Design and Operation of Multistage Flash (MSF) Desalination: Advanced Control Strategies and Impact of Fouling. Design operation and control of multistage flash desalination processes: dynamic modelling of fouling, effect of non-condensable gases on venting system design and implementation of GMC and fuzzy control

The rapid increase in the demand on fresh water due the increase in the world population and scarcity of natural water puts more stress on the desalination industrial sector to install more desalination plants around the world. Among these desalination plants, multistage flash desalination process (MSF) is considered to be the most reliable technique of producing potable water from saline water. In recent years, however, the MSF process is confronting many problems to cut off the cost and increase its performance. Among these problems are the non-condensable gases (NCGs) and the accumulation of fouling which they work as heat insulation materials. As a result, the MSF pumps and the heat transfer equipment are overdesigned and consequently increase the capital cost and decrease the performance of the plants. Moreover, improved process control is a cost effective approach to energy conservation and increased process profitability. Thus, this study is motivated by the real absence of detailed kinetic fouling model and implementation of advance process control (APC). To accomplish the above tasks, commercial modelling tools can be utilized to model and simulate MSF process taking into account the NCGs and fouling effect, and optimum control strategy. In this research, gPROMS (general PROcess Modeling System) model builder has been used to develop the MSF process model. First, a dynamic mathematical model of MSF is developed based on the basic laws of mass balance, energy balance and heat transfer. Physical and thermodynamic properties of brine, distillate and water vapour are included to support the model. The model simulation results are validated against actual plant data published in the literature and good agreement with these data is obtained. Second, the design of venting system in MSF plant and the effect of NCGs on the overall heat transfer coefficient (OHTC) are studied. The release rate of NCGs is studied using Henry’s law and the locations of venting points are optimised. The results reveal that high concentration of NCGs heavily affects the OHTC. Furthermore, advance control strategy namely: generic model control (GMC) is designed and introduced to the MSF process to control and track the set points of the two most important variables in the MSF plant; namely the Top Brine Temperature (TBT) which is the output temperature of the brine heater and the Brine Level (BL) in the last stage. The results are compared to conventional Proportional Integral Derivative Controller (PID) and show that GMC controller provides better performance over conventional PID controller to handle a nonlinear system. In addition, a new control strategy called hybrid Fuzzy-GMC is developed and implemented to control the same aforementioned loops. Its results reveal that the new control outperforms the pure GMC in some areas. Finally, a dynamic fouling model is developed and incorporated into the MSF dynamic process model to predict fouling at high temperature and high velocity. The proposed dynamic model considers the attachment and removal mechanisms of calcium carbonate and magnesium hydroxide with more relaxation of the assumptions. Since the MSF plant stages work as a series of heat exchangers, there is a continuous change of temperature, heat flux and salinity of the seawater. The proposed model predicts the behaviour of fouling based on the physical and thermal conditions of every single stage of the plant

Crystallization of calcium carbonate and magnesium hydroxide in the heat exchangers of once-through multistage flash (MSF-OT) desalination process

YesIn this paper, a dynamic model of fouling is presented to predict the crystallization of calcium carbonate and magnesium hydroxide inside the condenser tubes of Once-Through Multistage Flash (MSF-OT) desalination process. The model considers the combination of kinetic and mass diffusion rates taking into account the effect of temperature, velocity and salinity of the seawater. The equations for seawater carbonate system are used to calculate the concentration of the seawater species. The effects of salinity and temperature on the solubility of calcium carbonate and magnesium hydroxide are also considered. The results reveal an increase in the fouling inside the tubes caused by crystallization of CaCO3 and Mg(OH)2 with increase in the stage temperature. The intake seawater temperature and the Top Brine Temperature (TBT) are varied to investigate their impact on the fouling process. The results show that the (TBT) has greater impact than the seawater temperature on increasing the fouling

A Review of the Configurations, Capabilities, and Cutting-Edge Options for Multistage Solar Stills in Water Desalination

The desalination of saltwater is a viable option to produce freshwater. All the desalination processes are energy-intensive and can be carried out on a large scale. Therefore, producing freshwater using renewable energy sources is the most desirable option considering the current energy crisis and the effect that fossil-fuel-based energy has on our carbon footprint. In this respect, the tray-type still, one of several solar power desalination still varieties, is popular owing to its straightforward design, economic materials of construction, and minimal maintenance requirements, especially in isolated island regions with restricted energy and natural water supplies. The traditional tray-type solar power has a few drawbacks, such as the inability to recover latent heat from condensation, reduced thermal convection, a large heat capacity, and comparatively minimal driving power through evaporation. Therefore, the improvement of heat and mass transfer capabilities in tray-type stills has been the subject of many studies. However, there is a lack of a comprehensive review in the open literature that covers the design and operational details of multistage solar stills. The purpose of this paper is to present a thorough overview of the past research on multistage solar stills, in terms of configurations, capabilities, and cutting-edge options. In comparison to a unit without a salt-blocking formation, the review indicates that a multistage distillation unit may run continuously at high radiation and generate pure water that is around 1.7 times higher than a unit without a salt-blocking formation. The most effective deign is found to be “V”-shaped solar still trays that attach to four-stage stills, since they are less expensive and more economical than the “floor” (Λ-shape) design, which requires two collectors. Additionally, it can be stated that the unit thermal efficiency, solar percentage, and collected solar energy (over the course of a year) increase by 23%, 18%, and 24%, respectively, when the solar collectors are increased by 26% (at the constant inflow velocity of the water)