PRESENTATION

ON
DESALINATION

Bharat Heavy Electricals Limited

Ranipet, India

March 11

Water
79%

d
Lan
21%

Earths Surface
Salt water
98.5%

Water on Earth

Fresh
water
1.5%

<1%
Readily
Accessible
Replenished by
rain & snowfall
(Hence
sustainable)
Deep
Underground
Reservoirs

Lakes, rivers
& Reservoirs
Shallow
underground
Reservoirs.

Frozen in Ice
Caps in
Greenland and
Antarctica (70%)

Moisture in
Soil

Fresh water
availability

Water resources on the earth and available fresh water

DESALINATION PROCESS
DESALINATION
PROCESSES

PHASE CHANGE

FREEZING

MULTI EFFECT
DISTILLATION

DISTILLATION

VAPOUR
COMPRESSION

MULTISTAGE
FLASH

NON-PHASE CHANGE

MEMBRANE

ELECTRODIALYSIS

REVERSE OSMOSIS

OTHERS

ION EXCHANGE

SOLVENT EXTRACTION

GLOSSARY

MGD : Million Gallons per Day (1 MGD = 3785 m3/day)

MIGD : Million Imperial Gallons per Day
(1 MIGD = 4546 m3/day )

MLD : Million Liters per Day (1 MLD = 1000 m3/day)

PPM : Parts Per Million = mg/l
TDS : Total Dissolved Solids

Global Scenario on Desalination A snapshot

RO

THERMAL

Installed membrane Vs Thermal capacity 1980-2009

RO Vs Thermal

Exponential growth in Desalination over last 30 years

RO technology getting preference over thermal during last
15 years

Source: GWI Desal Data /IDA

Annual new contracted capacity by feedwater type,

1990-2009

Source: GWI DesalData / IDA

Installed Capacity as of June 2009

Indian Scenario on Desalination A snapshot

FILTRATION SPECTRUM

PRINCIPLE OF REVERSE OSMOSIS(RO)

REVERSE OSMOSIS

Osmosis :It is the diffusion of water through semi permeable

membrane separating two different solutions of different solute
concentration. The water flows in a direction to equalize the
concentration.

Reverse Osmosis:Transport of the solvent from a concentrated

to a dilute solution through a membrane under the influence of
a pressure head,which exceeds the osmotic pressure of the
solution.Product water flux is proportional to excess pressure.

HOLLOW FINE FIBRE MEMBRANE MODULE

SPIRAL WOUND CONFIGURATION OF

RO MEMBRANE

SPIRAL WOUND CONFIGURATION OF

RO MEMBRANE

FACTORS CONSIDERED FOR THE DESIGN OF RO PLANT

Raw

water source Open sea, beach well, deep

bore well etc.,

Feed water quality- Physical, Chemical &

biological
End use of water- Potable, Industrial, wastewater

treatment etc.,
Recovery of the plant desired
Capacity of the plant
Operation of the plant
Type of brine disposal

Our Experience
In Building

SWRO & BWRO

Desalination plants

RO PLANT REFERENCE LIST BAP, BHEL RANIPET

1. 1MGD (SWRO)
2. 300 M3/Day (SWRO)
3. 300 M3/Day (HBWRO)
4.
5.
6.
7.

Narippaiyur : 1NO.
Rameswaram : 1 No.
Kusavankudi : 2 Nos.
Pottagavayal
300 M3/Day (BWRO)
Panaikulam : 1 No.
50 M3/Day (BWRO)
Uthirakosamangai : 1 No.
30 M3/Day (BWRO)
Urathur
: 1 No.
20 M3/Day (BWRO)
Perungulam : 4 Nos.
Keelambal, Keelaparithiyur, Kidathirukkai

8. 560 M3/Day (BWRO) Airport Chennai

: 1 No.
9. 2280 M3/Day (Stage-1, BWRO) Bellary TPS : 1 No.
1824 M3/Day (Stage-2, BWRO) Bellary TPS : 1 No.

TWAD
SWRO & BWRO
Desalination plants

20 Cu.M/Day - BWRO DESALINATION PLANT

300 Cu.M/Day - HBWRO DESALINATION PLANT

Process Flow Diagram-1 MGD SWRO Plant

1 MGD - SWRO DESALINATION PLANT FOR

DRINKING WATER AT RURAL TAMIL NADU

1 MGD - SEAWATER INTAKE SYSTEM

1 MGD - FILTER FEED PUMPS

1 MGD - DUAL MEDIA FILTERS

1 MGD - MEMBRANE RACK ASSEMBLY

PLANT HIGHLIGHTS

Largest Capacity In India For Drinking

Water
Maximum Recovery of 50% For Seawater
Power < 6 KWHr /Cu.M with ERD
Inbuilt Chlorine Generation
PLC based Auto Operation
Corrosion Resistant Materials Like
Duplex SS, SS316L, uPVC, GRP, HDPE
etc.,
Low Consumption of Chemicals

RO-DM Plant
at
BTPS Bellary 500 MW

GENERAL DETAILS
Customer

: Karnataka Power Corporation

Limited, Bellary.
1x500 MW Thermal Power Plant

Plant Description

: RO-DM Plant

Raw water Source

River

: From Maralihalla
water

Design Raw water TDS : 1500 PPM

Plant Capacity
Design Temperature

: 75 M3/Hr (Net)- DM water

: 10 M3/Hr - Potable water
: 30 deg C

DESIGN - PLANT PERFORMANCE

1. Pretreatment System
Inlet TSS
: 100 ppm
Outlet SDI15
:<5
2. Membrane Life
: 3 years
RO Stage - I Permeate TDS : 80 ppm
RO Stage - II PermeateTDS : 10 ppm
3. Mixed Bed Exchanger
Inlet TDS : 10 PPM
(21 mic.S/cm)
Outlet Cond. : 0.1 mic.S/cm

DM PLANT - GUARANTEED
1. pHOUTPUT QUALITY
: 6.8 - 7.2
2. Conductivity
Max
: 0.1 mic.S/cm
3. Silica reactive as SiO2
: 0.015 PPM
4. Organic matter
: < 0.2 mg of
KMnO4/l

KPCL UNIT - 1

34

RAW WATER POND

KPCL - BELLARY RO-DM PLANT- CLARIFIER

FILTER, RO-DM PLANT EQUIPMENT LAYOUT

FILTER SHED

RO MEMBRANE RACK

MB SYSTEM & PIPING

DGT

MB
MB

CONTRACTS ON HAND
1. KPCL-Bellary Unit-2 RO-DM Plant (UF+BWRO1+BWRO2+MB)
Plant Capacity

: 96 M3/Hr BWRO1 x 1W
: 76 M3/Hr BWRO2 x 1W
: 75 M3/Hr DM plant x 1W

2. GSPC, Gujarat, Pipavav 2x350 MW (PT+SWRO+BWRO+DM) Combined Cycle Plant

Plant Capacity
: 100 M3/Hr SWRO x 2W+1SB
: 26 M3/Hr BWRO x 1W+1SB
: 25 M3/Hr DM plant x 1W+1SB
3. TNEB, North Chennai 2x600 MW (PT+UF+BWRO+DM)
Plant Capacity
: 100 M3/Hr BWRO x 2W+1SB
: 90 M3/Hr DM plant x 2W+1SB
4. PPCL, PRAGATHI-III, NEW DELHI 1500 MW (MBR+BWRO1+BWRO2+MB)
Plant Capacity
: 28.5 M3/Hr BWRO1 x 2W
: 25.5 M3/Hr BWRO2 x 2W
: 25 M3/Hr MB plant x 2W+1S
5. YERMARUS- 2 X 800 MW (PT+UF+BWRO1+BWRO2+MB)
Plant Capacity
: 105 M3/Hr BWRO1 x 2W
: 87 M3/Hr BWRO2 x 2W
: 87 M3/Hr MB plant x 2W+1S
6. RPCL-EDLAPUR 1 X 800 MW RO-DM Plant (UF+BWRO1+BWRO2+MB)
Plant Capacity
: 2x107 M3/Hr BWRO1 1W + 1S
: 2x87 M3/Hr BWRO2 1W + 1S
: 2x85 M3/Hr MB plant 1W +1S
7. KPCL-Bellary Unit-3 RO-DM Plant (UF+BWRO1+BWRO2+MB)
Plant Capacity
: 96 M3/Hr BWRO1 x 1W
: 76 M3/Hr BWRO2 x 1W
: 75 M3/Hr DM plant x 1W

MAJOR EQUIPMENT SCOPE

COMPARISON KPCL, BELLARY

UNIT -1
1.PRETREATMENT : (127m3/hr)
-Clarifier (1x100%)
-PSF (4x50%)
-ACF (4x50%)
2.
RO Stage-1 (2x100%) (95
m3/hr)
3.
RO Stage-2 (2x100%) (76
m3/hr)
4.
MB System (2X100%)
(75m3/hr)

UNIT -2
1.PRETREATMENT : (127m3/hr)
-UF System (2x50%)
(Submerged)

2. RO Stg-1 (1x100%) (95

m3/hr)
3. RO Stg-2 (1x100%) (76
m3/hr)
4. MB Sys (1x100%) (75 m3/hr)
42

KPCL UNIT-1 & UNIT-2

MAJOR SCOPE COMPARISION
S.NO

DESCRIPTION

UNIT-1

UNIT 2

127 m3/hr
1x100%
500 m3
2 x 100%
4 x 50%
4 x 50%
N/ A
200 m3

127 m3/hr
N/ A
N/ A
N/ A
N/ A
N/ A
2 x 50%
300 m3

PRE TREATMENT
Clarifier
CWST
CW pumps
PSF
ACF
UF system
FW tank

RO Stage -1

RO block (2x100%)

RO block (1x100%)

RO Stage -2

RO block (2x100%)

RO block (1x100%)

MB SYSTEM

2 x 100%

1 x 100%

Total weight (MT)

KPCL UNIT - 2

UF system

RO 2

RO 1

MB system

44

KPCL , BELLARY- 500 MW

RO-DM PLANT UNIT-1

DM SYSTEM
RO SYSTEM

PT SYSTEM

45

IMPROVEMENTS IN KPCL UNIT-2

UF system In place of Clarifier, PSF & ACF

ULTRA
FILTRATION
SYSTEM

UF system
Unit 2

Clarifier
Unit-1

PSF & ACF

Unit-1

46

Improved Dosing System Skid

47

NORTH CHENNAI UNIT-1 & 2

GENERAL DETAILS
S.NO

DESCRIPTION

CAPACITY

PRE TREATMENT
-DMF
-UF (pressurized)

268 m3/hr
6 Nos
3 x 50%

BWRO system

200 m3/hr
(3 x 50 %)

DM SYSTEM
-Degasser
-SAC
-SBA
-MB

180m3/hr
3 x 50%
3 x 50%
3 x 50%
3 x 50%

48

NORTH CHENNAI UNIT 1 & 2

UF system

BWRO

DM
system

49

R
E
LT D
I
F E
SH

NORTH CHENNAI RODM PLANT EQPT.

LAYOUT

M
B
S
B
A

ROCCT
S
A
C

Hollow Fiber Configurations - Pressurized

Outside-In

Inside-Out

TYPICAL UF SYSTEM SKID (PRESSURIZED)

TYPICAL RO SYSTEM SKID

Tenders Participated
Sl.
No.

Customer / Project

Remarks

HEL Haldia 2x270MW

Offer submitted

PPCL Pragati II CCPP 750MW,

Bamnauli

Offer submitted

TNEB Ennore 1x600MW

Offer submitted

India Bulls Tertiary treatment plant,

STP, Nashik , 130 MLD

Offer submitted thro ROD

TNEB- Udangudi 2x 800MW

RODM confirmed

DB Power

Offer submitted to L&T thro ROD

Visa power

Offer submitted to L&T thro ROD

RO-DM ECONOMICS

Boiler Feed Makeup Water Quality

Requirement
Drum Pressure

Kg/cm2

61 100

>100

Conductivity @ 25C

S/cm

0.3 - 0.5

0.1 0.2

Silica as SiO2

ppm

0.02

0.01

6.8 - 7.2

6.8 7.2

pH

Max.

Available Strategies for Boiler

Pretreatment
Softeners
Dealkalizers
Demineralizers
Reverse Osmosis (RO)
Electro De-Ionization (EDI)

Process Vs Impurity Removal

SYSTEM
Impurity

Softener

Softener Reverse
DM
with
Osmosis (SAC,
Dealkalizer
(RO)
SBA &
MB)

RO
+
MB

Total Dissolved
Solids

No

No

Yes

Yes

Yes

Hardness

Yes

Yes

Yes

Yes

Yes

Alkalinity

No

Yes

Yes

Yes

Yes

Silica

No

No

Yes

Yes

Yes

CO2 & Oxygen

No

No

No

Yes

Yes

Feed Water Quality

Considered
Unit
Case-1
Case-2
Parameters
200 ppm

400 ppm

Case- 3
800 ppm

Feed source

RW

RW

RW

pH

8.4

8.4

8.4

Ionic load as CaCO3

ppm

260

560

1190

Approx. TDS

ppm

200

400

800

Calcium as CaCO3

ppm

40

80

125

Magnesium as CaCO3

ppm

40

79

115

Sodium as CaCO3

ppm

44

121

347

Potassium as CaCO3

ppm

Chloride as CaCO3

ppm

35

104

251

Sulfate as CaCO3

ppm

18

36

151

carbonate as CaCO3

ppm

16

17

Bicarbonate as CaCO3

ppm

71

123

167

Silica as SiO2 (Total)

ppm

25

25.0

25

Basis for O & M cost General

Description
Plant Life

Details
(Years)

20

Interest Rate Per Year

(%.)

8.0

Net output - DM water

(M 3/h)

170

(days/yr.)

330

Plant Availability
Operating hours per day

24

No. of streams

(W)

Temperature

( 0C)

30

Electrical Power Cost

IX Regen. Waste discharge pH

(Rs / Kwh.)

3.24
Neutral

Contd

BASIS OF CALCULATION FOR DIFFERENT FEED

TDS
1. FOR 400 ppm TDS
-Detailed calculation made w.r.t above said basis for 2
stage RO and conventional treatment
2. FOR 200 ppm TDS
-RO-2 is not in operation & RO-1 is alone operational
-MB regen. once in 36 hrs & MB regen chemicals
twice the consumption as compared to that of 400
ppm feed TDS due to higher ionic load for MB feed.
-Conv. DM plant regn. chemicals Half that of 400
ppm feed TDS due to lower ionic load for MB feed of
400 ppm
-3. FOR 800 ppm TDS
-RO1 additional power 10 KW due to
TDS

higher feed

-Conv. DM plant regen. chemicals - twice the

consumption as compared to that of 400 ppm feed
TDS due to higher ionic load for DM feed TDS

Comparison
Between

Single Stage RO
and

Two Stage RO

O & M COST SAVING WITH RO-DM PROCESS

1. For 400 ppm feed TDS
Savings in Rs/ m3 x flow/hr x no of Hrs/day x no of
days /yr
8.61 x 170 x 24 x 330 = Rs.116 lakhs/ year
2. For 800 ppm feed TDS
25.91 x 170 x 24 x 330 = Rs. 349 lakhs/ year
3. If the plant operation for 8 months per annum
(2/3) with 400 ppm feed TDS & 4 months per annum
(1/3) with 800 ppm feed TDS
Deducing from 1 & 2 above , 116 x 2/3 + 349 x 1/3
The saving per year is Rs. 193 lakhs

Advantages of RO-DM over a Conventional DM

EFFLUENT GENERATION AND DISPOSAL
Lower IX effluent & Minimize disposal cost
(~1/16th )

Lower capacity of neutralising pit.

BWRO reject can be used for cooling tower
make up or wash water or gardening.

CHEMICAL CONSUMPTION / HANDLING

Lower regeneration chemicals / cost (~1/10th).

To minimise the TDS loading in the effluent

discharge.

Lower storage, handling (~1/10th) & minimise

hazards.

Increasing cost of regeneration chemicals leads RO

option more cheaper.

Contd.

Advantages of RO-DM over a

Conventional DM
RAW WATER QUALITY

Economical at Moderate & high TDS

Break even at feed TDS of 100 to 200 ppm.
Effective removal of Silica & Organics
RESIN PERFORMANCE

Lower organic load increases resin

performance

Less resin volume leads to smaller vessel size

and lower replacement cost.
OUTPUT QUALITY & QUANTITY

OBR of DM will be increased due to lower ionic