Mega-ton Water System

Transcription

1 January 14 th, 2015 SWPF CWC Technical Seminars Session 3 - Water Treatment Technologies - Mega-ton Water System Large Scale Desalination System for 21 st Century Key Technology with Low Energy and Low Environmental impact Dr. Masaru Kurihara Senior Scientific Director, Mega-ton Water System of FIRST Project (FY ) (Fellow, Toray Industries, Inc.)

2 Urbanization is Progressing 1970/145 Year and Number of Cities for Urban Agglomerations of 1 million Inhabitants or more 2011/ /668 53% 47% Coastal city Inland city Mega-ton Water System Project. All rights reserved. Authority: World Urbanization Prospects, The 2011 Revision by United Nations 2

3 World Population Prospects and Dynamics of Water Use by Kind of Economic Activity World Population (million) Water Use in the World (km 3 /year) World Urbanization Prospects, The 2011 Revision, United Nations It is necessary to install more than fifty million m 3 /d Water plants every year Mega-ton Water System Project. All rights reserved. WORLD WATER RESOURCES AND THEIR USE a joint SHI/UNESCO product 3

4 History of Desalination Plant Shifting from Distillation to Reverse Osmosis Online Capacity m 3 /d (Cumulative) 60,000,000 Toray has created under DesalData 2014/GWI/IDA Desalination Plants Inventory 50,000,000 40,000,000 MED MSF RO Growth rate 25% Number of Plants RO 14,000 30,000,000 20,000,000 10,000,000 Desalination is approved as a national project by JFK (1961) MSF+MED 2, st generation 2 nd generation 3 rd generation 4

5 1,000, ,000 Changes in RO plant scale Desalination Reclamation Trend of Largest Plant Soreq Magtaa Melbourne Tuaspring Hadera Sulaibiya Ashkelon Target 1,000,000m 3 /d 10,000 1,000 Industrial Water Daily Life Water Agricultural Water Technological development for 1,000,000 m 3 /day plant is required 5

6 Research Scheme & Organization For sustainable management of water environment and for low-carbon path, all-japan team members are working together to develop Key 21st century water treatment technologies and contribute to global water issues. Council for Science & Technology Policy/Cabinet Office, Government of Japan Mega-ton Water System Dr. Masaru Kurihara Senior Scientific Director of Mega-ton Water System Japan Society for the Promotion of Science (JSPS) Research Support Overall Management Recommendation Budget (3.4 Billion JY = 40 M US$ ) New Energy and Industrial Technology Development Organization (NEDO) International Experts Duration: FY2009-FY2013 (4years) Kickoff Meeting:June 11, 2010 Contracts Research Organization University: 11 Company: 17 Others: 2 Registered Researcher: 140 6

7 Mission of Mega-ton Water System 1. Energy Reduction % less Energy 2. Low Environmental Impact--- No or Minimum Chemical 3. Low Water Production Cost-- Reduction by Half Sustainable Desalination and Reclamation 7

8 For the Sustainable Desalination Subject-1 Subject-2 Subject-3 Energy Resources Fossil Fuels Nuclear Renewable Sources Wind Hydroelectric, Solar Biomass Geothermal Tidal Seawater RO System RO Technology Desalination Drainage Mega-ton Water System Energy Reduction No or minimum Chemical Process Brine Discharge Used as Electrical Energy Pressure Energy Recovery (ERD) Conservation of Energy Resources Pressure Retarded Osmosis (PRO) Reduction of Marine Pollution 8

9 Water Cycle in Mega-ton Water System Seawater RO System Mega-ton Water System Wastewater Treatment System Pre-treatment Reverse Osmosis Membrane Municipal Water Wastewater Treatment Concentrated Seawater Intake Pressure Retarded Osmosis (PRO) System Treated Water Seawater 9

10 FIRST Program: Mega-ton Water System Mission & Output Mission Theme Output 1-1 High Efficiency, Large Size Element, Module Low Environmental Impact Energy Reduction (Energy Production ) Low cost 1,000,000m 3 /d SWRO System 100,000m 3 /d Waste Water Treatment System Intake Technology Highly Efficient Energy Recovery Highly Durable Low Cost Pipes Environmental Friendly SWRO System 2-1 Optimization of Mega-ton scale SWRO Plant Pressure Retarded Osmosis (PRO) Resource Reproductive Sewage Integrated Membrane System Pursuit of ultimate technology Pursuit of future essential technology 2014 Mega-ton Mega-ton Water Water System System Project. Project. All rights All rights reserved. reserved. Core Technology System Technology :Main :Sub 10

11 Seawater Bio-Friendly Pre-treatment Low Pressure Multistage High Recovery SWRO System PRO Municipal Water Seawater

12 Polyamide Composite RO Membrane Structure of polyamide composite RO membrane Separating layer Cross-linked aromatic polyamide, 0.2µm Membrane surface Support layer Substrate Poly sulfone, 60µm Non-woven fabric, 150µm Protuberance structure Interfacial polycondensation Polyamide Thin layer Acid halide Organic Layer Supposed chemical structure Amine Aqueous Layer 2013 Mega-ton Water System Project. All rights reserved. Insoluble to any solvent 12

13 Innovative Low Pressure Seawater RO membrane 1.Protuberance Structure with Leading-Edge method SEM TEM (N-S-O) Polymer SEM 観 察 Substrate Prepared by Pretreatment to keep wet condition Elemental mapping by STEM-EELS Target of High Efficiency Membrane ( for Reduction of Energy Consumption ) NaCl NaCl (1) Fine Structural Analyses of Functional Layer in RO membrane (a) Pore Size Estimation (b) Precise Estimation of the protuberance structure (2) Innovative Low Pressure Seawater RO membrane NaCl H 2 O H 2 O H 2 O H 2 O H 2 O H 2 O Permeate NaCl Schematic diagram of water permeation 13

14 Innovative Low Pressure Seawater RO membrane Comparison of High and Low Pressure Desalination 99.9 Low Pressure Seawater RO membrane 99.8 Conventional High Pressure RO membrane Rejection(%) 99.5 High Pressure Desalination Low Pressure Desalination measured value Operation Pressure for Energy Saving 1.0m 3 /m 2 /d) Energy Reduction Low Pressure Seawater RO membrane will contribute to Large Energy Reduction of the System 14

15 Low Pressure Multi-stage Seawater RO System (LMS) Conventional Process Seawater UF RO/ Conventional Process Product TDS 35,000 mg/l ERD Brine LMS/ Megaton Process Seawater UF RO/ LMS Megaton Process 1 Product TDS 35,000 mg/l Low Pressure Seawater RO Element Next-Generation ERD 2 New ERD Brine Advantages of LMS/ Megaton Process Energy Reduction (20%) is possible due to Low Pressure Operation. Water Production Cost Reduction(50%) and Footprint reduction is possible due to High Recovery Operation (up to 65%). 15

16 Pressure (MPa) Pressure Reduction by LMS Process One Stage Eff. Press. 30% down Conventional Mega-ton Membrane Two Stage Eff. Press. 50% down Low Pressure Two Stage Conventional Mega-ton Membrane Rec=45% Rec=60% Seawater Concentration (TDS %) 16

17 Low Pressure 2-stage High Recovery SWRO System Conventional system Low Pressure Multi-stage High Recovery RO System High pressure pomp RO Capacity 100,000 m 3 /d High pressure pomp RO UF UF ERD ERD Intake pump Intake pump 5 trains 1 train 30% footprint reduction will be possible due to High Recovery Operation (up to 65%) 17

18 Next-Generation Energy Recovery Device Characteristic Feature of Next-Generation ERD Image of New ERD installation for a Mega-ton Seawater RO plant Piston-less No-leakage Low Brine/Seawater Mixing Flexible Control Quiet Operation Impact on plant Specific Energy Consumption (S.E.C.) (Single stage RO, Recovery=45%, Feed TDS=4%) Energy Recovery Effectiveness Ideal ERD New ERD New ERD Conventional ERD with Over-Flush Conventional ERD without Over-Flush 100 % 98.3 % 96.4 % 96.4 % Mixing 0.0 % 1.3 % 2.5 % 6.0 % Over-Flush 0.0 % 0.0 % 5.0 % 0.0 % Normalized S.E.C. for RO core process Suitability for large-scaled 〇 〇 18

19 Durable Resin Piping System Feature of Durable Resin Piping and Fittings No Corrosion in Seawater Condition Suitable for High Pressure Applications in SWRO Plants Lightweight & Easy to Handle Comparison with SDSS SDSS: Super Duplex Stainless Steel Resin Piping System Prefabricated Resin Piping (made by Asahi) Conventional Piping SCH80 Components PP+FRP SDSS Durability (Safety Factor) 6~8MPa (4.0) 6~8MPa Size Up to 300A - Weight 100A*5m 45kg 115kg Cost Reduction 30% OFF - 19

20 Cell density [cells/ml] 菌 数 (cells/ml) Cell density [cells/ml] 菌 数 (cells/ml) Research problem related to biofouling Solution 1 1Re-examination of bacteria quantification method 2Verification of hypothesis 3Establishment of biofouling risk predictive index. Solution 2 3 Classical method Plate count method) 1,000,000 Colony 生 菌 数 forming cell 1,000,000 Fluorescence Microscopic observation 全 Total 菌 数 ( 生 cell 菌 + 死 菌 ) 生 Membrane 菌 数 ( 細 部 まで 健 undamaged 全 ) cell 生 Respiratory 菌 数 ( 呼 吸 活 性 あり) active cell Clarification of the influence of chlorination/de-chlorination on biofouling 100, ,000 10,000 10,000 Differential Pressure 1,000 1, 海 水 塩 素 殺 菌 海 水 Raw Chlorinated seawater seawater Detection sensitivity can be increased 100 times by direct count by fluorescence microscopic observation Only about 30% of live marine bacteria were sterilized by chlorination. Selection of proper detection method is important. Sterilization effect of low concentration chlorination is limited. 100 海 水 塩 素 殺 菌 海 水 Raw Chlorinated seawater seawater BFI ATP It was verified that continuous chlorination/de-chlorination will be the trigger of biofouling. Novel index BFI was established for RO monitoring. Influence of chemical addition was verified and biofouling risk predictive index was established. 20

21 Bio-fouling on RO membrane Non-Chemical Process (Pretreatment Process Design Concept) Categorization of Seawater Quality based on Mega-ton Water System Bio-Fouling Risk Index BFRI Biodegradable Filtration Process Pilot Test Results 1000 BFRI High Moderate Low 500 Clear seawater Pretreatment Process Design Concept No Chemical Seawater Quality BFRI : Low Conventional Filtration Process 0 HP Pump RO Time Seawater BFRI : Moderate BFRI : High No or Minimum Chemical Biodegradable Filtration Process HP Pump RO Necessary Pretreatment Process can be estimated by Mega-ton Water System BFRI 21

22 PRO system Outline of PRO system UF Treated Water Treated Waste Water Fresh Water UF-Unit LRO-Unit Effluent Tank UF-Unit Release Brine To Effluent Tank Press Exchanger PRO Unit Membrane Module Turbine & Generator Pump LRO-Unit PRO Unit in Prototype PRO System 22

23 Pressure Retarded Osmosis (PRO) Seawater Pretreatment Product Fukuoka Prototype PRO Plant SWRO Brine MBR + RO PRO Draw solution: 460 m 3 /d of SWRO brine Feed water: 420 m 3 /d of treated sewage PRO membrane:10-inch hollow fiber x 8 pcs. The world highest power density of 13 W/m 2 at 7% Seawater RO Brine has been achieved. Energy Reduction by Seawater RO Brine PRO System Process Seawater Conc. (%) Brine Conc. (%) Specific Electric Consumption (SEC) kwh/m 3 without PRO With PRO Reduction Rate Conventional (R=45%) Mega-ton (R=65%) % Energy Reduction is 10% by PRO System. Total Energy Reduction is 30% by Combination with PRO and LMS. 23

24 Proposal of Mega-ton Water System Integration of Advanced Device and Advanced System Technology Materials & Equipment Low Pressure Seawater RO Element Next-Generation ERD New High Pressure Resin Pipes System Low pressure Multi-stage Inter-boosted System (LMS) with High Recovery Chemical-Free Seawater RO Plant Intake & Pre-treatment System (Non-Chemical) Pressure Retarded Osmosis (PRO) System 24

25 SEC (Specific Energy Consumption (kwh/m 3 ) Energy Reduction by Megaton Water System 5.0 Seawater Concentration=TDS 3.5% >20% Others RO Conventional 0.1MCMD (R=45%) Conventional Process Conventional 1 MCMD (R=45%) Conventional Process Mega-ton LMIS 1 LMS Process with Mega-ton Technologies MCMD (R=65%) Capacity 100,000 m 3 /d 1,000,000 m 3 /d 1,000,000 m 3 /d Recovery 45% 45% 65% 25

26 Reduction of Water Production Cost Water Production Cost Breakdown This figure presents an example of FS cost estimation for a 1,000,000 m 3 /day seawater RO desalination project. 120% Seawater TDS=3.5%, Electricity Price= 0.1USD/kWh 100% 80% 30% 50% 60% 40% 20% Capital O&M Power 0% Conventional 0.1MCMD Conventional Conventional 1MCMD Conventional Process with Mega-ton Water System 1MCMD Capital 50% 35% 25% O&M Process 14% Large-scale 10% 7% Power 37% 26% 20% Technologies LMS Process with Mega-ton Technologies Capacity 100,000 m 3 /d 1,000,000 m 3 /d 1,000,000 m 3 /d Recovery 45% 45% 65% 2013 Mega-ton Water System Project. All rights reserved. 26

27 Mega-ton Water System will help realize the Global Water Solutions 1. Mega-ton Water System is a project by the state support of Japan to develop mega-scale seawater desalination plant system technologies necessary in the 21st century 2. Mission and Progress by Mega-ton Water System 1) Energy Reduction % less Energy 2) Low Environmental Impact No or Minimum Chemical 3) Low Water Production Cost Reduction by Half 3. Output of Mega-ton Water System Materials and Equipment System i. Low Pressure Seawater RO Element, Large Size Hollow Fiber RO Element ii.next-generation ERD iii.new High Pressure Resin Pipes i. Mega-ton Scale Desalination RO Plant System with LMIS Process ii.chemical-free Seawater RO Plant Intake & Pre-treatment System iii.seawater RO Brine PRO System 4. Mega-ton Water System technologies are also applicable to Small Size Decentralized Systems and conventional plants as Retrofit along with the ultra-large system under the concept of resilient economy 27

28 Acknowledgement This research is granted by the Japan Society for the Promotion of Science (JSPS) through the Funding Program for World-Leading Innovative R&D on Science and Technology (FIRST Program) initiated by the Council for Science and Technology Policy (CSTP). 28