Download - KSB Influence of Pumps on Energy Consumption
II. International Seminar Desalination Antofagasta / Chile1
Influence of Pumps and Energy Recovery Systems on the Specific Energy Consumption in
Seawater Reverse Osmosis FacilitiesUwe Dortmund (Presenter)
Wolfgang KochanowskiStephan Bross
Gerhard SchwarzKSB Aktiengesellschaft67227 Frankenthal (D)
II. International Seminar Desalination Antofagasta / Chile2
5. Session Title = Operation and Maintenance of Desalination Plants
Core Hydraulic System
The Core Hydraulic System is the Arrangementof a High Pressure Pump/Recirculation Pump and an Energy Recovery System (ERS)
Water CostsEnergy Consumption
MaintenanceReliability
II. International Seminar Desalination Antofagasta / Chile3
5. Session Title = Operation and Maintenance of Desalination Plants
Schematic Representation of different Core Hydraulic System
Energy Recovery Systems decrease the specific Energy Consumption
Permeate 40%
HP-Pump100% Brine 60%
No Energy Recovery SystemE ∼ 5-6 kWh/m3
Permeate 40%
HP-Pump100%
Turbine
Brine 60%
Turbine SolutionE ∼ 3.5 kWh/m3
100%
HP-Pump40%
Brine 60%
Permeate 40%
Pressure ExchangerIsobaric Pressure Exchanger Solution
E ∼ 2.4 kWh/m3
Recirculation Pump60%
Permeate 40%
Turbocharger
Brine 60%
Turbocharger SolutionE ∼ 3.2 kWh/m3
HP-Pump100%
QPermeate = 5.000m3/d
II. International Seminar Desalination Antofagasta / Chile4
5. Session Title = Operation and Maintenance of Desalination Plants
Individual Losses to be considered in the Design of the Core Hydraulic System
Calculating of specific Energy Consumption includesall losses of the Components inside the Hydraulic System
Pressure Exchanger
η Pressure Exchanger
Feed Water Pump
ζ 2ζ 1
ζ 4
ζ 3
ζ 4
HP PumpηHP Pump
Recirculating PumpηRecirculating Pump
Core Hydraulic System
Membrane
ηArray
II. International Seminar Desalination Antofagasta / Chile5
5. Session Title = Operation and Maintenance of Desalination Plants
Q - p Diagram of the Core Hydraulic System (κ = 0.4)
Power Share of the Components of Core Hydraulic System
HP PumpQPressure
Exchanger
60%
QFeed Water Pump
40% 100% Q [m3/h]
p [bar]
∆p
∆p - pv
pv
Q HP Pump
Q Permeate
∆p = SWRO Processrequired Pressure
pv = Pressure Loss Array, Valves,Pressure Exchanger
QRecirculating Pump
II. International Seminar Desalination Antofagasta / Chile6
5. Session Title = Operation and Maintenance of Desalination Plants
Operating Conditions
H [
m]
210
650
The Program calculatesthe real Energy Consumptionfor different Operating Conditions or different Components
Plant Parameter Efficiencies
Plant Size: Qpermeate = 5000 m3/d ηHP Pump (turbocharger) = 84%
Temperature: T = 20 °C ηHP Pump = 82%
Salinity: TDSFeed = 38,500 ppm (turbine and pressure exchanger solution)
Required Pressure: ∆p = 65 bar ηTurbine = 85%
Pressure Loss: ∆pMembrane = 1,0 bar ηRecirculation Pump = 82%
ηPressure Exchanger = 94%
ηElectrical Motors = 95%
HGM-RO Selection Chart
II. International Seminar Desalination Antofagasta / Chile7
5. Session Title = Operation and Maintenance of Desalination Plants
Specific Energy Consumption and Water Quality- Variation of HP-Efficiency -
0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60Recovery Rate κ
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Sp
ecif
ic E
ner
gy
E [
kWh
/m3 ]
200
300
400
500
600
700
800
Per
mea
te S
alin
ity
TD
S [
pp
m]
ηHP=80%ηHP=82% Turbine-Kit
ηHP=84%
ηHP=80%ηHP=82% PE-Kit
ηHP=84%
TDSPermeate
70,000 $US/aPressure
ExchangerKit
II. International Seminar Desalination Antofagasta / Chile8
5. Session Title = Operation and Maintenance of Desalination Plants
Specific Energy Consumption and Water Quality- Variation of ERS-Efficiency -
0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60Recovery Rate κ
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Sp
ecif
ic E
ner
gy
E [
kWh
/m3 ]
200
300
400
500
600
700
800
Per
mea
te S
alin
ity
TD
S [
pp
m]
ηT=83%ηT=85%
Turbine-Kit
ηT=87%
ηPE=92%
ηPE= 94%
PE-Kit
ηPE=96%
TDSPermeate
PX-KitηPX=92%
ηPX=94% ηPX=96%
PressureExchanger
Kit
II. International Seminar Desalination Antofagasta / Chile9
5. Session Title = Operation and Maintenance of Desalination Plants
Energy Savings by Efficiency Improvements of the HP Pump and ERS of a 5000 m3/d RO Plant
Higher Reliability saves more Money than optimized Efficiencies in SWRO
12242 4897 4747 5933
0
2000
4000
6000
8000
10000
12000
14000
Variation of HP-Efficiency
Variation of ERS-Efficiency
Turbine-KitPX-Kit
1%-Reliability Improvement
En
erg
y S
avi
ng
s [$
US
/a]
Higher Energy Cost: - Turbine Kit 288.000 $US/a- Pressure Exchanger Kit 218.000 $US/a
Variation of HPEfficiency of 2%
Variation of ERSEfficiency of 2%
Pressure Exchanger-Kit
II. International Seminar Desalination Antofagasta / Chile10
5. Session Title = Operation and Maintenance of Desalination Plants
SalTec®:Hydraulic System for Reverse Osmosis (RO)
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.
As easy as one, two, three: the key components
II. International Seminar Desalination Antofagasta / Chile11
5. Session Title = Operation and Maintenance of Desalination Plants
SalTec®:Working Principle
-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 toughconditions of a desalination plant in its own labs
HP Feed Outlet
LP
HP
Step Motor
LP Feed Inlet
LP Brine Outlet
HP Brine Inlet
v = 1.02 m/s
v = 0.98 m/s
Check Valves
Rotating Valve
HP Feed Outlet
LP
HP
Step Motor
LP Feed Inlet
LP Brine Outlet
HP Brine Inlet
v = 1.02 m/s
v = 0.98 m/s
Check Valves
Rotating Valve
II. International Seminar Desalination Antofagasta / Chile12
5. Session Title = Operation and Maintenance of Desalination Plants
Reduction of Water Costs with KSB’s SalTec®
Save on energy and water, for low life cycle costs
Virtually loss-free energy recoveryMixing by volume of flow, ≤1,0% through pressure exchanger
Constantly high efficiency during long term operationIdeally matched components from one single sourceNo efficiency drop over timeAutomatic adjustment to changed operating conditionsConstant salt concentration upstream the membrane
High operational availabilityAnti corrosive duplex stainless steel materialNo vibrations, less noise
Low investment costsAll components from one single sourceWear-free operation because of
- low speed- SIC bearings
No lubrication requiredNo hydraulic drive system requiredNo risk of site contamination from oilWide operating range
Saltec-System:= Keep specific energy consumption down to low levels= lowest life cycle costs
II. International Seminar Desalination Antofagasta / Chile13
5. Session Title = Operation and Maintenance of Desalination Plants
Features of Advanced High Pressure Feed Pump Design HGM-ROProven hydraulics from KSB boiler feed
pumps guarantee highest efficiencies
Medium-lubricated axial bearing for start-up / stop
Feet and flange for
main tie bolts separate
Balancing by patented, self-
adjusting balancing device
ensures highest efficiencies
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
Dry shaft
Axial inlet:
4 Minimum
NPSH
required
4 only one
mechanical
seal
required
Medium-lubricated
radial bearings:4 extremely short distance
between bearings for
maximal smooth running
4 no oil/grease necessary
4 reduced maintenance
II. International Seminar Desalination Antofagasta / Chile14
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: [email protected]