to summarise our presentation:
1. Water resource diversification. Consider availability of different resources and cost of water production.
2. Capital and operational efficiency for cost savings. Learn from previously installed plans (SA and globally). The top art technology could be installed, but without correct operation could be turned into a disaster. Knowledge transfer and education on plant operation is vitally important as well.
3. Stakeholder Management and their involvement. Early management helps to prevent issues, which could lead to delays in construction and execution.
4. Design & Engineering. Learn and understand available technologies and suitability for particular site/ project.
5. Digitalisation. Use of technology.
6. Lesson learned. Share experience.
Water Balance Study is carried out for a Super Thermal Power plant as a part of the M. Tech final
project which is published in the Sustainable Water Resources Management (Springer) Journal (https://
doi.org/10.1007/s40899-020-00487-4).
Pumps are used in virtually all industries and are big uses of energy. This presentation shows methods of condition monitoring and how to optimise time to overhaul.
Water Balance Study is carried out for a Super Thermal Power plant as a part of the M. Tech final
project which is published in the Sustainable Water Resources Management (Springer) Journal (https://
doi.org/10.1007/s40899-020-00487-4).
Pumps are used in virtually all industries and are big uses of energy. This presentation shows methods of condition monitoring and how to optimise time to overhaul.
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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…
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
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)
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
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
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 ($)
33.
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
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.