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Desalination Conference Cape Town. Grundfos desalination presentation 2017
- 2. Grundfos is a World Leader Water scarcity and the place of desalination. Securing water for the future; Capital and operational cost considerations; Evaluation of system efficiency (recovery and energy consumption) from components point of view.
- 3. Floods 2.4billionpeople Pumps secure and remove water. This is essential to life on earth withoutsanitation 663millionpeople withoutcleanwater Droughts And with climate changes - now more than ever…
- 4. Meet the water challenge NOW
- 5. The global water usage is uneven and natural resources are quickly depleting Increasing consumption due to Growing populations Booming industrialization From now to 2030, World water consumption will have increased by 20% Diversification of water resources Surface fresh water; Waste water reuse Sea water Water scarcity is rising BUT: 97% of the world’s water resources is seawater
- 6. Cape Town Water Scarcity
- 7. “The question is no longer “Is desalination feasible?” but “Is it feasible NOT to use desalination?”” Jacques Laubscher
- 8. Desalination methods • Reverse Osmosis • Thermal • Freezing
- 9. Desalination: Thermal processes Multi Stage Flash Distillation (MSF) Multiple Effect Distillation (MED) Source: http://www.sidem-desalination.com/en/Process/MSF/ Technologies
- 10. Desalination: Thermal processes Current status • Thermal plant capacity: 28 million m³/day (31 % of all installed desalination capacity) • 75 % of all thermal plants are located in the Arabian peninsula UAE: 8 million m³/day Saudi Arabia: 13 million m³/day • Dominating technologies: Multistage flash (MSF): 20 – 800 ML/day Multi-effect distillation (MED): 2 – 20 ML/day Vapor compression (VC): 0.5 – 10 ML/day
- 13. SWRO plant – key components Intake Pre- treatment Energy recovery Post- treatment RO system
- 14. SWRO cost driver Cost reduction as key driver for innovative solutions in SWRO 39% 33% 9% 4% 16% Cost Capital Energy Chemicals Membr. repl. Labour / mainten. Main energy consumer is RO system Focus on cost reduction for: • equipment / installation cost • energy cost for pre-treatment and RO Comparison of eqiv. electrical energy MSF: 12-15 kWh/m³ (80% heat) MED: 6 kWh/m³ (75% heat)
- 15. DESIGN CONSIDERATION AND POSSIBLE SAVINGS ENERGY
- 16. SWRO system – energy recovery system SWRO single train basic setup HP Pump Seawater 23 m³/h 2 bar 23 m³/h 70 bar Permeate 9 m³/h Concentrate 14 m³/h 68 bar RO Energy use: 6.6 kWh/m³ 40% recovery rate
- 17. SWRO system – energy recovery system SWRO single train advanced setup Energy use: 2.5-3.5 kWh/m³ HP Pump Seawater feed 23 m³/h; 2 bar 9 m³/h 70 bar Permeate 9 m³/h Concentrate 14 m³/h RO 68 bar Seawater feed 14 m³/h; 2 bar 14 m³/h; 68 bar14 m³/h 70 bar VFD 14 m³/h 1 bar Booster Pump VFD 40% recovery rate Pressure exchanger
- 18. SWRO system – energy recovery system Several ERD devices used in parallel
- 19. SWRO system – energy recovery system SWRO energy efficiency comparison 0% 75 % 85 % 98 % 0 20 40 60 80 100 No recovery Turbocharger Pelton turbine ERD Conversion efficiency / %
- 20. Low cost Efficiency Reliability Pump 1 Pump 2 Pump 3 Low Cost Size Brand Pressure ex 1 Pressure ex 2 Pressure ex 3 Product Comparison Selection of correct product Product Comparison
- 21. CAPEX & OPEX. Case by case consideration Power consumption at duty point (kW) Efficiency (ɳ) (pump + motor + VFD) Equipment cost (CAPEX) Pump price Accessories Variable frequency drive Installation cost (time + parts) Set local price Total CAPEX Additional equipment cost vs. AC pump Total CAPEX annually Operating Cost (OPEX) Annual electricity cost Total maintenance cost Annual maintenance cost Total annual OPEX Total OPEX for 10 years Total cost for 10 years Total cost annually Savings per year (€) Savings per year (kWh) Payback time of PM pump solution (years) J J J L Small footprints of motor J 311 mm K 406 mm J 485 kg L 643 kg J J J J Critical parts in Super Duplex Stainless Steel J J 155 739 € 159 292 € 3 000 € 3 609 € 1 500 € 1 500 € 35 853 € 27 089 € 8 764 € 3 585 € 68,2% 64,8% 179,6 183,7 34 353 € 22 589 € 35 886 3 609 € 156 100 € 1 623 618 € 159 653 € 1 596 856 € 159 686 € 162 362 € 1 561 003 € 1 596 530 € 361 361 2 709 € Minimised pump length due to high speed motor Built in check valve Quick maintenance with only two tools J LVariable-frequency drive self-test at startup Plug and play, configured from factory Weight of booster system without VFD J L Sales Arguements Remote control Via Internet 3,3 2 676 € AC PumpCurve 35 853 27 089 156 100 159 653 0 20 000 40 000 60 000 80 000 100 000 120 000 140 000 160 000 180 000 PM Pumps AC Pumps CAPEX & OPEX Total CAPEX Total annual OPEX inEUR (€) 0 5000 10000 15000 20000 25000 30000 0 2 4 6 8 10 12 Years Savings on TCO Additional cost on CAPEX inEUR (€) Cost comparison for PM pumps GRP GRP AC PumpCurve 32 453 24 631 115 424 117 369 0 20 000 40 000 60 000 80 000 100 000 120 000 140 000 PM Pumps AC Pumps CAPEX & OPEX Total CAPEX Total annual OPEX inEUR (€) 0 2000 4000 6000 8000 10000 12000 14000 0 2 4 6 8 10 12 Years Savings on TCO Additional cost on CAPEX inEUR (€) Cost comparison for PM pumps Power consumption at duty point (kW) Efficiency (ɳ) (pump + motor + VFD) Equipment cost (CAPEX) Pump price Accessories Variable frequency drive Installation cost (time + parts) Set local price Total CAPEX Additional equipment cost vs. AC pump Total CAPEX annually Operating Cost (OPEX) Annual electricity cost Total maintenance cost Annual maintenance cost Total annual OPEX Total OPEX for 10 years Total cost for 10 years Total cost annually Savings per year (€) Savings per year (kWh) Payback time of PM pump solution (years) J J J L Small footprints of motor J 305 mm K 406 mm J 250 kg L 643 kg J J J J Critical parts in Super Duplex Stainless Steel J J 88 388 € 99 376 € 3 000 € 3 609 € 1 500 € 1 500 € 28 134 € 24 631 € 3 502 € 2 813 € 66,8% 60,6% 101,9 114,6 26 634 € 20 131 € 110 993 3 886 € 88 777 € 1 022 004 € 99 737 € 915 901 € 91 590 € 102 200 € 887 767 € 997 373 € 389 361 2 463 € Minimised pump length due to high speed motor Built in check valve Quick maintenance with only two tools J LVariable-frequency drive self-test at startup Plug and play, configured from factory Weight of booster system without VFD J L Sales Arguements Remote control Via Internet 0,3 10 610 € AC PumpCurve 28 134 24 631 88 777 99 737 0 20 000 40 000 60 000 80 000 100 000 120 000 PM Pumps AC Pumps CAPEX & OPEX Total CAPEX Total annual OPEX inEUR (€) 0 20000 40000 60000 80000 100000 120000 0 2 4 6 8 10 12 Years Savings on TCO Additional cost on CAPEX inEUR (€) Cost comparison for PM pumps GRP GRP
- 22. Water treatment Heating Cooling Drinking Industry Irrigation Farming … … … Utility
- 23. 9 out of 10 pumps are running full speed - Even when there is no need - YET MOST PUMPS RUN FULL SPEED 24/7 THE FLOW DEMAND VARIES
- 24. We invented auto adaptable pumps and motors - that can potentially save 5% of global electricity
- 25. REGULATION TOTAL COST AWARENESS Unfulfilled potential - why? 2 out of 3 pumps use up to 60% too much energy
- 26. 85% 10% 5% PURCHASE MAINTENANCE POWER CONSUMPTION TOTAL COST Long term investmentFirst challenge TIME TOTAL COST REGULATION AWARENESS
- 27. Long term energy savings require regulation TOTAL COST Second challenge Promoted energy- and environment friendly regulation MINIMUM ENERGY STANDARDSAWARENESS REGULATION
- 28. - We engage in global issues Water ison top of the agenda TOTAL COST Third challenge AWARENESS REGULATION IDENTIFY PROBLEM Public awareness
- 29. Chemical consumption DESIGN CONSIDERATION AND POSSIBLE SAVINGS
- 30. SWRO flow chart
- 31. Do any of these challenges sound familiar? Achieving safe and reliable dosing processes Hazardous, concentrated, degassing, or highly viscous liquids Dosing accuracy Dosing pump reliability Keeping costs down Pump energy consumption System life-cycle cost – installation, operation, service, and maintenance Specifying and installing systems Pump selection for a wide flow range Integration into existing systems and processes Solutions that work worldwide Ensuring trouble-free operation Ease of operation Robustness and long service intervals
- 32. EXAMPLE of payback period calculationsOnly the cells highlighted in green need to be filled in. Please don't overwrite formulas. Grundfos does not accept responsibility for any inaccuracy in the program operation, calculation, or data contained therein. Currency Pump A Pump B Pump A Pump B 2 161 XXXX DDA 120-7 XXXX Flow Chemical consumption Nominal flow (Qmax) 120,0 l/h 120,0 l/h Rated nominal flow of pump (data sheet) Hourly dosage 101,62 102,36 litres ... based on pump accuracy Target flow 100,0 l/h Average flow during operation Annual cost Chemicals $1 160 907 $1 169 361 Accuracy... Equipment (depreciation) $580 $380 ... realtive to setpoint 1,5 % 2 % Steady state accuracy (data sheet) Annual total cost $1 161 487 $1 169 741 ... relative to full scale 0,1 % 0,3 % Steady state accuracy based on nominal Additional equipment cost $1 000 flow (data sheet) Chemical savings/year $8 454 Price of... ... pump $2 500 $1 500 As offered to the customer Payback time 0,12 years (just by chemical savings) ... accessories $400 $400 E.g. for pulsation damper, flow meter, ... a Total $2 900 $1 900 ... chemical $2,00 per litre Ask customer Time of operation 16 hours/day 7 days/week 5712 hours/year Depreciation time After this time the equipment will be written off 5 years -5 000 0 5 000 10 000 15 000 20 000 25 000 30 000 35 000 40 000 45 000 0 1 2 3 4 5 6 year Savings over depreciation periodin USD ($) 0 2 000 4 000 6 000 8 000 10 000 Total CAPEX and Savings TotalCAPEX Additional chemical cost/year Savings on CAPEX DDA 120-7 XXXX in USD ($)
- 34. Product Leadership - Innovation, design and efficiency More water and energy can be saved by optimizing total systems and not just the individual products PUMP Product approach E-SOLUTIONS Extended Product approach iSOLUTIONS System approach PRODUCT LEADERSHIP
- 35. Available Intelligence - the present wave 4 is a giant leap forward + MOTOR + MOTOR + ELECTRONICS + MOTOR + ELECTRONICS + CONNECTIVITY + VALUE ADDED SERVICES + SOFTWARE PRODUCTS + NEW BUSINESS MODELS + NEW SALES CHANNELS WAVE 1 1945-1960 WAVE 2 1960-1990 WAVE 3 1990-2006 WAVE 4 2006-FUTURE
- 36. Other industries technologies could be used in our applications 36
- 37. 37
- 38. Water resource diversification; Capital and operational efficiency for cost savings; Stakeholder Management (early engagement); Design & Engineering – available technology evaluation; Optimisation of existing plants; Lesson learned. “Tell me and I forget; Teach me and I remember; Involve me and I learn” Summar y
- 39. Grundfos is a global leader in advanced pump solutions and a trendsetter in water technology. We contribute to global sustainability by pioneering technologies that improve quality of life for people and care for the planet. THANK YOUKatrina Zlobich kzlobich@grundfos.com Our Purpose
Editor's Notes
- Floods increase in many places. In other places droughts are getting worse. 663 million people rely on polluted water and 2.4 billion people do not have access to sanitation. (Source: WHO & Unicef 2015)
- Multi-Stage Flash Distillation (MSF) is the most commonly used desalination method, producing 60% of all desalinated water. In MSF vaporization occurs at low temperatures in a vacuum and the vapor condenses, providing fresh water. Since the pressure in a vacuum is lower, lower temperatures are needed for boiling. MSF flashes a portion of water into stream in multiple stages of countercurrent heat exchangers. MSF plants are based on the principles of heat exchangers and condensate collectors. There is a hot and cold end with intermediate temperatures between them. Multiple Effect Distillation (MED) evaporates and distills seawater in multiple stages while reusing the energy from vapor condensation. Total energy consumption for water heating is reduced due to energy reuse. Water is evaporated at lower temperatures, < 70 ֯C. MED is a sequence of closed spaces with successively lower pressures and temperatures. Each sequence has a heat source for the previous one and a heat sink which leads to the next sequence. The horizontal tubes in each stage are sprayed and cooled with the seawater make-up flow. The heating system is inside the tubes and the steam condensates into pure water inside the tubes. Simultaneously, the seawater gets heated on the outside of the tubes gets heated and evaporates. Only the first effect is heated from the external source of steam.
- Intake: intake pumps, transfer pumps Pre-treatment: coagulation, filters, dosing, transfer and pressure pumps RO-system: high-pressure pumps, membranes Energy recovery: energy recovery device, booster pump Post-treatment: transfer pumps, dosing, tanks,
- Focus on cost reduction for equipment, installation and energy
- Envelope principle
- Danfoss life 1,5 years Grundfos 6 years
- Minimum 10% of the world’s electricity consumption is consumed by pumps. (Source: Grundfos’ own estimate)
- Minímum 10% of the world’s electricity consumption is consumed by pumps.
- Minimum 10% of the world’s electricity consumption is consumed by pumps.
- The customer has to pay more short term – to gain long term, as power usage makes up 85% of total cost. (Grundfos estimate based on customer experiences)
- Lack of knowledge about the potential of pumps in water and energy efficiency. But the voice of Grundfos is heard globally with our CEO as spearhead
- Simplified overview
- Product Leadership is core to our business and our world class efficiency of the individual pump is not enough. This is why we have a system approach to our solutions.
- We have built more intelligence into our pumps.