WINDPOWERED SEAWATER DESALINATION PLANT: PROGRESS BY NEW MATERIALS

ULRICH PLANTIKOW1, RAINER HUSS2

 1WME Gesellschaft für windkraftgetriebene
 Meerwasserentsalzungs mbH., 2FH
Kempten


The steadily rising world population in connection with changing climatic conditions is not only leading to nutrition problems, but also above all, to those regarding the potable water supply. You can study it in the Middle-East region dramatically. Between 1940 and 2000, the world population has more than doubled. Simultaneously water consumption per capita doubled over the same period. Following this development total water consumption has more than quadrupled, making potable water an increasingly scarce commodity in many parts of the world also in colder latitudes despite ample total reserves.

Apart from an economical use of already existing resource, increasing importance is being attached to the development and expansion of treatment facilities for potable water from sea and brackish water. In particular, decentralized units offer good solutions because they can be geared to local water needs and to existing sources of energy.

Over the past 30 years, the production of potable water by seawater plants has increased from zero to almost 20,000,000 m³/day. In many countries they contribute significantly to the supply of potable water.

Of the various processes available today, vapour compression has emerged to be most sophisticated for capacities of up to
2,000 m³/day. This simple but effective method ensures max. reliability with an almost maintenance-free operation. Both the reliability and economic efficiency of such plants have been demonstrated in numerous installations worldwide.

Growing interest in decentralized systems has also prompted efforts to design new plants that operate off the public electric grid and do not, necessarily, require any infrastructure for the supply of fossil sources of energy and also chemicals. Especially remote areas need to run their own desalination plants because water transport is expensive. Through poor infrastructure in these areas a desalination plant that is dependent on the existence of an electric grid in many cases is no solution to the water problem. The use of wind energy allows the grid-independent operation of a new desalination system and besides, having considerable ecologic advantages, is a very economic solution.

The stand-alone windpowered mechanical vapour compression (MVC) seawater desalination would be of special interest to the tourism industry as it is ideally suited for remote areas and islands in particular. Large numbers of tourists lead to an substantial increase in water consumption per capita, mostly in areas in which water is already scarce.

The idea to use wind power as an alone or main energy source for desalination is not new. Wind conditions for example in coastal areas are often in favour of this kind of desalination system. The new generation of small and medium sized wind turbines that has been developed in the past years offers a high amount of reliability in service combined with low investments costs.

The variable nature of wind power is not a problem, because water can be stored inexpensively even for long periods of time without deterioration. With a plant that is dimensioned according to the local wind conditions water becomes available any time.

For the operation of a windpowered desalination plant it is most important to have a plant that has to be insensitive against repeated start up and shut down cycles caused by sometimes rapidly changing wind conditions.

MVC plants are widely used all around the world and have proven to be efficient and economic for many applications. Both, wind turbine and high pressure blower of the MVC-plant, are fluid flow machines with similar characteristics. There is therefore a natural affinity of both machines. By variation of the compressor speed and the evaporation temperature the power consumption can be adapted also to rapid changes in wind conditions.

A combination of a wind turbine and a MVC plant is therefore able to utilize wind energy to a very high degree at all times and conditions (Fig. 1).

The plant described in the following is therefore a MVC-plant with a vertical tube evaporator-condensor-unit.

I. DESCRIPTION OF THE DESALINATION PLANT

The filtered seawater is pumped into an intermediate tank of about 4 m³. From here the water is pumped into the desalination plant (Fig. 2).

For preheating incoming seawater flows in two parallel lines through plate heat exchangers. In these exchangers heat is transferred from the outgoing distillate and brine to the incoming seawater.

The pressure in the following degasifyer is reduced to almost the level of the evaporation pressure of the preheated seawater using a vacuum pump. The gaseous components (air and CO2) dissolved in the seawater escape and are removed.

 

 

 

 

 

 

 

 

 

 

 


Figure. 1. MVC-plant with a vertical tube evaporator-condensor-unit.

The more water evaporates the higher is the salt concentration in the remaining seawater. Usually the salt concentration should not become higher than 7 - 9 %, therefore continuously concentrated seawater is led back into the sea and fresh seawater is supplied.

II. DESIGN OF THE MAIN COMPONENT - THE EVAPORATOR-CONDENSOR UNIT (ECU)

The evaporator-condensor unit (ecu) is the heart of the plant.

It consists of a bundle of tubes placed between the upper and the lower tube sheets. The tube sheets divide the ecu in 2 spaces: the seawater contacted room and the distillat contacted.

The distillate contacted walls consist of conventional stainless steel 1.4571, but the seawater contacted walls of steel of the quality 1.4565 S.


 

 

 

 

 

 

 

 

 

 

 

 

 

 


Figure. 2. Wind driven desalination plant (principal scheme).


This is an excellent material for thermal seawater desalination plants.

In the first 2 years there exists huge difficulties to run the plant in a normal way. Because of the changing wind speed and therefore of the produced energy of the wind energy converter it was not possible to run the plant longer than 2 month without scaling. Thermal desalination plants use normally antiscaling agents like malein acid or polyphosphates. We did it of course too.

There were tested all in the whole world known chemicals against scaling, but there were not a real progress.

The incrustations in the plant were terrible. They occured in the whole plant that means in the upper tube sheet, in the sump, on the inner walls of the evaporator/condensor unit, in the circulation pump and in the plate heat exchangers.

The only way to longer the time up till totally incrustation was to lower the evaporation temperatures up to at maximum 60 °C. 60 °C is for this reason the normal temperature of constant running MVC-plants. To lower the temperature means to decrease the efficiency of the desalination process because the vapor density is substantial low at lower temperatures and therefore also the production of potable water. This bad situation led in connection with the observed corrosion of the copper-nickel-tubes and the start of the production of laser welded tubes of 1.4565-steel (Thyssen Company) by the Fischer Company (Germany) to the decision to change the more than 1000 tubes (about 4 km!) of the evaporator-condensor-unit.

Then it was possible to change radically conditions for running the plant. Our measurements showed in the first 2 years, that the pH-value increased in the process of evaporation and vacuum pumping from about 7 from the incoming seawater to more than 10 of the outgoing brine. This was caused by removing not only the air by our vacuum pump but also the CO2, that means the acidity of the carbonic acid will vanish and the rest of the calciumcarbonat is no more soluble at these changed boundary condition, described by the formula: Ca(HCO3)2, soluble ® CaCO3, insoluble + CO2 + H2O.

The solution of this problem was to change the pH in the incoming seawater up to about 5 by dosing hydrochloric acid. Than the pH of the brine will increase up to constant 7 only. That was only possible because of using 1.4565 steel. The danger of corrosion with these steel was lower on the structure and the tubes of the plant.

The success of this new operation modus was overwhelmingly. Today the plant is running up to 80 °C. So the production of potable water is about 30 % higher, there is no sign of any corrosion in the whole plant. But there was also no drawback on the thermodynamics of the process. Last not least we don´t need any chemicals to run the plant. And that is not a contradiction against the description of the process.

A new developed electrochemical technique, an inline membranelectrolysis allows the change of the pH of the incoming seawater in a way we need. The necessary energy for the changing procedure is less than 2 % at maximum input.

And therefore we are convinced that our system is also a technique without ecological competition worldwide. And, very important: because not to use chemicals means no disposal to the sea.

III. CONCLUSION

Because of the use of steel in the quality 1.4565 S in thermal seawater desalination plants, esp. with an energy input of wind energy converters it is possible to run the plant up to higher evaporation temperatures of 80 °C without any corrosion in the whole plant and especially not in the evaporator-condensor unit. Because of these higher temperatures the specific energy efficiency and the volume-time-yield and therefore the specific costs of desalination process of these plants were considerable improved. This is the result of 4 years praxis test on a wind driven seawater desalination at the island of Rügen in the baltic sea.