Energy Optimization in BWRO and SWRO
Energy Optimization in BWRO and SWRO
[Link]/IECR
ABSTRACT: A unified mathematical model is developed to describe both brackish water (BW) and seawater (SW) reverse
osmosis (RO) desalination processes. The model contains two dimensionless parameters: κ, quantifying the effect of retentate
pressure drop, and γ, reflecting the membrane capacity demand ratio. A γ vs. κ map derived from data obtained from RO
desalination plants worldwide is used to show that BWRO and SWRO are in completely different regions. The minimization of
specific energy consumption (SEC) is formulated and solved as a nonlinear optimization problem using representative values of γ
and κ in both BWRO and SWRO. Several computational case studies are carried out to demonstrate the differences in operating
BWRO and SWRO. Discussions are made on the effect of fractional recovery, RO configurations (single-stage, two-stage, and
two-stage with booster pump) as well as brine recirculation on SEC.
■ INTRODUCTION
Specific energy consumption (SEC), or pump energy
■ DIMENSIONLESS RO MODEL
On the basis of assumptions of Darcy’s law for mass transfer
consumption divided by water production rate, is a very and quadratic dependence of retentate pressure drop on
important topic in RO desalination.1,2 There have been velocity, the following mathematical model was derived to
significant research and development efforts in model-based describe a single-stage RO process14
analysis and optimization of RO design and operation.3−9
Model-based control has also been developed recently to dQ (x) ⎛ Q ⎞
− = ALp⎜ΔP − 0 Δπ0⎟
reduce SEC in a pilot-scale RO system10,11 dx ⎝ Q ⎠
In two previous papers, 12,13 the author provided a
comprehensive analysis of single- and multistage SWRO d(ΔP(x))
=−kQ 2
with/without energy recovery device (ERD) from first- dx
principles, based on the assumption of negligible retentate
Q (x ) =Q 0@x = 0
pressure drop. Several dimensionless parameters (γ, α, and Y)
were introduced to show the coupled behavior between ΔP(x) = ΔP0@x = 0 (1)
membrane property (area and permeability), feed conditions
(flow rate and salinity), and operating conditions (hydraulic where Q is the retentate flow rate, −dQ is the flow rate of water
pressure difference and fractional recovery). Later on, the across membrane of area dA (dA = Adx; x is the distance from
retentate pressure drop effect was explicitly accounted for in the entrance normalized by the pressure vessel length, and A is the
optimization model for both single-train and multitrain BWRO total area of all RO elements in this stage), Lp is the membrane
processes.14,15 A validation of model-based optimization results hydraulic permeability, ΔP and Δπ are the differences in
was carried out in a BWRO plant in Chino, California, and a hydraulic pressures and osmotic pressures across the
10% decrease in SEC and a substantial reduction in brine membrane, respectively. Δπ0, Q0, and ΔP0 are Δπ, Q, and
disposal cost were demonstrated.16 ΔP at the stage entrance. k is a coefficient describing the
As a continuation of the author’s previous work, this paper pressure drop along the pressure vessel in the retentate stream.
aims to utilize a unified dimensionless model to explain the Note that the pressure differential in the permeate stream is
similarities and differences between SWRO and BWRO. The typically small. More detailed assumptions and justifications of
model is based on several dimensionless parameters, including eq 1 are discussed in the author’s previous work.14 This coupled
κ, quantifying the effect of retentate pressure drop, and γ, a differential equation captures the profile of driving force and
previously derived parameter reflecting the membrane capacity water flux, and is more advanced than standard membrane
demand ratio.12 Data from both BWRO and SWRO plants projection model in literature, which uses averaged flux and
worldwide are used to show the typical ranges of γ and κ. Using driving force.
representative values of γ and κ in both BWRO and SWRO, a Defining α = Δπ0/ΔP0, γ = ALpΔπ0/Q0, κ = kQ20/Δπ0, q =
mathematical model is formulated to reduce SEC by optimizing Q/Q0, p = ΔP/ΔP0, the following equation is derived:
a dimensionless pressure parameter α. The optimal SECs in
both BWRO and SWRO using three different RO config- Received: September 18, 2013
urations (single-stage, two-stage, and two-stage with booster Revised: November 8, 2013
pump) are compared. The effect of brine recirculation on SEC Accepted: November 15, 2013
is also discussed. Published: November 18, 2013
© 2013 American Chemical Society 17241 [Link]/10.1021/ie4031083 | Ind. Eng. Chem. Res. 2013, 52, 17241−17248
Industrial & Engineering Chemistry Research Article
dp(x) relationships between p and q at the stage level and those at the
= −καq2(x) system level are shown as follows
dx
dq(x) ⎛ p(x ) 1 ⎞ i−1
= −γ ⎜ − ⎟ p(x) = pi (x) ∏ pk (k), i − 1 < x ≤ i , i = 1, 2, ..., N
dx ⎝ α q(x) ⎠
k=0
p(x ) = 1, @x = 0 i−1
q(x) = qi(x) ∏ qk (k), i − 1 < x ≤ i , i = 1, 2, ..., N
q(x) = 1, @x = 0 (2) k=0
(5)
An integration of eq 2 would provide the profiles of p(x) and
q(x) along the RO stage. The fractional recovery of water is where p0(0) ≡ q0(0) ≡ 1. The system recovery at the end of all
then calculated as Y = 1 − q(1), where q(1) is q evaluated at x = stages Y = 1 − Πi N= 1qi(i).
1, or the end of this stage. The parameters αi, γi, and κi should be updated as eq 4 is
It is seen from eq 2 that the RO system is characterized by solved sequentially from stage to stage. For example, in a typical
three different dimensionless parameters α, γ, and κ, all two-stage RO process with a 2:1 array to achieve a high system
described in the form of ratios. As discussed in previous system recovery and to maintain a relatively uniform feed flow
publications,12,13 α is the ratio of osmotic pressure difference to in each stage,14,17 A2 = A1/2, Ac2 = Ac1/2, k2 = 22k1, Δπ1 = Δπ0/
hydraulic pressure difference across the membrane at the q1(1), ΔP1 = ΔP0/p1(1), Q1 = Q0q1(1). As a result, γ2 = γ1/
entrance of the stage, and γ is the ratio of flow rate across the 2q21(1), α2 = α1/q1(1)/p1(1), κ2 = 4q31(1)κ1. Once the first stage
membrane assuming a constant drive force of Δπ0 to the is solved, α2, γ2, and κ2 are determined so that the second stage
retentate flow rate at the entrance of the stage. γ may be can be solved in a similar way. The system recovery at the end
considered as a measure of the membrane capacity demand of the second stage is calculated as Y = 1−q1(1)q2(2).
ratio. κ introduced in this work is the ratio of maximum The SEC normalized by the feed osmotic pressure, or NSEC,
retentate pressure drop (i.e., the theoretical pressure drop when is a dimensionless number12
there is no water recovery, or the retentate flow rate is always
the same as the intake flow rate) to the osmotic pressure Q 0ΔPpump
difference at the entrance of the stage. It is a measure of driving NSEC =
force loss that adversely affects the water production. According ηpump(Q 0Y )Δπ0 (6)
to fluid mechanics of channel flow, κ can be described as
follows where ΔPpump is the pressure increase across the pump, ηpump is
the pump efficiency. Note that ΔP0 = Pbp + ΔPpump − Pp, where
κ = kQ 02/Δπ0 = 2f (Lpv /DH)ρ(Q 0/Ac)2 /Δπ0 (3) Pbp is the feed pressure before pump, and Pp is the permeate
pressure. Therefore
where f is the Fanning friction coefficient, DH is the hydraulic
diameter between membrane sheets, Ac is the total cross- 1/α − (Pbp − Pp)/Δπ0
sectional area in the RO stage for retentate flow, and Lpv is the NSEC= N
total length of the pressure vessel that houses the membrane ηpump(1 − ∏i = 1 qi(i)) (7)
elements in series. Apparently, κ will reduce if more pressure
vessels are put in parallel in a RO stage, or fewer membrane The minimization of NSEC in a single- or multistage RO is
elements are enclosed in a pressure vessel. then formulated as an optimization problem as follows
The introduction of dimensionless parameters simplifies the
analysis of RO process as the results are scalable. Because 1/α1 − (Pbp − Pp)/Δπ0
BWRO and SWRO differ in Δπ0 (around 10−20 psi in BWRO min J = N
α1 ηpump(1 − ∏i = 1 qi(i))
and 390 psi in SWRO), they may exhibit different process
characteristics and require different design and operation s. t .
strategies.
Equation 2 can be easily extended to describe RO networks dpi (x)
= −κiαiqi2(x), i = 1, 2, ..., N
with complicated configurations. For example, a RO system dx
with N stages in series may be modeled as follows
dqi(x) ⎛ p (x ) 1 ⎞⎟
= −γi⎜⎜ i − , i = 1, 2, ..., N
dpi (x)
= −κiαiqi2(x), i = 1, 2, ..., N dx ⎝ αi qi(x) ⎟⎠
dx
pi (x) = 1, @x = i − 1, i = 1, 2, ..., N
dqi(x) ⎛ p (x ) 1 ⎞⎟
= −γi⎜⎜ i − , i = 1, 2, ..., N
qi(x) ⎟⎠
qi(x) = 1, @x = i − 1, i = 1, 2, ..., N (8)
dx ⎝ αi
pi (x) = 1, @x = i − 1, i = 1, 2, ..., N The optimization of a RO network with more complicated
configurations can be formulated using methods developed in
qi(x) = 1, @x = i − 1, i = 1, 2, ..., N (4) the author’s previous work.13 For a two-stage RO with
interstage booster pump, the optimization problem (neglecting
where pi and qi are defined based on the ratio of ΔP(x) and pump efficiency and assuming pbp = pp for simplicity) may be
Q(x) in RO stage i to the ones at the entrance of stage i. The formulated as follows
17242 [Link]/10.1021/ie4031083 | Ind. Eng. Chem. Res. 2013, 52, 17241−17248
Industrial & Engineering Chemistry Research Article
pi (x) = 1, @x = i − 1, i = 1, 2
qi(x) = 1, @x = i − 1, i = 1, 2
γ1 = (2/3)γtotal
γ2 = γ1/2/q12(1)
κ2 = 4κ1q13(1)
α2 ≤ α1/p1 (1)/q1(1)
−αi ≤ 0, i = 1, 2
αi ≤ 1, i = 1, 2 (9)
In eq 9, γtotal is defined based on the total area of all RO
elements in both stages (γtotal = AtotalLpΔπ0/Q0). Note that
while Atotal = A1 + A2, γtotal ≠ γ1 + γ2. Inequality constraint α2 ≤ Figure 1. γ and κ in BWRO and SWRO.
α1/p1(1)/q1(1) is included to ensure non-negative pressure
increase across the interstage pump.
The optimization models described by eqs 8 and 9 can be the osmotic pressure of seawater is at least 1 order of
solved using common constrained multivariable nonlinear magnitude higher than the one of brackish water. Current
optimization packages, e.g., fmincon in Matlab. BWRO plants are not built with a large γ because of constraints
Table 2. Comparison between Single-Stage BWRO and SWRO under typical Operation Conditions
calculation shows that a ΔP0 of 163 psi (10% lower than 180
psi in the current two-stage design) could keep the 81%
recovery with the same Q0. Therefore, the single-stage
configuration is more effective than its two-stage counterpart
in BWRO from a viewpoint of SEC (about 10% lower in this
case). However, it should be noted that the two-stage design
has a less drastic change in retentate flow per stage and less
tendency for concentration polarization36 because of a higher
velocity.
The same conclusion may be drawn for SWRO, even though
the difference between single-stage and two-stage configura-
tions is small, given the fact that κ is close to zero in SWRO.
However, it is worth pointing out that when an interstage
booster pump is used in conjunction with the two-stage design
in SWRO, it would be advantageous over the single-stage
design, according to the author’s published theoretical
Figure 5. Effect of retentate pressure drop on water recovery in an analysis.12,13 The computational analysis is based on the
industrial two-stage BWRO train without interstage booster pump. assumption κ = 0. The works also show that when γtotal < 0.2,
the optimal solution is corresponding to a zero pressure
increase in the interstage booster pump, or the two-stage
configuration is essentially one-stage. There are industrial cases
to substantialize reduced SEC in SWRO brine conversion using
interstage booster pumps.37 For example, in the SWRO plant in
Las Palmas III, Spain, an increase of 8% in the recovery of and
an improvement of 12.65% in the specific energy consumption
were observed after interstage booster pumps were installed.38
To theoretically validate whether a booster pump would
always reduce SEC for a nonzero κ in SWRO and BWRO, the
optimization problems described by eqs 8 and 9 are solved for
three different configurations (single-stage, two-stage, and two-
stage with booster pump, see Figure 8) using representative
Figure 9. Optimal (a) NSECs and (b) recoveries in BWRO for single- Figure 10. Optimal (a) NSECs and (b) recoveries in SWRO for
stage, two-stage, and two-stage with booster pump using κ = 1. single-stage, two-stage, and two-stage with booster pump using κ = 0.1.
and κ∝Q20/Δπ0. The model-predicted pressures and flow rates retentate pressure drop. However, with an interstage
based on the new values of α, γ, and κ are shown in Table 3 for booster pump, two-stage may be more energy efficient
a comparison. than single-stage in SWRO. In both BWRO and SWRO
Without ERD, the recovery predicted by the model is 90% studied in this paper, the two-stage RO without booster
(see Figure 12), implying that the pump power may be reduced pump is always no better than the other two
configurations from a viewpoint of SEC.
• In brine recirculation and/or ERD, mixing of brine and
feed may increase salinity, adversely affecting SEC. A
trade-off between increased feed salinity and increased
energy recovery should be carefully evaluated.
■ AUTHOR INFORMATION
Corresponding Author
*E-mail: minghengli@[Link]. Phone: +1-909-869-
3668. Fax: +1-909-869-6920.
Notes
The authors declare no competing financial interest.
■
α
NOMENCLATURE
Δπ0/ΔP, dimensionless
Figure 12. Effect of brine leakage in ERD on retentate pressure drop Δπ0 osmotic pressure difference across the membrane at
and recovery. entrance, dimensionless
γ ALpΔπ0/Q0, dimensionless
to maintain the same production. Without blending the fresh κ κQ20/Δπ0, dimensionless
feed with the highly concentrated brine stream, a lower osmotic π osmotic pressure, bar
pressure is maintained in the retentate. Moreover, a smaller A membrane area, m2
feed flow rate (1774 gpm instead of 2299 gpm) leads to a Ac cross-sectional area for retentate flow, m2
smaller pressure drop in the retentate stream. Both factors DH hydraulic diameter between membrane sheets, m
contribute to a larger driving force for permeate production. f Fanning friction coefficient, dimensionless
This case indicates that a trade-off between reduced driving k pressure drop coefficient, bar/(m3/s)2
force and increased energy recovery should be carefully Lp hydraulic permeability of membrane, m/s/bar
evaluated from a viewpoint of SEC when brine recirculation Lpv length of pressure vessel, m
is used. This is especially important for BWRO because the P pressure, bar
pressure drop effect is significant. P ΔP/ΔP0, dimensionless
■ CONCLUSIONS
The following conclusions are drawn based on the computa-
Pb permeate pressure, bar
Pbp pressure before pump, bar
Q flow rate, m3 s−1
tional studies of RO desalination in this work: q Q/Q0, dimensionless
Y recovery, dimensionless
■
• Even though BWRO and SWRO may be described by
the same mathematical model, their process character-
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