ChE-413-MSF Multi-Stage Flash Desal Ination

1/10/2011
ChE-413: Desalination and Water treatment
Introduction
The MSF process is innovative where vapor formation takes place within the bulk liquid instead of the surface of hot tubes.
Water Desalination Multi-Stage Flash (MSF)

Introduction Principle of MSF MSF Classification Stage Configuration: Cross / Long tube
In other thermal processes, submerged tubes of heating steam are used to perform evaporation. This always resulted in scale formation on the tubes less heat transfer & costly scale inhibition or removal.
Once Through MSF

Brine recirculation MSF Energy Balances
Prof. Ibrahim S. Al-Mutaz King Saud University 1 Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 2
Chemical Engineering Dep.
Principle of MSF
Principle of MSF
Weirs
When saturated brine enters through slot at lower pressure stage. It senses the new lower pressure environment, and Flashes!
Prof. Ibrahim S. Al-Mutaz
King Saud University
1/10/2011
Principle of MSF
Principle of MSF
Principle of MSF - energy

from the energy flow diagram, the great part of the heat input to the MSF system is returned back to the sea with the seawater drain stream
Development in MSF
Plant operation has improved with

More efficient antiscalent Better corrosion control chemicals Construction material capable of standing harsh conditions
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Development in MSF
Increase in the unit capacity from 454.4 m3/d to a current capacity of 32731 m3/d. The largest unit was commissioned in Al-Taweela with a capacity of 57,734 m3/d. Each capacity doubling is associated with 24% reduction in unit product cost. Decreasing the specific power consumption cost from 7-25 kW/m3 in 1955 to 4-10 kW/m3
Pretreatment
Treatment of the intake seawater is limited to screening and filtration Treatment of the feed seawater includes:
Dearation Addition of antiscalent Addition of foaming inhibitors
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MSF Flashing stage

Demister
Tube Bundle
MSF Flashing stage
Air Buffle Vent Line
Distillate duct Outlet Distillate
Inlet Distillate
Distillate Tray
Outlet Brine Flashed off Vapor

Inlet Brine Brine Pool

Submerged Orifice
King Saud University 11 Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 12
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MSF Flashing stage

Demister Tube Bundle
MSF Flashing stage
Vent line Distillate Duct
Air Baffle
Outlet Distillate
Inlet Distillate Distillate Tray
Outlet Brine Brine Pool Orifice Weir

Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz
Inlet Brine
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Single Stage Flash Desalination

Cooling Seawater M cw = 103.9 kg/s Xf = 42000 ppm T1 = 35 OC
Single Stage Flash Desalination
Intake Seawater M f+M cw= 115.44 kg/s Xf= 42000 ppm Tcw= 30 oC Distillate Product M d = 1 kg/s
Heating Steam M s = 1.18 kg/s Ts = 100 oC
Feed Seawater M f = 11.54 kg/s Xf = 42000 ppm To = 90 oC

Reject Brine M b = 10.54 kg/s Xb = 45984.8 ppm Tb = 40 oC
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Assumptions
Distillate product is salt free Cp is the same for all streams and equal 4.18 kJ/kg
oC
Temperature profile
Brine Heater Ts Flashing Stage TTDh To Top Brine Temperature To T1 TTDc T1 DTst Feed Preheater
U is the same for preheater and brine heater and equal 2 kW/m2. oC Subcooling of condensate or superheating of the heating steam has negligible effect on the energy balance The heat loss is negligible Power consumption is not considered.
Tv
Tb DTloss
Tcw
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Advantages of Single Stage
Drawbacks of single stage

PR is always less than 1.0 The flow rate of the feed seawater is much larger than the distillate produced ( about ten times) which means a large amount of additives and chemicals needed for feed treatment The flow rate of cooling water is very high which increases the pumping power consumption
The salinity of the rejected brine is much smaller than maximum allowable The heat transfer area for the brine heater and preheater is small due to the large temperature driving force. The specific heat transfer area in the brine heater is inversely proportional to the performance ratio.
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MSF Process Classification
MSF Process Classification
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MSF Flow Configuration
Cross-Tube Configuration
Partiti on Walls
Cond enser Tubes Distilla te Brine
Demi ster
Condenser Tubes Demister Tube Sheet
Side Walls
Brine Side Walls
Cross-tube MSF distiller
Long-tube MSF
Cross-tube MSF
King Saud University 23 Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 24
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Partition Walls
Condenser Tubes
Demister
Tube Sheet
Brine Side Walls
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Cross-Tube Internal Layout
Long-Tube Configuration
Long-tube MSF distiller
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Demister Condenser Tubes
Distillate Side Walls
Brine
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Long-Tube Internal Layout
Comparison between Cross Tube and Long Tube MSF Plant Parameters
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Multi-stage MSF
There are 2 types of Multi-stage MSF Once Through (OT) MSF Brine recalculated (recycled)
Objective of Multi-stage MSF
To overcome the main drawbacks of the single flash units To improve the system performance ratio This is achieved by adding more flash units and reducing the temperature drop per stage
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System Components
Once Through MSF
N number of stages : all of the stages are identical Brine heater No recycle of any portion of brine Does not contain cooling water stream: because the brine rejected with low temperature and large flow rate contains the energy to be removed from the system.
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Once Through MSF
Once Through MSF
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Once Through MSF
Once Through MSF
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Process description
The intake seawater at Tcw flow through the preheater of stage n to 1. When it leaves stage 1 its temperature increases to t1. The seawater leaving the condenser enters the brine heater, where its temperature rises from t1 to To The heated brine flashes off as it flows through the successive stages where its temperature decreases from To to Tn
Process description cont.
Simultaneously, flashing vapor condenses around the condenser tubes in each stage where it heats the the seawater flowing through the tubes. The collected distillate leaves from stage n. The brine leaving the last stage is rejected to the sea.
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Advantages vs. Disadvantages

Drastic increase in performance ratio Does not use cooling water for removing excess heat added in the brine heater. Operation at low salinity of both feed and flashed brine High flow rate of intake seawater High total condenser surface area
Brine recirculation (BR) MSF
Heat input Section
Heat Recovery Section
Heat Rejection Section
Cooling Seawater Mcw Condenser Tubes Water Boxes Distillate Trays Demister
Cooling Seawater Recycle Winter Temperature Control Intake Seawater Mf +Mcw
Heating Steam Ms 1 2 3 1 9 20 21 2 2 2 3 24
Distillate Product Md
Condensate
Feed Brine
Brine Pool Brine Recycle Mr Feed Seawater Mf Brine Blow-down Mb
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It is considered the industry standard The process consists of three section
The heat recovery sections The heat rejection section (2-3 stages) The brine heater

The heat rejection section is used to remove the excess heat added to the system in the brine heater It is used to control the temperature of the of the recycled brine This is achieved through recovery of a controlled amount of energy from the flashing brine into the brine recycle and rejection of the remaining energy into the cooling water stream
The system is driven by the heating steam which increases the temperature of the brine recycle or feed seawater to the desired value in the brine heater
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Advantage of brine recirculating MSF

Experience in design and operation of MSF has led to use of inexpensive construction material capable of standing harsh conditions at high salinity The MSF systems does not include moving parts other than pumps. Construction is simple and contains a small number of tubes which limits leakage problems and simplify maintenance work
Description
The hot brine flashes in the consecutive stages, where the brine recycle flow inside the condenser tubes recover the latent heat of the formed vapor. In the heat rejection section of brine circulation system, the excess heat added to the system by the hating steam is rejected to the environment by the cooling seawater stream
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Process Description
The cooling water is introduced in the last stage of the heat recovery section. The cooling water leaving the first stage of the heat rejection section is divided into two parts
Cooling water to the sea Feed water to the dearator to remove O2
The feed is mixed with a portion of the brine from the last stage of the heat recovery section.
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Process Description cont.

The brine recirculation pump pumps the water through the condenser/preheater tubes of the last stage of the heat recovery section Leaving the condenser in the first stage, the feed is introduced into the brine heater (steam-heated), where the temperature rises to the top brine temperature Flashing occurs in each stage and a small amount of water is generated and is cascaded through the stages

Vapor formation results because of the reduction of brine saturation temperature
The stage temperature changes from the hot to cold The brine flows across the stages without the aid of pumping power (from high to low P).
The flashed-off vapor is condensed on the preheater tubes
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From the last stages
Part of brine is rejected to the sea Another part is recycled
The rejection of the brine is necessary to control the salt concentration in the plant
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Stream flow rate, salinity, and temperature
Material balances on the heat rejection section
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Temperature Profile
Energy Balances
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Energy Balances
Energy Balances
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Energy Balances
Modelling a Flashing Stage
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Modelling a Brine Heater
Interface with Rest of the Plant: Layout
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Multi Stage Flash
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General view of low side flash chamber

Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 77 Chemical Engineering Dep.
General view of low side flash chamber

Prof. Ibrahim S. Al-Mutaz King Saud University 78
General view of Cu-Ni 70-30 alloy heat transfer tubes in heat recovery section of Al-Kkafji MSF plant
Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 79 Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 80
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Al-Taweelah Az Power & Desalination Plant
Operational experience show desalination plants operating after 15 years successfully improved material selection suggests that the design life can be extended to 40 years operation
Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 81 Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 82
Umm Al Nar Desalination Station B Plant
Shoaiba Desalination Plant, Saudi Arabia

Chemical 7 Section Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 83 Chemical Engineering Dep. Prof. Ibrahim S. Al-Mutaz King Saud University 84
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Shoaiba Desalination Plant, Saudi Arabia Process type: Multi-Stage Flash Distillation (MSF) Estimated project cost: $1.06 billion Population served: 1.5 million Product water output: 74,000m/day (Phase 1); 450,000m/day (Phase 2) Final total production capacity: 150 million m/year Project Timeline: Construction started: 1997 Phase 1 completed: August 2000, Phase 2 completed: March 2003
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ChE-413-MSF Multi-Stage Flash Desal Ination

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1/10/2011

ChE-413: Desalination and Water treatment

ChE-413: Desalination and Water treatment

Water Desalination Multi-Stage Flash (MSF)

Once Through MSF

Chemical Engineering Dep.

ChE-413: Desalination and Water treatment

ChE-413: Desalination and Water treatment

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

ChE-413: Desalination and Water treatment

ChE-413: Desalination and Water treatment

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

ChE-413: Desalination and Water treatment

ChE-413: Desalination and Water treatment

Principle of MSF - energy

Plant operation has improved with

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

ChE-413: Desalination and Water treatment

ChE-413: Desalination and Water treatment

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

ChE-413: Desalination and Water treatment

ChE-413: Desalination and Water treatment

MSF Flashing stage

MSF Flashing stage

Air Buffle Vent Line

Distillate duct Outlet Distillate

Outlet Brine Flashed off Vapor

Inlet Brine Brine Pool

ChE-413: Desalination and Water treatment

ChE-413: Desalination and Water treatment

MSF Flashing stage

MSF Flashing stage

Vent line Distillate Duct

Inlet Distillate Distillate Tray

Outlet Brine Brine Pool Orifice Weir

King Saud University

Chemical Engineering Dep.

Prof. Ibrahim S. Al-Mutaz

King Saud University

ChE-413: Desalination and Water treatment

ChE-413: Desalination and Water treatment

Single Stage Flash Desalination

Single Stage Flash Desalination