Hybrid RO MSF: a practical option for nuclear desalination

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1 Int. J. of Nuclear Desalination, Vol. 1, No. 1, Hybrid RO MSF: a practical option for nuclear desalination Ibrahim S. Al-Mutaz Chemical Engineering Dept., College of Engineering, King Saud University, PO Box 800, Riyadh 11421, Saudi Arabia Abstract: Hybrid RO MSF desalination combines the advantages of the high desalting performance of distillation processes and lower energy requirement of membrane processes. It allows better match between power and water requirements and enables better utilization of the power generated from MSF into the RO. Hybrid RO MSF can lead to an optimized feedwater temperature of the RO plant since is possible to use cooling seawater from the reject stage of the MSF plant as feed to RO plant. Higher feed temperature is advantageous for the RO plant since water flux of the membrane is about 2.5% higher per degree temperature rise at a fixed pressure. Various RO MSF combinations coupled with nuclear power plant were studied. The optimum hybrid RO MSF scheme will be reviewed in order to illustrate the considerable gain of this option. The potential advantages of RO MSF hybrid desalination systems with nuclear plant will be discussed. The appropriate combinations depend on the local conditions and power/water requirements. The required power to water ratio and product water quality is among the important factors determining the particular RO MSF schemes to be used. Keywords: Reference to this article should be made as follows: Al-Mutaz, I.S. (2003). Hybrid RO MSF: a practical option for nuclear desalination, Int. J. of Nuclear Desalination, Vol. 1,???. Biographical notes: 1 Introduction Total world capacity of desalinated water is about 30 million m 3 /d (7,925 mgd). The current number of desalination plants is about 12,500 plants. Most of these plants are operated with fossil fuels. Approximately 60% of the installed desalination capacity is in the Middle East. The installed capacity has been rapidly growing not only due to increasing numbers of plants but also increasing sizes of plants. The largest individual operating plant capacity is nearly 454,000 m 3 /d (119.9 mgd). The major technologies in use are the multi-stage flash (MSF) distillation process and reverse osmosis (RO). A minority of plants uses multi-effect distillation (MED) or vapor compression (VC). RO MSF hybrid plants exploit the best features of each technology for different quality products. Fujairah seawater desalination project in the United Arab Emirates consists of 284,000 m 3 /d (75 mgd) of multi-stage flash distillation and 170,000 m 3 /d (45 mgd) of seawater reverse osmosis. The hybrid system will permit the plant to maximize and balance the use of power, water consumption and water quality to produce Copyright 2003 Inderscience Enterprises Ltd.

2 2 I.S. Al-Mutaz the best performance at the lowest operating costs. The plant scheduled for start-up in June In Kalpakkam on the east cost of India, a hybrid RO MSF nuclear desalination is being considered [1]. This will include MSF plant producing 1,800 m 3 /d (0.47 mgd) and RO units producing 4,500 m 3 /d (1.19 mgd). The desalination facilities will be coupled with MWe nuclear power station. MSF plant requires about 21 tons/hr steam at around 3.5 bar and 400 kg/hr steam for ejectors at 7 bar. Steam will be tapped at 3.5 bar from a suitable point in the turbine for heating the brine in the MSF plant. The hybrid RO MSF system offers several interesting prospects for water cost reduction. Integration of MSF and RO systems at same location offers the opportunity to meet diverse requirements for product water quality [2]. MSF can produce water with high purity. The high TDS product water of RO plant can be blended with for other uses. The different rates of blending can be done depending on the type of water quality requirement. 2 Nuclear desalination experience Nuclear power plants today produce about 17% of world's power. There are about 438 nuclear reactors operating in various countries with a total net installed capacity of 353 GW(e) as of January These are of different capacities ranging from 100 to 1450 MW(e). About 32 nuclear power plants are under construction. Chernobyl 3 in Ukraine and two units at Hinkley Point A, United Kingdom were declared permanently shutdown. Integrated nuclear desalination plants have been operated in Kazakhstan and Japan for many years [3]. In Aktau, Kazakhstan, the liquid metal cooled fast reactor BN-350 has been operating as an energy source for a multi-purpose energy complex since 1973 supplying 135 MWe of electricity, about 80,000 m 3 /d (21 mgd) potable water and heat to the local population and industries. While In Japan, ten electric power companies are operating fifty-one nuclear power plants as of March The first Japanese nuclear power plant, a gascooled reactor (GCR), came into operation in The first Japanese nuclear power and seawater desalination plant started operation in 1978 at the Ohi Nuclear Power Station. The plant used a 1175 MW(e) pressurized water reactor (PWR) coupled to a MSF distillation process with a capacity of 1300 m 3 /d (0.34 mgd). Nine additional nuclear seawater desalination plants were installed by India has been engaged in desalination research since the 1970s. It has successfully operated an experimental facility in Trombay since 1984 and is planning to couple a 6300 m 3 /d (1.66 mgd) hybrid RO MSF plant to its Kalpakkam pressurized heavy water reactor (PHWR) in Tamil Nadu. Regarding the national program, China s programme on nuclear desalination involves coupling an indigenously developed nuclear heating reactor to a MED based seawater desalination plant. The first 5 MWt heating reactor has been in operation since In late 1996, South Korea launched an R and D programme for nuclear desalination. The purpose of the program primarily lies in the development of a relatively small-sized advanced nuclear reactor as an energy source for seawater desalination. The initial effort is focused on the design of a new advanced light water-cooled reactor, System-integrated Modular Advanced Reactor (SMART), which has a thermal power output of 330 MWt and utilizes enhanced safety features.

3 Hybrid RO MSF: a practical option for nuclear desalination 3 Russian Federation desalination programme was focused on development of a small power floating nuclear seawater desalination complex based on the KLT-40 reactor. The main design performance characteristics of the KLT-40 are: a thermal power up to 160 MWt, a steam production capacity up to 240 tons/hr, a steam temperature of 285 C and a steam pressure of 3.5 MPa. Canada s nuclear desalination/co-generation development programme, CANDESAL, is based on integrating a Canada Deuterium Uranium (CANDU) reactor, as a source of electrical and thermal energy, with seawater RO plant. Other countries gained large experience in nuclear desalination [3]. Argentina has also developed a small nuclear reactor design for cogeneration or desalination alone the 100 MWt Central Argentina de Reactor Modular (CAREM) which is an integral PWR. Pakistan is continuing efforts to set up a demonstration desalination plant coupled to its Karachi Nuclear Power Plant (KANUPP) reactor (125 MWe PHWR) near Karachi and producing 4500 m 3 /d (1.19 mgd). Tunisia is looking at the feasibility of a cogeneration (electricity-desalination) plant in the southeast of the country, treating slightly saline groundwater. Morocco is conducting a pre-project study with China, at Tan-Tan on the Atlantic coast, using a 10 MWt nuclear heating reactor (NHR) which produces 8000 m 3 /day (2.11 mgd) of potable water by MED plant. Egypt has launched a feasibility study of a cogeneration plant for electricity and potable water at El-Dabaa, on the Mediterranean coast. The feasibility of building a cogeneration unit employing MSF desalination technology for Madura Island in Indonesia was studied. 3 RO and MSF process description The reverse osmosis process consists of three main steps: 1 pretreatment, 2 membrane assembly system and 3 post-treatment. The purpose of the pretreatment step is to avoid any risk of clogging, fouling or scaling of the membrane. Pretreatment is an important aspect of RO system. All RO devices required pretreatment to remove the suspended solids, scalants, foulants and colloidal matter. Several types of RO membranes are commercially available. These are prepared either as flat sheet or as hollow fibers made from cellulose acetate (CA) ester or aromatic polyamide (PA). There are different ways of packing RO membranes. Of these, three configurations have been produced commercially: tubular, spiral wound (SW) and hollow fine fiber (HFF). Hollow fine fiber and spiral wound modules have proved to be appropriate for seawater and brackish water RO desalination. In the membrane system, water and small portion of dissolved salt pass through the membrane due to the application of high pressure. The flow of water and salts, Q w and Q s, across the membrane depend on many factors. The flow of water is directly proportional to the differential pressure across the membrane, P. Part of the differential pressure across the membrane had to be use to overcome the osmotic pressure across the membrane, π. On the other hand, the salt flow rate is directly proportional to the

4 4 I.S. Al-Mutaz differential salt concentration across the membrane, C. The basic mathematical relations often used in RO system are: Q w = A( P π) (1) Q s = K s ( C) (2) C p = Q s /Q w (3) S P = C p 100/C f (4) where A is the membrane permeability coefficient for water K s is the membrane permeability coefficient for salt C p is the salt concentration in the product stream C f is the salt concentration in the feed stream S P is the percentage of salt passage In the post-treatment step, product water passes through a decarbonation system, a ph adjustment system and chlorine injection to comply with the required quality and use of the product water. Calcium hydroxide with a concentration of ppm is added to the product water to adjust its alkalinity. The purpose of chlorine addition is to eliminate the presence of microorganisms during storage and distribution. MSF process has three distinct sections: heat rejection, heat recovery and brine heater. The feed water (WT) passes through the heat rejection and heat recovery sections. The fraction of brine that flashes in the first stage, W 1, is given by: W 1 = (C p (TB 0 TB 1 + BPE))/λ (5) where C p is the specific heat of water TB 0 is the flashing stream temperature at the first stage TB 1 is the temperature of the flashing brine in the first stage BPE is the boiling point elevation. λ is the latent heat of evaporation of water. The following are the basic mathematical relations in MSF system: 1 Heat balance on the feed stream: D λ = (CW + WT) C p (T w T s ) + (F + R) C p (TF 1 T w ) (6) 2 Heat balance on the flashing stream: D λ = (F + R) C p (TB 0 TBN) (7) 3 Heat balance on the brine heater: W s λ = (F + R) C p (TB 0 TF 1 ) (8)

5 4 Heat balance on the entire plant: Hybrid RO MSF: a practical option for nuclear desalination 5 W s λ = CW C p (T w T c ) + BD C p (TBN T c ) + D C p (TBN T c ) (9) 5 Overall mass balance: F = D + BD (10) where D is the distillate flow rate F is the feed flow rate CW is the cooling water flow rate WT is the total feed flow rate, WF = CW + F BD is the blowdown flow rate W s is the steam flow rate used in the brine heater R is the recycle flow rate T c is the feed water temperature T w is the temperature at the heat rejection exit TF 1 is the feed temperature at the brine heater TB n is the flashing stream temperature at the exit of last stage The following can summarize some of the technical differences between RO and MSF: 1 Seawater intake in MSF is twice that of RO. 2 Energy consumption per cubic meters in MSF is about three times that of RO. 3 Volume and area required for MSF are large compared to those required for RO. 4 Pumping energy in RO is about 25% of that required for MSF. A possible decrease in pumping consumption in RO might be while using energy recovery systems. 5 RO has no thermal energy consumption. In 22,750 m 3 /d (6 mgd) MSF about 89 MW of thermal energy is consumed. This can be very expensive if not extracted from the steam turbine. 6 Heavy foundation and extensive civil work is required by MSF due to its heavy weight. The benefits of RO verses MSF were as follows: RO flexibility to meet various water and power ratios while maintaining maximum process efficiency. Fewer corrosion problems in RO than MSF. Lower energy consumption in RO than MSF. At low fuel cost MSF will continue to be the optimum choice for large desalting plants [4]. For moderate capacities, RO offers low water cost. RO would be the correct selection if fuel costs were increased. In any case an RO MSF hybrid plant is worth considering. It gives the lowest possible water cost if it is associated with a dual plant.

6 6 I.S. Al-Mutaz 4 The hybrid RO MSF scheme The hybrid RO MSF plant aims in reducing operation and maintenance costs of the product water with an overall increase in recovery and reduction of energy consumption. Both RO and MSF plants will have common seawater intake and outfall facilities. Blending of product waters and post treatment can be shared as well. Hybrid desalination systems have potential advantages of a higher overall availability, low power demand, and improved water quality. In the hybrid RO MSF plant, the MSF process draws waste steam from the power plant and uses the energy in the steam to preheat seawater, which is then distilled in the MSF unit. The RO unit uses electricity from the power station and operates during periods of reduced power demand, thus optimizing the overall efficiency of the entire operation. Advantages of the hybrid design include: reduced energy costs and reduced capital and operating costs from reuse of shared facilities of cooling water, feedwater or steam. Figure 1 shows the optimum RO MSF hybrid process scheme. It was selected among various RO MSF coupling combinations with power plant. Figure 1 Optimum RO MSF hybrid process scheme. This hybrid scheme allows an increase in the RO productivity. The rate of water permeation through the membrane increase as the feed water temperature increases since the viscosity of the solution is reduced and higher diffusion rate of water through the membrane is obtained [5]. Increasing feed water temperature will yield lower salt rejection or higher salt passage due to higher diffusion rate for salt through the membrane [6]. The change in the permeate flux with temperature can be described by the following Equation:

7 Hybrid RO MSF: a practical option for nuclear desalination 7 TCF = exp(k*(1/(273 + t) 1/298)) (11) where TCF is temperature correction factor, K is a constant characteristic for a given membrane material, and t is feed water temperature in degrees Celsius. In this Equation, a temperature of 25 C is used as a reference point, with TCF = 1. The rate of change in permeate flux is about 3% per degree. Alternatively, the temperature correction factor, TCF, can be expressed as follows: TCF = a(t 25) = flux at t C/flux at 25 C (12) where a is constant between and Table 1 shows the expected increase in the flux due to temperature rise with reference to 25 C. Table 1 Expected increase in flux due to temperature rise Temperature, C TCF % Increase in flux Coupling RO MSF with nuclear plant Desalination plants require significant amounts of energy for their operation. They are considered as energy-intensive processes. Desalination normally uses a variety of lowtemperature heat sources, including low-pressure steam, or electricity. The choice generally depends on the relative economic values of fresh water produced, the particular fuels used and the location where the desalination plant installed [7 10]. Desalination processes require energy in the form of heat and/or electricity, which can be supplied by nuclear reactors. Nuclear desalination is defined to be the production of potable water from seawater in a facility in which a nuclear reactor is used as the source of energy for the desalination process. MSF plants often use low pressure steam as an energy source. The energy consumption in MSF plant depends on the distillate flow rate and the plant performance ratio. For Large MSF plants, about 4 6 kwh/m 3 of electrical energy is consumed. Heat consumption is in the range of kwh/m 3 of thermal energy. In general, the thermal efficiency of MSF plant is expressed in kg of water produced per kg of steam used. This ratio is called the gain output ratio, GOR. Values of GOR are 8 10 with a practical maximum of 12, which corresponds to about 55 kwh/m 3 of thermal energy. GOR of 3, 8 and 10 correspond without loses to thermal energy of 216, 82 and 65 kwh/m 3 of product water. Also MSF consumes kwh of electric energy for pumping per one cubic meter of product water. RO plants are operated by electrical power to derive the high pressure pumps and other plant auxiliaries, mainly the pretreatment processes. RO power consumption depends mainly on water recovery and the working pressure. Typically 9.7 kwh of electric power is consumed in a 30% recovery RO plant per one cubic meter of produced water without energy recovery. If an energy recovery turbine of 80% efficiency is used, the energy requirement will fall to 6.5 kwh/m 3.

8 8 I.S. Al-Mutaz Nuclear reactors are used mainly for the production of either heat or power. In the nuclear heating reactors (NHR), heat can be extracted at various temperature levels, both in the form of hot gas or steam. The low pressure and temperature steam may be used in supplying the necessary energy to derive the MSF or any other distillation units. Electricity can be generated from the nuclear power reactor (NPR) to derive the high pressure pumps of the RO desalination plants. Developing the most appropriate plant configuration of nuclear reactor (NHR or NPR) and desalination process (distillation or membrane) is indeed the most crucial factor that will determine the feasibility of nuclear desalination. Small and medium sized nuclear reactors (SMRs) are suitable for desalination, often with cogeneration of electricity using low-pressure steam from the turbine and hot seawater feed from the final cooling system. Currently SMRs are defined as power reactors that have power outputs in the range of MW(e). The development of cost competitive small and medium size nuclear power reactors are more suitable for grid sizes in developing countries as well as for coupling with desalination plants of 10,000 m 3 /d (2.64 mgd) to 100,000 m 3 /d (26.4 mgd) capacities. About one-third of the SMRs under construction are expected to supply heat or electricity or both to integrated seawater desalination plants. Coupling MSF and RO with nuclear steam supply system (NSSS) will yield some economical and technical advantages. A comparison between NSSS-MSF and NSSS-RO desalination plants is illustrated in Table 2 [11]. Table 2 Comparison between NSSS-MSF and NSSS-RO desalination plants Item NSSS-MSF NSSS-RO Availability Product salinity, kg/m Capital cost High Low Operation interface Yes No Energy consumption Steam and power Power only Safety consideration Radiation contam. Nuclear plant only Load regulation Flexible No load regulation Coupling Require extensive care Direct coupling Thermal pollution High Medium Manpower Highly qualified Qualified in nuclear Plant site On the same site RO near the city Transportation cost Required Not required Coupling of a nuclear power plant to hybrid desalination system consists of an MSF plant followed by an RO plant, which may take reject cooling water from the last effect of the MSF system as feedwater to the RO system. Normally, the nuclear power plant is designed for optimum production of electricity. However, there is a large amount of lowgrade thermal energy available in the form of waste heat discharged from the nuclear plant through the condenser cooling system. Heat in the form of steam can be supplied by the nuclear reactor through one or more intermediate circuits to the MSF desalination system. Heat may also be supplied in the form of hot water, depending on the temperature and pressure conditions specific to the desalination plant design. Also part or all of the feedwater to the RO/MSF system can be drawn from the condenser cooling water discharge stream. The RO system, which uses electricity as its primary energy

9 Hybrid RO MSF: a practical option for nuclear desalination 9 input, may draw either from the electrical grid or by direct connection to the nuclear plant with an auxiliary connection to the grid. The choice of the suitable nuclear reactor and desalination process depends on several factors. In case of coupling between NHR and distillation process, it will be necessary for the two plants to be on the same site to cut down the cost of transporting heat over long distances and avoid unnecessary losses. While for coupling NPR and RO, there will be no special arrangements other than an electrical connection between the two plants. As in the Indian case which will couple a 6300 m 3 /d (1.66 mgd) hybrid RO MSF plant to its Kalpakkam pressurized heavy water reactor (PHWR) in Tamil Nadu [1]. The plant coupled to twin 170 MWe nuclear power reactors (PHWR) at the Madras Atomic Power Station, Kalpakkam, in southeast India. The MSF and RO desalination plant have capacities of 1800 and 4500 m 3 /d, respectively. The MSF plant uses the required quantity of low-pressure steam for seawater desalination. An isolation heat exchanger between steam supply and the brine heater of MSF is used to avoid any chance of ingress of radioactivity. The LP steam is tapped from the manholes in the cold reheat lines after high-pressure turbine exhaust from the nuclear reactors. The steam temperature in brine heater is designed to below 130 C to avoid scaling on the tube side. The condensate from the isolation heat exchanger is returned back to the deaerator section of the power station. The seawater reject from the heat rejection section of MSF (about 40 C) is mixed with seawater and fed to the RO plant. According to previous studies [7 10], CANDU PHWR is the appropriate type of nuclear reactor for the developing countries such as the Arabian Gulf countries. Hybrid RO/MSF CANDU PHWR is the candidate system for the application of dual purpose nuclear desalination plants in these countries. The electrical and thermal power produced from CANDU reactor may be utilized to derive the desalination plans. This makes such option more favorable for in these countries to meet the increasing demand of power and water. The possible coupling schemes of heat and power are pure back pressure cycle, the extraction scheme and the combination of back pressure and condensing turbines cycle. PHWR provides a safer steam generation due to an additional barrier. It uses heavy water (D 2 O) as primary coolant and de-mineralized water as the secondary coolant. The steam required for MSF is extracted by coupling to the low pressure turbine. The steam is tapped from a suitable point on the low pressure turbine for heating the brine in the MSF plant. The selection of tapping point depends on the maximum brine temperature selected. The arrangement is also made to tap the steam from both the reactor systems for MSF to ensure the continuous operation of the desalination plant. Part of the power generated in the nuclear power station is used for operating seawater RO plant by coupling it thermally and electrically with the power plant. The thermal coupling gives higher throughput due to higher feed sea water temperature up to 40 C. The remaining power is used for distribution. 6 Conclusions The hybrid RO MSF desalination plant coupled to a nuclear power plant gives high overall availability factor. This system also has potential advantages of a low power demand, improved water quality and possible lower running cost as compared to standalone RO plants. It can lead to significant technical and economic advantages such as:

10 10 I.S. Al-Mutaz Common, small seawater intake Optimized feedwater temperature of the RO plant by using cooling water from the heat rejects section of the MED or MSF plant. Improved performance and extended life of membranes. Single stage RO process with high recovery ratio may be selected. Blending of product waters and common post treatment. Low power to water ratio (important when water production is the main requirement). Low water production cost. Various RO MSF combinations coupled with nuclear power plant were reviewed. The optimum coupling of hybrid RO MF was discussed. By this arrangement hybrid RO MSF can lead to an optimized feedwater temperature of the RO plant since is possible to use cooling seawater from the reject stage of the MSF plant as feed to RO plant. The appropriate combinations depend on the local conditions and power/water requirements. References 1 Misra, B.M. (1997 ) RD on desalination and membrane technology at Bhabha Atomic Research Center, India, The International Desalination and Water Reuse, Quarterly, Vol. 6, No. 4, p. 35, February March. 2 Al-Mutaz,I.S, Soliman,M.A, and Daghthem,A.M., Optimum Design for a Hybrid Desalting Plant, Desalination 76, 177, Introduction to Nuclear Desalination: A Guidebook, Technical Report Series Number 400, International Atomic Energy Agency, Vienna, Al-Mutaz,I.S., A Comparative Study of RO and MSF Desalination Plants in Saudi Arabia, The International Specialist Conference on Desalination and Water Reuse, Murdoch University, Perth, Western Australia, Dec. 1-2, S. Sourirajan, Pure and Applied Chemistry 50, 593, Al-Mutaz,I.S., M. A. Al-Ghunaimi, Performance of Reverse Osmosis Units at High Temperatures, THE IDA WORLD CONGRESS ON DESALINATION AND WATER REUSE, BAHRAIN, OCTOBER 26 31, Al-Suliman, K, Al-Mutaz,I.S., and Alabdulaaly,A.I., Prospects of Nuclear Desalination, IDA World Congress on Desalination and Water Sciences, Abu Dhabi, United Arab Emirate, Nov , Al-Mutaz, I.S., Nuclear Desalination Opportunity In The Arabian Gulf Countries, Expert Meeting on User Requirement of Nuclear Desalination Systems in the Arabian Gulf and North Africa Regions, The Arab Atomic Energy Agency, Cairo, Egypt, April 2-5, Al-Mutaz, I.S, Nuclear Desalination Implementation in Saudi Arabia, The 1997 Symposium on Prospects for Desalination with Nuclear Energy, Taejon, Korea, May 26-30, Al-Mutaz,I.S., Potential of Nuclear Desalination in the Arabian Gulf Countries, International Congress on Seawater Desalination Technologies on the Threshold of the New Millennium, Kuwait, November 4-7, Kutbi,I.S Sabri,Z.A. and Hussein,A.A., Selection of Desalination Processes for Dual- Purpose Desalination 58, 113, 1986.

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