Presentación de PowerPoint...Apr 02, 2020 · Presentador: Rafael Ramos Ruiz (Danfoss) High...

“Planta desaladora en Bahrein. Medidas de ahorro de energía y de la repercusión total en la planta”

Presentador: Rafael Ramos Ruiz (Danfoss)

High Efficiency Technologies - for Increased Energy Savings in Reversed Osmosis

• Motors

• Variable Speed Drives

• High Pressure Pumps

• Axial Piston Pumps

• Centrifugal Pumps

• Energy Recovery Devices

• Installation and Energy costs

• Business Case

High Efficiency Areas

Efficiency in Pumps

Efficiency in Motors

Objective – Affordable water for all plant sizes

0

1

2

3

4

5

6

7

8

Baseline Energy Recovery

Other EnergyImprovements

Future Improvements

kWh

/m3

-----------------------------------------------------------------

First-pass RO Process Energy Consumption

40% recovery and 60 abrg. – Qualitative values.

Thermodynamic minimum

SWRO Energy Innovations

Room for improvement in HPP Efficiency!

SWRO Setup without Energy Recovery

Isave 21

RO Membrane

Back

Pressure

Valve

Permeate

HP ConcentrateHP FeedHP Feed

Balanced flow

Clean Sea

Water

∑ 67 m3/h

30 m3/h 37 m

3/h 37 m

3/h

37 m3/h37 m

3/h

∑ 67 m3/h

60 bar

30 m3/h

InOut

APP 30 LP Concentrate

30 m3/h 37 m3/h 37 m3/h

30 m3/h∑ 67 m3/h

37 m3/h

∑ 67 m3/h

37 m3/h

Clean

seawater

iSave

SWRO Setup with High Efficiency Recovery device

Reverse Osmosis – Components

In a RO plant, following components are used:

• High Pressure Pumps, Leak valves, a pressure transmitter to control the HPP, a pressure switch to protect the HPP, a booster pump and small dosage pumps for bisulfite, sulfuric acid, etc.

All pumps are composed by an electrical motor and a mechanical component, and each part of the pump has a particular efficiency.


• Motors







• Business Case

Permanent Magnetic Motors

• Synchronous motors.

• They have magnets mounted or embedded, to help to create magnetic field for rotation, it means they use less energy.

• Efficiency IE3 and IE4

Motors• Machines driven by electrical motors consume around 2/3 of all the electrical energy used in

industry, which has also a great impact on the environment.• Motors work for a large number of hours and have long lifetimes• Reducing motors’ energy consumption, by increasing their efficiency, reduces its

environmental impacts as well as its operational costs.

Induction Motors• Stator built of cover or aluminum • Electricity is needed to create a magnetic

field to output rotary motion. Old motors have efficiency class IE1,and IE2. Current induction motors are efficiency class IE3

IEC 60034-30-1 Standard on Efficiency Classes for Low Voltage AC Motors

• Defines efficiency classes IE1-IE4 for motors rated for start and operation on a sinusoidal voltage supply

• No distinction is made between motor technologies (e.g. Induction or PM motors)

• IE classes are defined at the nominal motor load

Permanent Magnetic Motors

Induction Motors

Motors Efficiency Comparison


• Motors







• Business Case

14

Increased System efficiency with VSD

• With VSD • Without VSD

Motor Start Up

• Direct on Line, consume 7 times Nominal Current of the motor

• Soft Started, consume 2 Times

• Start and Triangle started 2 and 4 Times

• Speed Frequency Drive adaptsconsume to the load


Per each 2 kw wasted in losses we need 1 Kw for Air conditioning


Two technologies to refrigerate Drives• Air Cooled• Liquid Cooled

20-25kw Losses to air 1,5-3kw Losses to air


• Motors







•

18

Aplicaciones en que la carga no varía con la velocidad

La potencia necesaria es proporcional al par requerido y a la velocidad del motor

Se puede producir un ahorro si se reduce la velocidad con carga constante

El ahorro de energía no justifica la inversión en un variador.

High Pressure Pumps

100% Speed, 100% Torque 50% Speed, 100% Torque

Speed SpeedTo

rqu

e

Torq

ue

Operation Point Operation Point

Energy Energy

• Positive Displacement (PD) pump = nearby constant flow regardless of the pressure. • Flow regulated by VSD• Near constant High Efficiency

High Pressure Pumps

Positive Displacement Pump Flow Curve

High Pressure Pumps Reduced energy consumption for increased savings

• APP pumps deliver up to 90% total efficiency• Consistent across all

flow rates

• Compared to 60-80% for centrifugal

• Save up to 50% electricity compared to centrifugal pumps


• Motors







• Business Case

High Pressure Pumps

•

Pump Characteristics

Pump Characteristics-

OperationPoint

OperationPoint

System Characteristics

System Characteristics

EnergyEnergy

Flow QFlow Q

Pre

ssu

re B

ar

Pre

ssu

re B

ar

24

High Pressure Pumps

• Variable Torque – Centrifugal Pumps

High Pressure Pumps Up to 50% Energy Savings

SWRO Plant

Saves 100KW per pump, decreasing 6 Hz


• Motors







• Business Case

Energy Recovery Pumps

Isave 21

RO Membrane

Back

Pressure

Valve

Permeate


Balanced flow

Clean Sea

Water

∑ 67 m3/h

30 m3/h 37 m

3/h 37 m

3/h

37 m3/h37 m

3/h

∑ 67 m3/h

60 bar

30 m3/h

InOut


30 m3/h 37 m3/h 37 m3/h

30 m3/h∑ 67 m3/h

37 m3/h

∑ 67 m3/h

37 m3/h

Clean

seawater

iSave

SWRO Setup with isobaric iSave ERD

High Pressure Pumps Pelton Turbine Recovery

High Pressure Pumps Turbocharger Recovery

High Pressure Pumps Isobaric Recovery

Energy Recovery Pumps

Isave 21

RO Membrane

Back

Pressure

Valve

Permeate


Balanced flow

Clean Sea

Water

∑ 67 m3/h

30 m3/h 37 m

3/h 37 m

3/h

37 m3/h37 m

3/h

∑ 67 m3/h

60 bar

30 m3/h

InOut


30 m3/h 37 m3/h 37 m3/h

30 m3/h∑ 67 m3/h

37 m3/h

∑ 67 m3/h

37 m3/h

Clean

seawater

iSave

SWRO Setup with isobaric iSave ERD

High Efficiency ERD

Features:

• Isobaric Principle (High efficiency)

• Positive displacement booster pump incorporated.

• Constant flow and constant efficiency regardless DP across the system


• Motors







• Business Case

High Pressure Pumps SWRO Performance Comparison

ERD TYPE1,000 m3/d

(kWh/m3)

5,000 m3/d

(kWh/m3)

>15,000 m3/d

SYSTEM (kWh/m3)

Pelton Turbine 4.01 3,42 2.79

Turbocharger 3,58 3,03 2,62

Isobaric ERD

(iSave®) 2,76 2.42 2,29

SWRO Plant 5000m3/dayPressure to Membrane 66 bar @ 45%Different Recovery systemsHP CF Pump with VSD

ERD TYPE1000 m3/d

(kWh/m3)

5,000 m3/d

(kWh/m3)

>15,000 m3/d

SYSTEM (kWh/m3)

Pelton Turbine 4.01 3,42 2.69

Turbocharger 3,58 3,03 2,61

Isobaric ERD

(Isave®)2,76 2.42 2,292,29 2,29

3,01 2,69

3,13 2,86


SWRO Plant 5000m3/dayPressure to Membrane 66 bar @ 45%Different Recovery systemAxis Piston Pump by VSD

SWRO Plant 5000m3/dayPressure to Membrane 66 bar @ 45%Different recovery system, changing CF for Piston Axis Pump


Energy consumption with variation in membrane pressure

Energy consumption: 4.764 MWh/year (2,61 kwh/m3)

Throttle loss: 373.000 kWh/year(0,2 kwh/m3)


VSD loss: 90.000 kWh/year(0,05 kwh/m3)


VSD loss: 6.800 kWh/year(0,0004 kwh/m3)

SWRO Plant 5000m3/dayPressure to Membrane 60-66 bar @ 45%With isobaric recovery systemHP CF Pump with throttle Valve vs Axis Piston Pump by VSD

Positive displacement Axial Piston Pump @ Same operating conditions

Pump skid - total: 3.875 MWh/year ( 2,12 average)VSD Loss: 39,500 kWh/year (1% of total) (0,02 kwh/m3)

High Pressure Pumps

Using multiple APP pumps in parallel and only one APP pump controlled with a VSD provide the lowest annual power consumption. Savings up to 22 % can be achieved.

High Pressure Pumps Conclusions


• Motors







• Business Case

SWRO Plant 3500m3/dayLocated: Bahrein - AsryCostumer: Gulf House Markets.Water costs increased from 0,35dinares/m3 to 0,75dinares/m3Technology installed: 6 High Pressure Pumps with Frequency ConverterIsobaric recovery system.

Business Case INEXA-Bahrein Plant

30% Save

Energy


30% Save

Energy



30% Save

Energy


Conclusions

• Energy efficiency in SWRO Plants has improved significantly thanks to different technology improvements

• Big SWRO pump have developed • Economy of scale

• Optimized efficiency of centrifugal technology

• With High efficient technologies the same or increased efficiency can be obtained

• Positive displacement pumps allow highest efficiency.

Conclusions

Room for improvement is possible!• More efficient motors • Implementation of Drives

• New Plants• Exisitng Plants

• Positive displacement pumps• Isobari energy recovery devices accepted as state of the art ERD

• This analysis is based on Efficiency• Life cycle cost analysis with CAPEX needs to be implemented.• In general the analysis is favorable for APP / Isobaric / Drives• Energy Price is a key factor (however, analysis is based on

Efficiency)

Gracias

Date post:	15-Aug-2020
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Presentación de PowerPoint...Apr 02, 2020 · Presentador: Rafael Ramos Ruiz (Danfoss) High...

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