evolution of thermal desalination processes
TRANSCRIPT
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Saline Water Conversion CorporationSaline Water Desalination Research Institute (SWDRI)
Evolution of Thermal Desalination
Processes
Dr. OSMAN AHMED HAMED
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OUTLINE
Background
Evolution of MSF desalination plantsEvolution of MED desalination plants
Dual purpose power/water and hybriddesalination plants
R&D Prospects
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Evolution of Installed membrane and thermalcapacity (cumulative ) 1980-2012
Thermal33%
Membrane 67%
0
10
20
30
40
50
60
70
80
1980 1985 1990 1995 2000 2005 2008 2010 2012
membrane
thermal
year
m i l i o n m 3
/ d
0
10
20
30
40
50
60
70
80
1980 1984 1988 1992 1996 2000 2004 2008 2012
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Breakdown of Total Worldwide Installedcapacity by technology
Other (2%) Hybrid (1 %)
ED (3 %)
MED (8 %)
MSF (23%RO (63%)
74.8 million m 3 /d
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MULTI EFFECTDISTILLATION(MED)
COMMONSEAWATERTHERMAL
DESALINATIONPROCESSES
MULTI STAGEFLASH (MSF)
DISTILLATION
Evolution of Thermal DesalinationProcesses
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The multi-stage flash
(MSF) desalination process
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High reliability
& availability.Life-time over 30years
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
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Life TimeCapacity(migd)
YearPlantsS.#
344x51979Jeddah-III1
3210 x 51981Jeddah-IV2316 x 6.21982Al-Jubail-I33110 x 61982Al-Khobar-II43040 x 5.381983Al-Jubail-II5272 x 2.61986Al-Khafji-II62410 x 5.061989Shoaiba-I7244 x 6.51989Shuqaiq-I8
325 x 51981 Yanbu-I9
144 x 7.941999 Yanbu-II10128 x 7.52001Al-Khobar-III111110 x 102002Shoaiba-II12
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11
90%
7% 3%
Availability
Planned ShutdownForced Shutdown
91%
9%
Water ProductionDesign Deficiency
88%
12%
Power ProductionDesign Deficiency
Average Availability for Al-Jubail Plant Phase II(1983-2012)
Average Water and Power Load Factors for Al-Jubail Plant Phase II (1983-2012)
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12
Reasons For high reliabilityand availability
Selection ofHigh Design
Fouling Factor
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13
BHDesignFoulingFactors
Al-Khobar III 0.264 m 2 oC/kW
Al-Khobar II 0.160 m 2 oC/kW (1982)
Shuaiba II 0.211 m 2 oC/kW
Shuaiba I 0.30 m 2 oC//kW (1982)
Tawaleh B 0.15 m 2 oC/kW
Jebel Ali 0.12 m 2 oC/kW
Al-Jubail II 0.176 m 2 oC/kW (1983)
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14
Reasons For high reliabilityand availability
Selection ofHigh Design
Fouling Factor
Effectivealkaline scale
control
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16
3
4.5
6.5
9
15
0
2
4
6
8
10
12
14
16
85 90 95 100 105 110 115 120
A n t i s c a l a n t D o s e R a t e ( p p m )
Top Brine Temperature (oC)
Dose Rate recommended in 1981
Optimization Tests
Improvement ofChemical
Formulation
Adoption of On-Line Sponge BallCleaning System
1.5
1 .75
3.53
2.5
0
2
4
6
8
10
12
14
16
85 90 95 100 105 110 115 120
Dose Rate Optimized in 1987
SWCCs ACHIEVEMENTS IN CONTROLLING
ALKALINE SCALE FORMATION
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17
0.8 1
2.521.5
0
2
4
6
8
10
12
14
16
85 90 95 100 105 110 115 120
Dose Rate Optimized in 2003
3
4. 5
6.5
9
15
0
2
4
6
8
10
12
14
16
85 90 95 100 105 110 115 120
A n t i s c a l a n t D o s e R a t e ( p p m )
Top Brine Temperature (oC)
Dose Rate recommended in 1981
Optimization Tests
Improvement ofChemical
Formulation
Adoption of On-Line Sponge BallCleaning System
1.5
1 .75
3.53
2.5
0
2
4
6
8
10
12
14
16
85 90 95 100 105 110 115 120
Dose Rate Optimized in 1987
SWCCs ACHIEVEMENTS IN CONTROLLING
ALKALINE SCALE FORMATION
2010
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18
Economic Impact of Antiscalant Dose RateReduction in SWCC MSF Plants
7.86
4.65
3.21
0 1 2 3 4 5 6 7 8 9
Antiscalant Annual Operating cost as
per 1987 dose rate
Antiscalant Annual Operating cost as per current dose
rate
Annual Savings
M i l l i o n U S $
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19
Reasons For high reliabilityand availability
Selection ofHigh Design
Fouling Factor
Effectivealkaline scale
control
GoodSelection ofMaterial of
Construction
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20
Section Material of Construction
Brine Heater
Shell Carbon steel (all plants)
Tubes Either 70/30 o,90/10 Cu-Ni or modified 66/30/2/2Cu/Ni/Fe/Mn except Al-Jubail I (Titanium)
Heat RecoverySection
FlashChamber
First high temperature stages Al-Jubail, Al-Khafji andthe first two modules of Jeddah IV cladded withstainless steel
Al-Khobar II completely cladded with 90/10 Cu/Ni Al-Shuqaiq 1completely claded with stainless steel
Tubes All plants except Yanbu and Al-Jubail I: 90/10 Cu Ni
Jubail I: TitanuimYanbu 70/30 (1 to 10 stages)90/10 (11 to 21 stages)
Heat Rejection Tubes All plants except Jeddah & Shoaiba : TitaniumJeddah II, III, IV 90/10 Cu/NiShoaiba 70/30 Cu Ni
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21
Flash chamber of both recovery
and heat rejection sections
Carbon steel lined with stainless steel(floor lined with 317L, walls with316L and roof with either 316L or
304.
Water boxes Carbon steel lined with 90/10Copper-Nickel
TubesBrine heater tubes modified 66/30/2/2
Cu/Ni/Fe/Mn ; heat recovery tubes:
Copper/Nickel (first four stages 70/30and remaining stages 90/10)
Heat rejection tubes Titanium &modified 66/30/2/2 Cu/Ni/Fe/Mn
Projects which were recently built use the following materials ofconstruction for the major components
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Increase in distillersize
High reliability
& availability.Life-time over 30years
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
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Historical Growth of MSF Distiller Size
2.5
5.1
7.9
10
17.5
20
0
5
10
15
20
25
1973-1978 JeddahI&II kKhobar I
1979-1988 Jeddah III&IV Yanbu I Jubail
I&II Khobar II
Shuaiba I
1999-2001 Yanbu IIkhobar II
2002 Shuaiba II 2003 UAE 2011 Ras Alkhair
Low investment cost for auxiliary equipment such as interconnection and controlpiping .
Operating and maintenance people depends on the number of unit installed. Savings in operational cost.
Large unit size:
23
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Reasons Constant Reduction of Investment per MIGD optimized use of material of construction. Reduction of redundant equipment. Optimized mechanical design of evaporator vessel. Optimized thermo-dynamic design parameters.
8
6 54
12
0
2
4
6
8
10
12
14
1985 1990 1995 2000 2004
year
$ / I G D
Price Trend for turn-key complete MSF plants
2010
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Use of thermallyefficient powergeneration cycles
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants
Evolutionary
Developmentsof MSF Plants Increase in distillersize
High reliability
& availability.Life-time over 30years
Evolutionary
Developmentsof MSF Plants
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2828
After 1983 SWCC employed back-pressure turbine arrangement
Condensate Pump
MSF Distillers
Deaerator
Heater # 2 Heater # 1
G
Boiler
Fuel
Back PressureTurbine
Ejector MoistureSeparator
Power to water ratio 5 to 7.9 MW/MIGD
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After 1983 SWCC employed back-pressure turbine arrangement
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2012 Combined Gas-vapor power generation cycles coupled with MSF/RO desalinationplants
Compressor GasTurbine
CombustionChamber
SteamTurbine
Exhaustgases
Air in
RecoverySection
GAS CYCLE
STEAM CYCLE
Waste Heat Boiler
RejectionSection
Product Water
Blow downBrineHeater
Fuel in
Recycle Brine
Power Output
Power Output
Seawater in
CoolingSeawater
Reject
SWRO
1100 oC
613 oC539 oC
140 oC, 2.89 Bar EjectorSteam
18 bar, 50MW
230 oC
300,000m 3 /d 1,000,000 m 3 /d
62.5 MW
700,000m 3 /d
81MWCommonEquipment
Net 2400 MW
5 x 129.7 MW
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Financial Benefits for Dual Purpose Plants
Tremendous saving in fuel consumption related tothe desalting process
Elimination of some equipment(power plant condenser)
Dual purpose power/water plants have an overallfinancial gain against two single purpose plants.
Sharing of some common equipment (boiler and its
associated facilities, intake and outfall facilities).
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243 MW
204 MW
100Electrical
Water Production15 MIGD
DualPurpose
DualPurpose
=447 MWMW
Fuelrequirements
285 MW
280 MW
SinglePurpose
SinglePurpose
=565 MW
Fuelrequirements
Thermal Benefits of Cogeneration Plants
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ThermalProcesses
MSF
MED/TVC
MED TVC
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MED_TVCoffers the best potential method of improving the performance of straight MED desalination plants and
achieving high performance ratios and hence low water cost.
or SteamTransformer
GOR=61kg
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They provide higher overall heat transfer coefficients whencompared to multistage flash (MSF) desalination systems.
MED does not employ recycling and are thus based on theonce through principle and have low requirements for
pumping energy.The power consumption of MED/TVC plants is only around1.5 kWh/m 3 as there are no requirements to re-circulate largequantities of brine.
Increase of MED unit capacity results in the decrease of theinvestment cost.
Multi-effect distillation also offers the possibility of reducingthe plant size and footprint
Factors responsible for the recent market emergence ofMED-TVC desalination plants
EVOLUTION OF MED/TVC DESALINATION PLANTS
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0
3
69
1215
1990 2000 2009year
u n i t c a p a c i t y
M I G D
MED UNIT CAPACITY GROWTH
5MIGD
8-10 MIGD
EVOLUTION OF MED/TVC DESALINATION PLANTS
1MIGD
15MIGD
2012
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1 2 3 4 5 6 7
B
A
B
A
B
A
B
A
B
A
A A
C C
B B
Steam
ProducedSteam
Distillate throughguillotine
Distillate throughSaw line
Distillate throughU pipe
Brine suction
Cell 1 / distillatesuction
REB 5REB 3
8
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HYBRID CONCEPTS
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Integrated Hybrid systemsthe plant is designed fromthe beginning
as a combined plant .
HYBRIDSYSTEMS
Simple hybrid Systemsadding a stand- alone
RO desalinationplant to an existing MSF complex
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Power Plant
Electricity
To main grid
To RO Plant
To MSF Plant
MSF Unit
CondensateReturn
Steam to MSF
Heat
Rejection
SeawaterOut
CommonOutfallFacility
BlendedProduct
MSF Product
MSFMake-up
Brine
Blow Down
Single Pass
RO Unit
CommonIntakeFacility
MSFFeed
ROFeed
Seawater FeedRO
Product
Schematic diagram of simple hybrid configuration
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ADVANTAGES
Such arrangement allows to operate the RO unit with relativelyhigh TDS and consequently allows to lower the replacementrate of the membranes.
If the useful life of the RO membrane can be extended from 3 to5 years the annual membrane replacement cost can be reducedby nearly 40 percent . Blending the products of the thermal andSWRO allows for the use of a single stage SWRO instead of thetwo stage SWRO plant normally employed in standalone SWROplants.
Combining thermal and membranes desalination plant in thesame site will allow to use common intake and outfall facilitieswith less capital cost.
An integrated pretreatment and post-treatment operation canreduce cost and chemicals.
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Hybridsystems
Simple hybrid
IntegratedHybrid
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Schematic diagram of fully integrated hybrid configuration
Power Plant
Electricity
To main grid
To RO Plant
To MSF Plant
MSF Unit
CondensateReturn
Steam to MSF
Heat
Rejection
SeawaterOut Common
OutfallFacility
BlendedProduct
MSF Product
MSFMake-up
Brine
Blow Down
Single Pass
RO Unit
CommonIntakeFacility
MSFFeed
ROFeed
Seawater Feed RO
Product
Common PostTreatment
Facility
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Commercially AvailableHybrid Desalination
Plants
JeddahMSF/SWRO
YanbuMSF / SWRO
Al-Jubail
MSF/SWRO
Ras Al KhairMSF/SWRO
Product blended with MSF Product
SWRO 28.16 MIGD
Phase II MSF 40 MIGD
20 MIGD
Comman intake/outful with MSF
Product blended with MSF
1989 , Phase ISingle stage , 12.5 MIGD
1994 , Phase II
Single stage , 12-5 MIGD
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HHGas
turbine
system
HRSG
Steamturbine
MSFplant
SWROplant
Natural gas
P=10*199.7 MW
P=5*129.7 MW
P= 10*199.7 MW Pnet2400 MW
P MSF
P RO
300000m3/d
700000m3/d
1000000m3/d
P RO
Fluegases
SteamSteam
Condensatereturn
Block diagram of the combined power cycle integratedwith the hybrid MSF/SWRO desalination plant
P aux
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R&DPROSPECTS IN
THERMAL DESALINATION
Address the shortcomingsOf currently employed thermal
desalination processes
Development of desalination conceptsThat have not been fully explored and
Applied in commercial scale
Development of new desalination concepts
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R&DPROSPECTS IN
THERMAL DESALINATION
Address the shortcomingsOf currently employed thermal
desalination processes
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NF Reject
SeawaterNF Unit
NF Product
Ca = 481
Mg = 1507
TH = 7406HCO3 = 145
SO4 = 3257
TDS =45400
Ca = 72
Mg = 63
TH = 440HCO3 = 51
SO4 = 23
TDS =32060
NF/RO/MSF or NF/RO/MED Tri -hybird System
RO Reject
SWRO UnitRO Product
Ca = 281
Mg = 437
TH = 2502
HCO3 = 101
SO4 = 124
TDS = 61080
Ca = 1
Mg = 2
TH = 9HCO3 = 4
SO4 = -
TDS = 660
MSF/MED UnitMSF/MED Product
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CONCEPTUAL DESIGN OF THE HIGHTEMPERATURE AND UNIT CAPACITYMED-TVC DESALINATION PLANT
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S h i fl di f MED
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Schematic flow diagram of MEDunit of Tri-Hybrid Desalination Plant
The impact of energy cost in $/bbl oil equivalent on the water production cost
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0
2
4
6
8
10
12
14
16
0 10 20 30 40 50 60 70 80 90 100
W a t e r C o s t ( S R
/ m 3 )
($/bbl)
Standalone MED
0
2
4
6
8
10
12
14
16
0 10 20 30 40 50 60 70 80 90 100
W a t e r C o s t ( S R
/ m 3 )
($/bbl)
Standalone MED
MED+Power Plant
0
2
4
6
8
10
12
14
16
0 10 20 30 40 50 60 70 80 90 100
W a t e r C o s t ( S R
/ m 3 )
($/bbl)
Standalone MED
MED+Power Plant
StandaloneNF/RO/MED(70-30)
0
2
4
6
8
10
12
14
16
0 10 20 30 40 50 60 70 80 90 100
W a t e r C o s t ( S R
/ m 3 )
($/bbl)
Standalone MED
MED+Power Plant
StandaloneNF/RO/MED(70-30)
NF/RO/MED (70-30)+Power Plant
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Schematic flow diagram of trihybrid NF/RO/MSF desalination system
RO Unit
RO ProductBlendedProduct
MED/TVC Unit
MED Product
Steam
Cooling Seawater out
Cooling Seawater in
CondensateReturn
RO Reject
NF Unit
NF Reject
Seawater Intake
NF Product
Pretreatment
Make-up Seawater
MED Brine
RO Unit
RO ProductBlendedProduct
MED/TVC Unit
MED Product
Steam
Cooling Seawater out
Cooling Seawater in
CondensateReturn
RO Reject
NF Unit
NF Reject
Seawater Intake
NF Product
Pretreatment
Make-up Seawater
MED Brine
MSF
MSF
The impact of TBT on water production and energy consumption
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The impact of TBT on water production and energy consumption
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Comparison between the standalone MSF and
MSF combined with NF/RO configuration
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Standalone MSF MSF Wthin Trihybrid Scheme
Ad*102( m2 /kg/hr )
34%
Pumping Power (kWh/m3) 10% 42 %
Mc/Md23 %
Mr/Md17 %PR
39 %
68
Saline Water Conversion Corporation (SWCC)
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Prospects of reduction of operational cost
of SWCC small scale thermal desalinationplants using solar energy
Saline Water Conversion Corporation (SWCC)
Synergy between desalination and solar energy
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Electricity
RO ED MVC
RO = Reverse OsmosisED = Electrodialysis (ED)MVC = Mechanical vapor compressionTVC = Thermal Vapor compressionMED = Multieffect distillationMSF = Multistage flash distillation
TVC MED MSFRO ED MVC
Heat
TVC MED MSF
HeatElectricityThermal power
cycle
Thermalenergy
Electricity togrid
Synergy between desalination and solar energySolar desalination combinations
Concentrating solarcollector field,
Photovoltaic cells(PV)
Solar energy drivendesalination processes
solar ponds,evacuated tube , flat
plate,parabolic trough
SWCC-SWDRI/HITACHI ZOSEN Joint Solar Research Project
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j
Schematic diagram of the solar assisted thermal desalinationexperimental set-up
l
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SWDRISWCC
Solar En ergy for
Desal inat ion Plants
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R&DPROSPECTS IN
THERMAL DESALINATION
Address the shortcomingsOf current thermal desalination processes
Development of desalination conceptsThat have not been fully explored and
Applied in commercial scale
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R&D PROSPECTS
Development ofdesalination conceptsThat have not beenfully explored and
Applied in commercialscale
Membrane distillation
Freezing processes
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W a t e r
P r o
d u c t i o n
C o s
t
Year
Step Change
Evolutionary change
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Thank You
77
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