WRF-08-14, Selecting the Best Energy Recovery

Device at RO Plants
Tyler Nading and Steve Alt
CH2M HILL
March 2013
Discussion Outline

• Project Scope
• Reverse Osmosis Basics
• Introduction to ERDs
• Tutorial of the “Tool”
• Discussion

OBJECTIVE:
•Crash course in Energy Recovery Devices
•Tool tutorial

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Project Scope

• WRF-08-14
– ERD Literature Review
– Excel-based comparison tool
• 5 selected ERDs
• Capital and operating cost estimate
• Funded by California Energy Commission and USBR
• CH2M HILL Acknowledgments:
– Rob Huehmer (PI)
– Jim Lozier

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Reverse Osmosis Basics
Reverse Osmosis

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Typical Single Stage Seawater RO System

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Typical Two-Stage Brackish RO System

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Energy Recovery Devices
Energy Recovery Devices

To boost
this pressure

Use this
pressure

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RO Feed Pressure and Energy Consumption is a
function of feed salinity

1200

1000

800

600
psi

400

200

0
Seawater Brackish NF UF MF
RO RO
Evolution of SWRO Energy Consumption

20

15
kWh/m 3

10

0
1970 1980 1990 2000 2007

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Technology Contribution to SWRO Energy Minimization

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Centrifugal Turbocharger

- Can be used in front of stage 1 (SWRO)

or in between stages (BWRO) Selected Devices
- ERI: HTC
- Turbine connected directly to pump - FEDCO: HPB
- Operation:
1. High pressure brine fed to the turbine
2. Turbine rotation turns shaft
3. Shaft turns pump impeller

3 2 1

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Turbocharger for Feed Pump Pressure Reduction

25 psi 570 psi 840 psi

Feed Turbo
Pump
- SWRO applications
- Reduces TDH of feed pump

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Two-Stage System with Interstage Turbocharger

Turbo - BWRO applications

- Provides interstage boost
and flux balancing

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Two-Stage System with Interstage Turbocharger
128 psi 152 psi

105 psi
Turbo - BWRO applications
- Provides interstage boost
and flux balancing

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Centrifugal – Direct Coupled
- Typically used for SWRO applications Selected Device
- Flowserve: Pelton Wheel
- Permits smaller HP pump motor
- Operation:
1. High pressure brine fed to the turbine
2. Rotating power used to assist motor
3. HP Pump operates normally

3 High Pressure Turbine

1

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Pelton Wheel for Feed Pump Motor Energy Reduction

25 psi 840 psi

Feed
PW
Pump
- SWRO applications
925 hp 600 hp - Reduces size of feed pump motor

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Isobaric Device
Selected Devices
- Positive displacement ERD - ERI: PX
- Flowserve: DWEER
- Highest efficiency of ERD types
- Operation:
1. Low pressure feed enters device – piston to the right
2. Device rotates
3. High pressure brine enters device – piston to the left
4. High pressure feed exits device
5. Device rotates

4 3
5 2
1

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Isobaric Device for Feed Pump Flow Reduction

1400 gpm

700 gpm
- SWRO applications
700 gpm - Reduced flow to Feed Pump
- Circulation Pump required

Circulation
pump
ERD

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ERD Comparison
- Isobaric has best efficiency
- Turbocharger is least expensive and easiest to implement

Efficiency Range Cost Range*

ERD Type Low High Low High

Turbocharger 55% 65% $ 55,000 $ 75,000
Pelton Wheel 65% 75% $ 120,000 $ 130,000

Isobaric 90% 96% $ 115,000 $ 170,000

*For 1,500 gpm brine flow application

- Isobaric most common for SWRO

- Turbocharger most common for BWRO

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WRF 08-14 Tool Tutorial
Introduction to ERD Tool

• Similar to vendor provided projections

Enter Water Quality Data
software
• Allows for comparison of different
system configurations and different
devices Enter RO System Design
Information
– Isobaric vs. Centrifugal
– PX vs. DWEER
– Booster pump vs. throttling valve
• Estimates Present Worth cost ($/1,000 gal) Calculate System Pressures
and ERD payback period and Water Quality Data

Display Results

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Sample Case Study
• 1-Stage SWRO System
• Permeate Flow = 1 mgd
What is the best
• Recovery = 50% device and what is
• Flux = 10 gfd the payback period?

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Tool: Inputs Page

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Tool: Inputs Page

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Tool: Inputs Page

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Tool: Inputs Page

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Tool: Inputs Page

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Tool: Inputs Page

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Tool: Inputs Page

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Tool: Inputs Page

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Tool: Cost Summary Page

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Tool: Cost Summary Page

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Tool: Cost Summary Page

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Tool: Cost Summary Page

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Actual Case Study – Bonita Springs Retrofit
• Literature analysis performs 5 case study validations
• CH2M HILL performed a manual case study at Bonita Springs Utilities
– Groundwater desalter in Florida
– Four 1.5 mgd RO trains
– Feed TDS currently 4,700 mg/L and rising
– Power $0.08 Kwh

Is an ERD suitable?
If so, which type?

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Bonita Springs Analysis Cost Summary
Bonita Springs

• Centrifugal devices offer better payback period

• Isobaric case has to consider reduced efficiency of HPP
– Reduced HPP flow by 25%
– Efficiency reduced from 74% to 68%
– Even though the device is more efficient, it is not the best for this application.
• If it was a new build, both centrifugal devices and the PX provide similar
payback periods
High Pressure Pump Efficiency Calculation

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 High Pressure Pump Efficiency Calculation

1
2

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Tool Equations and Accuracy
• RO Projections calculations based off of Tom Wolfe’s Total
Flux and Scalant Program (TFSP)
• Feed pressure estimated consistently within 10%
compared to vendor provided software
• ERD efficiency calculations and cost from manufacturers
• Pump, piping, and valve costs created from cost curves
• Capital cost accuracy: +40%/-25%
• Overall accuracy: +30%/-15%

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Tool Application
• Valuable for anyone considering RO
– New Builds or Retrofits
• Use in conjunction with vendor provided programs
• Alternative evaluations
– Different ERDs Free to download from
– Different manufacturers WateReuse Research Foundation
– Different feed pumps
– Different system configurations
• Conceptual cost estimates

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Discussion

CH2M HILL gratefully acknowledges WRF’s financial,

technical, and administrative assistance in funding and
managing this project. CH2M HILL would also like to
thank the California Energy Commission and the
USBR for their financial support.

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