Influence of Pumps and Energy Recovery Systems on the Specific Energy Consumption in Seawater Reverse Osmosis Facilities

Uwe Dortmund (Presenter) Wolfgang Kochanowski Stephan Bross Gerhard Schwarz KSB Aktiengesellschaft 67227 Frankenthal (D)

II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

Core Hydraulic System

Water Costs Energy Consumption Maintenance Reliability

The Core Hydraulic System is the Arrangement of a High Pressure Pump/Recirculation Pump and an Energy Recovery System (ERS)
2 II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

Schematic Representation of different Core Hydraulic System

QPermeate = 5.000m3/d
Permeate 40% Permeate 40% HP-Pump 100% HP-Pump 100% Turbine Brine 60% HP-Pump 100% Turbocharger Brine 60% Permeate 40%

Brine 60%

No Energy Recovery System E 5-6 kWh/m3

Recirculation Pump 60% HP-Pump 40%

Turbine Solution E 3.5 kWh/m3

Permeate 40%

Turbocharger Solution E 3.2 kWh/m3

Pressure Exchanger

Isobaric Pressure Exchanger Solution E 2.4 kWh/m3

100%

Brine 60%

Energy Recovery Systems decrease the specific Energy Consumption

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II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

Individual Losses to be considered in the Design of the Core Hydraulic System

1 4
Recirculating Pump Recirculating Pump Pressure Exchanger Pressure Exchanger Feed Water Pump Core Hydraulic System

2 Membrane Array 3 4

HP Pump HP Pump

Calculating of specific Energy Consumption includes all losses of the Components inside the Hydraulic System
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II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

Q - p Diagram of the Core Hydraulic System ( = 0.4)

p [bar]

p p - pv

QRecirculating
Pump

pv p = SWRO Process required Pressure pv = Pressure Loss Array, Valves, Pressure Exchanger

Q HP HP Pump Q Permeate
Pump

QPressure
Exchanger

60%

QFeed Water Pump

40% 100% Q [m3/h]

Power Share of the Components of Core Hydraulic System

5 II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

Operating Conditions
Plant Parameter Plant Size: Qpermeate Temperature: T Salinity: TDSFeed Required Pressure: p Pressure Loss: = 5000 m3/d = 20 C = 38,500 ppm = 65 bar Efficiencies HP Pump (turbocharger) HP Pump
(turbine and pressure exchanger solution)

= 84% = 82% HGM-RO Selection Chart = 85% = 82% = 94% = 95%

H [m]
650

Turbine Recirculation Pump Pressure Exchanger Electrical Motors

pMembrane = 1,0 bar

The Program calculates the real Energy Consumption for different Operating Conditions or different Components

210

II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

Specific Energy Consumption and Water Quality - Variation of HP-Efficiency 4.0 3.5 HP=82% 3.0 2.5 HP=82% 2.0 TDSPermeate 1.5 1.0 0.25 300 200 0.60
II. International Seminar Desalination Antofagasta / Chile

800
HP=80%

HP=84% HP=80%

600
70,000 $US/a Pressure PE-Kit Exchanger Kit

500 400

HP=84%

0.30

0.35

0.40 0.45 Recovery Rate

0.50

0.55

Permeate Salinity TDS [ppm]

Specific Energy E [kWh/m3]

Turbine-Kit

700

5. Session Title = Operation and Maintenance of Desalination Plants

Specific Energy Consumption and Water Quality - Variation of ERS-Efficiency 4.0 3.5 T=85% 3.0 2.5 2.0 1.5 1.0 0.25
PE=92% PX=92% PE= =94% 94%
PX

800 Permeate Salinity TDS [ppm]

8 II. International Seminar Desalination Antofagasta / Chile

Specific Energy E [kWh/m3]

T=83%

Turbine-Kit
T=87%

700 600

PX=96% PE=96%

Pressure PX-Kit PE-Kit Exchanger Kit

500 400

TDSPermeate

300 200 0.60

0.30

0.35

0.40 0.45 Recovery Rate

0.50

0.55

5. Session Title = Operation and Maintenance of Desalination Plants

Energy Savings by Efficiency Improvements of the HP Pump and ERS of a 5000 m3/d RO Plant
Energy Savings [$US/a]
14000 12000 10000 8000 6000 4000 2000 0 Variation of HPVariation of HP Efficiency of 2% Efficiency Variation of ERS ERSVariation Efficiency of 2% Efficiency
12242 4897 4747 5933 Turbine -Kit PX-Kit Pressure Exchanger-Kit

1%-Reliability Improvement

Higher Energy Cost:

- Turbine Kit - Pressure Exchanger Kit

288.000 $US/a 218.000 $US/a

Higher Reliability saves more Money than optimized Efficiencies in SWRO

9 II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

SalTec:
Hydraulic System for Reverse Osmosis (RO) As easy as one, two, three: the key components
SalTec System Hydraulic System for seawater desalination by reverse osmosis with three key components. - SalTec DT pressure exchanger - HGM-RO high-pressure pump - RPH-RO booster pump KSB perfectly matches all components to create one hydraulic system that markedly minimizes energy consumption.

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II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

SalTec:
Working Principle
HP Brine HP Brine Inlet Inlet

HP Feed HP Feed Outlet Outlet

vv==0.98 m/s 0.98 m/s

HP HP

Rotating Rotating Valve Valve

LP LP

LP Feed LP Feed Inlet Inlet

vv==1.02 m/s 1.02 m/s Check Valves Check Valves

Step Motor Step Motor

LP Brine LP Brine Outlet Outlet

-The Pressure Exchanger operates trouble free controlled by the speeds of the recirculation pump and the step motor controlled rotating valve - KSB is the only manufacturer to recreate the tough conditions of a desalination plant in its own labs
11 II. International Seminar Desalination Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

Reduction of Water Costs with KSB SalTec s

Save on energy and water, for low life cycle costs
Virtually loss-free energy recovery Mixing by volume of flow, 1,0% through pressure exchanger Constantly high efficiency during long term operation Ideally matched components from one single source No efficiency drop over time Automatic adjustment to changed operating conditions Constant salt concentration upstream the membrane High operational availability Anti corrosive duplex stainless steel material No vibrations, less noise Low investment costs All components from one single source Wear-free operation because of - low speed - SIC bearings No lubrication required No hydraulic drive system required No risk of site contamination from oil Wide operating range

Saltec-System: = Keep specific energy consumption down to low levels = lowest life cycle costs II. International Seminar Desalination
12 Antofagasta / Chile

5. Session Title = Operation and Maintenance of Desalination Plants

Features of Advanced High Pressure Feed Pump Design HGM-RO

4 Due to static pressure difference acting on the shaft, reliable in operation as well as in transient operating conditions. 4 Compact design 4 Disassembly / reassembly from either side 4 Wetted metallic parts made of duplex material Axial inlet: 4 Minimum NPSH required Medium-lubricated axial bearing for start-up / stop 4 only one mechanical seal required Proven hydraulics from KSB boiler feed pumps guarantee highest efficiencies Medium-lubricated radial bearings: 4 extremely short distance between bearings for maximal smooth running 4 no oil/grease necessary 4 reduced maintenance

Balancing by patented, selfadjusting balancing device ensures highest efficiencies

Dry shaft

Feet and flange for main tie bolts separate

II. International Seminar Desalination Antofagasta / Chile

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5. Session Title = Operation and Maintenance of Desalination Plants

Thank you very much for your attention

Uwe Dortmund
Dipl.-Ing. (TU) Senior Manager Sales and Engineering Desalination and Seawater Intake

KSB AG Johann-Klein-Str. 9, 67227 Frankenthal, Germany Tel. +49 6233 86-3148 Mobile +49 173 32 99 745 E-mail: uwe.dortmund@ksb.com
II. International Seminar Desalination Antofagasta / Chile

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