Simulation, optimisation and flexible scheduling of MSF desalination process under fouling. Optimal design and operation of MSF desalination process with brine heater and demister fouling, flexible design operation and scheduling under variable demand and seawater temperature using gPROMS.

Abstract

Among many seawater desalination processes, the multistage flash (MSF) desalination process is a major source of fresh water around the world. The most costly design and operation problem in seawater desalination is due to scale formation and corrosion problems. Fouling factor is one of the many important parameters that affect the operation of MSF processes. This thesis therefore focuses on determining the optimal design and operation strategy of MSF desalinations processes under fouling which will meet variable demand of freshwater. First, a steady state model of MSF is developed based on the basic laws of mass balance, energy balance, and heat transfer equations with supporting correlations for physical properties. gPROMS software is used to develop the model which is validated against the results reported in the literature. The model is then used in further investigations. Based on actual plant data, a simple dynamic fouling factor profile is developed which allows calculation of fouling factor at different time (season of the year). The role of changing brine heater fouling factor with varying seawater temperatures (during the year) on the plant performance and the monthly operating costs for fixed water demand and fixed top brine temperature are then studied. The total monthly operation cost of the process are minimised while the operating parameters such as make up, brine recycle flow rate and steam temperature are optimised. It was found that the seasonal variation in seawater temperature and brine heater fouling factor results in significant variations in the operating parameters and operating costs. The design and operation of the MSF process are optimized in order to meet variable demands of freshwater with changing seawater temperature throughout the day and throughout the year. On the basis of actual data, the neural network (NN) technique has been used to develop a correlation for calculating dynamic freshwater demand/consumption profiles at different times of the day and season. Also, a simple polynomial based dynamic seawater temperature correlation is developed based on actual data. An intermediate storage tank between the plant and the client is considered. The MSF process model developed earlier is coupled with the dynamic model for the storage tank and is incorporated into the optimization framework within gPROMS. Four main seasons are considered in a year and for each season, with variable freshwater demand and seawater temperature, the operating parameters are optimized at discrete time intervals, while minimizing the total daily costs. The intermediate storage tank adds flexible scheduling and maintenance opportunity of individual flash stages and makes it possible to meet variable freshwater demand with varying seawater temperatures without interrupting or fully shutting down the plant at any-time during the day and for any season. Finally, the purity of freshwater coming from MSF desalination plants is very important when the water is used for industrial services such as feed of boiler to produce steam. In this work, for fixed water demand and top brine temperature, the effect of separation efficiency of demister with seasonal variation of seawater temperatures on the final purity of freshwater for both cleaned and fouled demister conditions is studied. It was found that the purity of freshwater is affected by the total number of stages. Also to maintain the purity of freshwater product, comparatively large number of flash stage is required for fouled demister.