KSB Influence of Pumps on Energy Consumption

II. International Seminar Desalination Antofagasta / Chile1

Influence of Pumps and Energy Recovery Systems on the Specific Energy Consumption in

Seawater Reverse Osmosis FacilitiesUwe Dortmund (Presenter)

Wolfgang KochanowskiStephan Bross

Gerhard SchwarzKSB Aktiengesellschaft67227 Frankenthal (D)


5. Session Title = Operation and Maintenance of Desalination Plants

Core Hydraulic System

The Core Hydraulic System is the Arrangementof a High Pressure Pump/Recirculation Pump and an Energy Recovery System (ERS)

Water CostsEnergy Consumption

MaintenanceReliability



Schematic Representation of different Core Hydraulic System

Energy Recovery Systems decrease the specific Energy Consumption

Permeate 40%

HP-Pump100% Brine 60%

No Energy Recovery SystemE ∼ 5-6 kWh/m3

Permeate 40%

HP-Pump100%

Turbine

Brine 60%

Turbine SolutionE ∼ 3.5 kWh/m3

100%

HP-Pump40%

Brine 60%

Permeate 40%

Pressure ExchangerIsobaric Pressure Exchanger Solution

E ∼ 2.4 kWh/m3

Recirculation Pump60%

Permeate 40%

Turbocharger

Brine 60%

Turbocharger SolutionE ∼ 3.2 kWh/m3

HP-Pump100%

QPermeate = 5.000m3/d



Individual Losses to be considered in the Design of the Core Hydraulic System

Calculating of specific Energy Consumption includesall losses of the Components inside the Hydraulic System

Pressure Exchanger

η Pressure Exchanger

Feed Water Pump

ζ 2ζ 1

ζ 4

ζ 3

ζ 4

HP PumpηHP Pump

Recirculating PumpηRecirculating Pump

Core Hydraulic System

Membrane

ηArray



Q - p Diagram of the Core Hydraulic System (κ = 0.4)

Power Share of the Components of Core Hydraulic System

HP PumpQPressure

Exchanger

60%

QFeed Water Pump

40% 100% Q [m3/h]

p [bar]

∆p

∆p - pv

pv

Q HP Pump

Q Permeate

∆p = SWRO Processrequired Pressure

pv = Pressure Loss Array, Valves,Pressure Exchanger

QRecirculating Pump



Operating Conditions

H [

m]

210

650

The Program calculatesthe real Energy Consumptionfor different Operating Conditions or different Components

Plant Parameter Efficiencies

Plant Size: Qpermeate = 5000 m3/d ηHP Pump (turbocharger) = 84%

Temperature: T = 20 °C ηHP Pump = 82%

Salinity: TDSFeed = 38,500 ppm (turbine and pressure exchanger solution)

Required Pressure: ∆p = 65 bar ηTurbine = 85%

Pressure Loss: ∆pMembrane = 1,0 bar ηRecirculation Pump = 82%

ηPressure Exchanger = 94%

ηElectrical Motors = 95%

HGM-RO Selection Chart



Specific Energy Consumption and Water Quality- Variation of HP-Efficiency -

0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60Recovery Rate κ

1.0

1.5

2.0

2.5

3.0

3.5

4.0

Sp

ecif

ic E

ner

gy

E [

kWh

/m3 ]

200

300

400

500

600

700

800

Per

mea

te S

alin

ity

TD

S [

pp

m]

ηHP=80%ηHP=82% Turbine-Kit

ηHP=84%

ηHP=80%ηHP=82% PE-Kit

ηHP=84%

TDSPermeate

70,000 $US/aPressure

ExchangerKit



Specific Energy Consumption and Water Quality- Variation of ERS-Efficiency -

0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60Recovery Rate κ

1.0

1.5

2.0

2.5

3.0

3.5

4.0

Sp

ecif

ic E

ner

gy

E [

kWh

/m3 ]

200

300

400

500

600

700

800

Per

mea

te S

alin

ity

TD

S [

pp

m]

ηT=83%ηT=85%

Turbine-Kit

ηT=87%

ηPE=92%

ηPE= 94%

PE-Kit

ηPE=96%

TDSPermeate

PX-KitηPX=92%

ηPX=94% ηPX=96%

PressureExchanger

Kit



Energy Savings by Efficiency Improvements of the HP Pump and ERS of a 5000 m3/d RO Plant

Higher Reliability saves more Money than optimized Efficiencies in SWRO

12242 4897 4747 5933

0

2000

4000

6000

8000

10000

12000

14000

Variation of HP-Efficiency

Variation of ERS-Efficiency

Turbine-KitPX-Kit

1%-Reliability Improvement

En

erg

y S

avi

ng

s [$

US

/a]

Higher Energy Cost: - Turbine Kit 288.000 $US/a- Pressure Exchanger Kit 218.000 $US/a

Variation of HPEfficiency of 2%

Variation of ERSEfficiency of 2%

Pressure Exchanger-Kit



SalTec®:Hydraulic System for Reverse Osmosis (RO)

SalTec® System Hydraulic System for seawater desalination by reverse osmosis with three key components.

- SalTec DT pressure exchanger- HGM-RO high-pressure pump- RPH-RO booster pump

KSB perfectly matches all components to create one hydraulic system that markedly minimizes energy consumption.

As easy as one, two, three: the key components



SalTec®:Working Principle

-The Pressure Exchanger operates trouble free controlled by the speeds of the recirculation pump and the step motor controlled rotating valve

- KSB is the only manufacturer to recreate the toughconditions of a desalination plant in its own labs

HP Feed Outlet

LP

HP

Step Motor

LP Feed Inlet

LP Brine Outlet

HP Brine Inlet

v = 1.02 m/s

v = 0.98 m/s

Check Valves

Rotating Valve

HP Feed Outlet

LP

HP

Step Motor

LP Feed Inlet

LP Brine Outlet

HP Brine Inlet

v = 1.02 m/s

v = 0.98 m/s

Check Valves

Rotating Valve



Reduction of Water Costs with KSB’s SalTec®

Save on energy and water, for low life cycle costs

Virtually loss-free energy recoveryMixing by volume of flow, ≤1,0% through pressure exchanger

Constantly high efficiency during long term operationIdeally matched components from one single sourceNo efficiency drop over timeAutomatic adjustment to changed operating conditionsConstant salt concentration upstream the membrane

High operational availabilityAnti corrosive duplex stainless steel materialNo vibrations, less noise

Low investment costsAll components from one single sourceWear-free operation because of

- low speed- SIC bearings

No lubrication requiredNo hydraulic drive system requiredNo risk of site contamination from oilWide operating range

Saltec-System:= Keep specific energy consumption down to low levels= lowest life cycle costs



Features of Advanced High Pressure Feed Pump Design HGM-ROProven hydraulics from KSB boiler feed

pumps guarantee highest efficiencies

Medium-lubricated axial bearing for start-up / stop

Feet and flange for

main tie bolts separate

Balancing by patented, self-

adjusting balancing device

ensures highest efficiencies

4 Due to static pressure

difference acting on the shaft,

reliable in operation as well as

in transient operating conditions.

4 Compact design

4 Disassembly / reassembly

from either side

4 Wetted metallic parts

made of duplex material

Dry shaft

Axial inlet:

4 Minimum

NPSH

required

4 only one

mechanical

seal

required

Medium-lubricated

radial bearings:4 extremely short distance

between bearings for

maximal smooth running

4 no oil/grease necessary

4 reduced maintenance



Thank you very much for your attention

Uwe Dortmund

Dipl.-Ing. (TU)

Senior Manager Sales and Engineering

Desalination and Seawater Intake

KSB AG

Johann-Klein-Str. 9, 67227 Frankenthal, Germany

Tel. +49 6233 86-3148

Mobile +49 173 32 99 745

E-mail: [email protected]

mailto:[email protected]

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KSB Influence of Pumps on Energy Consumption

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