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Trends & Developments
in Advanced Energy
Recovery Technologies
for Desalination
May 30, 2013
Distributor for Germany,
Austria, Switzerland, Czech &
Slovak Republic
www.roc-ch.com
Agenda
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Case Studies – PX Installations
Desalination Systems
Retrofit and Expansion Plant Designs
Who is Energy Recovery “ERI”?
The PX™ Pressure Exchanger Technology
SWRO Engineering Design & Optimization
Centrifugal Pumps & ERD Solutions
PX Hands-On
WHO IS ENERGY RECOVERY?
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Making Desalination Affordable
Energy Recovery Inc
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
HEADQUARTERS/MANUFACTURING/CERAMICS
San Leandro (San Francisco)
California USA
REGIONAL OFFICES
China, Spain, UAE
Company Profile
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Background • Established in 1992, Headquarters in California
• More than 14,000+ Energy Recovery Devices &
Pumps Installed/Contracted
• Global Sales and Technical Presence
• Saving more than 10 Billion kWh of Energy per Year
Technical
Expertise
• Highest Efficiency, Durability and Reliability ERDs
• 24/7 Service and Support
• Precision Manufacturing and Ceramics Expertise
• Technical Review, On-site Commissioning, Start-up, Training
• Best-in-it’s-Class ERD and Pump Solutions
• More than 400 OEMs
• PEI acquisition in 2009
State-of-the-Art, Materials
Science Manufacturing
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Creating advanced ceramics components requires specialized equipment,
a fully equipped materials lab, engineers, and optimized processes
Over 400 Clients
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Capital
Expense
43%
Operating
Expense
57%
ASSUMPTIONS
Power Cost USD/kWh 0.09
Debt Equity Ratio 80/20
Debt Interest Rate 8%
Equity ROI 18%
Desalination Plant Capital & Operating Costs
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Chemical /
Consumables
9%
Power
41%
Parts
Replacement
13%
Operating
Margin
17%
Office 3%
Membranes
8%
Labor, G&A
9%
Perth Seawater
Desalination Plant
2008
Operating Expenses— Breakdown
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Source: Affordable Desalination Collaboration, 2008
Pre-filtration
8%
Permeate Treatment 1% Permeate Distribution 7%
Reverse
Osmosis Process
68%
Intake
15%
RO power consumption is approximately 20%
(up to 45%) of total SWRO cost
Power Use — Breakdown (Seawater RO)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
DESALINATION SYSTEMS
Making Desalination Affordable
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Desalination Systems
Pelton Turbine
Turbocharger
Piston Exchanger
Francis Turbine
Dyprex
Rotary Exchanger
1980 1990 2000 2010
MEMBRANES
HIGH
PRESSURE
PUMP
Seawater RO: Before Energy Recovery Devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Issues: high pumping costs, wasted energy, lack of optimization
Seawater RO: Pelton Wheel/Francis
Turbine Energy Recovery Devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Hydraulic --> Mechanical --> Hydraulic
Seawater RO: ERI TurboCharger™
Energy Recovery Devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Seawater RO: ERI TurboCharger™
Energy Recovery Devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Seawater RO: ERI PX Pressure
Exchanger™ Energy Recovery Devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Seawater RO: ERI PX Pressure
Exchanger™ Energy Recovery Devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
95 – 98% efficiency
MEMBRANES
HIGH
PRESSURE
PUMP 65-SERIES
DEVICE
CIRCULATION
PUMP
Seawater RO: Positive Displacement
Energy Recovery Devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Smaller pump, high constant efficiency, flexible operation
Hydraulic --> Hydraulic
Increasing Flow
100
80
60
40
20
Efficiency
%
Isobaric
Turbocharger
Pelton Turbine
Isobaric energy recovery systems have high
efficiency regardless of system size
Constant High Efficiency
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
THE PX™ PRESSURE EXCHANGER™ DEVICE
An Isobaric High Efficiency Energy Recovery Solution
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
The PX™ Device
• 2 high-pressure connections
• 2 low-pressure connections
• Ceramic cartridge
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
rotor/sleeve assembly, end covers
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
1 2
3 4
The PX™ Device at Work
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
A Look Inside the PX™ Device
Pressure Vessel
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Product
Quadribaric
Technology™
PX-300
PX-Q300
Circulation Pumps
Product
65-Series
PX-180
PX-220
PX-260
PX-Q260
4S-Series
PX-30S
PX-45S
PX-70S
PX-90S
PX-140S
Isobaric Technology:
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
GRUNDFOS
• BMEX Skid
The PX™ Energy Recovery
Technology Advantage
• Highest Energy Efficiency Guarantees ~ 97.2%
 Performance never degrades over time
 Saving clients more than $1 billion in energy costs alone each year!
• Uptime: 99.8% Availability Advantage
 Zero unplanned downtime can offer average savings of $15 million over
the life of a plant*
• *estimated for a typical 100K m3/d plant
 PX energy recovery devices are never responsible for plant down-time
or loss of production
• Lowest Lifecycle Costs
 Best Economics: Highest Return on Investment
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Energy Recovery Device – PX™
Technology Advantages
• Durability – Designed for a lifetime
 Designed for plant lifetime (25+ years minimum)
 Robust ceramics- improved formulation
 Never corrodes or fatigues
• No Scheduled Maintenance
• Modularity & Flexibility
 Scalable (limitless capacity)
 Flexible operations (recovery/flows)
 Built-in redundancy
 Flexible orientation
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Energy Recovery Device – PX™
Technology Advantages
Quickest Start-up
• Installation time - Starts up within days
 5-6 times faster than other piston-type isobaric ERDs
 Weeks versus months
• No controls, wires or electrical connections
• All devices automatically adjust speed to match flow
• Lightweight/Small footprint
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Energy Recovery Device – PX™
Technology Advantages
• Rotor
 One moving part Hydrodynamic bearing
 Automatic speed adjustment
 No material to material contact
• State-of-the Art Materials
 Ceramics
 Extremely durable material (3X steel hardness)
 Never corrodes
 No fatigue
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
The Latest Generation:
Q Series PX-Q300
Benefits
• Highest Efficiency Guarantee – 97.2%
• Lowest Lifecycle Costs- Best ROI
• 99.8% Uptime – zero planned down-time
• Ease of Installation – minimal footprint
Features
• Quietest PX technology – Below 81dB
• All other nice features of the PX device family..
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
SWRO ENGINEERING DESIGN &
OPTIMIZATION
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
ERI Services
ERI is Pleased to offer the following Services:
• P&ID Reviews
• Control Logic Reviews
 Commissioning Services
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Energy Recovery Power Models and
Selector Tools
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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
Flow Control—Low Pressure
SWRO Engineering Design
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
LP flow rate set by discharge flow control valve
MEMBRANES
HIGH
PRESSURE
PUMP PX-260
DEVICE
CIRCULATION
PUMP
SWRO Engineering Design
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Flow Control—High Pressure MEMBRANES
HIGH
PRESSURE
PUMP PX-260
DEVICE
CIRCULATION
PUMP
HP flow rate set by booster pump
SWRO Engineering Design
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Flow Control—Permeate MEMBRANES
HIGH
PRESSURE
PUMP PX-260
DEVICE
CIRCULATION
PUMP
Permeate flow rate set by high pressure pump and membranes
SWRO Engineering Design
PX Flow Control
• The PX™ works like two parallel pipes
• High-pressure flow rate controlled by booster pump
• Low-pressure flow rate controlled by discharge valve
• High-pressure pump flow is permeate flow
• All three main flows are independent
• HP and LP flows must both be
metered and controlled
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
SWRO Engineering Design
Pressure Control
• LP valve does not directly affect membrane pressure
• System pressure determined by membrane condition, feed
temperature and feed salinity
• Supply pressure changes cause LP flow rate changes
• PX™ LP out pressure must be maintained above minimum
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
SWRO Engineering Design
Water Recovery
• Membrane water recovery = I / F
• System water recovery = I / A
• Membrane recovery = system recovery
if PX™ LP flow = PX HP flow
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
PERMEATE
SWRO Engineering Design
• PX Lubrication – High Pressure Flow Through Hydrodynamic Bearing
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
MEMBRANES
HIGH
PRESSURE
PUMP PX-260
DEVICE
CIRCULATION
PUMP
Lubrication flow rate dictated by system pressure
and temperature and PX seals
SWRO Engineering Design
Mixing Effects– Lead Flow or “Overflush”
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
MEMBRANES
HIGH
PRESSURE
PUMP
PX-260
DEVICE
CIRCULATION
PUMP
SWRO Engineering Design
Mixing
• Feed water salinity increase @ 40% recovery = 2.5%
• Operating pressure increase = 1.3 bar
• Operator Options:
 Accept pressure increase (= 2°C feed temp decrease)
 Decrease recovery by 2%
 Increase low-pressure supply to the PX™ by 5%
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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
SWRO Engineering Design
Engineering Design Summary
• HP and LP flows are independent
• Good flow control: stay within limits of PX™ unit
• Constant PX device feedwater pressure
• Get the air out
• Equal flow to all PX units in arrays
• Maintain adequate back-pressure
• Lowering recovery usually improves SWRO performance
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
RETROFIT AND EXPANSION
PLANT DESIGNS
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Retrofit
• Retrofit = modifying an existing plant by adding newly developed
devices that were not available when the plant was made.
• Improvements in ERD, membranes and centrifugal pumps designs have
enormously reduced the RO Specific Energy Consumption.
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
0
1
2
3
4
5
6
7
8
No ERD
Francis Turbine
Pelton Wheel
Isobaric Device
kWh
/
m
3
1980 2000 2009
Jeddah I
Las Palmas
Trinidad
Perth
Retrofit Benefits
• Highest Efficiency currently available
• Upgrade to the latest advanced technologies widely
used today
• Enhance plant performance
• Expand plant capacity and production supply
• Reduce operational costs
 Significant reduction in energy costs and CO2 emissions.
 All achieved with minimum additional equipment and reduced
civil works.
 Flexibility, constant efficiency over a wide range, variable recovery
rate operating ability.
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Retrofit with Isobaric ERD’s
• Before: Original system with Pelton Wheels
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
SEC: 3.2 kWh/m3
Retrofit with Isobaric ERD’s
• After: Modified system with Isobaric ERD’s
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
SEC: 2.3 kWh/ m3
28% reduction in energy consumption
Retrofit Case Study
Tordera SWRO Plant, Spain. Expansion Retrofit.
• Original capacity 28,000 m3/d, 4 trains 7,000 m3/d each.
• Expanded capacity 64,000 m3/d. 4 trenes de 16.000 m3/d c/u.
• Recovery 45%, 15 PX-260 units per train
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Before: SEC with Pelton:
3.06 KWh/m3
After: 2.56 kWh/m3
16.3% reduction in SEC
Same HPP, new motor, new membranes in the new trains.
Retrofit in two-stage systems
• SWRO system with inter-stage booster pump
BEFORE
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
SEC: 3.48 kWh/m3
Retrofit in two-stage systems
• SWRO system with inter-stage booster pump
AFTER
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
SEC: 2.68 kWh/m3
23% reduction
Las Palmas III SWRO Plant,
Grand Canary, Spain
Retrofit Case Study
• Las Palmas III SWRO Plant. Retrofit of
two-stage system
• Two 7,500 m3/d RO trains combined in
a single 15,000 m3/d train.
• 15 PX 220 units
• 48% Recovery
• Original HPP’s and motors
were used
• Almost 0.8 kWh/m3 in reduction
• Performed in less than 6 months
• Payback in less than 18 months
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Retrofit Case Study
• Palmachim SWRO Plant, Israel – Partial (Hybrid) Retrofit
• Original system
 100.800 m3/day, 6 trains 16.800 m3/day each
 88% efficiency on Pelton wheels.
 Feed Booster pump to the HPP with VFD.
• Retrofitted system
 All the HPP’s, Pelton wheels and electrical motors were keep in place without
any modification.
 120.000 m3/day, 6 trains 20.000 m3/day each
 Added flexibility by the Isobaric ER system. Trains can increase their production
up to 26.000 m3/day while maintaining the HPP close to its BEP. Additional
required feed flow is supplied by the energy recovery system.
 No additional civil works, wall-mounted installation
 8% reduction in SEC.
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Retrofit Case Study
• Palmachim SWRO Plant, Israel – Partial (Hybrid) Retrofit
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
More examples
• Pembroke – Malta 40,000 m3/day
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
More examples
• Dekhelia - Cyprus 60,000 m3/day
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Why a retrofit?
• Undeniable energy savings  Lower cost of water produced
• Extend the life time and/or plant capacity, optimizing and
modernizing the plant equipment.
• Improve environmental impact -energy saving programs and
reduction of emissions, e.g. “carbon credits”
• Regain competitiveness among newer plants being built
with the latest technologies.
• Increase system availability
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
PX™ TECHNOLOGY INSTALLATIONS
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Perth, Australia —
140,000 m3/day (36.9 MGD)
• GWI Award 2007
Environmental Contribution of the Year
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Hadera, Israel: 465,000 m3/day
• World’s Largest SWRO Plant in Operation
• 16 Trains of PX-220 devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Minjur - Chennai, India: 100,000 m3/day
• Minjur Seawater Desalination
Plant – Befesa CTA
• 5 Trains of PX devices
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Nemmeli - India: 100,000 m3/day
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Hamma, Algeria —
200,000 m3/ day (53 MGD)
• Largest membrane trains in the world
• 25,000 m3/ day
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Al Shoaibah (Saudi Arabia) —
150,000 m3/ day (40 MGD)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Barcelona (Spain) 200,000 m3/ day
(53 MGD)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
68
CONFIDENTIAL
6,300,000 m3/day
12 Billion kWh Energy per year
Sales Offices PX™ Installations
$1.2 Billion of Savings per year for our clients
Headquarters
San Leandro, California Madrid, Spain Dubai, UAE Shanghai, China
14,000+ Devices Installed Globally
~ 75% Market Share
©2012 Energy Recovery | Confidential & Proprietary
February 27, 2014
CENTRIFUGAL PUMPS &
TURBOCHARGER ERD SOLUTIONS
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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
Core Competences
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Customer
Requirements
Agile
Engineering
CNC
Programming
Machining of
Hydraulic
Passages
Performance
Test
Quality Control
Shipment
Agile Engineering
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Manufacturing Capability Expansion
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
LPT
ERI AquaSpire
pump
HTC AT
ERI (Centrifugal Technology) Products
Pumps
• ERI™ AquaBold™ High Pressure
RO Pumps
• ERI™ AquaSpire™ Single-stage Pump
Energy Recovery Devices
• Advanced Technology TC (HTC AT)
• AT Advantages now available for the
small capacity plants replacing the
Turbocharger (HALO)
• Low Pressure Turbocharger (LPT)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
ERI AquaBold
pump
TURBOCHARGER GENERAL THEORY
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
227 m3/h
2.4 bar
227 m3/h
38 bar
227 m3/h
70 bar
137 m3/h
67 bar
137 m3/h
1 bar
90 m3/h
0.3 bar
HIGH
PRESSURE
PUMP
ERI
TURBOCHARGER
DEVICE
SWRO Engineering Design –
Single Stage
• The ERI™ TurboCharger™ device uses brine energy to boost
the full feed stream to the RO, thereby reducing the
required boost from the high pressure pump.
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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
AT-7200 = (0.82) x (0.55) x (57.2 – 0.5) = 25.6 bar boost
Turbo Pressure Boost – Example II.
• Large 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???
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
LPT Process Design
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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
TURBO OPERATION
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Advanced Technology (AT)
Turbocharger
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Advanced Technology (AT)
Turbocharger
• Application
 Medium to large scale energy recovery device for SWRO
• Advantages
 Reliability
• Product lubricated bearings
• No scheduled maintenance
• Ease of installation
 Designed for Optimum Efficiency
• Customized Hydraulic Design for each specific application
• Customized 3-D geometry Impellers
 Removable volute inserts
 Compact design allowing for smallest foot print available
 Feed pump size reduction
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Advanced Technology (AT)
Turbocharger (Cross Section)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
THRUST BEARING
CENTER BEARING
PUMP IMPELLER
PUMP VOLUTE
TURBINE
IMPELLER
TURBINE VOLUTE
PUMP BEARING
Advanced Technology (AT)
Turbocharger Con’d
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Pump Side
Diffuser
Main
Turbine
Nozzle
Turbine Side
Volute
Pump Side
Volute
PEI Patent Pending
Volute Insert Technology
• ERI’s unique ability to improve efficiency and reduce water
cost over the life of the plant
• Does not require complete equipment replacement
• Simple field retrofit with virtually no downtime
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
HTCAT AquaSpire
Volute Insert Technology Con’d
• Ability to adapt to improvement in desalination technology
• Enhanced membrane recovery (Impact on feed flows)
 10 years ago 35% recovery was industry norm
 Now 40 – 45 % recovery is the norm
• Reduction in operating pressure
 10 years ago 70 -74 bar was SWRO norm
 Now 64 -68 bar is the norm
• Improved pretreatment technology
• Ability to take advantage of desal technology improvement without
negative impact on efficiency
1.5% - 2% of Efficiency will save a customer Millions $
over the entire Plant Life
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Volute Insert Technology Con’d
• 10% change in flow = 1.5% drop in efficiency
• Easily replicable volute and diffuser components allow for
best efficiency point operation even when operating
requirements change
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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)
SYSTEM CONTROL AND
OPTIMIZATION
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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 10-15% pressure range at a constant brine flow.
How does an ERI™ TurboCharger™
ERD work?
• The auxiliary nozzle valve on the turbocharger provides
brine flow and pressure adjustment to accommodate typical
variations in membrane requirements
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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.
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
• The Aux Nozzle valve can be manual (as shown) or actuated.
• If automated, the best control signal is the brine flow.
Low Pressure Turbocharger (LPT)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Low Pressure Turbocharger (LPT)
• Application
 Designed for use in low pressure,
multi-stage Brackish Water RO systems
• Advantages
 All components made from cast parts for long life
 Custom designed for customer specific conditions
 Balances first and second stage flux rates
 Eliminates interstage booster pump
 Reduces first stage fouling potential
 Replaces brine control valves
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
LPT Turbocharger Features
• Inter stage boost balances permeate flux rates between
stages
• Turbocharger combines energy recovery turbine and
interstage booster pump in single unit
• Can reduce fouling potential in 1st stage by reducing its flux.
• Entirely energized by brine pressure – no electrical
components, consumption, or cost.
• Lowest Life Cycle Cost pump for interstage booster service
• No Maintenance: Water lubricated bearings
• Low Noise: Vibration-free
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Low Pressure Turbocharger (LPT)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
THRUST BEARING
CENTER BEARING
PUMP
BEARING
PUMP
IMPELLER
TURBINE
IMPELLER
PUMP
VOLUTE
TURBINE
VOLUTE
ERI™ AquaBold™ Pump Line
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
ERI™ AquaBold™ Pump Overview
• High-Efficiency Centrifugal High Pressure RO Pump
• Uniquely designed for desalination applications
 Custom designs for specific operating conditions allows for optimum pump
efficiencies
• Quality materials & manufacturing
 Designed for 20 year service life
• Designed for use with PX energy recovery devices
 Highest efficiency package solution with minimal power consumption
• Available with short lead-times
• Customer service, training and support
 Highly qualified technical field services and training programs
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
ERI™ AquaBold™ Pump Advantages
• Industry-leading high efficiencies
 Performance-enhanced fluid modeling
 Proprietary thrust technology
eliminates losses
• State-of-the-art construction for
RO industry
 Precision machined investment-cast components
 Standard Duplex 2205
 Super Duplex 2507 optional
• Simple to maintain
 No disassembly required for mechanical seal replacement
 All product-lubricated bearings
 Thrust bearing can be replaced without removing pump or motor
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
ERI™ AquaBold™ Pump - Features
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
ERI™ AquaBold™ Pump (Cross Section)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Proprietary Thrust Bearing
• Product lubricated bearings –
eliminates maintenance of grease
bearings and auxiliary oil systems
and associated seals
• Simple, efficient design – allows field
retrofits without the need for
bearing change
• Reduced friction provides lower
power losses within the bearing
system, improving overall efficiency
• Eliminates need for costly external
thrust bearing system
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
ERI™ AquaBold™ Pump Line
(Current Products)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
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-
4x6x9
3x4x7-C
3x4x7-
2x3x5-
2x3x5-
3x4x7-
4x6x9-
Ancol SWRO, Jakarta, Indonesia -
1,680 m3/day
• ERI™ TurboCharger™ ERD installation
• ERI™ AquaBold™- High Pressure Pump (4x6x9-4)
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Turbocharger Installation: 3,000 m3/ day
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
Distributor in Germany, Austria, Switzerland, Czech and Slovak Republic
ROC Components AG – 4153 Reinach, Switzerland
info@roc-ch.com
Tel: +41 61 461 8303
Fax: +41 61 461 8304
EMAIL/PHONE>)

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turbo_presentation.pdf

  • 1. Trends & Developments in Advanced Energy Recovery Technologies for Desalination May 30, 2013 Distributor for Germany, Austria, Switzerland, Czech & Slovak Republic www.roc-ch.com
  • 2. Agenda February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Case Studies – PX Installations Desalination Systems Retrofit and Expansion Plant Designs Who is Energy Recovery “ERI”? The PX™ Pressure Exchanger Technology SWRO Engineering Design & Optimization Centrifugal Pumps & ERD Solutions PX Hands-On
  • 3. WHO IS ENERGY RECOVERY? February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Making Desalination Affordable
  • 4. Energy Recovery Inc February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary HEADQUARTERS/MANUFACTURING/CERAMICS San Leandro (San Francisco) California USA REGIONAL OFFICES China, Spain, UAE
  • 5. Company Profile February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Background • Established in 1992, Headquarters in California • More than 14,000+ Energy Recovery Devices & Pumps Installed/Contracted • Global Sales and Technical Presence • Saving more than 10 Billion kWh of Energy per Year Technical Expertise • Highest Efficiency, Durability and Reliability ERDs • 24/7 Service and Support • Precision Manufacturing and Ceramics Expertise • Technical Review, On-site Commissioning, Start-up, Training • Best-in-it’s-Class ERD and Pump Solutions • More than 400 OEMs • PEI acquisition in 2009
  • 6. State-of-the-Art, Materials Science Manufacturing February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Creating advanced ceramics components requires specialized equipment, a fully equipped materials lab, engineers, and optimized processes
  • 7. Over 400 Clients February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 8. Capital Expense 43% Operating Expense 57% ASSUMPTIONS Power Cost USD/kWh 0.09 Debt Equity Ratio 80/20 Debt Interest Rate 8% Equity ROI 18% Desalination Plant Capital & Operating Costs February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 9. Chemical / Consumables 9% Power 41% Parts Replacement 13% Operating Margin 17% Office 3% Membranes 8% Labor, G&A 9% Perth Seawater Desalination Plant 2008 Operating Expenses— Breakdown February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 10. Source: Affordable Desalination Collaboration, 2008 Pre-filtration 8% Permeate Treatment 1% Permeate Distribution 7% Reverse Osmosis Process 68% Intake 15% RO power consumption is approximately 20% (up to 45%) of total SWRO cost Power Use — Breakdown (Seawater RO) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 11. DESALINATION SYSTEMS Making Desalination Affordable February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 12. Desalination Systems Pelton Turbine Turbocharger Piston Exchanger Francis Turbine Dyprex Rotary Exchanger 1980 1990 2000 2010
  • 13. MEMBRANES HIGH PRESSURE PUMP Seawater RO: Before Energy Recovery Devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Issues: high pumping costs, wasted energy, lack of optimization
  • 14. Seawater RO: Pelton Wheel/Francis Turbine Energy Recovery Devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Hydraulic --> Mechanical --> Hydraulic
  • 15. Seawater RO: ERI TurboCharger™ Energy Recovery Devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 16. Seawater RO: ERI TurboCharger™ Energy Recovery Devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 17. Seawater RO: ERI PX Pressure Exchanger™ Energy Recovery Devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 18. Seawater RO: ERI PX Pressure Exchanger™ Energy Recovery Devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 19. 95 – 98% efficiency MEMBRANES HIGH PRESSURE PUMP 65-SERIES DEVICE CIRCULATION PUMP Seawater RO: Positive Displacement Energy Recovery Devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Smaller pump, high constant efficiency, flexible operation Hydraulic --> Hydraulic
  • 20. Increasing Flow 100 80 60 40 20 Efficiency % Isobaric Turbocharger Pelton Turbine Isobaric energy recovery systems have high efficiency regardless of system size Constant High Efficiency February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 21. THE PX™ PRESSURE EXCHANGER™ DEVICE An Isobaric High Efficiency Energy Recovery Solution February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 22. The PX™ Device • 2 high-pressure connections • 2 low-pressure connections • Ceramic cartridge February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary rotor/sleeve assembly, end covers
  • 23. 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 1 2 3 4 The PX™ Device at Work February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 24. A Look Inside the PX™ Device Pressure Vessel February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 27. The PX™ Energy Recovery Technology Advantage • Highest Energy Efficiency Guarantees ~ 97.2%  Performance never degrades over time  Saving clients more than $1 billion in energy costs alone each year! • Uptime: 99.8% Availability Advantage  Zero unplanned downtime can offer average savings of $15 million over the life of a plant* • *estimated for a typical 100K m3/d plant  PX energy recovery devices are never responsible for plant down-time or loss of production • Lowest Lifecycle Costs  Best Economics: Highest Return on Investment February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 28. Energy Recovery Device – PX™ Technology Advantages • Durability – Designed for a lifetime  Designed for plant lifetime (25+ years minimum)  Robust ceramics- improved formulation  Never corrodes or fatigues • No Scheduled Maintenance • Modularity & Flexibility  Scalable (limitless capacity)  Flexible operations (recovery/flows)  Built-in redundancy  Flexible orientation February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 29. Energy Recovery Device – PX™ Technology Advantages Quickest Start-up • Installation time - Starts up within days  5-6 times faster than other piston-type isobaric ERDs  Weeks versus months • No controls, wires or electrical connections • All devices automatically adjust speed to match flow • Lightweight/Small footprint February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 30. Energy Recovery Device – PX™ Technology Advantages • Rotor  One moving part Hydrodynamic bearing  Automatic speed adjustment  No material to material contact • State-of-the Art Materials  Ceramics  Extremely durable material (3X steel hardness)  Never corrodes  No fatigue February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 31. The Latest Generation: Q Series PX-Q300 Benefits • Highest Efficiency Guarantee – 97.2% • Lowest Lifecycle Costs- Best ROI • 99.8% Uptime – zero planned down-time • Ease of Installation – minimal footprint Features • Quietest PX technology – Below 81dB • All other nice features of the PX device family.. February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 32. SWRO ENGINEERING DESIGN & OPTIMIZATION February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 33. ERI Services ERI is Pleased to offer the following Services: • P&ID Reviews • Control Logic Reviews  Commissioning Services February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 34. Energy Recovery Power Models and Selector Tools February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary 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
  • 35. Flow Control—Low Pressure SWRO Engineering Design February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary LP flow rate set by discharge flow control valve MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 36. SWRO Engineering Design February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Flow Control—High Pressure MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP HP flow rate set by booster pump
  • 37. SWRO Engineering Design February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Flow Control—Permeate MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP Permeate flow rate set by high pressure pump and membranes
  • 38. SWRO Engineering Design PX Flow Control • The PX™ works like two parallel pipes • High-pressure flow rate controlled by booster pump • Low-pressure flow rate controlled by discharge valve • High-pressure pump flow is permeate flow • All three main flows are independent • HP and LP flows must both be metered and controlled February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 39. SWRO Engineering Design Pressure Control • LP valve does not directly affect membrane pressure • System pressure determined by membrane condition, feed temperature and feed salinity • Supply pressure changes cause LP flow rate changes • PX™ LP out pressure must be maintained above minimum February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 40. SWRO Engineering Design Water Recovery • Membrane water recovery = I / F • System water recovery = I / A • Membrane recovery = system recovery if PX™ LP flow = PX HP flow February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP PERMEATE
  • 41. SWRO Engineering Design • PX Lubrication – High Pressure Flow Through Hydrodynamic Bearing February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP Lubrication flow rate dictated by system pressure and temperature and PX seals
  • 42. SWRO Engineering Design Mixing Effects– Lead Flow or “Overflush” February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary MEMBRANES HIGH PRESSURE PUMP PX-260 DEVICE CIRCULATION PUMP
  • 43. SWRO Engineering Design Mixing • Feed water salinity increase @ 40% recovery = 2.5% • Operating pressure increase = 1.3 bar • Operator Options:  Accept pressure increase (= 2°C feed temp decrease)  Decrease recovery by 2%  Increase low-pressure supply to the PX™ by 5% February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary 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
  • 44. SWRO Engineering Design Engineering Design Summary • HP and LP flows are independent • Good flow control: stay within limits of PX™ unit • Constant PX device feedwater pressure • Get the air out • Equal flow to all PX units in arrays • Maintain adequate back-pressure • Lowering recovery usually improves SWRO performance February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 45. RETROFIT AND EXPANSION PLANT DESIGNS February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 46. Retrofit • Retrofit = modifying an existing plant by adding newly developed devices that were not available when the plant was made. • Improvements in ERD, membranes and centrifugal pumps designs have enormously reduced the RO Specific Energy Consumption. February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary 0 1 2 3 4 5 6 7 8 No ERD Francis Turbine Pelton Wheel Isobaric Device kWh / m 3 1980 2000 2009 Jeddah I Las Palmas Trinidad Perth
  • 47. Retrofit Benefits • Highest Efficiency currently available • Upgrade to the latest advanced technologies widely used today • Enhance plant performance • Expand plant capacity and production supply • Reduce operational costs  Significant reduction in energy costs and CO2 emissions.  All achieved with minimum additional equipment and reduced civil works.  Flexibility, constant efficiency over a wide range, variable recovery rate operating ability. February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 48. Retrofit with Isobaric ERD’s • Before: Original system with Pelton Wheels February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary SEC: 3.2 kWh/m3
  • 49. Retrofit with Isobaric ERD’s • After: Modified system with Isobaric ERD’s February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary SEC: 2.3 kWh/ m3 28% reduction in energy consumption
  • 50. Retrofit Case Study Tordera SWRO Plant, Spain. Expansion Retrofit. • Original capacity 28,000 m3/d, 4 trains 7,000 m3/d each. • Expanded capacity 64,000 m3/d. 4 trenes de 16.000 m3/d c/u. • Recovery 45%, 15 PX-260 units per train February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Before: SEC with Pelton: 3.06 KWh/m3 After: 2.56 kWh/m3 16.3% reduction in SEC Same HPP, new motor, new membranes in the new trains.
  • 51. Retrofit in two-stage systems • SWRO system with inter-stage booster pump BEFORE February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary SEC: 3.48 kWh/m3
  • 52. Retrofit in two-stage systems • SWRO system with inter-stage booster pump AFTER February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary SEC: 2.68 kWh/m3 23% reduction Las Palmas III SWRO Plant, Grand Canary, Spain
  • 53. Retrofit Case Study • Las Palmas III SWRO Plant. Retrofit of two-stage system • Two 7,500 m3/d RO trains combined in a single 15,000 m3/d train. • 15 PX 220 units • 48% Recovery • Original HPP’s and motors were used • Almost 0.8 kWh/m3 in reduction • Performed in less than 6 months • Payback in less than 18 months February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 54. Retrofit Case Study • Palmachim SWRO Plant, Israel – Partial (Hybrid) Retrofit • Original system  100.800 m3/day, 6 trains 16.800 m3/day each  88% efficiency on Pelton wheels.  Feed Booster pump to the HPP with VFD. • Retrofitted system  All the HPP’s, Pelton wheels and electrical motors were keep in place without any modification.  120.000 m3/day, 6 trains 20.000 m3/day each  Added flexibility by the Isobaric ER system. Trains can increase their production up to 26.000 m3/day while maintaining the HPP close to its BEP. Additional required feed flow is supplied by the energy recovery system.  No additional civil works, wall-mounted installation  8% reduction in SEC. February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 55. Retrofit Case Study • Palmachim SWRO Plant, Israel – Partial (Hybrid) Retrofit February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 56. More examples • Pembroke – Malta 40,000 m3/day February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 57. More examples • Dekhelia - Cyprus 60,000 m3/day February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 58. Why a retrofit? • Undeniable energy savings  Lower cost of water produced • Extend the life time and/or plant capacity, optimizing and modernizing the plant equipment. • Improve environmental impact -energy saving programs and reduction of emissions, e.g. “carbon credits” • Regain competitiveness among newer plants being built with the latest technologies. • Increase system availability February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 59. PX™ TECHNOLOGY INSTALLATIONS February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 60. Perth, Australia — 140,000 m3/day (36.9 MGD) • GWI Award 2007 Environmental Contribution of the Year February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 61. Hadera, Israel: 465,000 m3/day • World’s Largest SWRO Plant in Operation • 16 Trains of PX-220 devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 62. Minjur - Chennai, India: 100,000 m3/day • Minjur Seawater Desalination Plant – Befesa CTA • 5 Trains of PX devices February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 63. Nemmeli - India: 100,000 m3/day February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 64. Hamma, Algeria — 200,000 m3/ day (53 MGD) • Largest membrane trains in the world • 25,000 m3/ day February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 65. Al Shoaibah (Saudi Arabia) — 150,000 m3/ day (40 MGD) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 66. Barcelona (Spain) 200,000 m3/ day (53 MGD) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 67. 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 February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 68. 68 CONFIDENTIAL 6,300,000 m3/day 12 Billion kWh Energy per year Sales Offices PX™ Installations $1.2 Billion of Savings per year for our clients Headquarters San Leandro, California Madrid, Spain Dubai, UAE Shanghai, China 14,000+ Devices Installed Globally ~ 75% Market Share ©2012 Energy Recovery | Confidential & Proprietary February 27, 2014
  • 69. CENTRIFUGAL PUMPS & TURBOCHARGER ERD SOLUTIONS February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 70. 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 Core Competences February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 72. Manufacturing Capability Expansion February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 73. LPT ERI AquaSpire pump HTC AT ERI (Centrifugal Technology) Products Pumps • ERI™ AquaBold™ High Pressure RO Pumps • ERI™ AquaSpire™ Single-stage Pump Energy Recovery Devices • Advanced Technology TC (HTC AT) • AT Advantages now available for the small capacity plants replacing the Turbocharger (HALO) • Low Pressure Turbocharger (LPT) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary ERI AquaBold pump
  • 74. TURBOCHARGER GENERAL THEORY February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 75. 227 m3/h 2.4 bar 227 m3/h 38 bar 227 m3/h 70 bar 137 m3/h 67 bar 137 m3/h 1 bar 90 m3/h 0.3 bar HIGH PRESSURE PUMP ERI TURBOCHARGER DEVICE SWRO Engineering Design – Single Stage • The ERI™ TurboCharger™ device uses brine energy to boost the full feed stream to the RO, thereby reducing the required boost from the high pressure pump. February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 76. 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 AT-7200 = (0.82) x (0.55) x (57.2 – 0.5) = 25.6 bar boost Turbo Pressure Boost – Example II. • Large 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??? February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 77. LPT Process Design February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary 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
  • 78. TURBO OPERATION February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 79. Advanced Technology (AT) Turbocharger February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 80. Advanced Technology (AT) Turbocharger • Application  Medium to large scale energy recovery device for SWRO • Advantages  Reliability • Product lubricated bearings • No scheduled maintenance • Ease of installation  Designed for Optimum Efficiency • Customized Hydraulic Design for each specific application • Customized 3-D geometry Impellers  Removable volute inserts  Compact design allowing for smallest foot print available  Feed pump size reduction February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 81. Advanced Technology (AT) Turbocharger (Cross Section) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary THRUST BEARING CENTER BEARING PUMP IMPELLER PUMP VOLUTE TURBINE IMPELLER TURBINE VOLUTE PUMP BEARING
  • 82. Advanced Technology (AT) Turbocharger Con’d February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Pump Side Diffuser Main Turbine Nozzle Turbine Side Volute Pump Side Volute PEI Patent Pending
  • 83. Volute Insert Technology • ERI’s unique ability to improve efficiency and reduce water cost over the life of the plant • Does not require complete equipment replacement • Simple field retrofit with virtually no downtime February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary HTCAT AquaSpire
  • 84. Volute Insert Technology Con’d • Ability to adapt to improvement in desalination technology • Enhanced membrane recovery (Impact on feed flows)  10 years ago 35% recovery was industry norm  Now 40 – 45 % recovery is the norm • Reduction in operating pressure  10 years ago 70 -74 bar was SWRO norm  Now 64 -68 bar is the norm • Improved pretreatment technology • Ability to take advantage of desal technology improvement without negative impact on efficiency 1.5% - 2% of Efficiency will save a customer Millions $ over the entire Plant Life February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 85. Volute Insert Technology Con’d • 10% change in flow = 1.5% drop in efficiency • Easily replicable volute and diffuser components allow for best efficiency point operation even when operating requirements change February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary 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)
  • 86. SYSTEM CONTROL AND OPTIMIZATION February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 87. 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 10-15% pressure range at a constant brine flow. How does an ERI™ TurboCharger™ ERD work? • The auxiliary nozzle valve on the turbocharger provides brine flow and pressure adjustment to accommodate typical variations in membrane requirements February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 88. 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. February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary • The Aux Nozzle valve can be manual (as shown) or actuated. • If automated, the best control signal is the brine flow.
  • 89. Low Pressure Turbocharger (LPT) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 90. Low Pressure Turbocharger (LPT) • Application  Designed for use in low pressure, multi-stage Brackish Water RO systems • Advantages  All components made from cast parts for long life  Custom designed for customer specific conditions  Balances first and second stage flux rates  Eliminates interstage booster pump  Reduces first stage fouling potential  Replaces brine control valves February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 91. LPT Turbocharger Features • Inter stage boost balances permeate flux rates between stages • Turbocharger combines energy recovery turbine and interstage booster pump in single unit • Can reduce fouling potential in 1st stage by reducing its flux. • Entirely energized by brine pressure – no electrical components, consumption, or cost. • Lowest Life Cycle Cost pump for interstage booster service • No Maintenance: Water lubricated bearings • Low Noise: Vibration-free February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 92. Low Pressure Turbocharger (LPT) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary THRUST BEARING CENTER BEARING PUMP BEARING PUMP IMPELLER TURBINE IMPELLER PUMP VOLUTE TURBINE VOLUTE
  • 93. ERI™ AquaBold™ Pump Line February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 94. ERI™ AquaBold™ Pump Overview • High-Efficiency Centrifugal High Pressure RO Pump • Uniquely designed for desalination applications  Custom designs for specific operating conditions allows for optimum pump efficiencies • Quality materials & manufacturing  Designed for 20 year service life • Designed for use with PX energy recovery devices  Highest efficiency package solution with minimal power consumption • Available with short lead-times • Customer service, training and support  Highly qualified technical field services and training programs February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 95. ERI™ AquaBold™ Pump Advantages • Industry-leading high efficiencies  Performance-enhanced fluid modeling  Proprietary thrust technology eliminates losses • State-of-the-art construction for RO industry  Precision machined investment-cast components  Standard Duplex 2205  Super Duplex 2507 optional • Simple to maintain  No disassembly required for mechanical seal replacement  All product-lubricated bearings  Thrust bearing can be replaced without removing pump or motor February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 96. ERI™ AquaBold™ Pump - Features February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 97. ERI™ AquaBold™ Pump (Cross Section) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 98. Proprietary Thrust Bearing • Product lubricated bearings – eliminates maintenance of grease bearings and auxiliary oil systems and associated seals • Simple, efficient design – allows field retrofits without the need for bearing change • Reduced friction provides lower power losses within the bearing system, improving overall efficiency • Eliminates need for costly external thrust bearing system February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 99. ERI™ AquaBold™ Pump Line (Current Products) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary 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- 4x6x9 3x4x7-C 3x4x7- 2x3x5- 2x3x5- 3x4x7- 4x6x9-
  • 100. Ancol SWRO, Jakarta, Indonesia - 1,680 m3/day • ERI™ TurboCharger™ ERD installation • ERI™ AquaBold™- High Pressure Pump (4x6x9-4) February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 101. Turbocharger Installation: 3,000 m3/ day February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary
  • 102. February 27, 2014 ©2012 Energy Recovery | Confidential & Proprietary Distributor in Germany, Austria, Switzerland, Czech and Slovak Republic ROC Components AG – 4153 Reinach, Switzerland info@roc-ch.com Tel: +41 61 461 8303 Fax: +41 61 461 8304 EMAIL/PHONE>)