MSF process modelling, simulation and optimisation : impact of non-condensable gases and fouling factor on design and operation. Optimal design and operation of MSF desalination process with non-condensable gases and calcium carbonate fouling, flexible design operation and scheduling under variable demand and seawater temperature using gPROMS.
Desalination is a technique of producing fresh water from the saline water. Industrial desalination of sea water is becoming an essential part in providing sustainable source of fresh water for a large number of countries around the world. Thermal process being the oldest and most dominating for large scale production of freshwater in today¿s world. Multi-Stage Flash (MSF) distillation process has been used for many years and is now the largest sector in the desalination industry. In this work, a steady state mathematical model of Multistage Flash (MSF) desalination process is developed and validated against the results reported in the literature using gPROMS software. The model is then used for further investigation. First, a steady state calcium carbonate fouling resistance model has been developed and implemented in the full MSF mathematical model developed above using gPROMS modeling tool. This model takes into consideration the effect of stage temperature on the calcium carbonate fouling resistance in the flashing chambers in the heat recovery section, heat rejection section, and brine heaters of MSF desalination plants. The effect of seasonal variation of seawater temperature and top brine temperature on the calcium carbonate fouling resistance has been studied throughout the flashing stage. In addition, the total annual operating cost of the MSF process is selected to minimise, while optimising the operating parameters such as seawater rejected flow rate, brine recycle flow rate and steam temperature at different seawater temperature and fouling resistance. Secondly, an intermediate storage between the plant and the client is considered to provide additional flexibility in design and operation of the MSF process throughout the day. A simple polynomial based dynamic seawater temperature and different freshwater demand correlations are developed based on actual data. For different number of flash stages, operating parameters such as seawater rejected flow rate and brine recycle flow rate are optimised, while the total annual operating cost of the MSF process is selected to minimise.The results clearly show that the advantage of using the intermediate storage tank adds flexible scheduling in the MSF plant design and operation parameters to meet the variation in freshwater demand with varying seawater temperatures without interrupting or fully shutting down the plant at any time during the day by adjusting the number of stages. Furthermore, the effect of non-condensable gases (NCG) on the steady state mathematical model of MSF process is developed and implemented in the MSF model developed earlier. Then the model is used to study effect of NCG on the overall heat transfer coefficient. The simulation results showed a decrease in the overall heat transfer coefficient values as NCG concentrations increased. The model is then used to study the effect of NCG on the design and operation parameters of MSF process for fixed water demand. For a given plant configuration (fixed design) and at different seawater and steam temperatures, a 0.015 wt. % of NCG results in significantly different plant operations when compared with those obtained without the presence of NCG. Finally, for fixed water demand and in the presence of 0.015 wt. % NCGs, the performance is evaluated for different plant configurations and seawater temperature and compared with those obtained without the presence of NCG.
MSF, Modelling, Non-condensable gases, Simulation, Calcium carbonate fouling, Optimisation, gPROMS, Desalination
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