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Reverse Osmosis Desalination Plant in Nuweiba City (Case Study)
Dr. Eng. Ibrahim Khaled El-Sayed
Chairman
1 North & South Sinai Company for Water & Wastewater
North & South Sinai Company for Water and Wastewater
( NSSCWW )
Introduction
2 North & South Sinai Company for Water & Wastewater
• Desalination is a process removing dissolved minerals from the saline water.
• Many technologies have been developed for the sea and brackish water, but the most common and widely used process is the reverse osmosis (RO).
• The RO desalination plant consists of 4 major systems; pre-treatment system, high pressure pumps, membrane systems, and post-treatment.
• RO membranes are 2 types; spiral wound & hollow fiber.
• The major parameters affecting the RO plant performance are the feed water temperature, pressure and salinity.
Objectives of the study
3 North & South Sinai Company for Water & Wastewater
• This case study is carried out to study :
– the influence of main design and operating parameters on
the RO plant performance
– the cost analysis of the RO plant
– the evaluation of the overall system reliability for long-
term automatic operation for a certain maintenance
procedure
Considered Plant
4 North & South Sinai Company for Water & Wastewater
• The considered plant has been constructed at Nuweiba City in
South Sinai, Egypt.
• It started the actual production on August 2001.
• The required electrical power for the plant is supplied from
the local electrical power network.
• The saline water is supplied from 8 beach wells near the coast
of Aqaba Gulf.
• The salinity of feed sea water is in the order of 44000 ppm.
• The plant consists of 5 units; each has a capacity of 1000
m3/day.
Considered Plant
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Considered Plant
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Experimental Procedures
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• The plant consists of the following main systems :
1. Intake : – saline water is pumped from the beach wells through the deep well
pumps to a PVC header and then to the sand filters (activated carbon filters)
2. Raw water pre-treatment unit : – the water is sterilized to prevent the growth of bacteria and algae
– activated carbon (AC) filtration is most effective in removing organic contaminants from saline water. After new design by Px system, the activated carbon increased from 12 filters to 24 filters
– the plant is provided with one cartridge filter which ensure that particles larger than 5 microns, carried over from the dual media filters will not enter the membranes – This system changed from 1 filter to 5 cartridge filters (1 micron)
Experimental Procedures
8 North & South Sinai Company for Water & Wastewater
3. RO membrane units: – the membrane stainless steel skid consists of 15 vessels; each one
contains 5 elements of membranes of spiral wound type. Total elements 75 SU820. after using Px system, the total 24 vessels 120 elements TM820-400
4. Post-treatment system : – it consists of chlorinating to allow chlorine residual and pH adjusting
within the acceptable range of 7.5 to 8.5 ppm. This system is suitable for the new capacity
5. The plant working completely automatic control PLC using
SCADA system
The pressure required to operate Nuweiba RO plant is 60-70 bar.
Experimental Procedures
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4- Feed Pump 3- Raw Water Tank 2- Carbon Filter 1- Sand Filter
8- RO Membrane 7- Turbocharger 6- High Pressure Pump 5- Cartridge Filter
11- Chemicals Tank 10- Flushing Pump 9- Aerated Tank
Experimental Procedures
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Simply
activated
carbon filters
(Sand Filters)
Experimental Procedures
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Cartridge
Filters
Experimental Procedures
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Chemical
Pre-treatment
Experimental Procedures
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High Pressure
Pump
315 kW
Experimental Procedures
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Degasifier
Experimental Procedures
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Turbocharger
(before PX)
Experimental Procedures
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P X
Pressure Exchanger (PX)
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PX is an isobaric energy recovery device that transfers pressure from the
membrane reject stream to a seawater membrane feed stream with
extremely high efficiency :
High Pressure OUT
Low Pressure IN
High Pressure IN
Low Pressure OUT
Experimental Procedures
18 North & South Sinai Company for Water & Wastewater
• During the normal operation, the following data have been
recorded daily :
1. The pressure before and after each filter, pump,
turbocharger and RO element
2. Temperature before and after each RO element
3. Thermal conductivity before and after each RO element.
Salinity of a stream is calculated from the measured thermal
conductivity
4. The mass flow rate of both the product water and brine
Experimental Procedures
19 North & South Sinai Company for Water & Wastewater
• Site experimental work has been carried out on one RO unit of the plant to study the effect of feed water temperature, pressure and salinity on the productivity of the unit.
• The change in the salinity of feed water was carried out by adding product water to the feed saline water.
• The pressure of the feed water was changed by the pump and by passing the feed water.
• To study the effect of temperature of the feed water, tests are carried out during different times of the year with different ambient temperatures.
• The results are measured by the same instrumentation attached to the RO desalination plant.
Results & Discussion
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Effect of feed water pressure on the productivity
• The productivity increases from 7.2 to 124.8 % corresponding to an increase in the feed pressure from 41.37 to 72.4 bar respectively
Results & Discussion
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Effect of feed water temperature on the productivity
• The productivity increases from 74.4 to 112.8% corresponding to an increase in the feed temperature from 10 to 32°C respectively
Results & Discussion
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Effect of feed water pressure on the product water salinity
• The product salinity decreases from 1500 to 300 ppm corresponding to an increase in the feed pressure from 41.37 to 72.4 bar respectively
Results & Discussion
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Effect of feed water salinity on the productivity
• The plant productivity decreases from 120 to 100.8% as the feed water salinity increases from 15000 to 45000 ppm respectively
Results & Discussion
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Effect of feed water salinity on the product water salinity
• The salinity of feed water increases from 67 to 350 ppm corresponding to an increase in the feed water salinity from 15000 to 45000 ppm respectively
Economical Analysis
25 North & South Sinai Company for Water & Wastewater
1. Power Consumption Cost
Power Cost (Without PX) = 7.8 * 0.22 = 1.716 LE/m3
Power Cost (Using PX) = 3.2 * 0.22 = 0.704 LE/m3
Pump Without PX With PX
kW kWh/m3 kW kWh/m3
Sea Water Pump 18 0.432 18 0.432
Filter Pump 18 0.432 18 0.432
Additive Pump 1 0.024 1 0.024
Product Pump 3 0.072 3 0.072
RO H.P. Pump 285 6.84 84.85 2.036
Circulation Pump - - 8.5 0.204
Total 7.80 3.20
Economical Analysis
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2. Chemical Requirements Cost
Chemical Cost = 0.52 LE/m3
Item gr/m3 Cost (LE/m3)
Ca O Cl (Pre + Post) 20 0.03
H Cl (30%) 100 0.08
Anti Scalant 10 0.25
Na O H 80 0.04
Others --- 0.12
Total --- 0.52
Economical Analysis
27 North & South Sinai Company for Water & Wastewater
3. Maintenance & Repairs Cost
Maintenance & Repairs Cost = 0.24 LE/m3
Operation Name Cost (LE/m3)
Cartridge filter 0.03
Pumps and motors 0.08
Controls and electrical, etc. 0.05
Instrument, etc. 0.03
Miscellaneous 0.05
Total 0.24
Economical Analysis
28 North & South Sinai Company for Water & Wastewater
4. Capital Cost
Capital Cost = 5500000/3350000 = 1.642 LE/m3
Without PX
• Capital Cost = 5,500,000 LE/Unit
• Unit = 1000 m3/day
• Working Days = 335 days/year
• Expected Life Time = 10 years
Using PX
• Capital Cost = 5,500,000 LE/Unit
• Design Modify = 1,500,000 LE
• Unit = 2000 m3/day
• Working Days = 335 days/year
• Expected Life Time = 10 years
Capital Cost = 7000000/6700000 = 1.045 LE/m3
Economical Analysis
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Total Cost per One Cubic Meter
Total Cost without PX = 4.892 LE/m3
Total Cost using PX = 3.283 LE/m3
5. Labour & Administration Cost
Labor & Administration Cost = 0.50 LE/m3
6. Cost of Wells & Plant Civil Work
Civil Work Cost = 0.274 LE/m3
By using PX, the total cost decreased by 33%.
Conclusions
30 North & South Sinai Company for Water & Wastewater
• The following conclusions are obtained based on 5-year
operation :
1. The RO system is found to be sensitive to the variation in the
feed water temperature, pressure and salinity :
– Higher feed water temperature increases the plant productivity
– Increasing the feed water pressure increases the plant
productivity but decreases the permeate salinity
– Higher feed water salinity reports lower productivity and higher
product water salinity
Conclusions
31 North & South Sinai Company for Water & Wastewater
• The following conclusions are obtained based on 5-year
operation :
2. The cost analysis of the RO plant (without PX) reveals that
the major factors affecting the product water cost are the
power consumption cost (35%) and capital cost (33.6%) while
the chemical treatment represents 10% of the total cost
3. The cost analysis of the RO plant (using PX) reveals that the
major factors affecting the product water cost are the power
consumption cost (21.5%) and capital cost (31.8%) while the
chemical treatment represents 16% of the total cost
THANK YOU
32 North & South Sinai Company for Water & Wastewater