1/17/2017 SHUWAIKH (A) PLANT SHUWAIKH (A) PLANT. The Lecturer Background SHUWAIKH (C) & (D) PLANT SHUWAIKH (B) PLANT

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1 The Lecturer Background BRITISH UNIVERSITY IN EGYPT ENGINEERING CONFERENCE 2016 PLENARY SESSION DEVELOPMENT OF DESALINATION TECHNIQUES DR. M.H. ALI EL-SAIE NOVEMBER 2016 The lecturer started Development of Sea Water Distillation (Thermal Desalination) in Kuwait since 1955 and taken the major role as regards research and development for the first desalination plants: Shuwaikh A and B. He provided design and specification for subsequent plants (Shuwaikh C, D, E and F and Shuaiba A) and Contractors to build and carry out tests to prove the above mentioned design, negotiated with contractors, followed up tests on proto-type at the manufacturer's works, checked design, construction at site and commissioning and behavior of the plants and discussed the criteria for each plant together with his observations for each as follows: SHUWAIKH (A) PLANT Plant consists of 10 triple effect evaporator units, each producing 100,000 IGPD of distillate - type is submerged-tube sea water evaporators. Each evaporator consists of three horizontal steel cylindrical shells, the third-effect shell is longer than the other two effects. Each has a horizontal tube bundle cupro nickel 70/30 and horizontal shell tubes condenser. The shells are steel and the tubes are 70/30 Cu Ni. Steam is admitted at both ends of the bundle and condensate drains from the middle. The depth of the tube bundle extends between the center of the shell down to about halfway of the of the radius of the shell. Pump casings are bronze or cast iron, impellers are bronze, and shafts are stainless steel SHUWAIKH (A) PLANT All pumps are motor-driven. Each unit has its instrument panel adjacent to it and the plant is locally controlled. This plant was commissioned March to July 1953 by M/s. Westinghouse. At first, scale formation on the heating elements was very rapid and heavy. It was practically impossible to get rid of the scale without mechanical cleaning by chipping and hammering. Scale cracking was found necessary every 7 to 10 days SHUWAIKH (B) PLANT After study, a recirculation system in the 1 st and 2 nd effects of the evaporators to increase the velocity of the brine around the heating surface resulting in improved performance and outage of the plant. It is the same capacity and similar design as Shuwaikh (A) applying the same operational conditions as in Shuwaikh (A), this plant is commissioned in February to September 1955 by M/s Weir. The plant did not give the same satisfactory results. After research and tests of different methods of treatment, it was found that the best method was to run the evaporators using 2.5 ppm Hagevap (PD.8) and using anhydrous ferric chloride of 150 ppm of the feed water. SHUWAIKH (C) & (D) PLANT These plants consist of 4 flash type sea water evaporators, each producing 525,000 IGPD of distillate taking into consideration selection of suitable material for shell and tubes of heat exchangers. The 1 st unit is commissioned in October, 1957 by M/s. Westinghouse. Each unit consists of 4 rectangular stages, one on top of the other. On the very top, the cylindrical 2-flow heater is placed. A makeup evaporator is also provided to allow for purer distillate production for boiler feed. The shell and all internal partitions, baffles, and distillate trays are made of steel, the tubes on all heat exchangers aremade of 70/30 CuNi, while the brine nozzles, venting nozzles and also the sea water and brine recirculating pumps are all made of stainless steel

2 SHUWAIKH (C) & (D) PLANT SHUWAIKH (E) PLANT All pumps are motor driven. Each unit has an adjacent instrument panel. Operation of each plant itself is independent. In the lecturer's opinion, it represents a turning point in the history of sea-water distillation. Its success encouraged companies all over the world to undertake extensive research and development on large flash type evaporator units to achieve economical production costs. This plant consists of 2 flash type evaporators, each producing 1 MIGPD of distillate. Each unit consists of 3 tiers, one on top of the other. There are 16 heat gain stages and 3 heat rejection stages. The heat input heater is of cylindrical shape and is placed 4 feet high from the ground to make maintenance and acid cleaning easier and quicker. The evaporator materials are more or less as in the (C) plant, only pump casings are of Ni resist cast iron. The sea water and brine recirculating pumps are driven by variable speed steam turbines. This plant is commissioned in July and November, 1960 by M/s. Weir SHUWAIKH (F) & SHUAIBA (A) PLANT These plants consist of 2 units MSF at Shuwaikh and 3 units MSF at Shuaiba, each producing 1MIGPD. The 1 st unit is commissioned in June,1965 by M/s Weir. Each unit consists of 2 tiers. There are 27 heat-gain stages and 3 heat-rejection stages. The heat input heater is of cylinder type and is placed near the ground level. The material is almost the same as (E) plant with the exception that the main heater, first and second stages of the heat gain section, and heat rejection sections are 70/30 Cu Ni while the rest of the tubes are aluminum brass. This will be the first plant in Kuwait where aluminum brass tubes are used, but from previous experience we proved that scale and corrosion are mainly confined to the stages where we used Cu Ni tubes in this plant Preventive Methods Against Corrosion Continuous chlorination of sea water at rate of 2 ppm at the suction of sea water pumps. Cathodic protection of the impressed current for steel jetties for sea water intake and magnesium anodes for water boxes are used. Successful coatings and paints for steel pipes, tanks and other ferric surfaces. Separate venting from the 1 st and last stages of evaporator. Choice of suitable and efficient material for different components of the plant. Injection of caustic soda or Ca(OH) 2 to the distillate to protect the transmission product mains Water Production Cost: All calculations are for 1 MIGPD of each type. Overhead charges of 75% on wages and salaries included. Fuel is free except the depreciation and maintenance of gas line and accessories. Please refer to table in following slide. TABLE OF TOTAL COST FOR DIFFERENT DISTILLATION TECHNOLOGIES Shuwaikh Shuwaikh Shuwaikh Shuwaikh Shuwaikh COST ITEM F and A B C and D E Shuaiba Maintenance Wages: 10,335 10,409 2,616 2,616 2,616 Material Cost for Maintenance: 12,284 13,731 1,216 1,200 1,200 Maintenance Cost (workshops) 7,429 1, Operating wages: 22,524 20,971 11,250 6,000 6,000 Cost of PD8 2,168 1,945 4,375 4,375 4,375 Cost of Ferric Chloride 1,380 Cost of Acid For Cleaning: 1,125 1, Cost of chlorine: 8,175 8,175 5,017 3,190 2,100 Cost of Electricity Consumed: 11,500 10,420 13,900 1, Cost of Steam Consumed: 43,800 42,600 36,250 17,600 12, ,000 86,000 46,200 23,300 Depreciation of Unit (Incl 15 Y depreciation) 27,000 Depreciation of Unit (Incl 20 Y depreciation) Total Cost (incl 15 Y depreciation) 237, , ,530 60,287 57,137 Total cost based on 20 yrs. Depreciation: 109,822 48,693 49,253 Production in million gals/years Cost of 1,000 Imperial Gallons in fils (15 Y depreciation) 34,500 17,500 20, Cost of 1,000 Imperial Gallons in fils (20 Y depreciation) Note: one KD = 1000 fils = $2.8 = 1 GBP

3 Conclusion and Recommendation: Conclusion and Recommendation: 1. The multistage seawater flash-type evaporator is the most reliable equipment to produce distillate from sea at economical cost and the submerged tube type should be limited to very small plants where such outage is possible. 2. Scale formation is a complicated subject and local conditions are of major importance (nature of sea water, design conditions, chemical treatment, etc.) and hence the lecturer advises that any authority who decide to install a sea water distillation plant of large capacity should build up first a unit of reasonable size and carry out tests on scale formation and chemical treatment before committing themselves to the full installation required. 3. The importance of clear specification for ordering plant by experts who have site experience and appreciate the effort between receiving the offers and placing the order. Prototype tests in the shop or site is of great importance and can save much time and money. 4. Choice of materials, chemicals and coating is the principal factor for economy in the capital outlay as well as in maintenance. 5. Flash type evaporators are sensitive to variation in sea water temperature, brine temperature and brine concentration. The lecturer advises that changes should be reduced to a minimum and be automatically controlled and not left to manual operation. 6. The cost of sea water distillation has been declining since Multi Stage Flash (MSF) Before 1957, thermal plants were submerged tube type and the unit production was relatively small (100 to 450 m 3 /day). SHUWAIKH (A) DISTILLATION PLANT EVAPORATOR SHUWAIKH (A) DISTILLATION PLANT The 1 st unit of MSF plant (4 x 2386 m 3 /day) was commissioned in 1957 at Kuwait, since this time MSF plants have dominated the market till now. Large units of MSF reach 75,750 m 3 /day ( MIGPD). Several improvements/updates have been introduced to MSF plants hence it is considered the most reliable process for desalination - especially for medium and large capacity plants. Improvements such as: Multi Stage Flash (MSF) Thermal Vapor Compression (TVC) Using noble Metals for Heat Transfer Surface Area such as Cu-Ni, titanium and Al-Brass. Increasing of Top Brine Temperature by using Belgard as antiscale. Reduction in Friction losses of Brine Flow in Flash Chambers. Reduction in Energy Consumption by increasing the performance ratio considering optimization of increasing of Top Brine Temperature, increasing of number of stages with reducing the tube wall thickness to achieve economical products cost. Reduction in Operating/Maintenance Cost. Wise Selection of Sea Water Intake and Outfall TVC Plants have been developed after MSF Plants because the cost of water production is cheaper than in case of MSF due to lower electrical consumption and lower capital cost, However TVC is requires live steam at medium pressure with high temperature for ejector to create complete vacuum whereas MSF uses live steam at low pressure and temperature having maximum latent heat for heating the brine. TVC units are reliable for medium capacity. large units of TVC reach 44,000 m 3 /day (9.6 MIGPD)

4 Mechanical Vapor Compression (MVC) MVC plants are used when only electric or mechanical power is available. MVC plants are usually used in remote areas where thermal energy is not available. The capacity of MVC units is between (25 m 3 /day to 2500 m 3 /day). ISO & OHSAS HEAT & MASS BALANCE FOR 1x11 MIGPD MSF (P.R.8.5) ISO & OHSAS ISO & OHSAS ABU TARABA DESALINATION PLANT HEAT & MASS BALANCE DIAGRAM SUMMER CONDITIONS MVC DESALINATION FLOW DIAGRAM AL TAWEELAH (A) GAS TURBINE POWER & DESALINATION PLANT 3 GAS TURBINE 117 MW ISO RATING DESALINATION UNITS 3X6/7.2 MIGD SEAWATER INTAKE & OUTFALL COMPLETED 1989 UNIT 4 7.2/8 MIGD, 160 T/HR AUXILIARY BOILER COMPLETED 1996 LOCATION AL TAWEELAH- ABU DHABI GHUBRAH POWER & DESALINATION PLANT - OMAN PHASES: I 1X5/6 MIGD, II 5/6 MIGD, UMM AL-NAR POWER & DESALINATION PLANT ABU DHABI III 1X5/6 MIGD, V 1X5/6 MIGD, UMM AL-NAR EAST 3X5/6 MIGD VI 1X6/7 MIGD EAST EXT. 3X6/7.2 MIGD COMPLETED 2000 UMM AL-NAR WEST 6X4 MIGD WEST EXT. 7&8 4X5/6 MIGD

5 SALINE WATER DESALINATION BY REVERSE OSMOSIS (RO) 1- GENERAL MIRFA POWER & DESALINATION PLANT ABU DHABI 4X61 ISO MW GAS TURBINES 3X5.4 MIGD COMPLETED 1997 ABU TARABA DESALINATION PLANT - LIBYA CAPACITY 3X2.9 MIGD (40,000 M3/D) COMPLETED 2007 RO started to attract end users since 4 decades but with several ups and down with operation experience over several years due to problems in the pre-treatment, membranes type and material and the high electrical consumption (between 7 to12 KWH/m 3 ) for sea water plants. The RO system started with membrane called hollow fibers by M/s. Du-Pont (USA). The Hollow fiber membranes are of thread type with cavity in the centre of the thread, this results in extensive treatments for the feed water to ensure the absence of any suspend solid material in the feed water which result of increase the cost of pre-treatment and the frequency replacement of membrane GENERAL 1- GENERAL To solve this problems, a new type of membrane (spiral wound) was developed. The spiral wound is a flat sheet wound around a cylindrical rod. This system increased the permeate flux and hence reduced the cost of pre-treatment, electric consumption and rate of membrane replacement. In the last 2 decades, RO started to increase its role especially in areas with high price of thermal energy. During the last decade with better pre-treatment, application of reliable pressure recovery system e.g pressure exchanger and change of membrane type from hollow fiber to spiral wound, the electrical consumption for SWRO plants dropped to 4 to 2.5 KWH/m 3 of product water. The commonly used pre-treatment with SWRO plants is by flocculation, sedimentation and filtration, this will result in: Higher RO flux and hence higher recovery ratio. Less RO membrane replacement during the life time of the plant. Lower water production cost ONE PASS WITH PRESSURE EXCHANGER SUR RO PLANT OMAN

6 SUR RO PLANT OMAN st PASS RO DELMA ISLAND AT ABU DHABI USMGD COMPARISON BETWEEN THERMAL DESALINATION AND REVERSE OSMOSIS (RO) FOR CAPACITY 20,000 M3/DAY S.N. ITEM THERMAL DESALINATION PLANTS RO PLANTS MSF TVC 1. Raw Water m 3 /m 3 Product Factor Raw Water Pretreatment Normal Normal Extensive Pretreatment 3. Capital Cost Millions US$ Required Steam Requires steam from waste Requires steam from waste heat (e.g. in combination heat (e.g. in combination with gas turbines, steam with gas turbines, steam turbines, APG, NPP, CSP or turbines, APG, NPP, CSP or CC) for better economy CC) for better economy Not Required 5. Power KwH/m 3 Product Spare Parts More Wear & Tear Parts Wear & Tear Parts - Less Wear & Tear Parts - Membrane Replacement (high cost) 7. O&M Normal Normal Chemist is required continuously CARTRIDGE FILTERS DELMA ISLAND AT ABU DHABI USMGD Reliability Excellent Good Operation errors present high risk The lecturer introduced the 1 st remote control for MSF plants at Kuwait in The automatic control system had been highly developed with much innovation during last few decades as follows: A) Local Manual Control with Pneumatic Automatic Control. At this stage, the operator has to start, stop and adjust all parameters locally at site with some local gauges (pressure, temperature, level, flow, etc.) and minimum protection of running equipment B) Remote Manual Control with Pneumatic Control System. At this stage, the situation has been improved with respect to operation, the operator can control lot of aggregates remotely with some alarms, protection and some recording facility. C) Remote Control with Electronic Control System At this stage, the operator can remotely control the aggregates with automatic control of process including lot of alarms and protection. The process at this stage may be completely controlled from remote with minimum effort from operator and a lot of measurement and recording facilities of process parameters

7 D) Remote Full Automatic Control with the Programmable Logic Controllers (PLC) and Distributed Control System (DCS) At this recently stage the operator can adjust the required parameters and the PLC will start the process sequentially including the required production rate. The PLC will start the process in sequential mode with lot of remote measurement and recording facilities. The PLC will ensure full protection of equipment and safety of personnel at all stages of operation. The introducing of DCS system facilitated many improvements than those of PLC such as: Calculation of process parameters prior starting of the system to follow up the process and may be via golden push button to operate the process safely (hundreds of valves, pumps, dozing, heating up, agitators, blowers, etc.) Optimum control of process to increase efficiency. Hybrid interface with optimum consumption of power, cooling water, quality of product, chemicals,. etc. to achieve the maximum benefit Save extensive cable cost based on distribution of control, minimum operator interference and optimum use of chemicals and power. Consulting Engineering Co. DEVELOPMENTS IN CIVILS FOR DESALINATION Facilitate remote control through Load Dispatch Centers either for power or water production. Facilitate unmanned controls for remote areas either through fiber optic cables, satellite, radio waves, etc. or via telecommunication system. History record of process and give guidance to any failure or mal-operation of the process (pre and post trip logs) Pumping Station and Pipe Lines Network. Intakes and Outfall Structures Hydraulic Studies for intake and outfall system at desalination plants such as: 3-D hydrodynamic and dispersion numerical model for outfall / intake of the desalination plant at Al Yousr Hurghada Capacity 80,000m3/day

8 TYPICAL RECIRCULATION STUDY OUTPUT DIAGRAM THANK YOU! ISO & OHSAS END OF SESSION

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