. Bandi et al. / Desalination 394 (2016) 3043

Fig. 5. Sensitivity of MSF processes with respect to various process and operating parameters; (a) feed concentration, (b) TBT on TPR, (c) chemical cost multiplier, (d) steam cost multiplier.
(e) Labor cost multiplier, (f) power cost multiplier, (g) spares cost multiplier, (h) TBT on cost (+[3]).
 C.S. Bandi et al. / Desalination 394 (2016) 3043
production cost as a function of chemical cost multiplier for MSF pro-
cesses. It can be observed that the water production cost increased
non-linearly from 1.1345 to 1.2958, from 1.0866 to 1.12798, from
1.0015 to 1.1365 and from 1.022 to 1.161 $/m3 with increasing chemical
cost multiplier (0.252) for MSF-OT, MSF-M, MSF-BR and MSF-BR liter-
ature data. As it is apparent in other sensitivity analyses, the lowest
water production cost trends have been obtained in this work in com-
parison with the existing data trends of the MSF-BR process in the liter-
ature. The freshwater production cost varied linearly with chemical cost
multiplier in the range of 0.252. For such a case, the corresponding
slopes of the trend lines are 0.09, 0.11, 0.071, and 0.072. These slope
values are indicative towards water production cost sensitivity with re-
spect to chemical cost multiplier. Thus the water cost ($/m3) will in-
crease by 9 /m3, 11 /m3, 7.1 /m3, and 7.2 /m3 respectively for a
unit increase in chemical cost multiplier for MSF-OT, MSF-M, MSF-BR
and MSF-BR literature data [3]. For a variation in the cost multiplier
from 0.25 to 0.5, the corresponding optimal water cost varied non-
linearly from 1.1348 to 1.1752, from 1.0866 to 1.1271, from 1.0015 to
1.0495 and from 1.022 to 1.076 $/m3. A further increase in the chemical
cost multiplier from 0.5 to 2.0 enabled a linear enhancement for the op-
timal water cost from 1.1752 to 1.2958, from 1.1271 to 1.2798, from
1.0495 to 1.1365 and from 1.076 to 1.161 $/m3 for the said sequence
of processes. Compared to the literature, the obtained optimal cost is
22.46% better for variation in the chemical cost multiplier.
5.5.4. Steam cost multiplier
For the steam cost multiplier sensitivity analysis, the steam cost was
varied from 0.00104 to 0.00832 $/kg of steam (corresponding to a vari-
ation of steam cost multiplier from 0.25 to 2.0) at a constant TBT value of
110 C [3]. The obtained sensitivity analysis based cost trends with re-
spect to steam cost multiplier are presented in Fig. 5(d). As shown, for
a variation in steam cost multiplier from 0.25 to 2.0, the minimal
water cost varied from 0.8656 to 1.7123, from 0.8202 to 1.687, from
0.7284 to 1.4876 and from 0.739 to 1.5212 $/m3 for MSF-OT, MSF-M,
MSF-BR and MSF-BR literature data [3]. The obtained cost trends with
respect to steam multiplier indicate a linear variation in water cost
with steam multiplier. Such a trend is expected, given the fact that the
MSF is a thermal process and its performance is a strong function of
steam as a heat source for ash operation. The sensitivity parameters
can be obtained from the slope of the obtained data trends. These values
have been evaluated correspondingly as 0.48, 0.49, 0.43 and 0.44. Thus,
the water cost can be evaluated to increase by 48 /m3, 49 /m3, 43 /m3
and 44 /m3 respectively for a unit increase in steam cost for the said se-
quence of processes. The obtained simulation based trends indicate that
MSF-BR provides the lowest water cost trends which are placed margin-
ally below the cost trends reported in the literature [3]. For a variation in
steam cost multiplier from 0.2 to 2.0, the DE based optimal cost is 1.43
2.21% lower than that reported in the literature.
5.5.5. Labor cost multiplier
Fig. 5(e) shows that the optimal water production cost evaluated for
MSF processes is sensitive with respect to labor cost multiplier for all
processes. As shown, for a variation in labor cost multiplier from 0.25
to 2.0, the minimal water cost varied from 1.1395 to 1.3396, from
1.209 to 1.3008, from 1.0014 to 1.1813 and from 1.0239 to 1.2001 $/
m3 for MSF-OT, MSF-M, MSF-BR and MSF-BR literature data [3].
Hence, signicantly higher cost trends can be observed for MSF-OT
and MSF-M processes but not for MSF-BR and MSF-BR literature data.
The obtained cost trends with respect to labor cost multiplier indicate
that the variations are linear with slopes of 0.11, 0.10, 0.10 and 0.10
for MSF-OT, MSF-M, MSF-BR and MSF-BR literature [3] respectively.
Thus the water cost ($/m3) will increase by 11 /m3, 10.3 /m3, 10 /
m3, and 10 /m3 respectively for a unit increase in labor cost multiplier
for the said sequence of processes. The lowest data trends refer to the
data obtained with DE for the MSF-BR process. For a variation in labor
41
cost multiplier from 0.2 to 2.0, the DE based optimal cost is 1.572.2%
better than that reported in the literature.
5.5.6. Power cost multiplier
For a variation in power cost multiplier from 0.25 to 2.0,
Fig. 5(f) presents the variation of optimal water production cost trends
for various MSF desalination processes. The observed trends are similar
to those obtained for labor cost multiplier. As shown, for a variation in
power cost multiplier from 0.25 to 2.0, the minimal water cost varied
from 1.1286 to 1.3589, from 1.1139 to 1.3101, from 0.9915 to 1.1921
and from 1.02 to 1.213 $/m3 respectively for MSF-OT, MSF-M, MSF-BR
and MSF-BR literature data [3]. The corresponding slopes of the obtain-
ed cost trends are 0.13, 0.11, 0.11 and 0.11. Thus the water cost ($/m3)
will increase by 12.9 /m3, 11.2 /m3, 10.9 /m3, and 10.9 /m3 respec-
tively for a unit increase in labor cost multiplier for the said sequence
of processes. The lowest cost trend corresponds to that obtained with
MSF-BR and the DE algorithm in this work. For a variation in power
cost multiplier from 0.2 to 2.0, the DE based optimal cost is 1.72
2.79% better than that reported in the literature.
5.5.7. Spares cost multiplier
Fig. 5(g) illustrates the variation of minimal water production cost as
a function of spares cost multiplier for alternate MSF processes. As
shown, for the variation in spares cost multiplier from 0.25 to 2.0, the
minimal water cost varied from 1.1456 to 1.3102, from 1.1348 to
1.2823, from 1.0203 to 1.1628 and from 1.0375 to 1.1825 $/m3 for
MSF-OT, MSF-M, MSF-BR and MSF-BR literature data [3]. The cost trends
are similar to those obtained for labor and power cost multipliers. The
slopes of the linearized trends are 0.09, 0.08, 0.08 and 0.08 respectively
for the said sequence of processes. Thereby, the sensitivity of the spares
cost multiplier has been evaluated in terms of an increase by 9.2 /m3,
8.4 /m3, 8.2 /m3, and 8.2 /m3 respectively for a unit increase in
labor cost multiplier for the said sequence of processes. For a variation
in spares cost multiplier, the DE based optimal cost is 1.66% lower
than that reported in the literature.
5.5.8. Effect of top brine temperature
Fig. 5(h) presents the variation of optimal water production cost
with variation in top brine temperature for various cases. As shown,
for a variation in TBT from 90 to 110 C, the costs varied linearly from
1.1051 to 1.2251 and from 1.0845 to 1.1980 $/m3 for MSF-OT and
MSF-M processes. However, for the MSF-BR processes (reported in
this work and in literature), up to a temperature of 100 C, the optimal
water production cost was not at all affected with variation in TBT.
Above 100 C, the optimal water production cost increased with in-
creasing TBT. Based on these increasing trends, the slopes of the various
plots have been evaluated (5.9 103, 5.6 10 3, 2.5 103, and
2.8 103 respectively for the said sequence of processes). Thus, for a
unit increase in top brine temperature, the water cost will increase by
0.59 /m3, 0.56 /m3, 0.25 /m3, and 0.28 /m3 for the said sequence
of processes. Overall, the lowest data trends have been obtained for
the MSF-BR and DE algorithm case. For a variation in TBT from 95 to
110 C, the DE based optimal cost is 1.66% lower than that reported in
the literature.
In summary, the DE based sensitivity analysis of MSF-BR enables
one to infer that the slope based ranking of various process and
operating parameters is as per the following order: steam cost multipli-
er (43 /m3) N labor cost multiplier (10 /m3) N power cost multiplier
(8.2 /m3) N spares cost multiplier (8.2 /m3) N chemical cost multiplier
(7.1 /m3) N TBT (0.25 /m3) N feed concentration (fairly constant). In
other words, the optimal freshwater production cost for the MSF process-
es is highly sensitive to steam cost multiplier, marginally sensitive with all
other process parameters but not feed concentration and TBT. Since the
MSF process is highly energy intensive, the highest sensitivity of the
MSF-BR process optimal cost with steam multiplier is expected.
42 C.S. Bandi et al. / Desalination 394 (2016) 3043

6. Conclusions MEE multi-effect evaporator

MS-SQP multistart-sequential quadratic programming
Based on the global optimization approach involving differential MSF multi-stage ash
evolution algorithm, this work provided signicant insights and infer- MSF-BR brine recycle (BR) multistage ash system (MSF)
ences with respect to the comparative assessment of alternate MSF pro- MSF-M brine-mixing (M) multistage ash system (MSF)
cesses, non-deterministic/deterministic optimization methods and MSF-OT once through (OT) multistage ash system (MSF)
pertinent sensitivity analysis. The modeling approach adopted in this NG maximum number of generations
work might refer to design solutions under stringent uncertainty, NLP non-linear programming
given the inability to generate feasible solutions with methods other NP population size
than DE. The following conclusions are applicable from the insights de- OF objective function
duced in this work. OPR overall plant recovery
Firstly, DE has been proven to be effective to generate feasible ppm parts per million
optimal design variable values for MSF-BR, MSF-M but not MSF-OT pro- RO reverse osmosis
cesses. Compared to the literature optimal value, DE provided a reduc- sA specic heat transfer area
tion of about 2.31% in the optimal freshwater production cost. This is sF specic feed ow rate
due to the identication of better optimal decision variable value set sWCW specic cooling feed ow rate
of [2794.4 m3/h, 1.0499, 7.62 m, 3.359 kW/m2 K, 3.297 kW/m2 K, SQP sequential quadratic programming
3.042 kW/m2 K and 22] for variable set [WM, RH, LT, UB, UR, Uj and NR] re- TA Thomas algorithm
spectively where the optimal freshwater production cost corresponds TBT top brine temperature
to 1.0785 $/m3. Secondly, the deterministic optimization algorithms TDM tridiagonal matrix
such as SQP, MS-SQP and DE-SQP could not provide better solution TDS total dissolved solids
than the DE. This is primarily due to the dependence of the optimal var- TPR thermal performance
iable value set and objective function on the initial guess values. Thus, USA United States of America
compared to other optimization methods, DE would provide better ini- VC vapor-compression
tialization strategies and is expected to serve better for problems with
greater complexity in terms of decision variables. Symbols
Another important insight that has been deduced in this work is that
the MATLAB based optimization toolbox uses default optimization algo-
rithm parameters and they cannot be as such used for MSF optimization
problems studied in this work. Thirdly, the sensitivity analysis afrmed a coefcient to account for using average latent heat of
that DE based analysis provided 1.413.99% better proles than those vaporization
available in the literature. While such improvement could be regarded AB heat transfer area of brine heater, m2
to be optimal, it is important to note that the freshwater production Aj heat transfer area of the rejection section, m2
cost related improvement is signicant, given the fact that optimization AR heat transfer area of recovery section, m2
studies that allow even 1% reduction in water production cost could AT total heat transfer area of the MSF process, m2
turn out in terms of a huge amount of savings. Fourthly, inequality con- CDCC direct capital investment, $
straint resolution appears to be better tackled by DE than any other op- CDCLIC direct capital less intake investment, $
timization method. A further resolution of the generated solutions has CIC annual plant intake-outfall cost, $
also been demonstrated in this work i.e., to alter certain design param- CICC indirect capital investment, $/y
eter value for chamber width. Fifthly, the chosen literature might be rel- Clast concentration of brine stream from last stage of the heat re-
atively old in the existing state-of-the-art, but the trends obtained in jection section, ppm
this work appear to be generic to afrm upon the efcacy of DE as the CMBD concentration of reject stream leaving the heat rejection sec-
most versatile optimization method to yield feasible solutions under tion, ppm
strong conditions of uncertainty. In summary, it is inferred that DE CMF feed (seawater) concentration, ppm
based optimization is highly effective to obtain feasible global optimiza- CMR concentration of recycle stream (from splitter to heat recov-
tion solutions in conjunction with SQP, MS-SQP and DE-SQP. It is antic- ery section), ppm
ipated that DE would be able to provide condence in the solutions CMSMF concentration of feed stream to the MSF-M process, ppm
generated with complex and hybrid process congurations involving COMC operating and maintenance cost, $/y
MSF process congurations. This will be addressed in subsequent re- Cp heat capacity, kJ/kgK
search articles. CPR avg. specic heat capacity, recovery section, kJ/kgK
Cpj avg. specic heat capacity, rejection section, kJ/kgK
Nomenclature ID inside diameter of condenser tubes, m
LT tube length, m
Abbreviations M1 mixer 1
Nj number of rejection stages
CR cross over ratio NR number of stages in heat recovery stages
DE differential evolution OD outside diameter of condenser tubes, m
ED electrodialysis RH specic heat ratio (WMRCpR/WMFCpj)
F mutation factor S12 splitter 12 respectively
DICOPT++ DIscrete and Continuous OPTimizer sWCW specic cooling water ow rate
GA Genetic algorithm T1 temperature of reject coolant stream in the MSF-BR process, C
GAMS general algebraic modeling system T2 temperature of brine stream entering the brine heater in the
GOR gained output ratio MSF process, C
GRG generalized reduced gradient T3 top brine temperature, oC
ID inside diameter of condenser tubes, m T4 temperature of brine stream leaving last stage in the heat
IDA International Desalination Association recovery section of the MSF-BR process, C
 C.S. Bandi et al. / Desalination 394 (2016) 3043 43

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