THE CASE FOR AND FEASIBILITY OF VERY HIGH RECOVERY SEA WATER REVERSE OSMOSIS PLANTS by IRVING MOCH,

JR. I. MOCH & ASSOCIATES WILMINGTON, DELAWARE

ABSTRACT Sea water desalination by reverse osmosis (SWRO) has been in refinement since its inception some 25 years ago. Major efforts have been directed at improving membrane life, productivity and salt rejection. In the early 1980s, plants were operated, generally, at recoveries of 25% and pressures up to 1000 psig, producing water meeting WHO standards of less than 500 mg/L TDS and chloride under 250 mg/L. The manufacturer warranted these facilities for 2 or 3 years. Salt rejections were in the 98.5% to 99% range. Plant energy consumption was about 45 Kwh/Kgal (12 Kwh/m3). Over the past decades, many changes have taken place: membrane life has expanded such that suppliers will warrant a 10 or more year life at a fixed replacement rate. Product TDS can be 300 mg/L, at recoveries of 40% to 50% with system pressures raised to 1200 psig. Importantly, energy consumption has been halved to about 21 Kwh/Kgal (5.5 Kwh/m3) as a result of higher conversions and the use of energy recovery devices. Still it is apparent that, in today's market, 75% to 85% of the total cost of water (TCW) is energy use and capital amortization. The remaining costs; membrane replacements, chemicals, labor and supervision, and maintenance parts, together, amount to only 20% to 25% of the TCW. Thus, energy reduction becomes the main focus to improving desalting economics. A significant way to lower energy is to further raise system conversion. However, in doing this, the brine osmotic pressure begins to approach the applied pressure and this, in turn adversely affects product flow and quality. SWRO facilities are not designed efficiently; that is, they are limited by this mechanically derived differential between the osmotic and applied pressures. In brackish water, designs are based on the solubility product of the least sparingly soluble salt, as modified by antiscalants. Up to now, commercial membranes are not permitted to operate above 1200 psig (82.7 barg). Thus, in sea water, the osmotic pressure limitations are controlling versus the desired thermodynamic water chemistry. Recently, membranes have been commercialized, which can operate at very high recoveries (55% to 65%), thus allowing SWRO plants to be at their most efficient level. The modules are capable of performing at high pressure [up to 1400 psig (96.6 barg)] with a salt rejection of 99.7% (58,00 mg/L feed). This paper discusses this innovation and its effect on energy consumption and capital in a Caribbean Sea plant. Data obtained from other areas of the world are also reviewed.

INTRODUCTION
Performance of reverse osmosis (RO) plants over the past three decades has been noted for improvements in product quality and quantity, membrane life and, in particular, energy consumption. These changes have been very noticeable in brackish water desalination (BWRO) with the introduction of the composite membrane in the mid 1980s. Today, these membranes are capable of operation at pressures as low as 45 psig (3 barg), which, in some cases, is only slightly above the osmotic pressure of the brine stream leaving the RO modules. BWRO systems operate at recoveries, which are limited only by the solubility of the least soluble salt; even these conversions can be increased with the commercialization of more efficient antiscalants. In sea water, such dramatic improvements have not been as manifested, although membrane salt rejections have improved from 98.5% to over 99.6%. In earlier days, to achieve drinking water of less than 500 mg/L and 250 mg/L chloride, conversions were limited to 35% for the waters of the oceans and Caribbean and Mediterranean Seas and to less than that for the Arabian Gulf and Red Sea. Further, total system energy consumption was very high at around 45 Kwh/Kgal (12 Kwh/m3). With the introduction of energy recovery equipment (ERD), designed to recover most of the high pressure energy of the brine stream, the power consumption was reduced about 30,4. Most early plants used Francis turbines (reverse running pumps) to recover this spent energy. These units, however, are not very efficient, usually operating at around 75% efficiency. Parallel to the advent of ERDs, membrane manufacturers, spiral and hollow fiber configurations, were quite successful in improving the performance of their product. Life expectancy of the membranes has moved from 2 to 3 years to today's over 5 years and, in particular, salt rejections increased to over 99.6%. As a result of this work, system conversions were increased to the 40% - 50% range (depending on the sea water salinity) with permeate still meeting customer drinking water standards. Increasing the conversion of a RO system is very important cost-wise, as the higher the recovery, the less is the amount of water, which has to be pressurized. Thus, the energy used to do this function is reduced, as is the capital cost of the pump, pretreatment equipment, intake and outfall infrastructures and chemical additive systems. These efforts to date have lowered the energy consumption to about 21 Kwh/Kgal (5.5 Kwh/m3). Economically, when evaluating the Total Cost of Water (TCW), it is seen that energy and amortization, collectively, amount to about 75% to 85% of the TCW. Thus, membrane replacements (basically life), chemical consumptions, labor and supervision and maintenance parts are, individually, relatively small items in the TCW. Certainly, if a plant is operating inefficiently, these items can grow to significant values; but experience has shown that for plants, which have been properly designed and with well-trained operators, operating problems are minimal and costs for these items are well contained within the 15% to 25% factor allocated in the TCW ledger.

It is apparent from this discussion that further efforts must be directed towards lowering the energy utilization and through it, reduce the capital expenditures of associated equipment. Table 1 shows a typical breakdown for capital and operating costs for a 6 MGPD (22,710 m3/d) plant in the Caribbean running at a conversion of 40% with the source water obtained from an open sea intake. Such a facility can be installed, with minor changes, in the Atlantic and Pacific Oceans and Mediterranean Sea. For the Red Sea and Arabian Gulf, where the feed water salinity is higher and conversions lower, costs for a comparable facility might be increased up to 15% and, similarly, energy would be 20% to 30% higher. Table 1 Energy and Capital Costs for a 6 MGPD (22,710 m3/d) Caribbean SWRO Plant, Recovery @ 40% Capital Cost, MS Site Development Intake and Outfall Pretreatment High Pressure Pump and ERD Membranes Product Pump Other TOTAL 0.7 3.0 12.9 4.0 4.9 0.6 2.2 28.3 $4.72/GPD $1,246/m3/d Energy Consumption, Kwh/Kgal (Kwh/m3) --1.21 (0.32) 1.70 (0.45) 14.92 (3.94) --0.72 (0.19) 1.48 (0.39) 20.0 (5.29)

The TCW for the above mentioned facility would be $4.97/Kgal (($1.3 l/m3) of which energy, at $0.15/Kwh, is 61% of the TCW and capital amortization (20 years at 8%/yr) is 26%. It is interesting to note that, if the power cost were $0.08/Kwh, then the TCW would be $3.55/Kgal ($0.94/m3) with energy and capital amortization being 46% and 36% respectively of the TCW.
DEVELOPMENT NEED

It is apparent from the above table that, if sea water RO is to fulfill its destiny, there must be some further improvements made in the energy consumption. Longer lived membranes, improved operations and automated plants are interesting objectives, but they will not fundamentally affect the "bottom line" to the extent necessary to make SWRO a commodity technology. In examining the factors involved in energy use, over three quarters of it is associated with the high pressure pump and ERD. The above typical plant is operating at a 40% recovery, which means that well over half the energy is tied up in the brine stream with only about

85% of it recoverable. Also, sizing of plant equipment before the RO section is dictated by the water flow to the membranes. In other words, about 70% of the equipment and a significant portion of the facility's footprint is a function of the volumetric flow of feed water. Membrane technology limitations are a major factor in causing these poor economics. To obtain a desired production rate and product quality, a plant is designed at a recovery in which there is about a 300 psi (21 bar) differential between the brine osmotic pressure and the applied pressure present in the last element of a multi bundle pressure vessel. Increasing the recovery beyond a certain limit, therefore, while desirable in reducing energy consumption and fluid flow, cannot be accomplished effectively because the osmotic pressure due to the high recovery will reduce flow and at the same time adversely affect product quality. What is needed to obtain increased recoveries is a membrane of improved salt rejection and one, which has the capability of withstanding these higher pressures. The latter is a requirement in order to maintain or optimize the differential between the applied pressure and the brine osmotic pressure. There is an economic balance between a lower driving force (smaller differential between applied and osmotic pressure) and installing more membrane area. To even consider such options, the membrane has to have superior salt rejection and, structurally, is modified to withstand high pressure operation. There is a limit to how high the system recovery can go. The restriction is the point where the least soluble salt precipitates. Calcium carbonate is the least soluble salt in sea water, but its precipitation can be (and is) controlled by pH. The next compound to cause potential problems is calcium sulfate. Current technology suggests that a brine salinity of 90,000 mg/L is as high as you can go before CaSO4 will precipitate. Because SWRO operations are, today, so far removed from this value, the use of antiscalants to obtain even higher levels of brine salinity has not been effectively studied. In summary, to improve a SWRO plant's costs and energy use by operations at high recoveries (brine TDS about 90,000 mg/L), a new membrane system is required which has to have: Improved salt rejection Element intemals which have been redesigned to withstand high pressures Operating parameters in which these high pressures result in lower power costs
SATISFYING THE NEED

A number of the membrane suppliers have been working actively on this development need. Systems are now able to operate at pressures up to 1200 psig (82.7 barg), which could increase the recovery of our typical plant to 50%. One company, Toray Industries, is currently marketing a product with capability of operation at 1400 psig (96.6 barg). At this high pressure, the system conversion can be set at 60% (90,000 mg/L brine with a feed salinity of 36,000 mg/L), which would reduce the feed flow for this 6 MGPD (22,710

m3/d) Caribbean site to 6,944 gpm (26.3 m3/min) from 10,417 gpm (39.4m3/min), a 50% reduction. The membrane for this system is model SU 820 BCM (see Figure 1). The plant design for a 60% recovery/90,000 mg/L brine involves staging -- that is, the brine from the first stage (array) is the feed for the second array. In this manner, the fluid flow rate through the membrane elements is adequate to achieve a proper liquid distribution within the bundle. While the energy consumption of this arrangement is an improvement, it can be costly in that all the high pressure piping, fittings etc. would have to be designed for a rating of 1400 psi (96.6 bar). A more practical configuration is that shown in Figure 2. Here, the pump pressurizes the feed water to, say 1000 psig (69 barg) with the membranes in the first stage being today's conventional models. The brine from the first array, which is operating, say at a 40% conversion, is then boosted about 400 psi (27.6 bar) to become the feed for the ultra high pressure modules in the second stage. The second array, recovery is 33%, making the total system conversion 60%. The brine from the second stage units is then processed through an ERD. While a booster pump is feasible, there is still a second energy input to the plant, albeit small, as only 60% of the feed is further pressurized. An added modification to the system is to eliminate the booster pump completely and employ a hydraulic turbocharge (Figure 3). The turbocharger (TURBO) has been specifically designed for RO systems. In principle, the unit transfers hydraulic energy from the RO concentrate to a feed stream. It is entirely powered by the brine; it has no electrical cooling or pneumatic requirements. It is an integral turbine driven centrifugal pump. The turbine section is a single stage radial inflow type (similar to a reverse running pump). The pump portion is a single stage centrifugal with its impeller mounted on the turbine shaft. The.energy transfer results in a feed pressure increase. The entire rotating element is dynamically balanced as a complete unit. The unit has a by-pass around it, which enables the operator to control and balance the flow. This by-pass is needed in situations where the second stage brine flow is more than that which is needed for the boost pressure. This arrangement is particularly important in situations where the feed is subject to large temperature variations, suchas are usually seen in surface intake plants. In a system where the feed temperature varies, the first stage pressure is adjusted, accordingly, to meet production requirements. (When the feed temperature increases, the RO production improves at a rate of about 3%/deg C; a lowering of the feed pressure compensates for this higher flow.) These variations in feed pressure are also passed through to the booster section where the by-pass around the TURBO is adjusted to handle these fluctuations. Thus, it is possible that not all the second stage brine is employed to boost pressure. In order not to waste this non-used brine, the extra flow from the second array brine is processed through a small ERD, such as an impulse turbine (Pelton Wheel), so as to be sure that all the fluid pressure is effectually utilized and/or recovered. Where a TURBO is employed, in practice, it has been found that the best combination of first stage - second stage recoveries appears to be a 40%/33% ratio. In this way, the salinity of permeates emanating from each stage assures the customer of a satisfactory

product quality. In our typical case, Table 1 would be reformulated using the new ultra high pressure membranes as follows: Table 2 Energy and Capital Costs for a 6 MGPD (22,710 m3/d) Caribbean SWRO Plant Utilizing The Advanced Membrane Development Plus TURBO For Booster Pressure Total System Recovery @ 60% Capital Cost, M$ Site Development Intake and Outfall Pretreatment High Pressure Pump, TURBO, Impulse Turbine Membranes Product Pumps Other TOTAL 0.6 2.0 10.1 3.1 5.6 0.6 1.9 23.9 $3.98/GPD $1052/m3/d Energy Consumption, Kwh/Kgal (Kwh/m3) --0.72 (0.19) 1.13 (0.30) 13.55 (3.58) --0.72 (0.19) 1.29 (0.34) 17.4 (4.60)

A further advancement of this new technology is the retrofitting of an existing plant to both increase capacity and improve overall energy consumption. Here, an existing plant is operating with or without energy recovery and is usually a one stage facility. The brine from this array would be directed to a TURBO where the pressure is increased to a level sufficient to meet the new production needs of the customer. This higher pressure feed is then used in the second stage SWRO, employing the ultra high pressure membranes, at a conversion sufficient for its brine to be up to about 90,000 mg/L. In general, this second stage conversion will operate at a conversion of 25% to 35%, which means the plant capacity will be improved by as much as 50%. In such a retrofitted facility, the absolute energy use will be unchanged; the consumption, as measured as Kwh/Kgal or Kwh/m3, will be reduced 50% if no ERD was originally present. If an ERD were originally installed, it would be de-staged; the new plant's energy consumption would be reduced about 15%. The added capital to obtain this capacity increase would be only for the new membranes, TURBO and associated racks, high pressure piping and instrumentation. The intake and out fall infrastructures, pretreatment etc. would be untouched. The product delivery and posttreatment section would, of course, have to be expanded for the new capacity. To obtain the same increase in capacity, conventionally, the plant would have to expand or duplicate all equipment pieces, adding significantly to the capital costs. As noted earlier, the maximum brine salinity from the second stage should be under 90,000 mg/L to be sure calcium sulfate does not precipitate. In our typical example, where the feed TDS is 36,000 mg/L, the maximum recovery permitted is thus 60%. This

maximum conversion would be less, say, in the Arabian Gulf where the feed TDS is about 45,000 mg/L. Here the highest recovery possible would be 50% - about 35% in the first stage, 23% in the second stage. It is probable that with time, antiscalants will be certified for use in sea waters with salinities in the 90,000+ mg/L range. When these chemicals have been fully proven, the maximum permissible brine TDS could be 110,000 mg/L or more (67+% conversion in the typical case). The development just discussed is fundamental for SWRO. Minimizing energy consumption by high conversions means that the determinant for SWRO is control by water chemistry. Today, it is by osmotic pressure limitations.
D E M O N S T R A T I O N SITES

Demonstration of the functionality of this new membrane and system at recoveries of 60% are shown in Table 3. Table 3 Sea Water RO Plants Utilizing Ultra High Pressure Membranes And Hydraulic Turbocharger Plant Ehime, Japan Mas Palomas Spain Ibiza, Spain Mas Palomas 1 Spain KAE Curacao 1 Caribbean KAE Curacao 2 Caribbean Mas Palomas 2 Spain Mas Palomas 3 Spain Tortola Caribbean Muroto Japan Type Full Plant Retrofit Retrofit Retrofit FUllPlant Full Plant Retrofit Retrofit Retrofit Full Plant Capacity 55 KGPD (210 m3/d) 71 KGPD (270 m3.d) 71 KGPD (270 m3/d) 1.2 MGPD (4500 m3/d) 1.5 MGPD (5700 m3/d) 1.5 MGPD (5700 m3/d) 1.2 MGPD (4500 m3/d) 1.2 MGPD (4500 m3/d) 180 KGPD (690 m3/d) 330 KGPD (480 m3/d) Recovery 60% 60% 60 % 60% 57% 57% 60% 60% 60% 60% Start-up Date October 1996 October 1997 January 1999 March 1999 September 1999 October 1999 December 1999 February 2000 November 1999 March 2000

Figures 4, 5 and 6 show pictures of these above operating facilities. In all cases, the feed salinity is about 36,000 mg/L. Temperatures vary from about 20 deg C in Japan to 30 deg C in the Caribbean. Feed water sources are both from wells and the open sea. In all instances, the permeate quality is about 250 mg/L to 350 mg/L with product salinities

from the second arrays somewhat above those of the first stages when the membranes are of equivalent ages. Energy consumption for the RO section is essentially as noted in Table 2. Except for the Ehime plant (Toray's manufacturing and development facility), operations are under the control of local personnel. At Tortola (well feed), the addition of the ultra high pressure membranes plus hydraulic turbocharger (BCS) increased capacity 35% and reduced power consumption 69% to 13.2 Kwh/Kgal (3.5 Kwh/m3). The plant initial installation had an impulse turbine for ERD; a later 47% capacity increase occurred without using an ERD. This last capacity change installed the BCS, but did not replace the original membranes in the first 2 units. Even with these aged modules in operation, the total system permeate is under 400 mg/L. In Curacao (open sea intake), where the membranes are new, the first stage pressure is only 826 psig (57 barg) and the second stage BCS pressure is 1044 psig (72 barg). Permeate quality, at these low pressures, is 311 mg/L. The energy consumption, ignoring pretreatment, is 11.9 Kwh/Kgal (3.15 Kwh/m3). This plant has multi media filtration and an impulse turbine to process the brine not utilized by the BCS. CONCLUSIONS The need to reduce energy consumption and capital costs is fundamental to the market growth of SWRO. Programs are in progress by many to achieve these goals. Leading the way in one such successful development has been the commercialization of a new ultra high pressure membrane (BCM) by Toray Industries and the employment of it together with a hydraulic turbocharger in a second desalination stage. This energy saving installation, called Brine Conversion System (BCS), permits operation at a total plant conversion such that the second stage brine concentration is about 90,000 mg/L (limited only by CaS04 precipitation). The advantage of the BCS, in comparison to a conventional RO plant, is: A. Economic 1. Energy consumption reduced about 15% when compared to a plant using a ERD and about 50% where no energy recovery is employed 2. Plant capital costs down 10% to 20% 3. Plant installation area, at a given capacity, reduced more than 20% 4. Pretreatment and intake equipment sizes decreased 33% 5. Maintenance cost lowered 15% 6. Total Cost of Water reduced 10 to 20%
B. Environmental

1. Reduced intake and outfall flows limit disruptions to ecosystem 2. Lower energy consumption means less CO2 emission to atmosphere 3. Higher brine discharge concentration can be controlled by outfall diffusers and deep well injections

FIGURE l HIGH PRESSURE M O D U L E BY TORAY

Structure of RO element

Structure of Brine Conversion Seawater RO Membrane

Selwator

, Permeate

.ayer~'~ tamid~j

Brine Seal ~

L BrineWater
d Water Spacer

FoodWater ~'~ FEd Water ~ S ~ : ~ ' ~ Permeate

R O Membrane Permeate Spacer

Product Water

FIGURE 2 HYDRAULIC T O R B O C H A R G E R Pump Impeller

Feed

Center

Beating

FIGURE 3
BRINE CONVERSION SYSTEM

PUMP ~OTOR

l, ~%--_1
/-\
IMPULSE TL'RBINE

l ,,(

FIGITI~I: 4
T E S T P L A N T , E t l i M E , J A P A N - 55 KGPD (210 M3/D)

FIGURE $ T'fPICAL MAS PALO.MAS SECOND STAGE P L A N T - 1.2 MGPD (9,000 M3/D)

FIGURE 6 TWO KAE CURACAO DESALINATION LINES - 3 . 0 MGPD (11.400 M3/D)