TOPIC 4a

OVERVIEW OF VARIOUS DESALINATION PROCESSES

In this section, we will cover the following desalination processes:

1. Multi-Stage-Flash (MSF)
2. Multi-Effect (ME) Distillation, Multi-Effect Boiling (MEB)
3. Vapor Compression

4. Electrodialysis (ED) and Electrodialysis Reversal

5. Reverse Osmosis (RO)
6. Forward Osmosis
7. Membrane Distillation

8. Solar desalination
a. Solar Stills
b. PV-RO
c. CSP-MED

HISTORY OF DESALINATION

Desalination technology is not a new concept. Desalination has been used for thousands of years, such as
Greek sailors, boil water to evaporate fresh water away from the salt and Romans use clay filters to
trap salt. Up to the year1800 desalination was practiced on ship boards. The process involved using
single stage stills operated in the batch mode. The equipment and product quality varied
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considerably and were dependent on the manufacture and operator. Mist carryover was always a
problem.

In year 1912, a six effect desalination plant with a capacity of 75 m3/d was installed in Egypt.

In year 1957, four-stage flash distillation plant by Westinghouse was installed in Kuwait.

The MSF patent by Prof. Silver (Scotland) gives a major advancement over the Westinghouse
configuration because of the much smaller specific heat transfer area for the condenser tubing. This
reduced considerably the capital cost since the high tubing cost in the Westinghouse system was
replaced by inexpensive partitions in the MSF systems.

In 1960 First MSF plants commissioned in Shuwaikh, Kuwait and in Guernsey, Channel Island.
The MSF unit in Shuwaikh had 19 stages, a 4550 m3/d capacity, and a performance ratio of 5.7.

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LOCATIONS OF MSF DESALINATION PLANTS IN SAUDI ARABIA

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Evaporation vs Boiling
Evaporation and Boiling are two processes that are looked upon often without difference. Strictly speaking
there is difference between the two processes. Evaporation occurs on the surface of the liquid whereas
boiling occurs in the liquid in its entirety. This is the main difference between evaporation and boiling.

1. Evaporation happens at any temperature, boiling only at the boiling point.

2. Evaporation happens only at the surface, boiling happens throughout the liquid.
3. Boiling takes energy in (endothermic) to occur, while evaporation lets only the molecules with the
highest kinetic energy out, leaving the rest of the water net kinetic energy, so evaporation is
exothermic.

The main difference is that:

 Boiling happens when heat is added from the bottom, and
 Evaporation is when heat is added from the top.

For instance, when you boil water in a pot, it is being heated from the bottom, so air bubbles form at the
bottom and rise through the liquid, to the top. It would be evaporation if the heat was added from the top
(no bubbles would form).

There is difference between the two states in terms of the time taken too. Boiling takes place very quickly
and swiftly too. On the other hand evaporation takes place slowly and gradually. This is a very important
difference between the two processes.

It is interesting to note that the boiling point is reduced when the pressure of the surrounding atmosphere is
reduced.

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Single Stage Distillation or Evaporation Process

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 Single Stage Flash Desalination Process

Water-Superheating or flashing: https://www.youtube.com/watch?v=LpDs7Xm1uLo

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 Multiple Stage Flash Desalination Processes
ONCE-THROUGH FLASH DESALINATION PLANT

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FLASH DESALINATION PLANT WITH BRINE RECYCLING

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Dubai Electricity and Water Authority at Jebel Ali, natural gas is burned to produce electricity and to desalinate seawater f or drinking.

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 Brine Heater of Desal unit at Ghazlan power plant
Al Khobar 2 - Saudi Arabia MSF-BR - 10 units of 26,700 m3/day
(267,000 cubic meters daily production) SIDEM Contract Award:
1979 Completion date: 1982

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MSF plant at Jubail 0.880 million m3/day

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Shoaiba Desalination Plant, Saudi Arabia
The finished desalination plant currently ranks as the largest in the world and uses multi-stage flash (MSF) distillation
Product water output
74,000m³/day (Phase 1); 450,000m³/day (Phase 2)

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1.

World’s largest desalination plant goes on stream in Ras Al-Khair (1.025 million m3/day)
RAS AL-KHAIR – Minister of Water and Electricity Abdullah Al-Hussayen commissioned the first phase of world’s
largest desalination project here on Tuesday. Ras Al-Khair plant exceeds 80 percent, and it is expected to start producing
water before the end of the first quarter of 2014.

The plant for production and pumping of desalinated water and generation of electricity is located in the Ras Al-Khair
Industrial City, 75 km north-west of Jubail. The plant is set to generate 3,500 jobs.

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Al-Hussayen, who is also chairman of the SWCC board, said that the project, which is estimated to cost a total of more
than SR27 billion, consists of the largest desalination pumping plant ever built in the history of SWCC.

“The plant has the production capacity of 1.025 million cubic meters of desalinated water per day and electricity
production capacity of 2,600 MW. The plant will supply 1,350 MW of electricity to Maaden, and 1,050 MW to Saudi
Electricity Co., in addition to 200 MW to be used within the plant,” he said.

A total of 800,000 cubic meters per day of water will be supplied to Riyadh city. It will be capable of serving about 3.5
million people in the city of Riyadh.

Another 100,000 cubic meters to Al-Washm, Sudair, Majma, Al-Zulfi and Al-Ghat regions.

A total of 100,000 cubic meters per day will be supplied to the regions located north of the Eastern Province, including
Hafar Al-Batin, Qaisoomah, and Qaryat Al-Olya.

The desalination plant will comprise of eight MSF units and 17 RO units. The MSF units will have a capacity to produce
160 MIGD while the RO units will produce 68 MIGD. Three of the MSF units were built at Doosan Heavy Industries
Vietnam, while the other five were built at Doosan Korea facility.

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 Multi-Stage-Flash (MSF) Desalination Process
Description of the MSF Desalination Process with Brine Recycling
The simplified flow diagrams of an MSF process are shown in Fig. 4.1
and 4.2. The plant consists of three main parts namely, the heat input
section (brine heater), the heat recovery section, and the heat reject
section. The process itself can be described in terms of three streams:
seawater stream, recycle brine stream, and distillate stream.
The intake seawater pumps deliver the filtered and chlorinated seawater
to the tube side of the last stage (in Fig. 4.2, 17th stage) from where it
flows in cross flow pattern through tubes of the last three stages of the
reject section, effecting condensation of the flashing vapor on the outside
of these tubes. After the seawater leaves tube bundles of the reject
section, it is split up; a portion is discharged to the sea, and the remainder
becomes the make-up feed for the MSF plant.
To control scale, the make-up water is treated with an acid in which case
it is called an acid treatment plant, or with a scale inhibitor chemical in
which case it is called an additive treatment plant. Most modern plants,
whether acid or additive dosed, have de-aerator to remove up to 95% of
O2. The gases, stripped by the steam, are led to the shell side of the pre-
condenser which is cooled externally by the seawater.
The treated feed is sprayed into the last flash stage which is maintained at
the lowest temperature and highest vacuum (e.g. 42 °C and 27.6 in. vac.).
A substantial portion of the non-condensable gases is driven off in the last
stage which is vented directly to the pre-condenser. This helps minimize
O2 corrosion by minimizing its concentration in the brine.
The make-up feed mixes with the un-vaporized brine in the last stage and
the sum-total is taken up by the recycle brine pump and introduced to the
tube side of the last (i.e. 14th) stage of the recovery section. The brine
flows through tubes of the entire heat recovery section, being pre-heated
by the condensing vapor and the re-flashing distillate.
After the pre-heated brine comes out of the tube bundles of the recovery
section, its final heating is done in the heat input section (brine heater) by
means of steam drawn either from a boiler (single-purpose desalination
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plant), or as extraction/back pressure steam from a steam turbine (dual-
purpose power-desalination plant). The brine exits the brine heater at the
desired top brine temperature (TBT) and is dumped into the first flash
chamber. Here the prevailing pressure is such that the actual temperature
of the entering brine is higher than its saturation temperature. A fraction
of the supersaturated brine thus flashes off to vapor which passes through
the demisters near the ceiling of the flash stage and condenses on the
outside of the cooler tube bundle of the first stage, thereby giving up its
latent heat of condensation. The brine inside the tube bundle is pre-
heated and the vapor is condensed and collected in the so-called distillate
tray installed beneath the tube bundle. The gases including CO2 and O2
still in the brine are led along with some water vapor to the inter-
condenser for removal.
The brine from the first stage then enters through an orifice into the
second stage where more brine flashes off to vapor which, by condensing
on the cooler overhead brine-carrying tubes, pre-heats the brine and
produces more distillate. This flashing process continues from stage to
stage at progressively lower temperatures until the brine reaches the last
sage and the cycle is repeated.
The distillate produced in each stage joins with that from the previous
stages and flows on to the next stage. The total distillate from the last
stage (which is under vacuum) is withdrawn by a pump. Total dissolved
solids (TDS) of the distillate are typically 30 ppm.

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Figure 4.1 Process flow diagram of MSF plant

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 MSF DESALINATION UNIT AT GHAZLAN POWER PLANT

Figure 4.2 Block flow diagram of MSF unit at Ghazlan power plant

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Figure 4.3 Block flow diagram of MSF unit at Jeddah-II power & desal plant

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1. Single-Purpose vs. Dual-Purpose MSF Plant:
The single-purpose plant has its own steam producing boiler. The entire
capital, energy, and operating costs of steam generating plant are,
therefore, allocated to the MSF water plant.
In a dual-purpose power-water plant the steam produced in the steam
producing plant is shared between the power & water plants. The capital,
energy, and operating costs of steam generating plant are also shared
between the power & water plants. As a result, the cost of water is lower
than that produced by a single-purpose water plant.

2. Low Temperature (LT) vs. High Temperature (HT) Plants: MSF

plants with top brine temperature (TBT) of 85-90 oC at the brine heater
outlet are known as LT while those with TBT>90 oC are called HT plants.
In the Gulf region these days most MSF plants are designed for dual
temperature operation. In winter months when the water demand is low,
these plants are operated in the LT mode. To produce more water in the

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 summer months, they are operated in the HT mode, ranging from 100o to
113 oC TBT.
3. Acid-Dosed vs. Additive-Dosed Plants: All MSF plants are operated at
top brine temperatures ranging from 85o to 112oC. At these temperatures,
there is no potential for calcium sulfate scale to form. But the potential to
form alkaline scale (CaCO3 & Mg(OH)2) exists.
When acid (usually sulfuric) is injected to seawater make-up, the plant is
known as acid-dosed. Acid completely destroys the alkalinity from the
feed water so that the acid-dosed plants can be operated in the HT mode
where they are thermally more efficient.
When chemical additives are injected to inhibit the alkaline scale, the
plants are called additive-dosed. These days scale inhibitors are available
which permit plant operation up to 113 oC. The two modes of scale
inhibition are compared in the following:
● Acid-dosed plants are thermally more efficient due to better heat
transfer but more prone to corrosion;
● Additive-dosed plants are thermally less efficient but also less prone
to corrosion;
● The useful life of an additive plant is longer (>30 years) than an acid
plant about15 years.
● Most of the MSF plants in GCC region use additive for scale control.

4. Temperature Rise Through Brine heater (∆Th): Temperature by which

brine is heated in the brine heater as a result of steam condensing on the
outside of the tubes.

ΔTh = (Tho -Thi)

Thi = Brine heater inlet temperature

Tho = Brine heater outlet temperature

For definitions of Tho and Thi see Fig. 4.2 Ghazlan Plant block flow diag.
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5. Flash Range (ΔTF): Difference between the max. temperature & min.
temperature in the MSF plant.

ΔTF = (Tho – TB)

TB = Brine blowdown temp.

6. Recycle Ratio (RR):

RR = (MR /MD)

Where MD = Mass flow rate of distillate product

MR = Mass flow rate of recycle brine

Typically for LT plants, RR≈12

for HT plants, RR≈ 8

That is, for the same amount of distillate (MD) produced, the LT plant has
50% more brine circulating through it. So the pumping power
requirements of the LT plants will be greater than those of the HT plant.

7 Concentration Ratios (α):

αB = (XB / XF) Concentration Ratio w.r.t. brine blowdown, XB

αR = (XR / XF) Concentration Ratio w.r.t. brine recycle brine, XR

where: XF = TDS of feed seawater (mg/l)

XB = TDS of brine blowdown (mg/l)
XR = TDS of recycle brine (mg/l)
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 The two are related by the following equation:

αR = [(RR-1) / RR] αB

Clearly, αR < αB

αB relates the distillate output with the make-up feed by the following
relationship:

MF = MD

When the concentration ratio (αB) in an existing plant is increased from

1.5 to 2.0,
 Less amount of feed make-up (MF) is required to produce the same
amount of distillate (MD) which results in less pumping and less cost
of chemical treatment to the feed or
 More distillate (MD) can be produced from the same amount of feed
make-up (MF).
 But in both cases, the potential for scale formation is increased.
8. Gained Output Ratio (GOR) & Performance Ratio (PR):

The GOR is defined as:

pounds of distillate produced per pound of steam condensed in the brine
heater, or kgs of distillate produced per kg of steam.
A GOR of 8 means 1lb. of steam produces 8lbs. of distillate.
GOR= (MD / MS)
where: MD = kgs/hr of distillate produced
MS = kgs/hr of steam condensed

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PR is defined as:

pounds of distillate produced per 1000 Btu of heat input in the brine
heater, or kgs of distillate produced per 2325kJ of heat input.

PR = (MD /QH)(2325)

where: QH = kJ/hr of heat input

PR = 8.2lbs/1000 Btu = 8.2kg/2325kJ

where: 1 Kg= 2.2046 lb 1 Btu = 1.055 kJ
PR is regarded as a more useful unit as it depends on the energy content
of the condensing steam rather on its mass.
The PR & GOR are related by the following equation:
PR = (1000/λs). GOR

where λs = Latent heat of condensation of steam in brine heater (Btu/lb)

Generally, PR > GOR

The following is an exact equation for calculating PR from the operating conditions:

PR = (CPf / CPh) (2325/ λD) (ΔTF/ ΔTh)

where: CPf = Specific heat of recycle brine, calculated at (TDS of recycle

brine + TDS of brine blow-down)/2 & (Tho + TB)/2 temperature.

CPh = Specific heat of recycle brine, calculated at TDS of recycle brine and
(Thi + Tho)/2 temperature.

λD = Latent heat of distillate at (TIV + TLV)/2 temperature.

See Figure 4.2 for definitions of TIV and TLV.

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 Practically, (CPf / CPh) ≈ 1, and (2325/ λD) ≈ 1

Therefore, above equation of PR can be simplified as:

PR ≈ (ΔTF/ ΔTh)

≈ (Tho – TB)/(Tho –Thi)

It is clear from the above equation that PR of an MSF plant can be increased by;

i. Increasing the heater outlet temp. (Tho)

ii. Decreasing the brine blowdown temp. (TB)

iii. Increasing the heater inlet temp. (Thi)

9 Distillate Output (MD) and Recycle Brine (MR)

MR = MD [ or 4.13

MR = MD [ 4.14

Equation (4.14) calculates the MR more accurately than equation (4.13).

Clearly, for a given flash range ΔTF = (Tho – TB), Greater the recycle

brine flow rate (MR), greater is the distillate output (MD).

For a given recycle brine flow rate (MR):

Greater the flash range ( Tf); higher the distillate output (MD)
.

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EXAMPLE:

PERFORMANCE CALCULATIONS FOR MSF DESAL UNIT

DATA FOR GHAZLAN MSF PLANT

MULTI-STAGE-FLASH (MSF) DESALINATION PROCESS
(Refer to the accompanying Line Diagram, Fig. 4.2).

Mass flow rate % Seawater (MSW) = 1,179,138 Kg/h

Seawater Discharge (MSWO = 796,689
Feed Make-up (MF) = 382,449
Recycle Brine (MR) = 1,302,721
Brine Blow down (MB) = 244,354
Distillate (MD) = 138,095
Super-Heated Steam (MSS) = 23,038
Desuper-Heating Water (MDW)= 771
Condensate (MC) = 23,809

Total Dissolved Solids of Feed (XF) = 42,410 mg/L

Recycle Brine (XR)
Blow-Down (SB)
Distillate (SD)
Seawater pH
Recycle Brine pH
For Acid – Dosed
For Additive – Dosed
= 70,000
= 78,250
= 5
= 8.1
= 7.2 – 7.6
= 8.7

Temperatures
Seawater Inlet (TSWi) = 35 oC
Outlet (TSWo)= 46.1
Recycle Brine Inlet (TR) = 46.1
Feed Make-up (TF) = 46.1
Brine Blow-Down (TB) = 46.1
Last Stage or Bottom Brine (TB) = 46.1
Distillate (TD) = 43.9
Super-Heated Steam (TSS) = 162.8
Saturated Steam (TS) = 120
Condensate (TC) = 120
Desuper-heating Water (TDW) = 120
Brine heater Inlet Temperature (Thi) = 102.8
Brine heater Outlet Temperature (Tho) = 112.8
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HEAT TRANSFER DATA FOR GAZLAN DESAL UNIT

S.No. Parameter Units Brine HTR. Heat Recovery

1. No. of Stages - 1 14
2. Tube O.D. m 0.01585 0.01585
3. Tube I.D. m 0.01445 0.01257
4. Total No. of Tubes (N) - 1228 1680 Per Stage
5. No. of Tubes in Vertical Tier (Nv) - 18 25
6. Total Surface Area (A) m2 397.95 3992.84
7. Tube Thermal Cond. (KW) Kj/h.m.oC 61.24 172.82
8. Fouling Factor (FF) h.m2.oC/Kj 0.0376X10 0.0269X10
9. Design H.T. Coeff. (UD) Kj/h.m.oC 11,120 11,446
10. Brine Velocity Thru. Tubes (Ub) m/sec. 1.729 1.668

KG. Distillate 138,095

1. Gained output ratio (GOR)    5.8
KG. Steam 23,809

KG. Distillate 138,095 KG / h  2325

2. Performance Ratio (PR)  
2,325 Kj Heat in Heater 23,809 KG / h * 2,202 Kj / kg

= 6.1 Kg/2325 kJ
or
= 6.1 lbs./1000 BTU

= 11.0 Kg/1000 Kcal

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