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© Copyright 2010, ERI VERSION:0005-00 July 2010
Making Desalination Affordable
High Efficiency, Energy Recovery Solution
Technical Seminar
高效率的能量回收解决方案
SHANGHAI
JUNE 2011
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Agenda
Desalination Systems
The Pressure Exchanger
Centrifugal Pumps & ERD Solutions
Energy Recovery Inc
High Efficiency Integrated Power Solution
SWRO Engineering Design
Process Simulator
Desalination Plants with PX Technology
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Energy Recovery Inc
HEADQUARTERS/CERAMICS
San Leandro (San Francisco),
California USA
REGIONAL OFFICES
Spain, China, UAE
ENERGY RECOVERY NB
New Boston, Michigan
USA
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Company Profile 公司简介
Background
公司背景
• Established in 1992, Headquarters in California
公司成立于1992年,总部位于美国加州
• More than 10,000 Energy Recovery Devices Installed/Contracted
全球已经销售和安装了过一万多个PX®
• Global Sales and Technical Presence
全球销售和技术支持网络
• Saving more than 890 MW of Energy
节省890 MW 功率能量
• More than 180 OEMs
180多个OEMs使用过PX®
Technical
Expertise
技术专家
• Highest Efficiency, Durability and Reliability
高效、耐用和可靠
• 24/7 Service and Support
全方位、全天候服务和技术支持
• Precision Manufacturing and Ceramics Expertise
精密的制造及加工技术,陶瓷专家
• Technical Review, On-site Commissioning, Start-up
技术审核、现场调试和启动
• Isobaric and Turbine Energy Recovery Solutions
提供等压式和透平式能量回收解决方案
• ERI Acquires Pump Engineering in 2009
ERI在2009年成功收购PEI
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Over 180 Clients
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Capital
Expense
投资成本
43%
Operating
Expense
操作成本
57%
Desalination Plant Capital & Operating Costs
ASSUMPTIONS 基准
Power Cost 电费USD/kWh 0.09
Debt Equity Ratio 债权比 80/20
Debt Interest Rate 利率 8%
Equity Return on Inv 投资回报率 18%
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Chemical /
Consumables
化学消耗品
9%
Power
电能
41%
Parts
Replacement
备品备件
13%
Operating
Margin
运营利润
17%
Office 办公费用 3%
Membranes
膜更换费用
8%
Labor, G&A
劳动力
9%
Operating Expenses—Breakdown 操作成本分项
Perth Seawater
Desalination Plant
2008
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Source: Affordable Desalination Collaboration, 2008
Power Use—Breakdown (Seawater RO)电力消耗成本分项
Pre-filtration
预处理系统8%
Permeate Treatment
后处理系统1%
Permeate Distribution
产品水输送系统7%
Reverse
Osmosis Process
反渗透68%
Intake
取水15%
RO power consumption is approximately 20%
(up to 45%) of total SWRO cost
反渗透系统电力消耗大约占总的操作成本的20-45%
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Making Desalination Affordable
Desalination Systems
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Issues: high pumping costs, wasted energy, lack of optimization
问题:高压泵高投资、能量的浪费和无法优化
MEMBRANES
HIGH
PRESSURE
PUMP
Seawater RO: Before Energy Recovery Devices
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© Copyright 2010, ERI VERSION:0005-00 July 2010 11
Seawater RO: Pelton Wheel/Francis Turbine Energy Recovery Devices
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© Copyright 2010, ERI VERSION:0005-00 July 2010
TURBOCHARGER
MEMBRANES
900 PSI (62 bar)
5 PSI (.35 bar)
200 GPM (45.5 m3/h)
300 GPM (68.1 m3/h)
5 PSI (.35 bar)
300 GPM (68.1 m3/h)
595 PSI (41 bar)
500 GPM (113.6 m3/h)
920 PSI
(63.4 bar)
500 GPM
(113.6 m3/h)
30 PSI (2 bar)
500 GPM (113.6 m3/h)
HERO PUMP
HIGH PRESSURE PUMP
Seawater RO: TurboCharger Energy Recovery Devices
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Seawater RO: Positive Displacement Energy Recovery Devices
Smaller pump, high constant efficiency, flexible operation
较小尺寸的高压泵、恒定的高效率和灵活的操作性能
95 – 98% efficiency
MEMBRANES
HIGH
PRESSURE
PUMP PX-260
DEVICE
CIRCULATION
PUMP
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Constant High Efficiency
Isobaric Energy Recovery Systems Have High Efficiency
Regardless of System Size
无论系统大小等压式能量回收装置具有恒定的高效率
Increasing Flow
100
80
60
40
20
Efficiency
%
Isobaric
Turbocharger
Pelton Turbine
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Desalination Systems
Pelton Turbine
Turbocharger
Piston Exchanger
Francis Turbine
Dyprex
Rotary Exchanger
1980 1990 2000 2010
16 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
No ERD
Francis Turbine
Pelton Wheel
Isobaric Device
kWh
/
m
3
0
1
2
3
4
5
6
7
8
1980 2000 2009
Jeddah I
Las Palmas
Trinidad
Perth
Energy Recovery — Driving Down the Cost of Desalination
Advances in Membrane and Pump Technologies have also enabled these improvements
先进的泵和膜技术进一步降低了能耗
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© Copyright 2010, ERI VERSION:0005-00 July 2010
The PX Pressure Exchanger™ Device
An Isobaric Energy Recovery Solution
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Energy Recovery Inc
HEADQUARTERS/CERAMICS
San Leandro (San Francisco),
California USA
• Global Headquarters – Executive Staff, Engineering/R&D, Sales,
Support & Marketing 公司总部-管理部门、研发、销售、技术支持和市场
• Top-notch ceramics manufacturing facility 超级陶瓷生产工厂
• PX manufacturing and testing facility PX生产和测试工厂
• PX School training seminar PX培训学校
SLIDE 19
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© Copyright 2011, ERI
Version 005-01-11
State-of-the-Art, Materials Science Manufacturing
Creating advanced ceramics components requires
specialized equipment, a fully equipped materials lab,
engineers, and optimized processes
采用专门的设备生产的先进的陶瓷组件,完善的组装材料实验室和
最优化的加工工艺
SLIDE 20
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© Copyright 2011, ERI
Version 005-01-11
Special Features of PX Device Ceramics PX陶瓷的特性
• Made of specialty formulated high purity
Aluminum Oxide 采用特殊的高品质的氧化铝制备而成
• Ceramics are strong, withstand high pressures, and
are biologically inert 坚硬的陶瓷可以承受高压和防止生物的
侵蚀
• Will not leach chemicals into water that may hurt
membranes 不会将化学品加入水中而危害反渗透膜
• Unaffected by strong acids, oxidizers, and
seawater 不会受到强酸、氧化剂和海水的影响
• Material is extremely hard, therefore it resists wear,
cavitation and abrasion damage 材料超级坚硬,可以避
免磨损、气蚀等危害
• Dimensionally stable to enable manufacturing high
precision, low friction, process lubricated bearings
高精确的尺寸和稳定的制作可以获得低的摩擦和工艺中的水力润
滑
SLIDE 21
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© Copyright 2011, ERI
Version 005-01-11
ERI Ceramic Process Flow Diagram
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© Copyright 2010, ERI VERSION:0005-00 July 2010
The PX Device
• 2 high pressure connections
• 2 low pressure connections
• Ceramic cartridge
End cover rotor/sleeve end cover
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Low-pressure feed water
fills rotor chamber,
displacing brine
Rotor chamber seals,
containing low-pressure
feed water
High-pressure brine
pressurizes and displaces
feedwater
Rotor chamber seals,
containing high pressure
brine
The PX Device at Work
1 2
3 4
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© Copyright 2010, ERI VERSION:0005-00 July 2010
The PX Device
View from Inside Pressure Vessel
SLIDE 25
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
Product Product Model
65-Series
PX-180
PX-220
PX-260
Quadribaric
Technology™
PX-300
4S-Series
PX-30S
PX-45S
PX-70S
PX-90S
PX-140S
Circulation
Pumps
Isobaric Technology: California Facility
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Specification PX300 unit
Flow range 300-200 gpm
Technology
4 pressure exchanger per
rotation
Volumetric mixing 5%
Efficiency Up to 98%
Materials
Wet material: AL6XN or
equivalent
Temperature range 1-40 C (Not freeze)
Max operational
pressure
1200 psi
Housing Side port design
PX 300 unit
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Specification PX260 unit PX300 unit
Flow range
260-180 gpm
Range: 80 gpm
300-200 gpm
Range: 100 gpm
Technology
2 Pressure
exchanger per
rotation
4 pressure exchanger
per rotation
Volumetric
mixing
6% 5%
Installation End port design Side port design
PX300 unit vs PX260 unit
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Energy Recovery Device – PX Technology Advantages
• Best-in-class Performance 高等级性能
− Highest efficiency- up to 98%
高达98%的高效率
− Constant: flat efficiency curve 效率恒定
• Rotor 转子
− One moving part 单一运转部件
− Hydrodynamic bearing 水力润滑轴承
− Automatic speed adjustment自动速度调
整
• State-of-the Art Materials尖端材料
− Ceramics 陶瓷
− Extremely durable material (3X steel
hardness) 极其耐用材料,是钢硬度的3倍
− Never corrodes 绝不腐蚀
− No fatigue 无疲劳损伤
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© Copyright 2010, ERI VERSION:0005-00 July 2010
• Scalability and Reliability 可靠及方便扩容
− Modular–like membranes同膜一样、模块化设计理念
− Fail-safe redundancy:
no down-time故障自我保护冗余,无需停机
− Installed in any orientation仸意方向安装
• Ease of Installation易于安装
− Minimal footprint占地面积最小
− No extra civil works无额外的土建要求
− No electrical connections无电气连接
− Lightweight重量轻
• Smooth Start up and Operation启动平滑和操作稳定
− Flexibility-recovery, flow controls机动性强、流量可调节
− Vibration-free (no pistons)无活塞、无震颤
− Maintenance-free 免维护
Energy Recovery Device – PX Technology Advantages
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Making Desalination Affordable
SWRO Engineering Design
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Flow Control—Low Pressure
SWRO Engineering Design
LP flow rate set by discharge flow control valve
低压侧流量由PX出口低压排放阀控制
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
32 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
Flow Control—High Pressure
HP flow rate set by booster pump
高压侧流量由PX循环泵控制
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
33 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
Flow Control—Permeate
Permeate flow rate set by high pressure pump and membranes
产水侧流量由高压泵和膜的特性控制和决定
MEMBRANES
HIGH
PRESSURE
PUMP PX-260
DEVICE
CIRCULATION
PUMP
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© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
PX Flow Control 流量控制
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
• The PX works like two parallel pipes. PX工作就像两个平行的管道
• High-pressure flow rate controlled by booster pump 循环泵控制高压侧流量
• Low-pressure flow rate controlled by discharge valve 排放阀控制低压侧流量
• High-pressure pump flow is permeate flow 高压泵控制产水侧流量
• All three main flows are independent 这三个流量相互独立
• HP and LP flows must both be metered and controlled
高、低压侧流量都必须测量和控制
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© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
Pressure Control 压力控制
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
• LP valve does not directly affect membrane pressure
低压排放阀门不直接影响膜的进水和浓水压力
• System pressure determined by membrane condition, feed temperature
and feed salinity 系统压力由膜的特性、进水温度和含盐量等因数决定
• Supply pressure changes cause LP flow rate changes
供水压力变化会引起低压侧流量变化
• PX LP out pressure must be above minimum
低压出口排放压力必须高于最小排放压力
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© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
• Membrane water recovery = I / F
• System water recovery = I /A
• Membrane recovery = system recovery
if PX LP flow = PX HP flow
Water Recovery
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
PERMEATE
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© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
PX Lubrication – High Pressure Flow Through Hydrodynamic Bearing
Lubrication flow rate dictated by system pressure
and temperature and PX seals
润滑流量是PX的特性,由系统压力、温度以及PX自身结构决定
MEMBRANES
HIGH
PRESSURE
PUMP PX-260
DEVICE
CIRCULATION
PUMP
38 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
• The PX technology always
stays on its design curves
PX总在它的设计曲线上运行
• PX unit manifolds – same as
membrane manifolds
PX母岐管就像膜的母歧管
• Design manifold for
low pressure drop
母歧管设计尽量减少压损
DIFFERENTIAL PRESSURE
5
10
15
170 180 190 200 210 220 230
Flow Rate (gpm)
Pressure
(psi)
HP DP
LP DP
PX
1
PX
2
PX
3
PX
1
PX
2
PX
3
Z flow U flow
PX Device Arrays – Even Flow Distribution
Manifold Entrance
Velocities for Good
Flow Distribution
总管进水俩素土建设计导则
<7 ft/s (2.1m/s) <12 ft/s (3.7m/s)
Z flow U flow
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© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
Mixing Effects– Lead Flow or ―Overflush‖
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
40 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design
• Feed water salinity increase进水含盐量 @ 40% recovery = 2.5%
• Operating pressure increase 操作压力增加= 1.3 bar
• Operator Options:操作选择
− Accept pressure increase 接受压力增加(= 2°C feed temp
decrease)相当于降低2度水温
− Decrease recovery by 2%或降低2%系统回收率
− Increase low-pressure supply to the PX by 5%或向PX增加5%
的低压供水流量
Mixing
混合
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
-15.00 -10.00 -5.00 0.00 5.00 10.00 15.00 20.00
Lead Flow (%)= ((LP flow in ) – 1 )* 100
HP flow out
Salinity
Increase
(%)=
(Conductivity
at
PX
HP(out))
-
(Conductivity
at
PX
LP(in))
(Conductivity
at
PX
LP(in))
Paper presented at EDS Marrakech
Caramondani 40,000 m3/ D SWRO Plant
41 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
• HP and LP flows are independent
• 高、低压侧流量相互独立
• Good flow control: stay within limits of PX unit
• 最佳流量控制:高、低压流量始终控制在PX允许的流量范围
• Constant PX device feedwater pressure
• 恒定的PX原水供应压力
• Get the air out
• 彻底排气
• Equal flow to all PX units in arrays
• PX单元均一流量分布
• Lowering recovery usually improves SWRO performance
• 系统低回收率可以改善SWRO性能
SWRO Engineering Design
Engineering Design Summary工程设计汇总
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Making Desalination Affordable
PX™ Technology Desalination
Plants
43 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Tianjin Dagang SWRO Plant – Largest SWRO in China
• 100,000 m3/day (26 MGD), Largest
SWRO plant operating in China
• Source is the Bo Sea, Tianjin
Dagang is located in Tianjin City
• Started up May 2009.
• Product used for industrial
processing
SLIDE 44
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© Copyright 2011, ERI
Version 005-01-11
Qingdao SWRO Plant
• 100,000 m3/day (26 MGD)
• 6 TRAINS x 17-PX260
• Municipal use
• Start-up Date: Q4 2011
SLIDE 45
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© Copyright 2011, ERI
Version 005-01-11
YuHuan Power Station – 2nd Largest SWRO in China
•Located in Zheijang Province, source is the
East China Sea
•34,560 m3/day (9.1MGD)
− 1 x 76,800 m3/day (20MGD) UF pretreatment
system
− 6 x 5,760 m3/day (1.5MGD) SWRO trains
− 3 x 3,120 m3/day (0.8MGD) BWRO trains
•March 2006 start-up, designed and built by
Beijing CNC Technologies
•Power/SWRO plant built for
2008 Olympics
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Perth, Australia — 140,000 m3/day (36.9 MGD)
• GWI Award 2007
Environmental Contribution of the Year
SLIDE 47
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© Copyright 2011, ERI
Version 005-01-11
Hadera, Israel: 465,000 m3/day
• World’s Largest SWRO Plant in Operation
• 16 Trains of PX-220 devices
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Hamma, Algeria — 200,000 m3/day (53 MGD)
• Largest membrane trains in the world
• 25,000 m3/ day
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© Copyright 2010, ERI VERSION:0005-00 July 2010
Al Shoaibah (Saudi Arabia)—150,000 m3/day (40 MGD)
50 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Barcelona (Spain) 200,000 m3/day (53 MGD)
51 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
570 m3/day
MV Pacific Star
Sun Cruise Ship
(Australia)
6,000 m3/day
Sharm El-Sheikh
(Egypt)
16,000 m3/day
La Marina Cope
(Spain)
Small to Medium Installations
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© Copyright 2010, ERI VERSION:0005-00 July 2010
6 year MPD History - 36 Mega Projects Contracted
1 Perth, Australia DEGREMONT 140,000 m3
/d 37 MGD 2
2 Hamma, Algeria GE 200,000 m3
/d 53 MGD 340K
3 Skikda, Algeria GEIDA 100,000 m3
/d 26 MGD 4
4 Alicante II, Spain INIMA 65,000 m3
/d 17 MGD
5 Cartagena, Spain COBRA | TEDAGUA 63,000 m3
/d 16 MGD
6 Beni Saf, Algeria GEIDA 200,000 m3
/d 53 MGD 428K
7 Chennai Minjur, India BEFESA 100,000 m3
/d 26 MGD 6
8 Shuibah III, Saudi Arabia DOOSAN 150,000 m3
/d 40 MGD
9 Torrevieja, Spain ACCIONA 240,000 m3
/d 63 MGD
10 Barcelona, Spain DEGREMONT 200,000 m3
/d 53 MGD
11 Swakopmund, Namibia KEYPLAN 65,000 m3
/d 17 MGD
12 Hamriyah, UAE AQUA ENG 90,000 m3
/d 24 MGD 845K
13 Tianjin, China HYFLUX 100,000 m3
/d 26 MGD 9
14 Tlemcen Hounaine, Algeria GEIDA 200,000 m3
/d 53 MGD
15 Tlemcen Souk Tleta, Algeria HYFLUX 200,000 m3
/d 53 MGD
16 Fouka, Algeria ACCIONA 120,000 m3
/d 32 MGD
17 Larnaca, Cyprus IDE 60,000 m3
/d 16 MGD
18 Shuwaikh, Kuwait DOOSAN 140,000 m3
/d 37 MGD
19 Tordera, Spain ACCIONA | AQUALIA 60,000 m3
/d 16 MGD
20 Bajo Almanzora, Spain BEFESA | AQUALIA 65,000 m3
/d 17 MGD
21 Hadera, Israel IDE 388,000 m3
/d 102 MGD 1333K
22 Mostaganem, Algeria INIMA | AQUALIA 200,000 m3
/d 53 MGD 10
23 Cape Preston, Australia IDE 140,000 m3
/d 37 MGD
24 Paraguana, Venezuela ACCIONA 75,000 m3
/d 20 MGD
25 Cap Djinet, Algeria INIMA | AQUALIA 100,000 m3
/d 26 MGD
26 Palmachim Expansion, Israel VIAMARIS 137,000 m3
/d 36 MGD
27 Hadera Expansion, Israel IDE | H&C 74,000 m3
/d 20 MGD
28 Adelaide Port Stanvac, Australia ACCIONA 150,000 m3
/d 40 MGD
29 Perth 2 - Bunningup, Australia VALORIZA | SADYT 137,000 m3
/d 36 MGD
30 Tenes, Algeria BEFESA 200,000 m3
/d 53 MGD
31 Magtaa, Algeria ** HYFLUX 500,000 m3
/d 132 MGD 1713K
32 Adelaide Expansion, Australia ACCIONA 150,000 m3
/d 40 MGD 5
33 Melbourne - Wonthaggi, Australia DEGREMONT 411,000 m3
/d 109 MGD
34 Moncofa, Spain INIMA 60,000 m3
/d 16 MGD
35 Oropesa, Spain * TECNICAS REUNIDAS 50,000 m3
/d 13 MGD
36 Qingdao, China BEFESA 100,000 m3
/d 26 MGD 771K
* PX-300s -- ** AT-7200s 5.4 M m3
/d 1434 MGD
Totals
2010
2005
2006
2007
2008
2009
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© Copyright 2010, ERI VERSION:0005-00 July 2010
ERI PX Technology Mega Projects
• 31/35 Mega Projects
• 900 MW of Energy Savings
• 6 Billion Liters of water – enough for every person on the planet
Alicante
Cartagena
Torrevieja
Barcelona
Tordera
Bajo Almanzora
Paraguana
Hamma
Skikda
Beni Saf
Tlemcen H
Tlemcen ST
Mostaganem
Fouka
Oued Sebt
Cap Djinet
Tenes Swakopmund
Chennai
Hamriyah
Shoaibah
Shuwaikh
Tianjin
Hadera
Larnaca
Palmachim
Perth
Cape Preston
Adelaide
54 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Summary
• Energy is the largest operating cost of SWRO
• SWRO系统中能耗是最大的操作成本
• Most developments in SWRO address energy issues
• SWRO发展的制约因素是能耗
• SWRO energy improved > 60% in 20 years
• 最近20年SWRO能量消耗已经提高了超过60%
• Energy Recovery technologies cut energy costs by up to 60%
• 能量回收技术小姐能耗高达60%
• Approx. 97% efficient energy recovery in isobaric configurations – flexibility
• 灵活的等压式能量回收装置效率约97%
• Small additional reductions in energy consumption are feasible
• 额外的小幅能耗消减是可行的
• Additional energy cuts may be offset by capital cost increases
(for example, lower recovery)
• 投资的增加可以通过能耗的消减来弥补,例如,较低回收率
55 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Centrifugal Pumps
&
TurboCharger ERD Solutions
56 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Energy Recovery Inc
ENERGY RECOVERY INC
NEW BOSTON
New Boston, Michigan
USA
• Centrifugal Manufacturing Headquarters – Pumps and TurboChargers
离心式水泵和涡轮增压装置的生产基地
• Top-notch manufacturing facility 先进的制造工厂
• Pump/TurboCharger manufacturing and testing facility
水泵和涡轮增压装置的生产及测试基地
• 3,000 HP Test Stand 3,000马力测试平台
57 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Core Competences
Engineering
• CFD Analysis
& Simulation
• Custom
Design
• Extensive
R&D
• MSU Turbo
Machine Lab
• PWR Co-op
Machining
• Large VTL
• CNC Lathes
• 5 Axis CNC
• Grinding
• Honing
• Dynamic
Balancing
Assembly
• Prep & Polish
• QC
• Torque
control
• CMM Analysis
Testing
• Full Power
Performance
Testing
• Efficiency
Validation
• Hydrostatic
test
• Performance
baseline
58 CONFIDENTIAL
58 CONFIDENTIAL
Customer
Requirements
Agile
Engineering
CNC
Programming
Machining of
Hydraulic
Passages
Performance
Test
Quality
Control
Shipment
Agile Engineering
59 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
59
60 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Manufacturing Capability Expansion
61 NOT FOR DISTRIBUTION
© Copyright 2010, ERI
LPT
AquaSpire
HTC AT HALO
ERI (Centrifugal Technology) Products
Energy Recovery Devices
• Advanced Technology TC (HTC AT)
超技术型涡轮能量回收装置(HTC AT)
• Low Investment Turbocharger (HALO)
经济型涡轮能量回收装置(HALO)
• Low Pressure Turbocharger (LPT)
低压型涡轮能量回收装置(LPT)
Pumps
• AquaBold High Pressure RO
Pumps 离心式反渗透多级高压泵
• AquaSpire Single-stage Pump
单级泵
AquaBold
62 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaBold Pump Line
63 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
High-Efficiency Centrifugal High Pressure RO Pump
高效率的离心式RO系统高压泵
• Uniquely designed for desalination applications
为海水淡化系统独特设计的产品
– Custom designs for specific operating conditions allows for optimum pump
efficiencies 根据实际的操作工况定制的独特结构,可以达到最佳的泵效率
• Quality materials & manufacturing 优质材料和制造
− Designed for 20 year service life 20年设计使用寿命
• Designed for use with PX energy recovery devices
和PX能量回收装置配合设计使用
− Highest efficiency package solution with guaranteed power consumption
最高效率的能量解决方案保证了能耗指标
 For certain sizes & upon request 对于确认的尺寸和较高的要求
• Available with short lead-times 可以保证的较短的交货期
• Customer service, training and support 客户服务、培训和支持
− Highly qualified technical field services and training programs
高质量的技术现场服务和培训
AquaBold Pump Overview
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© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaBold Pump Advantages
• Industry-leading high efficiencies
行业领先---高效率
− Performance-enhanced fluid modeling
流动模型的建立可以提高性能
− Proprietary thrust technology eliminates
losses 专利的止推轴承技术减少了损耗
• State-of-the-art construction for RO
industry RO行业最有魅力的产品
− Precision machined investment-cast
components 精密的机械投资---浇铸部件
− Standard Duplex 2205 标准的2205双相不锈钢
− Super Duplex 2507 optional
超级双相不锈钢2507可作为选择
• Simple to maintain 简单的维护
− No disassembly required for mechanical seal
replacement 无需拆装要求的机械密封更换
− All product-lubricated bearings
所有的轴承都是产品自身润滑
− Thrust bearing can be replaced without
removing pump or motor
无需移动电机和水泵就可以自由地拆装止推轴承
65 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaBold Pump - Features
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© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaBold Pump (Cross Section)
67 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Proprietary Thrust Bearing
• Product lubricated bearings – eliminates
maintenance of grease bearings and
auxiliary oil systems and associated seals
润滑轴承---免去油脂轴承和辅助油系统及其相关密
封的维护
• Simple, efficient design – allows field retrofits
without the need for bearing change
简单、高效的设计---在无需改变轴承的情况下在现
场可以翻新改造
• Reduced friction provides lower power
losses within the bearing system, improving
overall efficiency
在轴承系统理减少的摩擦可提供较低的能量损失,
提高整体效率
• Eliminates need for costly external thrust
bearing system
无需外部昂贵的止推轴承系统
68 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaBold Pump Line (Current Products)
50
55
60
65
70
75
80
85
90
0 200 400 600 800 1000 1200 1400 1600
Efficiency
(%)
Q (gpm)
AquaBold High Pressure Pump
4x6x9-C
4x6x9-B
3x4x7-C
3x4x7-A
2x3x5-C
2x3x5-B
2x3x5-A
3x4x7-B
4x6x9-A
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© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaSpire Pump
70 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaSpire Pump
Application 应用范围
• Single-stage high pressure pump for medium to large scale SWRO
systems 适用于大中型海水淡化系统的单级高压泵
Advantages 优势
• Achievable efficiencies up to 90+% 最高效率可达到90%以上
• BEP always matches customer duty point 最佳效率点通常能匹配客户的需要
• Removable volute inserts 可移动更换式蜗壳
− Allows rerate to match changes in system conditions
允许为了配合系统的工况改变而再次修正
− Customized Hydraulic Design for each specific application
对于每一个特殊的应用窦可以进行量身定做的水力模型设计
− Customized 3-D geometry Impellers
量身定做的三维叶轮设计
• No scheduled maintenance 无需周期性维护
• Single-stage design 单级设计
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© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaSpire ½ AT
=
AquaSpire Pump
72 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaSpire Pump Con’d
THRUST BEARING
CENTER BEARING
PUMP
IMPELLER
PUMP
VOLUTE
SHAFT
73 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
AquaSpire Pump (exploded)
Pump
Volute
Pump
Diffuser
74 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
TurboCharger General Theory
75 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
SWRO Engineering Design – Single Stage
TURBOCHARGER
MEMBRANES
900 PSI (62 bar)
5 PSI (.35 bar)
200 GPM (45.5 m3/h)
300 GPM (68.1 m3/h)
5 PSI (.35 bar)
300 GPM (68.1 m3/h)
595 PSI (41 bar)
500 GPM (113.6 m3/h)
920 PSI
(63.4 bar)
500 GPM
(113.6 m3/h)
30 PSI (2 bar)
500 GPM (113.6 m3/h)
HP PUMP
• The Turbocharger uses brine energy to boost
the full feed stream to the RO, thereby
reducing the required boost from the high
pressure pump
涡轮式能量回收装置主要是利用反渗透浓水的能量给
进入反渗透装置的原水进行增压以达到降低高压泵的
扬程,起到节能的作用
76 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
LPT Process Design
1ST STAGE MEMBRANES
LPT TURBO CHARGER
2ND STAGE MEMBRANES
250 PSI
(17.24 bar)
2000 GPM
(454.2 m3/h)
30 PSI (2 bar)
2000 GPM (454.2 m3/h)
HIGH PRESSURE PUMP
5 PSI (.35 bar)
1000 GPM (227.1 m3/h)
5 PSI (.35 bar)
1500 GPM (340.7 m3/h)
5 PSI (.35 bar)
500 GPM (113.6 m3/h)
5 PSI (.35 bar)
500 GPM (113.6 m3/h)
311 PSI (21.44 bar)
326 PSI
(22.48bar)
1000 GPM
(227.1 m3/h)
230 PSI (15.86 bar)
1000 GPM (227.1 m3/h)
500 GPM (113.6 m3/h)
• Inter-stage pressure boosting: LPT
77 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
System Control and Optimization
78 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
• The auxiliary nozzle valve on the turbocharger provides brine flow and
pressure adjustment to accommodate typical variations in membrane
requirements
涡轮式能量回收装置上的辅助浓水管路阀门可调节浓水的流量和压力以适应膜系统变化的
要求
How does an ERI Turbocharger work?
BRINE
PRIMARY NOZZLE
TURBINE
IMPELLER
VOLUTE
AUXILIARY NOZZLE
VALVE
AUXILIARY NOZZLE
•The Main Nozzle is sized to provide a concentrate system resistance (concentrate pressure)
equal to the maximum design pressure at a constant design concentrate brine flow rate. The
auxiliary nozzle is sized to about 20-25% of the area of the Main Nozzle. The ANCV controls flow
to the AN in the turbine casing. The ANCV will provide a 20-30% pressure range at a constant
brine flow.
79 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
System control and optimization
• To reduce brine pressure, open the auxiliary nozzle valve until the desired brine flow and pressure are
obtained.
• Opening the ANCV reduces the brine pressure and consequently reduces the boost pressure.
Opening the ANCV increases the total nozzle area, allowing more flow and/or a lower pressure. This is
typically done during those periods of RO plant operation that require less pressure than the maximum
designed membrane pressure.
• To increase brine pressure, close the auxiliary nozzle valve until the desired brine flow and pressure
are obtained. The TURBO will produce the most boost pressure when the ANCV is fully closed.
• The Aux Nozzle valve can be manual (as shown) or actuated.
• If automated, the best control signal is the brine flow.
SLIDE 80
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
TurboCharger Rotating Assembly
SLIDE 81
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
dP = (Nte) x (Rr) x (Pbr – Pe)
Where Rr = ratio of brine flow to feed flow
Pbr = brine pressure at turbine inlet
Pe = Turbo exhaust pressure
Nte = Hydraulic Energy Transfer Efficiency from Curve
Turbo Pressure Boost – Example II.
Perth SWRO plant, Membrane feed flow 2‘453 m3/h, conversion 45 %, membrane feed pressure 57.9 bar,
brine pressure 57.2 bar, brine back pressure of 0.5 bar. What is the pressure boost???
AT-7200 = (0.82) x (0.55) x (57.2 – 0.5) = 25.6 bar boost
82 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Turbo Operation
83 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Advanced Technology (AT) Turbocharger
84 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Advanced Technology (AT) Turbocharger
Application 应用范围
• Medium to large scale energy recovery device for SWRO
适用于中大型海水淡化系统
Advantages 优势
• Reliability 可靠性
− Product lubricated bearings 润滑轴承
− No scheduled maintenance 无需周期性维护
− Ease of installation 易于安装
• Designed for Optimum Efficiency 可设计的最佳效率
− Customized Hydraulic Design for each specific application
对于每一个特殊的应用都可以进行量身定做的水力模型设计
− Customized 3-D geometry Impellers 量身定做三维立体的叶轮设计
• Removable volute inserts 可移动更换式蜗壳
• Compact design allowing for smallest foot print available
紧凑型设计更适合小型的占地面积
• Feed pump size reduction 减小给水泵的尺寸
85 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Advanced Technology (AT) Turbocharger (Cross Section)
THRUST BEARING
CENTER BEARING
PUMP IMPELLER
PUMP VOLUTE
TURBINE IMPELLER
TURBINE VOLUTE
PUMP BEARING
86 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Advanced Technology (AT) Turbocharger Con’d
Pump Side
Diffuser
Main
Turbine
Nozzle
Turbine
Side Volute Pump Side
Volute
PEI Patent Pending
87 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Volute Insert Technology 蜗壳内插技术
• ERI’s unique ability to improve efficiency and reduce water cost over the life
of the plant PEI 可更换式涡壳是提高效率和降低系统运行成本的最独特的产品
• Does not require complete equipment replacement 不需要完整的零部件更换
• Simple field retrofit with virtually no downtime 无需周期性的停机检修,现场更
换简单
HTCAT AquaSpire
88 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Volute Insert Technology Con’d
• Ability to adapt to improvement in desalination technology
能够适应海水淡化技术的改进
• Enhanced membrane recovery (Impact on feed flows)
提高膜的回收率(影响进水流量)
• 10 years ago 35% recovery was industry norm 10年前35%的回收率是标准设计
• Now 40 – 45 % recovery is the norm 现在回收率40-45%是标准设计
• Reduction in operating pressure 降低操作压力
• 10 years ago 70 -74 bar was SWRO norm 10年前70-74bar是海水淡化的标准设计
• Now 64 -68 bar is the norm 现在64-68bar是标准设计
• Improved pretreatment technology 提高预处理技术
• Ability to take advantage of desal technology improvement without negative
impact on efficiency
在无负效率的影响下能有效地提高淡化技术的发展
1.5% - 2% of Efficiency will save a customer
Millions $ over the entire Plant Life
效率的1.5%-2%的再增加可以节约系统数百万美元的运行成本
89 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Volute Insert Technology Con’d
• 10% change in flow = 1.5% drop in efficiency
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
Feed
Pump
Efficiency
Feed Flow (m3/h)
• Easily replicable volute and diffuser components allow for best efficiency
point operation even when operating requirements change
当操作工况改变时,简易的可复制的涡壳和扩散器部件可在最好的效率点下工作
90 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
HALO Turbocharger
91 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
HALO Turbocharger
Application 应用
• Small to medium skid mounted SWRO systems
适用于中小型海水淡化系统
Advantages优势
• Full 3-D geometry impellers 完全的三维立体叶轮
• More reliable thrust bearing 更可靠的止推轴承
• Reduces high pressure pump and motor size 较小的高压泵及电机
• Compact design 紧凑的设计
• Lower Installation cost 低安装成本
• Custom rotor designed for highest efficiency 最高效率的定制转动部件
92 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
HALO Turbocharger
THRUST BEARING
CENTER BEARING
PUMP BEARING
PUMP
IMPELLER
TURBINE
IMPELLER
PUMP
VOLUTE
TURBINE
VOLUTE
93 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Low Pressure Turbocharger (LPT)
94 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Low Pressure Turbocharger (LPT)
Application 应用
• Designed for use in low pressure, multi-stage Brackish Water RO
systems 适用于低压、多级苦咸水反渗透系统
Advantages 优势
• All components made from cast parts for long life 所有部件适用寿命长
• Custom designed for customer specific conditions
对于每个应用都进行量身定做设计
• Balances first and second stage flux rates 平衡第一和第二段的流量
• Eliminates interstage booster pump 取消段间增压泵
• Reduces first stage fouling potential 降低第一段的污堵的可能性
• Replaces brine control valves 取代浓水控制阀
95 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Low Pressure Turbocharger (LPT)
THRUST BEARING
CENTER BEARING
PUMP BEARING
PUMP
IMPELLER
TURBINE
IMPELLER
PUMP
VOLUTE
TURBINE
VOLUTE
96 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
LPT Process Design
1ST STAGE MEMBRANES
LPT TURBO CHARGER
2ND STAGE MEMBRANES
250 PSI
(17.24 bar)
2000 GPM
(454.2 m3/h)
30 PSI (2 bar)
2000 GPM (454.2 m3/h)
HIGH PRESSURE PUMP
5 PSI (.35 bar)
1000 GPM (227.1 m3/h)
5 PSI (.35 bar)
1500 GPM (340.7 m3/h)
5 PSI (.35 bar)
500 GPM (113.6 m3/h)
5 PSI (.35 bar)
500 GPM (113.6 m3/h)
311 PSI (21.44 bar)
326 PSI
(22.48bar)
1000 GPM
(227.1 m3/h)
230 PSI (15.86 bar)
1000 GPM (227.1 m3/h)
500 GPM (113.6 m3/h)
• Inter-stage pressure boosting: LPT
97 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Flux Balancing
What is Flux?
• Defined as the permeate produced per membrane area
− Lmh: Liters per square meter per hour
− Gfd: Gallons per square foot per day
• Balancing flux between stages spreads the rate of fouling
deposition over the greatest membrane area
• Improves final system permeate quality when the flux is
increased in the last stages
• Reduces recovery in 1st stage and increases it on the 2nd
stage
• Can reduce fouling potential in the 1st stage
98 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Interstage Boost
• Advantages
− Low operational costs
− Highest power efficiency
− Reduced feed pump HP
• Disadvantages
− Slightly higher capital costs
 Boost pump, manifold (if a turbo is not used)
99 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
BWRO Energy Cost Comparison
Case Basic Design (A)
Permeate
Throttling
(B)
Interstage
Turbo Boost (C)
Pump Power (hp) 309 355 280
Motor and VFD size (hp) 350 400 300
Permeate production (m3/hr) 500 500 500
Flux Rate (lmh)
1st stage 23.8 21.9 21.9
2nd stage 16.5 20.2 20.2
Specific Permeate Energy Rate
(kW/m3) 0.4575 0.5325 0.42
Annual Power Usage (8,322hrs/yr) 1,928,624 2,215,733 1,747,620
Annual Power Cost ($0.10kWhr)
$
192,862 $ 221,573
$
174,762
20 year Power Cost $ 3,857,240 $ 4,431,460 $ 3,495,240
Estimated Savings $ 936,220 USD
100 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Making Desalination Affordable
TurboCharger Technology
Desalination Plants
101 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Magtaa, Algeria — 500,000 m3/day (132 MGD)
• Largest membrane plant in the world
• 25 – AT-7200
To be commissioned in 2011…
SLIDE 102
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
TurboCharger Installation: 8,000 m3/day
SLIDE 103
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
TurboCharger + AquaBold Installation: 3,000 m3/day
SLIDE 104
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
TurboCharger Installation (Brackish): 10,000 m3/day
SLIDE 105
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
TurboCharger Installation Seawater RO Plant
106 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Making Desalination Affordable
ERD Trouble-shooting
能量回收装置的现场故障分析和解决方案
107 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
PX Device – Trouble-Shooting
Symptom: Excessive Noise
征兆:过高的噪音
− Operating the units above rated flow
操作工况超过额定流量
− Operating units with insufficient backpressure
操作工况背压过低
− Entrained air in the system
系统中有气体
− Damaged Ceramics 损坏的转子
Symptom: Stalled Rotor
征兆:转子停转
− Operating the units below rated flow 操作工况低于额定流量
− Operating the units above rated pressure rating 操作工况超过额定压力
− Foreign debris 外来的碎片
108 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Symptom: High Membrane Feed Pressure
征兆:高的反渗透膜进水压力
− Operating the main HPP at to high of a flow rate 主高压泵在高流量下运行
− Changes in membrane conditions or feed water 膜的工况或进水情况改变
− Unbalanced PX array flows PX列的流量不平衡
− Stuck Rotor 转子停转
Symptom: Low Permeate Flow
征兆:低的产水流量
− Malfunctioning high-pressure pump 高压泵故障
− High lubrication/leakage flow through PX device(s)
PX装置的高的润滑/泄漏流量
− Leakage from high-pressure to low-pressure circuit
从高压到低压流量圈的泄漏
PX Device – Trouble-Shooting
109 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
TurboCharger Device – Trouble-Shooting
Symptom: Stalled RA 征兆:RA停转
− Foreign Debris 外来的碎片
− Operating the units below rated flow/pressures 操作工况低于额定流量和压力
− Damaged thrust bearing 止推轴承损坏
− Incorrect recovery/recovery ratio 不正确的回收率
Symptom: Abnormal Noise
征兆:不正常的噪音
− Operating the units with
insufficient back pressure
操作工况背压过低
110 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
TurboCharger Device – Trouble-Shooting
Symptom: Unable to achieve design boost pressure
征兆:不能达到设计的增压压力
− Incorrect recovery/recovery ratio 不正确的回收率
− Aux/By-pass valve in incorrect position
辅助管道和旁路管道上的阀门在不正确的位置上
− Debris – damaged bearing 碎片-轴承损坏
− Changes in membrane or feed water
膜或进水工况改变
Symptom: Excessive boost pressure
征兆:超额的增压压力
− Incorrect recovery/recovery ratio 不正确的回收率
− Aux/By-pass valve in incorrect position
辅助管道和旁路管道上的阀门在不正确的位置上
− Change in high-pressure pump performance 高压泵的性能改变
− Changes in membrane or feed water 膜或进水工况改变
Misconceptions of ERD Technology
能量回收装置的误解
SLIDE 112
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
PX Device Misconceptions: Fact versus Fiction
Fiction: PX Devices have higher operating expense than other isobaric
devices. PX比其他的等压式能量回收装置操作压力高。
FACT: The PX device has a peak efficiency of 98% and is being
operated in some of the lowest power consuming plants in the world
today. The PX has one moving part, no scheduled maintenance and has
the highest availability of any ERDs currently available.
PX装置的最大的效率是98%,现在在全球正在以最低的能耗运行着。PX只
有一个运动部件,无需日常的维护并且是所有能量回收装置中最适用的。
Fiction: PX Devices require excessive pressure before they start to
rotate. PX装置在启动时需要更高的压力。
FACT: PX devices need process flows (high-pressure and low-
pressure flow) and lubrication flow in order to rotate.
为了启动转子,PX装置需要工艺流量(高压和低压流量)和润滑流量。
SLIDE 113
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
PX Device Misconceptions: Fact versus Fiction
Fiction: When operating multiple PX devices in an array, a stuck rotor will
cause overflow and damage to the operating PX devices.
当多个PX装置在一套系统中运行时,一个停转的PX会引起超流和对PX的损伤。
FACT: The PX device is passive in nature. The operable units will
continue to perform as designed. The inoperable unit will re-circulate
concentrate back to the membrane feed but the impact will be determined by
the number of devices in the array. Overflow to the operable units will NOT
occur. PX本身是被动转动的,运转的单元根据设计要求连续运行着。停转的转子将浓水直接送入
给水且对系统的影响主要取决于PX的数量。超流将不会发生 。
Fiction: PX devices can’t be operated at the maximum rated flow.
PX装置不能在最大的额定流量下操作。
FACT: All PX devices are designed to operate at full rated capacity and
the operators are free to do so. Installing additional capacity in an array does
have several benefits, including; optimizing performance, availability,
flexibility and longevity. 所有的PX产品都可以在最高的额定流量下设计同时可以仸意的操
作,在一列中安装额外的容量会有更好的优势:优化性能、实用、操作弹性 和寿命长。
SLIDE 114
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
PX Device Misconceptions: Fact versus Fiction
Fiction: The high-pressure portion of the system can be filled via the LP
INLET side of the PX device.系统的高压部分可以通过PX的低压给水部分填补。
Fiction: PX units have a 5 year useful-life. PX只有五年的使用期。
FACT: The PX device is a passive device. The low-pressure and high-
pressure flow paths act as independent pipes flowing in opposite
directions with an integrated seal zone between the “pipes”.
PX是一个被动装置。低压流量和高压流量由于完整的密封区的隔离可以看成是两个相互独立
流道相反的两根管道。
FACT: PX units that have been commercially released and
commissioned in 1997 are still operating today. PX devices have yet
to reach their end-of-life or wear-out periods.
PX产品从1997年正式得投入市场和运行至今,还在不断的延伸其使用期和磨损期。
SLIDE 115
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
PX Device Misconceptions: Fact versus Fiction
Fiction: ―Over-flush‖ is required by the PX device. PX需要超流。
FACT: The PX device does not require over-flush and a
majority of the PX installations operate with “balanced” flows. The
salinty increase at the membranes is typically between 2-3%
(depending on membrane recovery). Over-flush can be
implemented at the operators discretion.
PX装置不需要超流运行通常是要求在水量平衡的情况下安装及运行。膜进口的含盐
量将会增加2-3%(依据膜的回收率)。是否超流运行主要依靠操作者的要求。
Fiction: Small particles can cause a rotor to stop.微小颗粒可造成转子的停转
FACT: Large debris such as broken pieces of PVC can cause a
rotor to stop but there are no known incidences of “small” particles
causing severe damage or stalling issues.
大的碎片,像PVC碎片将会引起转子的停转,但是小的颗粒并没有听说会引起危害等情
形
SLIDE 116
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
PX Device Misconceptions: Fact versus Fiction
FACT: PX devices require no maintenance. In fact, even after 5
years of operation, no spare parts or servicing is needed. This
provides more valuable, up-time (> 98%) compared with competing
technologies that need scheduled maintenance and a large stock
pile of spare parts.
PX无需定期维护。事实上,即使超过5年的运行也无需备品备件,这与需要定期维护和
大量的备品备件储备的其他的能量回收来说,这是非常有价值的。
Fiction: PX devices require some maintenance and spare parts.
PX 需要定期维护和备品备件。
SLIDE 117
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
Turbo Device Misconceptions: Fact versus Fiction
Fiction: The turbos need to be isolated when cleaning/flushing the
system. 涡轮增压装置在清洗和冲洗的时候需要隔离。
FACT:. The turbo does not require isolation during CIP, however it
is best practice to do so or flush thoroughly with fresh water
during system flush.
涡轮增压装置在清洗时无需隔离,但是系统清洗是最好采用新鲜水进行冲洗。
Fiction: You must have a brine control valve upstream /downstream
of the turbo. 在涡轮增压的进出水口必须设置浓水控制阀门
FACT: NO, the turbine side of the turbo along with the aux valve
replaces the brine valve completely.
不需要。涡轮增压的透平段采用了辅助管路阀门完全可以替代浓水阀门。
SLIDE 118
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
Turbo Device Misconceptions: Fact versus Fiction
Fiction: You can flush the system through the Turbo
可以通过涡轮增压装置冲洗系统
FACT: The turbine side of the turbo acts like an orifice plate and
requires a dP to pass water through. In fact, a bypass is used
for flushing.
涡轮增压装置的透平段实际上像一个收缩孔,要求有一定的压差的水才能通过,
所以需要一个旁路冲洗。
Fiction: Turbocharger must be coupled with high pressure pump.
涡轮增压装置必须和高压泵相连接
FACT: Not true, turbocharger can be mounted anywhere in the
plant for best fit into the plant design.
这是不正确的,涡轮增压装置可以安装在系统设计中认为最适合的地方。
SLIDE 119
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
Turbo Device Misconceptions: Fact versus Fiction
Fiction: Plant design with turbocharger requires brine disposal
pump. 设置涡轮增压装置的系统设计时需要设置浓水泵
FACT: Not true, turbocharger operates with brine exit back
pressure which can reach several bars thus eliminating need
for brine disposal pump.
这是不正确的,涡轮增压装置是利用浓盐水的出口压力得到一定的压力,因此无
需浓水泵。
ERI Services
SLIDE 121
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
ERI Services
ERI is Pleased to offer the following Services:
− P&ID Reviews
− Control Logic Reviews
− Commissioning Services
SLIDE 122
NOT FOR DISTRIBUTION
© Copyright 2011, ERI
Version 005-01-11
Energy Recovery Power Models and Selector Tools
1/4/2008 PX®
Energy Recovery Device System Analysis
A B C D E F G H
FLOW US gpm 408 222 186 222 408 183 224 224
m3/hr 93 50 42 50 93 42 51 51
m3/day 2,222 1,211 1,012 1,211 2,222 1,000 1,222 1,222
PRESSURE psi 24 24 943 919 943 0 928 15
bar 1.7 1.7 65.0 63.4 65.0 0.0 64.0 1.0
QUALITY mg/l 39,000 39,000 39,000 41,025 40,103 200 72,751 70,745
PX UNIT PERFORMANCE INPUT DESCRIPTIONS INPUTS
PX-260 Units Metric or English M or E M
Number of PX units quantity 1 Manual or auto efficiencies m or a a
m3/hr 50.9 Permeate flow m3/day 1,000
PX lubrication per array m3/hr 0.5 RO recovery rate % 45%
PX lubrication flow % 0.9% RO feed pressure bar 65.0
Dfferential pressure HP side bar 0.6 Membrane differential pressure bar 1.0
Differential pressure LP side bar 0.7 PX LP discharge pressure bar 1.0
PX efficiency % 97.2% Feedwater salinity mg/l 39,000
PX mixing at membrane feed % 2.8% Cost of power $/kWh $0.10
Operating capacity % 86.2% HP pump efficiency % 80%
Energy recovered kW 139.9 HP pump motor efficiency % 96%
Circulation pump efficiency % 80%
HIGH PRESSURE PUMP Circulation pump motor efficiency % 94%
HP pump efficiency % 68% Circulation pump VFD efficiency % 97%
HP pump motor efficiency % 92% PX device design margin % 5%
HP pump power consumed kW 118.0
PX SYSTEM POWER RESULTS
CIRCULATION / BOOSTER PUMP Total power consumption kW 122
Circulation pump efficiency % 65% Specific power consumption kWh/m3 2.93
Circulation pump motor efficiency % 91% Specific power consumption kWh/kgal 11.1
Circulation pump VFD efficiency % 97% Power cost saved with PX $/year 122,510
$
Total circulation pump power kW 3.9
Warnings
SYSTEM FEED PUMP kW 0.0 Suggestions
NONE
NONE
PX model
PX unit flow
123 NOT FOR DISTRIBUTION
© Copyright 2010, ERI VERSION:0005-00 July 2010
Contacts
• Ms. Ping Zou, pzou@energyrecovery.com
• Mr. Mike Zhan, xwzhan@energyrecovery.com
• Ms. Jesse Yu, jasmine.yu@ewp-china.com
• Mr. Eric Kadaj, ekadaj@energyrecovery.com
• Mr. Rodney Clemente. rclemente@energyrecovery.com
THANK YOU

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ERI Technical Presentation.pdf

  • 1. 1 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Making Desalination Affordable High Efficiency, Energy Recovery Solution Technical Seminar 高效率的能量回收解决方案 SHANGHAI JUNE 2011
  • 2. 2 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Agenda Desalination Systems The Pressure Exchanger Centrifugal Pumps & ERD Solutions Energy Recovery Inc High Efficiency Integrated Power Solution SWRO Engineering Design Process Simulator Desalination Plants with PX Technology
  • 3. 3 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Energy Recovery Inc HEADQUARTERS/CERAMICS San Leandro (San Francisco), California USA REGIONAL OFFICES Spain, China, UAE ENERGY RECOVERY NB New Boston, Michigan USA
  • 4. 4 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Company Profile 公司简介 Background 公司背景 • Established in 1992, Headquarters in California 公司成立于1992年,总部位于美国加州 • More than 10,000 Energy Recovery Devices Installed/Contracted 全球已经销售和安装了过一万多个PX® • Global Sales and Technical Presence 全球销售和技术支持网络 • Saving more than 890 MW of Energy 节省890 MW 功率能量 • More than 180 OEMs 180多个OEMs使用过PX® Technical Expertise 技术专家 • Highest Efficiency, Durability and Reliability 高效、耐用和可靠 • 24/7 Service and Support 全方位、全天候服务和技术支持 • Precision Manufacturing and Ceramics Expertise 精密的制造及加工技术,陶瓷专家 • Technical Review, On-site Commissioning, Start-up 技术审核、现场调试和启动 • Isobaric and Turbine Energy Recovery Solutions 提供等压式和透平式能量回收解决方案 • ERI Acquires Pump Engineering in 2009 ERI在2009年成功收购PEI
  • 5. 5 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Over 180 Clients
  • 6. 6 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Capital Expense 投资成本 43% Operating Expense 操作成本 57% Desalination Plant Capital & Operating Costs ASSUMPTIONS 基准 Power Cost 电费USD/kWh 0.09 Debt Equity Ratio 债权比 80/20 Debt Interest Rate 利率 8% Equity Return on Inv 投资回报率 18%
  • 7. 7 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Chemical / Consumables 化学消耗品 9% Power 电能 41% Parts Replacement 备品备件 13% Operating Margin 运营利润 17% Office 办公费用 3% Membranes 膜更换费用 8% Labor, G&A 劳动力 9% Operating Expenses—Breakdown 操作成本分项 Perth Seawater Desalination Plant 2008
  • 8. 8 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Source: Affordable Desalination Collaboration, 2008 Power Use—Breakdown (Seawater RO)电力消耗成本分项 Pre-filtration 预处理系统8% Permeate Treatment 后处理系统1% Permeate Distribution 产品水输送系统7% Reverse Osmosis Process 反渗透68% Intake 取水15% RO power consumption is approximately 20% (up to 45%) of total SWRO cost 反渗透系统电力消耗大约占总的操作成本的20-45%
  • 9. 9 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Making Desalination Affordable Desalination Systems
  • 10. 10 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Issues: high pumping costs, wasted energy, lack of optimization 问题:高压泵高投资、能量的浪费和无法优化 MEMBRANES HIGH PRESSURE PUMP Seawater RO: Before Energy Recovery Devices
  • 11. 11 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 11 Seawater RO: Pelton Wheel/Francis Turbine Energy Recovery Devices
  • 12. 12 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 TURBOCHARGER MEMBRANES 900 PSI (62 bar) 5 PSI (.35 bar) 200 GPM (45.5 m3/h) 300 GPM (68.1 m3/h) 5 PSI (.35 bar) 300 GPM (68.1 m3/h) 595 PSI (41 bar) 500 GPM (113.6 m3/h) 920 PSI (63.4 bar) 500 GPM (113.6 m3/h) 30 PSI (2 bar) 500 GPM (113.6 m3/h) HERO PUMP HIGH PRESSURE PUMP Seawater RO: TurboCharger Energy Recovery Devices
  • 13. 13 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Seawater RO: Positive Displacement Energy Recovery Devices Smaller pump, high constant efficiency, flexible operation 较小尺寸的高压泵、恒定的高效率和灵活的操作性能 95 – 98% efficiency MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 14. 14 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Constant High Efficiency Isobaric Energy Recovery Systems Have High Efficiency Regardless of System Size 无论系统大小等压式能量回收装置具有恒定的高效率 Increasing Flow 100 80 60 40 20 Efficiency % Isobaric Turbocharger Pelton Turbine
  • 15. 15 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Desalination Systems Pelton Turbine Turbocharger Piston Exchanger Francis Turbine Dyprex Rotary Exchanger 1980 1990 2000 2010
  • 16. 16 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 No ERD Francis Turbine Pelton Wheel Isobaric Device kWh / m 3 0 1 2 3 4 5 6 7 8 1980 2000 2009 Jeddah I Las Palmas Trinidad Perth Energy Recovery — Driving Down the Cost of Desalination Advances in Membrane and Pump Technologies have also enabled these improvements 先进的泵和膜技术进一步降低了能耗
  • 17. 17 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 The PX Pressure Exchanger™ Device An Isobaric Energy Recovery Solution
  • 18. 18 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Energy Recovery Inc HEADQUARTERS/CERAMICS San Leandro (San Francisco), California USA • Global Headquarters – Executive Staff, Engineering/R&D, Sales, Support & Marketing 公司总部-管理部门、研发、销售、技术支持和市场 • Top-notch ceramics manufacturing facility 超级陶瓷生产工厂 • PX manufacturing and testing facility PX生产和测试工厂 • PX School training seminar PX培训学校
  • 19. SLIDE 19 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 State-of-the-Art, Materials Science Manufacturing Creating advanced ceramics components requires specialized equipment, a fully equipped materials lab, engineers, and optimized processes 采用专门的设备生产的先进的陶瓷组件,完善的组装材料实验室和 最优化的加工工艺
  • 20. SLIDE 20 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 Special Features of PX Device Ceramics PX陶瓷的特性 • Made of specialty formulated high purity Aluminum Oxide 采用特殊的高品质的氧化铝制备而成 • Ceramics are strong, withstand high pressures, and are biologically inert 坚硬的陶瓷可以承受高压和防止生物的 侵蚀 • Will not leach chemicals into water that may hurt membranes 不会将化学品加入水中而危害反渗透膜 • Unaffected by strong acids, oxidizers, and seawater 不会受到强酸、氧化剂和海水的影响 • Material is extremely hard, therefore it resists wear, cavitation and abrasion damage 材料超级坚硬,可以避 免磨损、气蚀等危害 • Dimensionally stable to enable manufacturing high precision, low friction, process lubricated bearings 高精确的尺寸和稳定的制作可以获得低的摩擦和工艺中的水力润 滑
  • 21. SLIDE 21 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 ERI Ceramic Process Flow Diagram
  • 22. 22 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 The PX Device • 2 high pressure connections • 2 low pressure connections • Ceramic cartridge End cover rotor/sleeve end cover
  • 23. 23 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Low-pressure feed water fills rotor chamber, displacing brine Rotor chamber seals, containing low-pressure feed water High-pressure brine pressurizes and displaces feedwater Rotor chamber seals, containing high pressure brine The PX Device at Work 1 2 3 4
  • 24. 24 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 The PX Device View from Inside Pressure Vessel
  • 25. SLIDE 25 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 Product Product Model 65-Series PX-180 PX-220 PX-260 Quadribaric Technology™ PX-300 4S-Series PX-30S PX-45S PX-70S PX-90S PX-140S Circulation Pumps Isobaric Technology: California Facility
  • 26. 26 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Specification PX300 unit Flow range 300-200 gpm Technology 4 pressure exchanger per rotation Volumetric mixing 5% Efficiency Up to 98% Materials Wet material: AL6XN or equivalent Temperature range 1-40 C (Not freeze) Max operational pressure 1200 psi Housing Side port design PX 300 unit
  • 27. 27 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Specification PX260 unit PX300 unit Flow range 260-180 gpm Range: 80 gpm 300-200 gpm Range: 100 gpm Technology 2 Pressure exchanger per rotation 4 pressure exchanger per rotation Volumetric mixing 6% 5% Installation End port design Side port design PX300 unit vs PX260 unit
  • 28. 28 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Energy Recovery Device – PX Technology Advantages • Best-in-class Performance 高等级性能 − Highest efficiency- up to 98% 高达98%的高效率 − Constant: flat efficiency curve 效率恒定 • Rotor 转子 − One moving part 单一运转部件 − Hydrodynamic bearing 水力润滑轴承 − Automatic speed adjustment自动速度调 整 • State-of-the Art Materials尖端材料 − Ceramics 陶瓷 − Extremely durable material (3X steel hardness) 极其耐用材料,是钢硬度的3倍 − Never corrodes 绝不腐蚀 − No fatigue 无疲劳损伤
  • 29. 29 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 • Scalability and Reliability 可靠及方便扩容 − Modular–like membranes同膜一样、模块化设计理念 − Fail-safe redundancy: no down-time故障自我保护冗余,无需停机 − Installed in any orientation仸意方向安装 • Ease of Installation易于安装 − Minimal footprint占地面积最小 − No extra civil works无额外的土建要求 − No electrical connections无电气连接 − Lightweight重量轻 • Smooth Start up and Operation启动平滑和操作稳定 − Flexibility-recovery, flow controls机动性强、流量可调节 − Vibration-free (no pistons)无活塞、无震颤 − Maintenance-free 免维护 Energy Recovery Device – PX Technology Advantages
  • 30. 30 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Making Desalination Affordable SWRO Engineering Design
  • 31. 31 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Flow Control—Low Pressure SWRO Engineering Design LP flow rate set by discharge flow control valve 低压侧流量由PX出口低压排放阀控制 MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 32. 32 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design Flow Control—High Pressure HP flow rate set by booster pump 高压侧流量由PX循环泵控制 MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 33. 33 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design Flow Control—Permeate Permeate flow rate set by high pressure pump and membranes 产水侧流量由高压泵和膜的特性控制和决定 MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 34. 34 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design PX Flow Control 流量控制 MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP • The PX works like two parallel pipes. PX工作就像两个平行的管道 • High-pressure flow rate controlled by booster pump 循环泵控制高压侧流量 • Low-pressure flow rate controlled by discharge valve 排放阀控制低压侧流量 • High-pressure pump flow is permeate flow 高压泵控制产水侧流量 • All three main flows are independent 这三个流量相互独立 • HP and LP flows must both be metered and controlled 高、低压侧流量都必须测量和控制
  • 35. 35 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design Pressure Control 压力控制 MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP • LP valve does not directly affect membrane pressure 低压排放阀门不直接影响膜的进水和浓水压力 • System pressure determined by membrane condition, feed temperature and feed salinity 系统压力由膜的特性、进水温度和含盐量等因数决定 • Supply pressure changes cause LP flow rate changes 供水压力变化会引起低压侧流量变化 • PX LP out pressure must be above minimum 低压出口排放压力必须高于最小排放压力
  • 36. 36 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design • Membrane water recovery = I / F • System water recovery = I /A • Membrane recovery = system recovery if PX LP flow = PX HP flow Water Recovery MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP PERMEATE
  • 37. 37 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design PX Lubrication – High Pressure Flow Through Hydrodynamic Bearing Lubrication flow rate dictated by system pressure and temperature and PX seals 润滑流量是PX的特性,由系统压力、温度以及PX自身结构决定 MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 38. 38 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design • The PX technology always stays on its design curves PX总在它的设计曲线上运行 • PX unit manifolds – same as membrane manifolds PX母岐管就像膜的母歧管 • Design manifold for low pressure drop 母歧管设计尽量减少压损 DIFFERENTIAL PRESSURE 5 10 15 170 180 190 200 210 220 230 Flow Rate (gpm) Pressure (psi) HP DP LP DP PX 1 PX 2 PX 3 PX 1 PX 2 PX 3 Z flow U flow PX Device Arrays – Even Flow Distribution Manifold Entrance Velocities for Good Flow Distribution 总管进水俩素土建设计导则 <7 ft/s (2.1m/s) <12 ft/s (3.7m/s) Z flow U flow
  • 39. 39 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design Mixing Effects– Lead Flow or ―Overflush‖ MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 40. 40 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design • Feed water salinity increase进水含盐量 @ 40% recovery = 2.5% • Operating pressure increase 操作压力增加= 1.3 bar • Operator Options:操作选择 − Accept pressure increase 接受压力增加(= 2°C feed temp decrease)相当于降低2度水温 − Decrease recovery by 2%或降低2%系统回收率 − Increase low-pressure supply to the PX by 5%或向PX增加5% 的低压供水流量 Mixing 混合 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 -15.00 -10.00 -5.00 0.00 5.00 10.00 15.00 20.00 Lead Flow (%)= ((LP flow in ) – 1 )* 100 HP flow out Salinity Increase (%)= (Conductivity at PX HP(out)) - (Conductivity at PX LP(in)) (Conductivity at PX LP(in)) Paper presented at EDS Marrakech Caramondani 40,000 m3/ D SWRO Plant
  • 41. 41 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 • HP and LP flows are independent • 高、低压侧流量相互独立 • Good flow control: stay within limits of PX unit • 最佳流量控制:高、低压流量始终控制在PX允许的流量范围 • Constant PX device feedwater pressure • 恒定的PX原水供应压力 • Get the air out • 彻底排气 • Equal flow to all PX units in arrays • PX单元均一流量分布 • Lowering recovery usually improves SWRO performance • 系统低回收率可以改善SWRO性能 SWRO Engineering Design Engineering Design Summary工程设计汇总
  • 42. 42 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Making Desalination Affordable PX™ Technology Desalination Plants
  • 43. 43 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Tianjin Dagang SWRO Plant – Largest SWRO in China • 100,000 m3/day (26 MGD), Largest SWRO plant operating in China • Source is the Bo Sea, Tianjin Dagang is located in Tianjin City • Started up May 2009. • Product used for industrial processing
  • 44. SLIDE 44 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 Qingdao SWRO Plant • 100,000 m3/day (26 MGD) • 6 TRAINS x 17-PX260 • Municipal use • Start-up Date: Q4 2011
  • 45. SLIDE 45 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 YuHuan Power Station – 2nd Largest SWRO in China •Located in Zheijang Province, source is the East China Sea •34,560 m3/day (9.1MGD) − 1 x 76,800 m3/day (20MGD) UF pretreatment system − 6 x 5,760 m3/day (1.5MGD) SWRO trains − 3 x 3,120 m3/day (0.8MGD) BWRO trains •March 2006 start-up, designed and built by Beijing CNC Technologies •Power/SWRO plant built for 2008 Olympics
  • 46. 46 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Perth, Australia — 140,000 m3/day (36.9 MGD) • GWI Award 2007 Environmental Contribution of the Year
  • 47. SLIDE 47 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 Hadera, Israel: 465,000 m3/day • World’s Largest SWRO Plant in Operation • 16 Trains of PX-220 devices
  • 48. 48 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Hamma, Algeria — 200,000 m3/day (53 MGD) • Largest membrane trains in the world • 25,000 m3/ day
  • 49. 49 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Al Shoaibah (Saudi Arabia)—150,000 m3/day (40 MGD)
  • 50. 50 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Barcelona (Spain) 200,000 m3/day (53 MGD)
  • 51. 51 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 570 m3/day MV Pacific Star Sun Cruise Ship (Australia) 6,000 m3/day Sharm El-Sheikh (Egypt) 16,000 m3/day La Marina Cope (Spain) Small to Medium Installations
  • 52. 52 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 6 year MPD History - 36 Mega Projects Contracted 1 Perth, Australia DEGREMONT 140,000 m3 /d 37 MGD 2 2 Hamma, Algeria GE 200,000 m3 /d 53 MGD 340K 3 Skikda, Algeria GEIDA 100,000 m3 /d 26 MGD 4 4 Alicante II, Spain INIMA 65,000 m3 /d 17 MGD 5 Cartagena, Spain COBRA | TEDAGUA 63,000 m3 /d 16 MGD 6 Beni Saf, Algeria GEIDA 200,000 m3 /d 53 MGD 428K 7 Chennai Minjur, India BEFESA 100,000 m3 /d 26 MGD 6 8 Shuibah III, Saudi Arabia DOOSAN 150,000 m3 /d 40 MGD 9 Torrevieja, Spain ACCIONA 240,000 m3 /d 63 MGD 10 Barcelona, Spain DEGREMONT 200,000 m3 /d 53 MGD 11 Swakopmund, Namibia KEYPLAN 65,000 m3 /d 17 MGD 12 Hamriyah, UAE AQUA ENG 90,000 m3 /d 24 MGD 845K 13 Tianjin, China HYFLUX 100,000 m3 /d 26 MGD 9 14 Tlemcen Hounaine, Algeria GEIDA 200,000 m3 /d 53 MGD 15 Tlemcen Souk Tleta, Algeria HYFLUX 200,000 m3 /d 53 MGD 16 Fouka, Algeria ACCIONA 120,000 m3 /d 32 MGD 17 Larnaca, Cyprus IDE 60,000 m3 /d 16 MGD 18 Shuwaikh, Kuwait DOOSAN 140,000 m3 /d 37 MGD 19 Tordera, Spain ACCIONA | AQUALIA 60,000 m3 /d 16 MGD 20 Bajo Almanzora, Spain BEFESA | AQUALIA 65,000 m3 /d 17 MGD 21 Hadera, Israel IDE 388,000 m3 /d 102 MGD 1333K 22 Mostaganem, Algeria INIMA | AQUALIA 200,000 m3 /d 53 MGD 10 23 Cape Preston, Australia IDE 140,000 m3 /d 37 MGD 24 Paraguana, Venezuela ACCIONA 75,000 m3 /d 20 MGD 25 Cap Djinet, Algeria INIMA | AQUALIA 100,000 m3 /d 26 MGD 26 Palmachim Expansion, Israel VIAMARIS 137,000 m3 /d 36 MGD 27 Hadera Expansion, Israel IDE | H&C 74,000 m3 /d 20 MGD 28 Adelaide Port Stanvac, Australia ACCIONA 150,000 m3 /d 40 MGD 29 Perth 2 - Bunningup, Australia VALORIZA | SADYT 137,000 m3 /d 36 MGD 30 Tenes, Algeria BEFESA 200,000 m3 /d 53 MGD 31 Magtaa, Algeria ** HYFLUX 500,000 m3 /d 132 MGD 1713K 32 Adelaide Expansion, Australia ACCIONA 150,000 m3 /d 40 MGD 5 33 Melbourne - Wonthaggi, Australia DEGREMONT 411,000 m3 /d 109 MGD 34 Moncofa, Spain INIMA 60,000 m3 /d 16 MGD 35 Oropesa, Spain * TECNICAS REUNIDAS 50,000 m3 /d 13 MGD 36 Qingdao, China BEFESA 100,000 m3 /d 26 MGD 771K * PX-300s -- ** AT-7200s 5.4 M m3 /d 1434 MGD Totals 2010 2005 2006 2007 2008 2009
  • 53. 53 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 ERI PX Technology Mega Projects • 31/35 Mega Projects • 900 MW of Energy Savings • 6 Billion Liters of water – enough for every person on the planet Alicante Cartagena Torrevieja Barcelona Tordera Bajo Almanzora Paraguana Hamma Skikda Beni Saf Tlemcen H Tlemcen ST Mostaganem Fouka Oued Sebt Cap Djinet Tenes Swakopmund Chennai Hamriyah Shoaibah Shuwaikh Tianjin Hadera Larnaca Palmachim Perth Cape Preston Adelaide
  • 54. 54 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Summary • Energy is the largest operating cost of SWRO • SWRO系统中能耗是最大的操作成本 • Most developments in SWRO address energy issues • SWRO发展的制约因素是能耗 • SWRO energy improved > 60% in 20 years • 最近20年SWRO能量消耗已经提高了超过60% • Energy Recovery technologies cut energy costs by up to 60% • 能量回收技术小姐能耗高达60% • Approx. 97% efficient energy recovery in isobaric configurations – flexibility • 灵活的等压式能量回收装置效率约97% • Small additional reductions in energy consumption are feasible • 额外的小幅能耗消减是可行的 • Additional energy cuts may be offset by capital cost increases (for example, lower recovery) • 投资的增加可以通过能耗的消减来弥补,例如,较低回收率
  • 55. 55 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Centrifugal Pumps & TurboCharger ERD Solutions
  • 56. 56 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Energy Recovery Inc ENERGY RECOVERY INC NEW BOSTON New Boston, Michigan USA • Centrifugal Manufacturing Headquarters – Pumps and TurboChargers 离心式水泵和涡轮增压装置的生产基地 • Top-notch manufacturing facility 先进的制造工厂 • Pump/TurboCharger manufacturing and testing facility 水泵和涡轮增压装置的生产及测试基地 • 3,000 HP Test Stand 3,000马力测试平台
  • 57. 57 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Core Competences Engineering • CFD Analysis & Simulation • Custom Design • Extensive R&D • MSU Turbo Machine Lab • PWR Co-op Machining • Large VTL • CNC Lathes • 5 Axis CNC • Grinding • Honing • Dynamic Balancing Assembly • Prep & Polish • QC • Torque control • CMM Analysis Testing • Full Power Performance Testing • Efficiency Validation • Hydrostatic test • Performance baseline
  • 58. 58 CONFIDENTIAL 58 CONFIDENTIAL Customer Requirements Agile Engineering CNC Programming Machining of Hydraulic Passages Performance Test Quality Control Shipment Agile Engineering
  • 59. 59 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 59
  • 60. 60 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Manufacturing Capability Expansion
  • 61. 61 NOT FOR DISTRIBUTION © Copyright 2010, ERI LPT AquaSpire HTC AT HALO ERI (Centrifugal Technology) Products Energy Recovery Devices • Advanced Technology TC (HTC AT) 超技术型涡轮能量回收装置(HTC AT) • Low Investment Turbocharger (HALO) 经济型涡轮能量回收装置(HALO) • Low Pressure Turbocharger (LPT) 低压型涡轮能量回收装置(LPT) Pumps • AquaBold High Pressure RO Pumps 离心式反渗透多级高压泵 • AquaSpire Single-stage Pump 单级泵 AquaBold
  • 62. 62 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaBold Pump Line
  • 63. 63 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 High-Efficiency Centrifugal High Pressure RO Pump 高效率的离心式RO系统高压泵 • Uniquely designed for desalination applications 为海水淡化系统独特设计的产品 – Custom designs for specific operating conditions allows for optimum pump efficiencies 根据实际的操作工况定制的独特结构,可以达到最佳的泵效率 • Quality materials & manufacturing 优质材料和制造 − Designed for 20 year service life 20年设计使用寿命 • Designed for use with PX energy recovery devices 和PX能量回收装置配合设计使用 − Highest efficiency package solution with guaranteed power consumption 最高效率的能量解决方案保证了能耗指标  For certain sizes & upon request 对于确认的尺寸和较高的要求 • Available with short lead-times 可以保证的较短的交货期 • Customer service, training and support 客户服务、培训和支持 − Highly qualified technical field services and training programs 高质量的技术现场服务和培训 AquaBold Pump Overview
  • 64. 64 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaBold Pump Advantages • Industry-leading high efficiencies 行业领先---高效率 − Performance-enhanced fluid modeling 流动模型的建立可以提高性能 − Proprietary thrust technology eliminates losses 专利的止推轴承技术减少了损耗 • State-of-the-art construction for RO industry RO行业最有魅力的产品 − Precision machined investment-cast components 精密的机械投资---浇铸部件 − Standard Duplex 2205 标准的2205双相不锈钢 − Super Duplex 2507 optional 超级双相不锈钢2507可作为选择 • Simple to maintain 简单的维护 − No disassembly required for mechanical seal replacement 无需拆装要求的机械密封更换 − All product-lubricated bearings 所有的轴承都是产品自身润滑 − Thrust bearing can be replaced without removing pump or motor 无需移动电机和水泵就可以自由地拆装止推轴承
  • 65. 65 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaBold Pump - Features
  • 66. 66 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaBold Pump (Cross Section)
  • 67. 67 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Proprietary Thrust Bearing • Product lubricated bearings – eliminates maintenance of grease bearings and auxiliary oil systems and associated seals 润滑轴承---免去油脂轴承和辅助油系统及其相关密 封的维护 • Simple, efficient design – allows field retrofits without the need for bearing change 简单、高效的设计---在无需改变轴承的情况下在现 场可以翻新改造 • Reduced friction provides lower power losses within the bearing system, improving overall efficiency 在轴承系统理减少的摩擦可提供较低的能量损失, 提高整体效率 • Eliminates need for costly external thrust bearing system 无需外部昂贵的止推轴承系统
  • 68. 68 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaBold Pump Line (Current Products) 50 55 60 65 70 75 80 85 90 0 200 400 600 800 1000 1200 1400 1600 Efficiency (%) Q (gpm) AquaBold High Pressure Pump 4x6x9-C 4x6x9-B 3x4x7-C 3x4x7-A 2x3x5-C 2x3x5-B 2x3x5-A 3x4x7-B 4x6x9-A
  • 69. 69 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaSpire Pump
  • 70. 70 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaSpire Pump Application 应用范围 • Single-stage high pressure pump for medium to large scale SWRO systems 适用于大中型海水淡化系统的单级高压泵 Advantages 优势 • Achievable efficiencies up to 90+% 最高效率可达到90%以上 • BEP always matches customer duty point 最佳效率点通常能匹配客户的需要 • Removable volute inserts 可移动更换式蜗壳 − Allows rerate to match changes in system conditions 允许为了配合系统的工况改变而再次修正 − Customized Hydraulic Design for each specific application 对于每一个特殊的应用窦可以进行量身定做的水力模型设计 − Customized 3-D geometry Impellers 量身定做的三维叶轮设计 • No scheduled maintenance 无需周期性维护 • Single-stage design 单级设计
  • 71. 71 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaSpire ½ AT = AquaSpire Pump
  • 72. 72 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaSpire Pump Con’d THRUST BEARING CENTER BEARING PUMP IMPELLER PUMP VOLUTE SHAFT
  • 73. 73 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 AquaSpire Pump (exploded) Pump Volute Pump Diffuser
  • 74. 74 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 TurboCharger General Theory
  • 75. 75 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 SWRO Engineering Design – Single Stage TURBOCHARGER MEMBRANES 900 PSI (62 bar) 5 PSI (.35 bar) 200 GPM (45.5 m3/h) 300 GPM (68.1 m3/h) 5 PSI (.35 bar) 300 GPM (68.1 m3/h) 595 PSI (41 bar) 500 GPM (113.6 m3/h) 920 PSI (63.4 bar) 500 GPM (113.6 m3/h) 30 PSI (2 bar) 500 GPM (113.6 m3/h) HP PUMP • The Turbocharger uses brine energy to boost the full feed stream to the RO, thereby reducing the required boost from the high pressure pump 涡轮式能量回收装置主要是利用反渗透浓水的能量给 进入反渗透装置的原水进行增压以达到降低高压泵的 扬程,起到节能的作用
  • 76. 76 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 LPT Process Design 1ST STAGE MEMBRANES LPT TURBO CHARGER 2ND STAGE MEMBRANES 250 PSI (17.24 bar) 2000 GPM (454.2 m3/h) 30 PSI (2 bar) 2000 GPM (454.2 m3/h) HIGH PRESSURE PUMP 5 PSI (.35 bar) 1000 GPM (227.1 m3/h) 5 PSI (.35 bar) 1500 GPM (340.7 m3/h) 5 PSI (.35 bar) 500 GPM (113.6 m3/h) 5 PSI (.35 bar) 500 GPM (113.6 m3/h) 311 PSI (21.44 bar) 326 PSI (22.48bar) 1000 GPM (227.1 m3/h) 230 PSI (15.86 bar) 1000 GPM (227.1 m3/h) 500 GPM (113.6 m3/h) • Inter-stage pressure boosting: LPT
  • 77. 77 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 System Control and Optimization
  • 78. 78 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 • The auxiliary nozzle valve on the turbocharger provides brine flow and pressure adjustment to accommodate typical variations in membrane requirements 涡轮式能量回收装置上的辅助浓水管路阀门可调节浓水的流量和压力以适应膜系统变化的 要求 How does an ERI Turbocharger work? BRINE PRIMARY NOZZLE TURBINE IMPELLER VOLUTE AUXILIARY NOZZLE VALVE AUXILIARY NOZZLE •The Main Nozzle is sized to provide a concentrate system resistance (concentrate pressure) equal to the maximum design pressure at a constant design concentrate brine flow rate. The auxiliary nozzle is sized to about 20-25% of the area of the Main Nozzle. The ANCV controls flow to the AN in the turbine casing. The ANCV will provide a 20-30% pressure range at a constant brine flow.
  • 79. 79 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 System control and optimization • To reduce brine pressure, open the auxiliary nozzle valve until the desired brine flow and pressure are obtained. • Opening the ANCV reduces the brine pressure and consequently reduces the boost pressure. Opening the ANCV increases the total nozzle area, allowing more flow and/or a lower pressure. This is typically done during those periods of RO plant operation that require less pressure than the maximum designed membrane pressure. • To increase brine pressure, close the auxiliary nozzle valve until the desired brine flow and pressure are obtained. The TURBO will produce the most boost pressure when the ANCV is fully closed. • The Aux Nozzle valve can be manual (as shown) or actuated. • If automated, the best control signal is the brine flow.
  • 80. SLIDE 80 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 TurboCharger Rotating Assembly
  • 81. SLIDE 81 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 dP = (Nte) x (Rr) x (Pbr – Pe) Where Rr = ratio of brine flow to feed flow Pbr = brine pressure at turbine inlet Pe = Turbo exhaust pressure Nte = Hydraulic Energy Transfer Efficiency from Curve Turbo Pressure Boost – Example II. Perth SWRO plant, Membrane feed flow 2‘453 m3/h, conversion 45 %, membrane feed pressure 57.9 bar, brine pressure 57.2 bar, brine back pressure of 0.5 bar. What is the pressure boost??? AT-7200 = (0.82) x (0.55) x (57.2 – 0.5) = 25.6 bar boost
  • 82. 82 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Turbo Operation
  • 83. 83 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Advanced Technology (AT) Turbocharger
  • 84. 84 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Advanced Technology (AT) Turbocharger Application 应用范围 • Medium to large scale energy recovery device for SWRO 适用于中大型海水淡化系统 Advantages 优势 • Reliability 可靠性 − Product lubricated bearings 润滑轴承 − No scheduled maintenance 无需周期性维护 − Ease of installation 易于安装 • Designed for Optimum Efficiency 可设计的最佳效率 − Customized Hydraulic Design for each specific application 对于每一个特殊的应用都可以进行量身定做的水力模型设计 − Customized 3-D geometry Impellers 量身定做三维立体的叶轮设计 • Removable volute inserts 可移动更换式蜗壳 • Compact design allowing for smallest foot print available 紧凑型设计更适合小型的占地面积 • Feed pump size reduction 减小给水泵的尺寸
  • 85. 85 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Advanced Technology (AT) Turbocharger (Cross Section) THRUST BEARING CENTER BEARING PUMP IMPELLER PUMP VOLUTE TURBINE IMPELLER TURBINE VOLUTE PUMP BEARING
  • 86. 86 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Advanced Technology (AT) Turbocharger Con’d Pump Side Diffuser Main Turbine Nozzle Turbine Side Volute Pump Side Volute PEI Patent Pending
  • 87. 87 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Volute Insert Technology 蜗壳内插技术 • ERI’s unique ability to improve efficiency and reduce water cost over the life of the plant PEI 可更换式涡壳是提高效率和降低系统运行成本的最独特的产品 • Does not require complete equipment replacement 不需要完整的零部件更换 • Simple field retrofit with virtually no downtime 无需周期性的停机检修,现场更 换简单 HTCAT AquaSpire
  • 88. 88 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Volute Insert Technology Con’d • Ability to adapt to improvement in desalination technology 能够适应海水淡化技术的改进 • Enhanced membrane recovery (Impact on feed flows) 提高膜的回收率(影响进水流量) • 10 years ago 35% recovery was industry norm 10年前35%的回收率是标准设计 • Now 40 – 45 % recovery is the norm 现在回收率40-45%是标准设计 • Reduction in operating pressure 降低操作压力 • 10 years ago 70 -74 bar was SWRO norm 10年前70-74bar是海水淡化的标准设计 • Now 64 -68 bar is the norm 现在64-68bar是标准设计 • Improved pretreatment technology 提高预处理技术 • Ability to take advantage of desal technology improvement without negative impact on efficiency 在无负效率的影响下能有效地提高淡化技术的发展 1.5% - 2% of Efficiency will save a customer Millions $ over the entire Plant Life 效率的1.5%-2%的再增加可以节约系统数百万美元的运行成本
  • 89. 89 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Volute Insert Technology Con’d • 10% change in flow = 1.5% drop in efficiency 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 Feed Pump Efficiency Feed Flow (m3/h) • Easily replicable volute and diffuser components allow for best efficiency point operation even when operating requirements change 当操作工况改变时,简易的可复制的涡壳和扩散器部件可在最好的效率点下工作
  • 90. 90 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 HALO Turbocharger
  • 91. 91 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 HALO Turbocharger Application 应用 • Small to medium skid mounted SWRO systems 适用于中小型海水淡化系统 Advantages优势 • Full 3-D geometry impellers 完全的三维立体叶轮 • More reliable thrust bearing 更可靠的止推轴承 • Reduces high pressure pump and motor size 较小的高压泵及电机 • Compact design 紧凑的设计 • Lower Installation cost 低安装成本 • Custom rotor designed for highest efficiency 最高效率的定制转动部件
  • 92. 92 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 HALO Turbocharger THRUST BEARING CENTER BEARING PUMP BEARING PUMP IMPELLER TURBINE IMPELLER PUMP VOLUTE TURBINE VOLUTE
  • 93. 93 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Low Pressure Turbocharger (LPT)
  • 94. 94 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Low Pressure Turbocharger (LPT) Application 应用 • Designed for use in low pressure, multi-stage Brackish Water RO systems 适用于低压、多级苦咸水反渗透系统 Advantages 优势 • All components made from cast parts for long life 所有部件适用寿命长 • Custom designed for customer specific conditions 对于每个应用都进行量身定做设计 • Balances first and second stage flux rates 平衡第一和第二段的流量 • Eliminates interstage booster pump 取消段间增压泵 • Reduces first stage fouling potential 降低第一段的污堵的可能性 • Replaces brine control valves 取代浓水控制阀
  • 95. 95 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Low Pressure Turbocharger (LPT) THRUST BEARING CENTER BEARING PUMP BEARING PUMP IMPELLER TURBINE IMPELLER PUMP VOLUTE TURBINE VOLUTE
  • 96. 96 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 LPT Process Design 1ST STAGE MEMBRANES LPT TURBO CHARGER 2ND STAGE MEMBRANES 250 PSI (17.24 bar) 2000 GPM (454.2 m3/h) 30 PSI (2 bar) 2000 GPM (454.2 m3/h) HIGH PRESSURE PUMP 5 PSI (.35 bar) 1000 GPM (227.1 m3/h) 5 PSI (.35 bar) 1500 GPM (340.7 m3/h) 5 PSI (.35 bar) 500 GPM (113.6 m3/h) 5 PSI (.35 bar) 500 GPM (113.6 m3/h) 311 PSI (21.44 bar) 326 PSI (22.48bar) 1000 GPM (227.1 m3/h) 230 PSI (15.86 bar) 1000 GPM (227.1 m3/h) 500 GPM (113.6 m3/h) • Inter-stage pressure boosting: LPT
  • 97. 97 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Flux Balancing What is Flux? • Defined as the permeate produced per membrane area − Lmh: Liters per square meter per hour − Gfd: Gallons per square foot per day • Balancing flux between stages spreads the rate of fouling deposition over the greatest membrane area • Improves final system permeate quality when the flux is increased in the last stages • Reduces recovery in 1st stage and increases it on the 2nd stage • Can reduce fouling potential in the 1st stage
  • 98. 98 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Interstage Boost • Advantages − Low operational costs − Highest power efficiency − Reduced feed pump HP • Disadvantages − Slightly higher capital costs  Boost pump, manifold (if a turbo is not used)
  • 99. 99 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 BWRO Energy Cost Comparison Case Basic Design (A) Permeate Throttling (B) Interstage Turbo Boost (C) Pump Power (hp) 309 355 280 Motor and VFD size (hp) 350 400 300 Permeate production (m3/hr) 500 500 500 Flux Rate (lmh) 1st stage 23.8 21.9 21.9 2nd stage 16.5 20.2 20.2 Specific Permeate Energy Rate (kW/m3) 0.4575 0.5325 0.42 Annual Power Usage (8,322hrs/yr) 1,928,624 2,215,733 1,747,620 Annual Power Cost ($0.10kWhr) $ 192,862 $ 221,573 $ 174,762 20 year Power Cost $ 3,857,240 $ 4,431,460 $ 3,495,240 Estimated Savings $ 936,220 USD
  • 100. 100 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Making Desalination Affordable TurboCharger Technology Desalination Plants
  • 101. 101 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Magtaa, Algeria — 500,000 m3/day (132 MGD) • Largest membrane plant in the world • 25 – AT-7200 To be commissioned in 2011…
  • 102. SLIDE 102 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 TurboCharger Installation: 8,000 m3/day
  • 103. SLIDE 103 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 TurboCharger + AquaBold Installation: 3,000 m3/day
  • 104. SLIDE 104 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 TurboCharger Installation (Brackish): 10,000 m3/day
  • 105. SLIDE 105 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 TurboCharger Installation Seawater RO Plant
  • 106. 106 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Making Desalination Affordable ERD Trouble-shooting 能量回收装置的现场故障分析和解决方案
  • 107. 107 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 PX Device – Trouble-Shooting Symptom: Excessive Noise 征兆:过高的噪音 − Operating the units above rated flow 操作工况超过额定流量 − Operating units with insufficient backpressure 操作工况背压过低 − Entrained air in the system 系统中有气体 − Damaged Ceramics 损坏的转子 Symptom: Stalled Rotor 征兆:转子停转 − Operating the units below rated flow 操作工况低于额定流量 − Operating the units above rated pressure rating 操作工况超过额定压力 − Foreign debris 外来的碎片
  • 108. 108 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Symptom: High Membrane Feed Pressure 征兆:高的反渗透膜进水压力 − Operating the main HPP at to high of a flow rate 主高压泵在高流量下运行 − Changes in membrane conditions or feed water 膜的工况或进水情况改变 − Unbalanced PX array flows PX列的流量不平衡 − Stuck Rotor 转子停转 Symptom: Low Permeate Flow 征兆:低的产水流量 − Malfunctioning high-pressure pump 高压泵故障 − High lubrication/leakage flow through PX device(s) PX装置的高的润滑/泄漏流量 − Leakage from high-pressure to low-pressure circuit 从高压到低压流量圈的泄漏 PX Device – Trouble-Shooting
  • 109. 109 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 TurboCharger Device – Trouble-Shooting Symptom: Stalled RA 征兆:RA停转 − Foreign Debris 外来的碎片 − Operating the units below rated flow/pressures 操作工况低于额定流量和压力 − Damaged thrust bearing 止推轴承损坏 − Incorrect recovery/recovery ratio 不正确的回收率 Symptom: Abnormal Noise 征兆:不正常的噪音 − Operating the units with insufficient back pressure 操作工况背压过低
  • 110. 110 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 TurboCharger Device – Trouble-Shooting Symptom: Unable to achieve design boost pressure 征兆:不能达到设计的增压压力 − Incorrect recovery/recovery ratio 不正确的回收率 − Aux/By-pass valve in incorrect position 辅助管道和旁路管道上的阀门在不正确的位置上 − Debris – damaged bearing 碎片-轴承损坏 − Changes in membrane or feed water 膜或进水工况改变 Symptom: Excessive boost pressure 征兆:超额的增压压力 − Incorrect recovery/recovery ratio 不正确的回收率 − Aux/By-pass valve in incorrect position 辅助管道和旁路管道上的阀门在不正确的位置上 − Change in high-pressure pump performance 高压泵的性能改变 − Changes in membrane or feed water 膜或进水工况改变
  • 111. Misconceptions of ERD Technology 能量回收装置的误解
  • 112. SLIDE 112 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 PX Device Misconceptions: Fact versus Fiction Fiction: PX Devices have higher operating expense than other isobaric devices. PX比其他的等压式能量回收装置操作压力高。 FACT: The PX device has a peak efficiency of 98% and is being operated in some of the lowest power consuming plants in the world today. The PX has one moving part, no scheduled maintenance and has the highest availability of any ERDs currently available. PX装置的最大的效率是98%,现在在全球正在以最低的能耗运行着。PX只 有一个运动部件,无需日常的维护并且是所有能量回收装置中最适用的。 Fiction: PX Devices require excessive pressure before they start to rotate. PX装置在启动时需要更高的压力。 FACT: PX devices need process flows (high-pressure and low- pressure flow) and lubrication flow in order to rotate. 为了启动转子,PX装置需要工艺流量(高压和低压流量)和润滑流量。
  • 113. SLIDE 113 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 PX Device Misconceptions: Fact versus Fiction Fiction: When operating multiple PX devices in an array, a stuck rotor will cause overflow and damage to the operating PX devices. 当多个PX装置在一套系统中运行时,一个停转的PX会引起超流和对PX的损伤。 FACT: The PX device is passive in nature. The operable units will continue to perform as designed. The inoperable unit will re-circulate concentrate back to the membrane feed but the impact will be determined by the number of devices in the array. Overflow to the operable units will NOT occur. PX本身是被动转动的,运转的单元根据设计要求连续运行着。停转的转子将浓水直接送入 给水且对系统的影响主要取决于PX的数量。超流将不会发生 。 Fiction: PX devices can’t be operated at the maximum rated flow. PX装置不能在最大的额定流量下操作。 FACT: All PX devices are designed to operate at full rated capacity and the operators are free to do so. Installing additional capacity in an array does have several benefits, including; optimizing performance, availability, flexibility and longevity. 所有的PX产品都可以在最高的额定流量下设计同时可以仸意的操 作,在一列中安装额外的容量会有更好的优势:优化性能、实用、操作弹性 和寿命长。
  • 114. SLIDE 114 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 PX Device Misconceptions: Fact versus Fiction Fiction: The high-pressure portion of the system can be filled via the LP INLET side of the PX device.系统的高压部分可以通过PX的低压给水部分填补。 Fiction: PX units have a 5 year useful-life. PX只有五年的使用期。 FACT: The PX device is a passive device. The low-pressure and high- pressure flow paths act as independent pipes flowing in opposite directions with an integrated seal zone between the “pipes”. PX是一个被动装置。低压流量和高压流量由于完整的密封区的隔离可以看成是两个相互独立 流道相反的两根管道。 FACT: PX units that have been commercially released and commissioned in 1997 are still operating today. PX devices have yet to reach their end-of-life or wear-out periods. PX产品从1997年正式得投入市场和运行至今,还在不断的延伸其使用期和磨损期。
  • 115. SLIDE 115 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 PX Device Misconceptions: Fact versus Fiction Fiction: ―Over-flush‖ is required by the PX device. PX需要超流。 FACT: The PX device does not require over-flush and a majority of the PX installations operate with “balanced” flows. The salinty increase at the membranes is typically between 2-3% (depending on membrane recovery). Over-flush can be implemented at the operators discretion. PX装置不需要超流运行通常是要求在水量平衡的情况下安装及运行。膜进口的含盐 量将会增加2-3%(依据膜的回收率)。是否超流运行主要依靠操作者的要求。 Fiction: Small particles can cause a rotor to stop.微小颗粒可造成转子的停转 FACT: Large debris such as broken pieces of PVC can cause a rotor to stop but there are no known incidences of “small” particles causing severe damage or stalling issues. 大的碎片,像PVC碎片将会引起转子的停转,但是小的颗粒并没有听说会引起危害等情 形
  • 116. SLIDE 116 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 PX Device Misconceptions: Fact versus Fiction FACT: PX devices require no maintenance. In fact, even after 5 years of operation, no spare parts or servicing is needed. This provides more valuable, up-time (> 98%) compared with competing technologies that need scheduled maintenance and a large stock pile of spare parts. PX无需定期维护。事实上,即使超过5年的运行也无需备品备件,这与需要定期维护和 大量的备品备件储备的其他的能量回收来说,这是非常有价值的。 Fiction: PX devices require some maintenance and spare parts. PX 需要定期维护和备品备件。
  • 117. SLIDE 117 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 Turbo Device Misconceptions: Fact versus Fiction Fiction: The turbos need to be isolated when cleaning/flushing the system. 涡轮增压装置在清洗和冲洗的时候需要隔离。 FACT:. The turbo does not require isolation during CIP, however it is best practice to do so or flush thoroughly with fresh water during system flush. 涡轮增压装置在清洗时无需隔离,但是系统清洗是最好采用新鲜水进行冲洗。 Fiction: You must have a brine control valve upstream /downstream of the turbo. 在涡轮增压的进出水口必须设置浓水控制阀门 FACT: NO, the turbine side of the turbo along with the aux valve replaces the brine valve completely. 不需要。涡轮增压的透平段采用了辅助管路阀门完全可以替代浓水阀门。
  • 118. SLIDE 118 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 Turbo Device Misconceptions: Fact versus Fiction Fiction: You can flush the system through the Turbo 可以通过涡轮增压装置冲洗系统 FACT: The turbine side of the turbo acts like an orifice plate and requires a dP to pass water through. In fact, a bypass is used for flushing. 涡轮增压装置的透平段实际上像一个收缩孔,要求有一定的压差的水才能通过, 所以需要一个旁路冲洗。 Fiction: Turbocharger must be coupled with high pressure pump. 涡轮增压装置必须和高压泵相连接 FACT: Not true, turbocharger can be mounted anywhere in the plant for best fit into the plant design. 这是不正确的,涡轮增压装置可以安装在系统设计中认为最适合的地方。
  • 119. SLIDE 119 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 Turbo Device Misconceptions: Fact versus Fiction Fiction: Plant design with turbocharger requires brine disposal pump. 设置涡轮增压装置的系统设计时需要设置浓水泵 FACT: Not true, turbocharger operates with brine exit back pressure which can reach several bars thus eliminating need for brine disposal pump. 这是不正确的,涡轮增压装置是利用浓盐水的出口压力得到一定的压力,因此无 需浓水泵。
  • 121. SLIDE 121 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 ERI Services ERI is Pleased to offer the following Services: − P&ID Reviews − Control Logic Reviews − Commissioning Services
  • 122. SLIDE 122 NOT FOR DISTRIBUTION © Copyright 2011, ERI Version 005-01-11 Energy Recovery Power Models and Selector Tools 1/4/2008 PX® Energy Recovery Device System Analysis A B C D E F G H FLOW US gpm 408 222 186 222 408 183 224 224 m3/hr 93 50 42 50 93 42 51 51 m3/day 2,222 1,211 1,012 1,211 2,222 1,000 1,222 1,222 PRESSURE psi 24 24 943 919 943 0 928 15 bar 1.7 1.7 65.0 63.4 65.0 0.0 64.0 1.0 QUALITY mg/l 39,000 39,000 39,000 41,025 40,103 200 72,751 70,745 PX UNIT PERFORMANCE INPUT DESCRIPTIONS INPUTS PX-260 Units Metric or English M or E M Number of PX units quantity 1 Manual or auto efficiencies m or a a m3/hr 50.9 Permeate flow m3/day 1,000 PX lubrication per array m3/hr 0.5 RO recovery rate % 45% PX lubrication flow % 0.9% RO feed pressure bar 65.0 Dfferential pressure HP side bar 0.6 Membrane differential pressure bar 1.0 Differential pressure LP side bar 0.7 PX LP discharge pressure bar 1.0 PX efficiency % 97.2% Feedwater salinity mg/l 39,000 PX mixing at membrane feed % 2.8% Cost of power $/kWh $0.10 Operating capacity % 86.2% HP pump efficiency % 80% Energy recovered kW 139.9 HP pump motor efficiency % 96% Circulation pump efficiency % 80% HIGH PRESSURE PUMP Circulation pump motor efficiency % 94% HP pump efficiency % 68% Circulation pump VFD efficiency % 97% HP pump motor efficiency % 92% PX device design margin % 5% HP pump power consumed kW 118.0 PX SYSTEM POWER RESULTS CIRCULATION / BOOSTER PUMP Total power consumption kW 122 Circulation pump efficiency % 65% Specific power consumption kWh/m3 2.93 Circulation pump motor efficiency % 91% Specific power consumption kWh/kgal 11.1 Circulation pump VFD efficiency % 97% Power cost saved with PX $/year 122,510 $ Total circulation pump power kW 3.9 Warnings SYSTEM FEED PUMP kW 0.0 Suggestions NONE NONE PX model PX unit flow
  • 123. 123 NOT FOR DISTRIBUTION © Copyright 2010, ERI VERSION:0005-00 July 2010 Contacts • Ms. Ping Zou, pzou@energyrecovery.com • Mr. Mike Zhan, xwzhan@energyrecovery.com • Ms. Jesse Yu, jasmine.yu@ewp-china.com • Mr. Eric Kadaj, ekadaj@energyrecovery.com • Mr. Rodney Clemente. rclemente@energyrecovery.com THANK YOU