Brine Management and! Zero Liquid Discharge (ZLD) Options

Transcription

1 Brine Management and! Zero Liquid Discharge (ZLD) Options Tom Pankratz Houston, Texas!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0)

2 Agenda ZLD Drivers ZLD or near- ZLD ConvenEonal Evaporators/Crystallizers Case Histories

3 ZLD Drivers Limited (or no) disposal opeons Inland desalina*on Oilfield produced water AlternaEve to NPDES PermiNng Power industry Regulatory issues Colorado River Basin Salinity control Resource recovery Water Brine Minerals

4 RelaEve Concentrate Disposal Costs EvaporaEon Pond Brine Concentrator Capital Cost Spray IrrigaEon Deep Well InjecEon Surface Water Sewer Concentrate Flow Rate source: Bureau of ReclamaEon (Mickley)

5 @"4/)A<YP<?)!<#'($49")) D/#5)/S)O"'/B"4H)JaG0 b K) &H7<'$%)O`)!"#$%) I<9()O"'/B"4H)!"#$%) O"'/B"4H)) +[) &!M])09GA))))) *]+++) Z+[) \]\++) ^-[) _+]+++) ^^[) *++]+++)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0) Treated Water

6 ZLD Energy Comparisons Low Grade Waste Heat Cost Electrical Energy Mechanical Misters No 1 2 Forward Osmosis Yes 4 1 Humidification-Dehumid Yes 3 2 Wind enhanced evap No 4 1 Membrane Distillation Yes 4 3 Electrodialysis Metathisis No 4 4 Thermal-ionic Yes 4 3 Freeze-Thaw Yes? 3 Humidification Yes 2 2 Evaporator/Crystallizer No 5 5 Treated Water

7 )) D/#5)/S)O"'/B"4H)JaG0 b K) 14<0$4H)!"#$%) I<9()O"'/B"4H)!"#$%) O"'/B"4H)) +[) &!M])09GA))))) *]+++) Z+[) \]\++) ^-[) _+]+++) ^^[) *++]+++)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0) Treated Water

8 ZLD Candidate Wastewater Wastewaters with soluble salts Cooling tower blowdown FGD scrubber purge Reverse osmosis reject Oil & gas produced water Mine wastewater Agricultural runoff Wastewaters with toxic, hard COD GasificaEon wastewater Some enhanced recovery oil & gas produced water Treated Water

9 MVC Brine Concentrator Evaporator Feed Deaerator Brine Heat Exchanger Vapor Compressor DisEllate DisEllate Pump RecirculaEon Pump source: Howden ExVel

10 U/4'"?)D<4')FB$7/4$5/4)JD4H#5$%%<6"4K) D//%<29)W$5"4) j"25) #/P4'"Q)eF)W$5"4) 14/'"##)D/2?"2#$5") D//%<29)W$5"4) T<#5)F%<0<2$5/4) D4H#5$%#) j$7/4)r/?h) M5"$0) U""?) j"25) 14<0")D/2?"2#$5") O"'<4')1P07)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0)

11 D4H#5$%%<6"4) D//%<29)W$5"4) j"25) #/P4'"Q)eF)W$5"4) 14/'"##)D/2?"2#$5") D//%<29)W$5"4) T<#5)F%<0<2$5/4) j$7/4)r/?h) D4H#5$%#) M5"$0) U""?) j"25) 14<0")D/2?"2#$5") #/P4'"Q)j"/%<$)I1!)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0) O"'<4')1P07)

12 TradiEonal Thermal ZLD System Feed Tank Heat DisEllate Exchanger Tank Brine Concentrator Vapor Compressor Crystallizer Brine Heater Vapor Compressor adapted from: GE Water

13 ZLD Specific Energy ConsumpEon Reverse Osmosis: Brine Concentration: Crystallization: 10 kwh/kgal (3.8 kwh/m 3 ) 70 kwh/kgal (18.5 kwh/m 3 ) 250 kwh/kgal (66 kwh/m 3 ) source: Veolia Water

14 ZLD OpEons Analysis Raw Water ReducEon Wastewater Reclaimed Basic Reclama+on 50% Simple Reclama+on 75% Complex Reclama+on 99% Simple Reclama+on 0% 7.3% 11.4% 14.4% 99% Complex Reclama+on 14.3% 0% 49.7% 77.8% 99.1% 97.8% Sludge ReducEon 0% 7.2% 11.1% 18.1% 8.6% Discharge Permit Compliance Direct Discharge Possible Direct Discharge Unlikely Direct Discharge Not Possible No Off- site Discharge No Off- site Discharge RecommendaEon Best OpEon Best ReclamaEon Value Not Recommended Best OpEon for 99% ReclamaEon Not Recommended O&M Staff Req d OpEx, $/d/pa, avg $3,923 $4,111 $7,316 $9,025 $12,113 O&M, NPV $13,498,939 $14,145,804 $25,172,166 $31,054,356 $41,680,278 Capital Cost $17,340,000 $27,050,000 $30,990,000 $32,019,296 $43,830,000 Total Cost, NPV $30,838,939 $41,195,804 $63,073,652 $63,073,652 $85,510,278 source: Dan Sampson / Worley Parsons (2014)

15 Evaporator/Crystallizer Challenges Expect 75 to 95% reliability Typical WTP staff can t operate ZLD systems Simple systems requires 7 to 9 extra staff Most systems don t have necessary redundancy Evaporators and crystallizers aren t garbage cans

16 California Municipal ZLD Project LocaEon: North California Prison Installed: March 2009 RO ProducEon Capacity: 406 gpm RO Feed TDS: 2,200 mg/l Evaporator Feed Flow: 155 gpm Evaporator Feed TDS: Evaporator Recovery: 97-98% Evaporator Concentrate: ~25% Total RO+ZLD CapEx: $26.5 million source: Carollo Engineers

17 California Municipal ZLD Project source: Carollo Engineers

18 California Municipal ZLD Project source: Carollo Engineers source: EPA

19 Power Plant Hybrid ZLD New York RO permeate: 55 gpm RO recovery: 65% RO feed TDS: 2,300 mg/l RO product TDS: <100 mg/l Evap feed: 30 gpm Evap feed TDS: 5,700 mg/l Evap disellate: 29 gpm ConsEtuent mg/l Sodium 320 Calcium 270 Magnesium 60 Chloride 190 Potassium 15 Sulfate 1165 Nitrate 10 Silica 10 Bicarbonate 135 CO2 25 TDS 2200 ph 7.0

20 U""?)S4/0)FYP$%<6$E/2)R$#<2) D//%<29)W$5"4)V2) D/2?"2#"4) O`)14"C'/2'"254$E/2) D$454<?9") U<%5"4) T"?<$) U<%5"4) j"25) j"25) FB$7/4$5/4)!"#P7"4("$5"4) U%$#() &$23)!"$"4$5/4) D/074"##/4) T$3"CP7) M5"$0) D4H#5$%%<6"4) I"$5) Fh'($29"4)!<#E%%$5") &$23) 1"40"$5")!<#E%%$5")!<#E%%$5") U<%5"4) 14"##) ^+[)?4H) U<%5"4)D$3") D//%<29)W$5"4)/P5)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0)

21 Hybrid ZLD Energy Advantage Hybrid ConvenEonal RO system, kwh 18 n/a Evaporator, kwh Crystallizer, kwh Total energy, kwh

22 Membrane Brine Concentrator FGD Wastewater Sosener Clarified Water Tank Media Filters WAC Polisher Changxing Power Plant 27m 3 /h 23m 3 /h 100 mg/l TDS Product Water First- pass RO RO Tank Second- pass RO Dis*llate FO Feed Saturated Brine Brine Membrane Brine Concentrator 22.3m 3 /h 27 m 3 /h Intermediate Product Packaging System Dryer Crystallizer Concentrated Draw Solu*on Diluted Draw Solu*on adapted from: Oasys Water Draw SoluEon Recovery

23 RO & FO Skids source: Oasys Water

24 Stripper Columns source: Oasys Water

25 El Paso s Kay Bailey Hutchison BWRO 12 MGD 27.5 MGD 18.5 MGD 3 MGD Reverse Osmosis Plant Airport Wells Ft Bliss Wells Concentrate Injection Wells Treated Water

26 F%)1$#/)RWO`);<5()R4<2")O"'/B"4H )) Brackish BWRO Desalination 85% recovery Disinfection 16 MGD Potable Water 1.25 MGD 12,000 mg/l TDS ~1 MGD Desalted Water :=>?$4@A Waste Brine to AB3C"3)2$1+223$!"#$%&'()#*+ Softener Degassifier Air + CO6 :;;<0,-./0 Electrodialysis Soft brine 93% recovery 90% recovery Heater 5-D-free brine 4*5267$5)526 brine /)68-9 brine NaCl brine Brine to Mineral Production $?$75"?)S4/0Q)FWT)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0) Treated Water

27 F%)1$#/)R4<2")14/'"##<29)U$'<%<5H )) #/P4'"Q)FWT)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0) Treated Water

28 IP0<?<i'$E/2C!"(P0<?<i'$E/2)) IP0<?<i"?) D$44<"4)e$#) I"$5"4) 1$'3"?)R"?) IP0<?<i"4)!"(P0<?<i"4) D$44<"4)e$#) R4<2") 1P4")W$5"4) M$%<2")W$5"4)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0)

29 D$44<"4)e$#)Fh54$'E/2)JDeFK )) IP0<?<i"?) D$44<"4)e$#) I"$5"4) 1$'3"?)R"?) IP0<?<i"4)!"(P0<?<i"4) D$44<"4)e$#) R4<2") 1P4")W$5"4) M$%<2")W$5"4)!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0)

30 D$44<"4)e$#)Fh54$'E/2)I!I) IP0<?<i"?) D$44<"4)e$#) #/P4'"Q)e4$?<$25) I"$5"4) 9(4%"*-%& 2'3-( Dehumidified '$( 03'5-&8 1$'3"?)R"?) IP0<?<i"4) RP::%")D/%P02)!"(P0<?<i"4) 03'5-&7 R4<2") D$44<"4)e$#) To Humidifier 9"(-&2'3-( 1P4")W$5"4) 14/?P'"?)W$5"4)!"#$%&'$( 03'5-&6 1--%2'3-( *4$/0.",,/-0 :;'(5-( )$(&*+'#,-(!"#$%&"'()*+,-).)&/0)1$234$56).)5789%/:$%;$5"4<25"%='/0)

31 12,000 bbl/d CGE HDH System source: Gradiant

32 12,000 bbl/d CGE HDH System source: Gradiant

33 Low- tech OpEons

34 Mechanical Spray Evaporators courtesy MineTek & Resource West

35 WAIV High- rate EvaporaEon WAIV Open Pan mm evaporated mm Evaporated source: Jack Gilron Days Days Elapsed Treated Water

36 Summary ZLD is the last opeon It s usually more difficult and chemistry sensieve than expected It s usually more expensive than expected But, it s pracece is becoming more common than ever And there are an increasing number of opeons that should be considered