intel water reclaim project final report 5/25/05

Intel Water Reclaim ProjectFinal Report 5/25/05

Intel Project Team

• Matt Lundervold• Bryan Gregory• Charles Brown• Dave Montero

• Academic Advisor: Professor Zareh• Industry Advisor: Steve Chen

Project Scope

• Design a full scale water reclaim system capable of recycling RO reject water.– Phase I: Design, build

& test Pilot system– Phase II: Design Full

Scale Reclaim System

Summary of Design Process

• Translate Customer needs into Engineering Targets

• Design & build Pilot• Collect water quality

data from pilot• Design reclaim

system based on pilot data

Phase 1: Pilot Design & Testing

• Key Design Decisions– Reverse Osmosis – Mobility– Flexible Hoses– Bypasses– Removable Components

• Startup, Testing, & Data– Data Collected for various

combinations of pretreatment– Test results determined

component selection and anti-scalant treatment

Pilot drawing

Phase II: Full Scale Water Reclaim Design

• The team utilized Pilot data, RO modeling software, and Intel design specifications to complete the final design.

2-1

2-2

1-2

1-1

1-3

Booster Pump

Softener

1.0 um Filter

Auto IsolationValve

Reclaim FeedWater

3x2 Reverse Osmosis

RO Product

RO Reject

Water Reclaim Schematic

AntiscalantInjection

SodiumBisulfiteInjection

Key Design Decisions

• RO Treatment• Membrane Selection• Water Softener• RO Configuration• Booster Pump

RO Treatment

• Proven technology• Widely used by Intel• Expandable for increasing water demands• Relatively inexpensive compared to other methods• Easily integrated into existing system

Membrane Selection

• Low fouling– resistant to scaling

and organic fouling– Durable– Low maintenance– High quality output– Relatively low energy

consumption

Water Softener

• Proven technology• Expandable• Prolongs life of RO

membranes and reduces maintenance

• Automated regeneration

• Optimized foot print

Booster Pump Selection • Grundfos BM 17-4N torpedo pump

– Highly reliable pump design– Integrates completely into RO design– Energy efficient– Accepts VFD– Submerged pump and motor, completely sealed unit

RO Configuration

• 3x2 single pass dual staged stacked design– Meets space

requirements– Maximizes product

quality– Ease of maintenance– Expandable for future

flow requirements– Ease of assembly

REVERSE OSMOSIS SKID

RO PIPING MODEL

RO FUTURE EXPANSION OPTION

Design vs. Targets100% of Design Targets met

Highlights Include:• Exceeded all water quality

specifications• System designed to meet 150% of

current demand• Maintainable by 1 technician• Capital cost under projected

budget• Future expansion possible to 180

gpm• Annual water cost savings of

$110k• One time connection fee cost

avoidance of $342k

Project Summary

• Future expansion opportunities– Blending bypass is a low cost

solution to increase capacity– Structure allows for another

RO

• Lesson’s Learned:– Navigating large corporation – Third party vendors

• Successes– Met all design criteria– Pilot validated design– Intel will use the pilot as a

development tool