TOPIC 6

THERMODYNAMICS & DESIGN OF MSF PLANTS

Since the early 1960s, most of the seawater desalination plants constructed are
based on MSF process. The general principles involved and the arrangement of
various components have been described in Topic 4a. The present chapter deals
with thermodynamics and general design principles of MSF plant. Initially the
following needs to be established.

 The required plant capacity or output (gpd, m3/day)

 The amount of energy required to produce the desired output.

The design calculations are based on the use of mass and energy balance
equations for:

 the determination of temperature and flow rates in the various parts of the
MSF system, and

 estimation of heat transfer areas using heat transfer equations.

Generally,

● The owner, who wishes to purchase the MSF plant, usually hires a consulting
Engineering Office, which prepares the technical specifications for the plant.

● The Consultant always specifies the total water production capacity of the
MSF plant. Often the Consultant also specifies the size of each MSF unit and
the number of MSF units; sometimes he leaves the size of each MSF unit and
the number of MSF units to the contractors (vendors).

● Sometimes, a contractor may offer larger sized unit and greater total capacity
for the same price. For example, the Consultant may specify 10 units, each 5
MGD, Total = 50 MGD. The Contractor may offer 10 units × 6 MGD = 60
MGD for the same price. The reason: He has already built a 10 unit, 60 MGD
plant for some other customer. The design and the drawings are ready and it
will be cheaper for him to supply the 10×6 MGD plant, rather than design and
fabricate the 10×5 MGD plant.

● In the Gulf region, now all MSF plants are specified to operate at dual
temperatures, low temperature (LT  90oC) & high temperature (HT 
113oC).

1
● The Consultant specifies the source of steam (whether from a waste heat
boiler, as an extraction steam from a steam turbine, or as a back pressure
steam from a steam turbine), and also the quality of steam (temp., pressure,
enthalpy).

● Performance Ration (PR) is also generally specified by the Consultant.

● In the Gulf region, PR  6 – 8.

● In the energy-short areas, such as Japan, PR ≥ 12.

● The number of stages is often left to the contractors.

● Often, based on the previous experience of the plant owner, the Consultant
specifies the materials of various heat transfer tubes because these tubes have
performed well in the Gulf plants.

● Most other things (pumps, instrumentation & control system, materials and
design of the flash stages, etc.) are left to the contractors.

● In the Gulf region, MSF plants almost always are part of the dual-purpose
Power & Desalination Station. Therefore, the seawater intake & brine
discharge systems, administration buildings, workshops, labs., and control
rooms are built and shared by both the power & desalination plants.

● Jubail Phase II Station has:

10 boilers
10 back-pressure steam turbines
40 MSF units.
Size of Power Plant = 1295 MW
Size of MSF plant = 40 units x 6.25 MGD each = 250 MGD total.

2
3
4
5
Brine circulation MSF process

6
System Mass and Energy Balances

Equation 2 can be written as:

MFXF = MBXB [ MPXP << MBXB or MFXF ] (3)

or MB = MFXF/XB or

MB = MF/ αB since αB = XB/XF

7
Substitute MB = MF/ αB in Eq. (1)

MF - MF/αB - MP = 0 or MF[1 - 1/αB ] = MP or

  
M F   B  . M P
  B 1 
Hence given the feed water TDS and maximum brine concentration; the feed
flow rate, and consequently the necessary blowdown or brine discharge rate
MB can be quickly established.
---------------------------------------------------------------------------------------
Details of a single flashing stage are illustrated in Figure 2 and the long tube
and cross flow tube configuration in a stage is shown in Figures 3 and 4
respectively.

In the MSF process the tubes are arrange in a long or cross tube configuration.

Fig. 2. MSF flashing stage

8
Al Khobar 2 - Saudi Arabia MSF - 10 units of 26,700 m3/day each.
SIDEM Contract Award: 1979 Completion date: 1982

9
10
 Fig. 3. Long Tube Configuration

The long tube arrangement is geared towards larger production volume with
current unit capacities up to 57,734 m3/d. In this system, a single bundle of tubes
span the whole length of a limited number of flashing stages.

This eliminates the water boxes found in the cross flow system and allows for the
increase of the flow rate per chamber width, and also reduces the required chamber
width.

Fig. 4. Cross Tube Configuration

The cross tube configuration is the original system design and its units have
production capacities in the range of 27,276 - 32,731 m3/d. In this configuration,
the tubes are aligned along the width of the flashing chambers and are connected
via external water boxes.

11
6.1 IMPORTANT MSF PARAMETERS DEFINATIONS

MD
GOR  (6.1)
MS

MD
PR  * 2,325 Kg / 2325 Kj or lbs / 1000 Btu (6.2)
QH

Where:
GOR = Gained Output Ratio
MD = Distillate Output ( MGD or m3/d or m3/h )
MS = Saturated steam used in Brine Heater ( m3/d or m3/h )
QH = Heat Input in Brine Heater (Kj/d or Kj/h )

The notations and symbols used in the following discussion refer to MSF plant
process flow diagram shown in Figure 5 at Ghazlan power plant.

Fig. 5 MSF unit at Ghazlan power plant

12
By definition

XB
B  (6.3)
XF

XR
R  (6.4)
XF
Where: XF = TDS of feed (mg/l, mg/kg)

XR = TDS of recycle brine (mg/l, mg/kg)

XB = TDS of brine blow down (mg/l, mg/kg)

MR
Recycle Ratio RR  (6.5)
MD

Where: MR = Recycle brine flow rate MGD; m3/d; m3/h, etc.

Inter-relationship of [B] and [R]:

 RR 1 
R   
 RR  B (6.6)
 

 RR 1 
Also XR    X
 RR  B (6.6a)
 

 RR 1 
Since Ratio   1

 RR 

  R   B 

and X R  X B 


13
 Temperature rise through:

Brine heater, Th  Tho  Thi 


Recovery section , TG  Thi  TB 

Reject section , TR  TSWO  TSWi  (6.7)


Flash range, T f  Tho  TB (6.8)

6.2 HEAT BALANCES

QS  M S  h fs (6.9)

QH  M R . C ph . Th (6.10)

QG  M R . C pg . TG (6.11)

QR  M SW . C pR . TR (6.12)

Where: QS = Heat input in Brine HTR by Saturated Steam

or QH = Heat picked up by Recycle Brine in BH (Kj/h, Kj/day)

QG = Heat picked up by recycle Brine in Heat

Recovery/Gain Section (Kj/h, Kj/day)

QR = Heat picked up by seawater in Heat

Reject Section (Kj/h, Kj/day)

hfs enthalpy of steam (Kj)

14
  Th  Tho 
C p is @  i  & XR
h
 2   TSW i  TSWO 
C PR is @  & XF

 T  Thi   2 
C p g is @  B  & X R
 2 

15
6.3 CALCULATION OF FEED FLOW [MF]

From simple mass & salt balances:

  
M F   B  . M D
  B 1 
(6.13)

In the Gulf MSF plants:

B = 1.25 – 2.00

 MF = 5 to 2 times MD

B MD MF

1.5 1.0 3.0 By increasing B, less feed

required for same distillate
2.0 1.0 2.0
output

B MF MD

1.5 3.0 1.0 By increasing B, more

distillate from same feed.
2.0 3.0 1.5

So, MSF process efficiency is increased by increasing B (or XB)

But at higher B, potential for scale in heat transfer tubes is also higher.

16
6.4 CALCULATION OF RECYCLE BRINE FLOW RATE (MR)

Consider Heat Gain Section

Heat given up by recycle Heat taken up by
Brine during flashing = Distillate vapor produced
Tho  TB

M R . C Pf . T f  M D . h fg
D

Which gives?

 hfg 
MR  D
M D
 C Pf T f  (6.14)

Where:

T f  Tho  T B

 Tho  TB 
C Pf is @   & X R
 2 

Tv 1st staqge   Tv Lasts stage 

h f gd is @
2

T1V  T17V
@
2
See Figure 5 above

Since stage vapor temp. T1V , T17V  are not known, they are approximated.
T1V = Tho - 4.0 oC

TLV = TB - 2.0 oC

17
 CORRECTION TO EQ. (6.14)

The actual quantity of [MR] is greater than given by Eq,. (6.14). The reason is
that liquid distillate from each flash stage, on entering the next stage, re-flashes,
thus requiring additional heat. All this requires additional [MR]. The following
equation gives the correct amount of [MR]:

 h fg 
MR  D
 M D  0.5 M D
 Cp f . T f 

(6.15)
 h fg 
MR  D
 0.5 M D 
 Cp f . T f 

6.5 CALCULATION OF STEAM REQUIRED [MS]

Thi

Tho

From Eqs. (6.9) and (6.10)

M S . h fs  QH  M RC ph Th
M R C ph Th
MS  (6.16)
h fs
Also, from Eqs. (6.2) and 6.9):

18
 M 
M S . h fs  QH   D  2325 
 PR 
 M D   2325 
MS   
 PR   h f s  (6.17)

6.6 CALCULATION OF COOLING SEAWATER [MSWO ]

Consider Reject Stage: From line diagram of MSF, Fig 5:

MSWT = MSWO + MF (6.18)

Where: MSWT = Total seawater entering heat rejection section

MSWO = SW used only as coolant and discharged to sea (from Eq. 6.19)

MF = Feed flow rate from Eq. 6.13

Heat removed [by distillate +

Heat input in brine = By Brine blowdown + by Cooling
heater seawater]

M S . h fs  M D CPD TD  TSWi  

M B CPB TB  TSWi  
M SWo CPSW TSWO  TSWi 

1  M S . h fs  M D CPD TD  TSWi  

M SWO   
CPSW TSWO  TSWi    M B CPB TB  TSWi  

Eq. 6.19

Calculation of total seawater [MSW]

From (6.18) : MSWT = MSWo + MF

MSWO from (6.19) and MF from (6.13)

19
SIMPLIFICATION OF EQ. (6.19) for MSWO

Generally,

TSWo  TD  TB

C PD C PB
1 1
C PSW C PSW

Then Eq. 6.19 can be written as:

M S h fs
 MD .
TSWo  TSWi 
C PD
 MSWO  C PSW . TR  C P TSWo  TSWi 
SW

C P TSWo  TSWi 
 MB . B

C P TSWo  TSWi 
SW

MSWO 
M S . h fs
 MD  MB
C PSW . TR 
Since MF = MD + MB

M S h fs
MSWO   MF
CPSW . TR 
(6.19-A)

From Eqs. (6.18) and (6.19-A) and since [ MSWT = MSWO + MF ]

MSWT  M S . h fs
C PSW . TR 

 TSWi  TSWo 
 
C PSW is @ XSW &   and
 2 
hfs is @ Ts

20
 MS hfs = MSWT C PSW T
is R EQ. 6.20:

This concludes that:

Heat input by Heat removed by total
condensing steam in = seawater in heat reject
brine heater section

6.7 EFFECT OF PERFORMANCE RATIO (PR) ON CAPITAL &

ENERGY COSTS

MD
PR   2325 from (6.2)
QH
Substitute for QH from Eq. (6.10)

Substitute for MD from Eq. (6.14)

M R C pf . T f 1
PR  .  2325
h fg M R .C ph . Th

(6.21)
 C Pf   2325   T f 
PR    .  .  
 h 
 Ph 
C  fg   Th 

EQ. (6.21) is an exact Eq. for PR based on temperature & thermodynamic

properties.

Approximate form of EQ. (6.21) :

C   2325 
practically ,  Pf  .  1,   1
 
 C Ph   h fg 

T f Tho  TB
 PR 

Th Tho  Thi (6.22)

21
(1) LOW ENERGY COST

For an owner who wants to spend less on capital cost:

● He will order a low [PR] plant.

● The ∆Tf of such a plant will be lower.

● The ∆Th of such a plant will be higher i.e. more energy will be required in
brine heater.

● Such a plant will have less number of stages [N], therefore lower cost.

● The energy bill will be higher

● In Gulf countries, plants are of this type [lower PR, lower capital cost,
higher energy consumption].

(2) HIGH ENERGY COST

● Such a plant will have higher [PR] and greater No. of stages [N].
Therefore, higher capital cost.

● The ∆Tf of such a plant will be large.

● ∆Th will be lower, requiring less energy.

CALCULATION OF HEATER INLET TEMP [Thi]

From EQ. (4.21) : 


 T f   C Pf   2325 
Thi  Tho    .     Exact Formula 
C   h  
 PR   Ph   fg  


From EQ. (4.22) :  (6.23)

 T f  
Thi  Tho    Approximate Formula 
 PR  

22
 6.8 HEAT TRANSFER AREAS (A).
OVERALL HEAT TRANSFER COEFFICIENTS (U) and

FOULING FACTORS (FF)

 One of the major objectives of the MSF plant design is to determine the
required heat transfer areas for the (i) brine heater, (ii) heat gain section, & the
(iii) heat reject section.
 Overall heat transfer coefficients are needed, among other things, to determine
the areas.
 Since the seawater brines at elevated temperatures always cause scale and
fouling (these may be minimized but can never be totally eliminated), there are
2 overall H.T. coefficients involved in the MSF design: (1) Clean (Uc) & (2)
fouled, or design (UD). These coefficients. are related to each other through an
important parameter, called the Fouling Factor (FF), as follows:

1 1 1 1
FF   or   FF
UD UC UD UC

 It is the (UD) on the basis of which the H.T. areas are calculated.
 Determination of (UD), therefore, requires determining (Uc) & FF.
 The (FF) are obtained from the literature.
 The Uc can be computed from the knowledge of the heat transfer tube
dimensions & properties (Do, Dj, Kw), and the individual film heat transfer
coefficients (hi & ho):

D 
Do ln  o 
1 1 D   Di   1
  o   (6.24)
U C hi  Di  2 Kw ho

where:

Di & Do = Inside & outside tube dias. (m, or ft.)

Kw = Thermal conductivity of the tube wall (kJ/h.m.oC, or Btu/h.ft. oF)
UC = Clean (un-fouled) overall H.T. Coeff. Based on outside H.T. area (Ao)
(kJ/h.m2.oC, or Btu/h.ft2.oF)
hi = Inside or brine side H. T. Coeff. based on Di (kJ/h.m2.oC, or Btu/h.ft2.oF)
ho = Outside or steam side H.T. Coeff. based on Do (kJ/h.m2.oC, or Btu/h.ft2.oF)

23
 CALCULATION OF CLEAN OVERALL HEAT TRANSFER COEFF. (UC)

 Looking at Eq. (6.24), it is clear that the tube Di , Do, KW are known.
Therefore, calculation of (Uc) amounts to calculating individual film
coeffs. (hi & ho)

6.9 Correlation of Inside or Brine Side Film Coeff. (hi)

Nu = 0.023 (Re)0.8 (Pr)0.4

0.8 0.4
hi . Di   .u . D   Cp b .  b 
 0.023  b b i   
Kb  b   Kb 
(6.25)

The above Eq. is the well known Dittus-Boelter equation for heating
inside pipes/tubes.
Instead of the brine side velocity (ub), the following Eq. in terms of the
recycle brine flow rate (MR) is used:

 K   4M R / N 
0.8 0.4
 Cpb . b 
hi  0.023 b      (6.26)
 Di   Di b   K b 

Where: Nu Nusselt Number, Re = Reynolds No., Pr = Prandtl No.

Di = Inside tube dia. (m, or ft.)
Kb = Therm. Cond. of brine (kJ/h.m.oC, or Btu/h.ft.oF)
μb = Viscosity of brine (kg/h.m, or lbs/h.ft.)
Cpb = Specific heat of brine (kJ/kg.oC, or Btu/lb oF).
b = Density of brine (kg/m3, or lb.lfe)
N = No. of Tubes.

Thi  Tho
For Brine heater, determine Kb, μb, Cpb, ρb @ & XR
2

Thi  TB
For Heat Gain, determine Kb, μb, Cpb ρb @ & XR
2

TSWi  TSWO
For Heat Reject, determine Kb, μb, Cpb, ρb @ & XF
2

24
6.10 Correlation Of Outside/Steam Side Film Coeff. (hO)
1/4
 g.h fg .ρ 2S . k 3S 
h o  0.725  1/3 
 V
N . D μ
o s . ΔT f 

(6.27)

Eq. (6.27) is called the modified Nusselt Equation

Where:
g = Gravitational constant (127.096x106 m/h2, 416.977x106 ft/h2
hfg = Latent heat of condensation (kJ/kg, or Btu/lb);
hfg is to be determined:
For brine heat at Ts

For heat gain at (TlGV+TLGV)/2

where: TlGV = (Tho – 4.0) o
C
o
TLGV = (TB- 2.0) C

For heat reject at (TlRV+TLRV)/2

o
TlRV = (TSWO - 2.0) C
TLRV = (TB – 2.0) o
C
Ρs, Ks, μs = Properties of steam condensate, to be determined at
condensate film temp [Tf], which is unknown.
Tf = Ts – 0.75x∆Tf
∆Tf = Ts –Two
= ∆Tf through condensate film, (unknown)
Two = Outside tube wall temp. (unknown)
Nv = No. of tubes in a vertical arrangement

Because [Tf] at which [ρs, Ks, μs] are to be determined, is unknown

[ho] in Eq. (6.27) is determined by iterative procedure.

25
6.11 TUBE WALL RESISTANCE

Do . ln Do / Di 
RW  (6.32)
2K w

6.12 OVERALL HEAT TRANSFER COEFF.

● Substitute hi (EQ. 6.26), ho (EQ. 6.27 and RW (EQ. 6.32)

in EQ. (6.24) to obtain [UC]

● Obtain a value of Fouling Factor [FF] for your particular system (brine
inside tubes in single phase, steam outside, etc.) from the literature.

● Obtain [UD] from:

1 1
  FF
U D UC

● The clean H.T. coefficient is obtained only at the start-up when the tubes
are clean.

● As the plant logs on hours of operation, the scale builds-up on the tube
surface, the magnitude of scale depending on the effectiveness of the scale
control treatment. So with time, [U] decreases initially rapidly; and then
relatively slowly. But the [U] can only be allowed to drop to a certain
value, after which the plant has to be de-scaled. The [U] at the end of cycle
(before cleaning) is called [UF], Fouled H.T. coefficient.

● Some MSF plant designers take

UD = [UF] (6.33)

Others based design on [U] in between [UC] and [UF] , i.e.

UF  UD  UC (6.34)

26
Alternatively, the Fouling Factors can be calculated of an operational plant by using the
design overall heat transfer coefficient (UD).

Brine Heater after fouling takes place

Variation of fouling factors of heater and recovery section during the

additive-only and the hybrid trials

27
● Recall that Heat Transfer area is given by:

Q = U.A. ∆T (6.35)

Q
A = (6.37)
U. ΔT

1
For constant [Q] and [∆T], A
U
● If we were to use [UC] in the design,

1
i.e.
A
UC
Then area [A] will be much smaller compared to using [UF]

1
A in this case, area [A] will be much greater.
UF
● So for the case U = UC

The H.T. area will be tight and due to fouling, the required [Q] will not be
delivered, and distillate output will fall.

● For the case U = UF

There will be plenty of H.T. area, the distillate output will be greater than
design initially, and will gradually fall. But it will still be close to design.

28
 HEAT TRANSFER AREA OF BRINE HEATER (AH)
Heat transferred to recycle brine in brine heater:

Qh = MR. Cph. ∆Th (6.38)

This is related to H.T. area of heater (Ah) and H.T. coefficient of heater (Uh) by the
following equation:

MR Cph ∆Th = Qh = Uh.Ah.LMTDh

M R . C ph . Th
Ah  (6.39)
U h . LMTD h

Thi

Ts

Tho

Where: LMTD = Log mean temp. difference (oC or oF)

1 = (Ts – Tho), 2 = (Ts – Thi),


 2  1 T  Thi   Ts  Tho 
 s
LMTD ln 2 / 1   Ts  Thi 
ln 
 Ts  Tho 

29
 Tho  Thi Th
 
LMTD  T  Thi   Ts  Thi  (6.40)
ln s  ln 
 Ts  Tho   Ts  Tho 
Substituting (6.40) in (6.39), and simplifying:

M R Cph  T  Thi 
Ah =  ln s  (6.41)
Uh  Ts  Tho 
Where: CPh = at (Thi + Tho)/2 kJ/(kg. oC) & at XR

MR = kg/h, Ts / Tho / Thi = oC

Uh = kJ/(h.m2.oC), Ah = m2

No. OF TUBES IN BRINE HEATER (nh)

FROM CONTINUITY EQ: MR = ρb Axh ub

Where: Axh = Total cross-sectional area of HTR’s all tubes (m2)


= nh . . Di 2 (flow inside tubes should be based on Di)
4

ub = Velocity of recycle brine through heater tubes (m/h)

ρb = Density of brine in heater tubes (kg/m3)

Calculated at (Thi + Tho)/2 & XR

 2
Therefore: MR = ρb nh  . Di  . ub (kg/h)
4 

4M R
No. of Tubes nh = (6.42)
 Di2  b u b

30
LENGTH OF TUBES IN BRINE HEATER
Total Heat Transfer surface area of HTR’s all tubes:

Ah = nh (π . Do . Lh) (surface area should be based on Do)

Substituting for nh from Eq. (6.42):

4 Do Lh M R
Ah = (6.43)
Di2  b u b

Equating Eq. (6.43) with Eq. (6.41),

4 Do Lh M R M R C ph  Ts  Thi 
 A  . ln  
Di2 b ub 
h
Uh  s ho 
T T

Di2 b ub C ph
(6.44)
 T T 
Lh  ln  s hi 
4 Do U h  Ts  Tho 
4.14. H.T. AREA OF HEAT GAIN SECTION (AG)
ASSUMTIONS:

(1) ∆Tf per stage is same for all stages.

i.e. ∆Tf (for plant) = (∆Tf per stage) * (N)G

(2) Similarly, avg. temp. loss ∆TL through tubes in each stage is same for
all stages

(3) All stages have equal H.T. areas

i.e. A1 = A2 = ----- = AN

31
  
N G . M R . C PG  ΔTh  ΔTL 
AG  ln  
UG  ΔT  ΔTf  ΔTh  ΔT  (6.53)
 h NG
L


Where: AG = H.T. area of all H.G. Sec. tubes (m2)

NG = No. of stages in H.G. Sec.

MR = Recycle Brine (kg/h)

UG = Overall H.T. coeff. For H.G. Sec. (kJ/h.m2.oC)

CpG = at (Thi + TB)/2 & XR

∆Th = Temp. rise through heater (oC)

∆Tf = Flash range (Tho - TB), (oC)

∆TL = Avg. temp. loss per stage = 1.39 (oC)

TOTAL NUMBER OF TUBES IN HEAT GAIN SECTION (NG)

 4 MR 
n G  N G   (6.56)
 π Di . ρ b u b 
2

Where: nG = Total number of tubes in H.G. Sec.

NG = No. of stages in H.G. Section

MR = Recycle Brine flow rate (kg/h)

32
 Di = Inside Dia. Of H.G. Sec. tubes (m)

b = Recycle brine density (kg/m3)

at (Thi + TB)/2 & XR

uG = Recycle brine velocity inside H.G tubes (m/h)

LENGTH OF EACH TUBE IN HEAT GAIN SECTION (LG)

 
 b . u b . D . C pG
2  ΔTh  ΔTL 
LG  ln  
i
(6.58)
4 Do .U G  ΔT  ΔTF  ΔTh  ΔT 
 h NG
L


Where: LG = Lengh of each tube in each H.G. Sec. (m)

Di = Inside Dia. Of H.G. Sec. tubes (m)

Do = Recycle Brine (kg/h)

b = Recycle brine density (kg/m3)

at (Thi + TB)/2 & XR

uG = Recycle brine velocity inside H.G tubes (m/h)

UG = Overall H.T. coeff. For H.G. Sec. (kJ/h.m2. oC)

CpG = at (Thi + TB)/2 & XR

∆Th = Temp. rise through heater (oC)

∆TF = Flash range (Tho - TB), (oC)

∆TL = Avg. temp. loss per stage = 1.39 (oC)

33
CALCULATION OF [AR.NR.LG] FOR HEAT REJECT SECTION
 Procedure for calculating [AR, NR, LR] for Reject Section is same as that for Heat Gain
Section

34
4.15 ENERGY REQUIRED BY MSF PLANT
● Two types of energies are used by the MSF process:

1. Thermal Energy of steam condensed in the brine heater + a small

steam amount for ejector condensers,

2. Electrical Energy for various pumps, and for instruments.

Total Energy = Thermal Energy + Electric Energy

BASIS OF CLACULATIONS = 1000 kg/h of Distillate or

= 1 Ton/h = 1 TPH

4.15.1 CALCULATION OF THERMAL ENERGY (SPQT)

(kg. Distillate )
Recall that PR 
2325kj

6.1kg
For Ghazlan: PR 
2325kj

From Eq. 6.2

 2325 
 QH     M D kj/h
 PR  (6.59)
 

 2325 
SPQH  QH / M D    kj/kg Distillate
 PR 
where MD = 1000 kg/h or 1 TPH (given above)

 2325 
and SPQH    1000 kj/Ton Distillate
 PR 

35
 2.325 10 6 (6.59-A)
SPQ H 
PR

Where:SPQH = Specific heat consumed in heater (Kj/Ton of Distillate)

If SPQEJ = Specific heat used in ejectors (Kj/Ton of distillate)

Then SPQEJ = 2% of SPQH (Typically)

 SPQT = SPQH + SPQEJ = SPQH + 0.02 SPQH

QT = 1.02 QH and SPQT = 1.02 SPQH (6.60)

Where:SPQT = Total specific thermal energy (kj/Ton of distillate)

Example:

For Ghazlan plant, PR=6.1

Then SPQH = [2.325 *106 /6.1] kj/Ton of distillate

= 381,147 kj/Ton [ if 3,600 kj = 1 kWh ]

= 105.8 kWh/Ton of distillate

36
CALCULATION OF ELECTRICAL ENERGY OR PUMPING ENERGY

Specific Electrical Energy (SPEE) Consumption

M i (kg/h) . TDH (m)
Hydraulic horse power HHPi  (6.61)
274,000

Where TDH is in ‘meters’

M i (kg/h) . TDH (kg/cm 2 )

Hydraulic horse power HHPi  (6.62)
27,400  (kg/l)

Where TDH is in ‘kg/cm2

Where: HHPi = Hydraulic horse power delivered by pump to liquid (H.P.)

TDH = Total dynamic head (m or kg/cm2)

= Outlet head – Inlet head

Mi,  = Flow rate and density of Liquid Pumped

HHPi
(Brake Horse Power) BHPi  η p ( in H.P.) (6.63)

BHPi = Brake H.P. in H.P. delivered by electric motor to pump

ηp = Pump hydraulic efficiency  80 – 85%

EPi = Electric power delivered by electric motor to pump [i] in kW

BHPi
EPi 
1.341  η M (6.64)

1 kW = 1.341 H.P.

M = Electric motor efficiency  90 – 92%

Substituting BHPi from 6.62 in 6.64

M i (kg/h) . TDH (kg/cm 2 )

EPi  (kW) (6.64a)
27,400  1.341   (kg/l)  p  M

37
38
TOTAL & SPECIFIC POWER CONSUMPTION
Np

Total Power EPT   EP

i 1
i kW (6.65)

Where: NP = Total number of pumps (recycle brine, blowdown, etc)

EPT = Total electric power consumed by all pumps (kW)
Total distillate produced = MD kg/h
Basis of calculation = 1,000 kg/h (kgph)
1 Ton/h (TPH)

EPT (kW )
SPP = . 1,000 (6.66)
M D (kg / h)

Where: SPP = Specific Power consumed by all pumps

= (kW/1000 kgph) or (kW/TPH)

SPECIFIC ELECTRICAL ENERGY CONSUMPTION

EPT (kW )
SPEEi = . 1,000 (6.67)
M D (kg / h)

Where: SPEEi = Specific electric energy consumed by each pump

= (kWh/1000 kgph) or (kWh/T)

Summation of all pumping energy will be:

Np
SPEE  Σ SPEE i
i 1

EPT (kW )
 . 1,000 (6.68)
M D (kg / h)

Where: SPEE = Specific electrical energy consumed by all pumps

= kWh/1000 kg or (kWh/T) of distillate

SPQT (kj / T )
And SPE =  SPEE (6.69)
3,600 (kj / KWh )

Where: SPE = Total (thermal + electrical) specific energy

consumed by MSF plant (kWh/1000 kg)

39
EXAMPLE: ELECRIC POWER AND ENERGY CALCULATION

● DISTILLATE PUMP

Distillate output : MD =6 MGD

= 250,000 gallons/h

= 6 X 3785.4 m3/D

= 6 X 3785.4 TPD

= 946,350 kg/h

Density of distillate: D = 1.0 gm/ml or kg/l

Dist. Pump suction press: PiD = 0.43 kg/cm2

Dist. Pump discharge press: PoD = 13.10 kg/cm2

Total dynamic head: TDH = PoD - PiD

= 13.10 – 0.43 = 12.67 kg/cm2

Pump efficiency: ηp = 80%

Motor efficiency: ηM = 90%

(946,350) (12.67)
From EQ (6.62): HHPD   437.6 H.P.
27,400  1.0)

437.6
From EQ (6.63): BHPD   547 H.P.
0.80

547
From EQ (6.64): EPD   453.23 kW
1.341  0.90

● The procedure used above for distillate pump is used to calc. power for other pumps:

EPC EPSW EPR EPB

● Total power consumed (EPT)

EPT = EPD + EPC + EPSW + EPR + EPB (6.65)

= 3,700 kW or 3.7 MWe (Given)

Where, sw = seawater pump; R= recycle brine pump; B=blowdown pump;

c=condensate pump

40
● Specific Power (SPP)

3,700 KW
From EQ. (6.66):   0.163 KW/TPD
6  3785.4 TPD
3,700 KW
  617 KW/MGD
6 MGD

● Specific Energy (SPEE)

3,700 KW
  1000  3.91 KWh / T
946,350 KG / h
From EQ. (6.68):
3,700 KW KWh
  1000  14.8
250,000 gallons/h 1000 gallons

Total Energy = Thermal Energy + Electric Energy

= 105.8 kWh/T + 3.9 kWh/T

= 96.4% + 3.6%

Total Energy =109.7 kWh/Ton of distillate

41
TYPICAL TEMPERATURES IN MSF PLANT [ oC ]

Seawater Inlet (TSWi) = 35

Outlet (TSWo) = 46.1

Recycle Brine Inlet (TR) = 46.1

Feed Make-up (TF) = 46.1

Brine Blow-Down (TB) = 46.1

Last Stage or Bottom Brine (TB) = 46.1

Distillate (TD) = 43.9

Super-Heated Steam (TSS) = 162.8

Saturated Steam (TS) = 120

Condensate (TC) = 120

Desuper – Heating Water (TDW) = 120

HEAT TRANSFER DATA FOR GAZLAN MSF DESAL UNIT

S.No. Parameter Units Brine HTR. Heat Recovery

1. No. of Stages - 1 14
2. Tube O.D. m 0.01585 0.01585
3. Tube I.D. m 0.01445 0.01257
4. Total No. of Tubes (N) - 1228 1680 Per Stage
5. No. of Tubes in Vertical Tier (Nv) - 18 25
2
6. Total Surface Area (A) m 398 3993
o
7. Tube Thermal Cond. (KW) Kj/h.m. C 61.24 172.8
8. Fouling Factor (FF) h.m2.oC/Kj 0.376×10-4 0.269×10-4
9. Design H.T. Coeff. (UD) Kj/h.m2.oC 11,120 11,446
10. Brine Velocity Thru. Tubes (Ub) m/sec. 1.729 1.668

42