SIMULATION OF MULTISTAGE FLASH

DESALINATION PROCESS 1
Osman A. Hamed, Mohammad AK. Al-Sofi, Monazir Imam, G. M. Mustafa
Khalid Bamardouf and Hamad Al-Washmi
Saline Water Conversion Corporation
P.O.Box 8328, Al-Jubail -31951, Saudi Arabia
Tel: + 966-3-343 0012, Fax: + 966-3-343 1615
Email: rdc@swcc.gov.sa

ABSTRACT

The majority of large-scale desalination plants in the Arab Gulf area employ the
multistage flash (MSF) processes. MSF processes are energy intensive and it is,
therefore, essential to search for design and operating conditions which lead to
reduction of energy dissipation and consequently lower water production cost. This
paper reports a simulation study which was carried out to examine to what extent the
thermal irreversibility of an MSF process is influenced by variation of the most
important design and operating parameters.

The impact of variation of top brine temperature, number of stages and terminal
temperature approach on the distiller performance ratio and irreversibility were
explored and presented graphically in the term of thermal grids. The simulation study
revealed that within the selected range of number of stages (16-40) and top brine
temperature (90 120o C), the MSF distiller irreversibility is highly influenced by the
number of stages and to a lesser extent by the variation of the top brine temperature.

The simulated results are compared with one year operating data obtained from an
MSF distiller. The distiller is a cross-tube configuration, which consists of 22 stages
and operating at a top brine temperature ranging between 90 to 98o C. Using a steady
state simulation program, an envelop of possible operating conditions is constructed
for the distiller to interrelate performance ratio, production, recycle flow and top brine
temperature. Stage-wise simulation of individual heat transfer coefficients and fouling
factors showed that both clean overall heat transfer coefficients (U c) and fouling
factors (FF) are stage dependent and conversely the operating overall heat transfer

1
Presented in the International Conference on Seawater Desalination Technologies on the Threshold on
the New Millennium, Kuwait, Nov. 4-7, 2000.
2. Published in Desalination Journal 134, (2001) 195-203.
coefficient (U D) is to a great extent less dependent. The dependence of the distiller
irreversibility on the process conditions is reported. The distiller exergy losses varied
between 52 and 62 kJ/kg of distillate. Process details, which are responsible for
distiller irreversibility are pinpointed and opportunities for better utilization of
available energy are discussed.

INTRODUCTION

The majority of desalination plants in the Arab Gulf Region are currently employing
the multistage flash process (MSF) which is producing around 67% of the total world
capacity of land-based desalting projects which are capable of producing 100 m3 /day
[1]. The success and popularity of the process is due to its simplicity, inherent
robustness and vast amount of acquired experience which resulted in reducing material
and operating costs and increasing life expectancy. The basic technology of modern
large scale MSF is similar to the early units and apart from the development of on-line
ball cleaning system and scale control techniques, use of corrosion resistant materials
and increase of unit capacity to 12 MIGD [2], the development of the process can be
considered as evolutionary rather than revolutionary [3]. A brief history of the
development of the MSF process as well as specific design features of a modern MSF
plant are presented by Darwish, et al. [4].

Although, coupling of MSF process with power generation system has greatly
contributed in reducing energy requirement by about 50% or more compared to single
purpose desalination plants using the same kind of fuel [5], but it is still considered as
an energy intensive process [6]. The need for detailed thermodynamic analysis is thus
quite evident in order to get a detailed understanding of the process and search for
optimal process irreversibility. Theoretical analysis of the MSF process has been
published [7,8] where the relationships among the various designs and operating
parameters were examined. Characteristics of a number of simplified configurations
including single stage flashing, once through and recycle MSF units were reported [9].

The exergy method is particularly useful for optimizing the design and operation of the
MSF process with the aim of reducing energy consumption. Concepts of first and
second laws of thermodynamics are both used rather than just the first law, to identify
process irreversibility and evaluate the thermodynamic losses of the process.
Applications of the exergy or availability method to distillation processes were reported
[10-15].

In this paper the operational performance of an MSF distiller representing Al-Jubail

Phase II plant is analyzed and simulated . A computer program is used for the
simulation study and its overall logic and algorithm has been previously reported by
Hamed et al. [10]. The simulation program has got the capability to perform
energy/exergy performance calculation of the MSF system. A detailed parametric
analysis is also intended to be carried out.

AL JUBAIL PHASE II PLANT

Al Jubail Phase II power and desalination plant is the largest in the world. It consists of
ten Boiler-Turbo-Generator ( BTG ) sets of about 130 MW output each . Each one of
the ten back-pressure turbine feeds low grade steam to four MSF distillers ( i.e. forty
distillers in total are installed). Thirty distillers have 19 stages in the recovery section
and 3 stages in the rejection section each. The remaining 10 distillers have 17 stages in
the heat recovery and 2 stages in the heat rejection section each. The evaporators are
designed for operation at a brine top temperature of 90.6o C with production of 5.2
MIGD and a top temperature of 112.8o C with a production of 6.29 MIGD [16,17].

One distiller from the group having 22 stages was selected for this simulation study
and its design and operating characteristics are shown in Table-1.

OPERATION SIMULATION

The simulation program was firstly used to verify that the distiller would operate at the
ce area requirements.
Comparison between design and simulated values are shown on Table 2. When
performance ratios are compared a good agreement was obtained between design and
simulated values and the difference between them is -0.23 and .14 percent for LTO and
HTO respectively. It also shows that the surface area requirements for LTO and HTO
are 9.93 and 5.2 percent less than the available area.
Steady state simulation are normally used to generate operating envelopes to describe
the possible operating conditions of the MSF distiller [18,19]. An envelope of possible
operating conditions of the selected distiller is shown on Figure 1 for winter conditions.
It illustrates the operation as performance ratio vs recycle to distillate mass ratio with
the following boundary conditions :

Nodes along line CF constant recycle concentration ratio of 1.4 and TBT
decreased from 112.8 to 90o C

Nodes along line FED constant TBT of 90o C and recycle concentration ratio
decreased from 1.4 to 1.25

Nodes along line DA constant recycle ratio of 1.25 and TBT increasing from
90 to 112.8o C

Nodes along ABC ″ constant TBT of 112.8o C and recycle concentration ratio
increased from 1.2 5 to 1.4

Simulated Stage-Wise Heat Transfer Coefficients and Fouling Factors

Very little information is published on the stagewise heat transfer coefficients and
fouling factors [20] and in most cases an average value for the whole recovery section
is determined. The simulation program has been used to calculate the overall heat
transfer coefficients and fouling factors of each individual stage and simulation results
are shown in Figure 2. The clean overall heat transfer coefficient (Uc) of each stage
which is calculated from the individual heat transfer coefficients of recycle brine and
condensing vapors inside and outside the tubes respectively, is highly dependent on the
number of recovery stage. The highest value of Uc is obtained in the first stage and is
progressively decreasing towards the low temperature stages. This is because the
individual heat transfer coefficients of the recycle brine and the condensing vapors are
dependent on their physical properties which are highly influenced by stage operating
pressure and temperature. Although, the high temperature stages of the recovery section
are having higher clean overall heat transfer coefficients compared to the low
temperature stages, the operating overall heat transfer coefficients (UD) of the different
stages remain virtually constant. This is due to the fact that stages of higher
temperature are experiencing high fouling factors which is offsetting the advantages
gained by the clean heat transfer coefficients. The simulated fouling factors of all stages
are lower than the design values and the gap between the two values widens towards
the low temperature stages.

OPERATIONAL PERFORMANCE

Operational data for the assigned distiller were collected for a period of one year. The
distiller was operating a TBT of 90o C for the first 200 days as shown in Figure 3. It
was then acid cleaned for the first time after 16 years of operation and the TBT was
raised to 98o C. Comparison between the observed and simulated performance ratio
was shown in Fig. 3(b) and very close agreement between the two values was observed.
Figures 3 (c) and (d) show the variation of the overall heat transfer coefficients (OHTC)
and fouling factors (FF) with time. It can be noticed that the impact of acid cleaning
was more significant on the thermal performance of the recovery section due to the
increase of its OHTC and reduction of FF.

Second law thermal analysis of the distiller is shown in Figure 3(a). the overall exergy
destruction during the pre-acid period was ranging between 58 and 62 kJ/kg and then
dropped to 55-52 kJ/kg after acid cleaning. It also shows the break down of exergy
losses among the major subsystems which included heat recovery and rejection section,
brine heater, ejector system and wasted in leaving streams. The exergy losses in the
recovery section after acid cleaning are less than that in the pre-acid period, which is
accordingly reflected in the reduction of the overall exergy losses. The large exergy
losses in the recovery section are the result of the exergy losses in feed heaters which
are having condensing area several times higher than that of the brine heater and heat
rejection section and those caused by flashing of brine and distillate in each recovery
stage.

PARAMATERIC ANALYSIS

A comprehensive simulation study was carried out to examine the interrelationships

between the top brine temperature, number of stages, performance ratio, exergy losses
and the terminal temperature approach. The terminal temperature approach is the
difference in temperature between the condensing vapor and the recirculating stream
leaving the condenser and is an important design parameter depending on the heat
transfer area and overall heat transfer coefficient. The interrelationships between the
different parameters are presented in the form of grid network which are shown in
Figures 4 and 5 for TTD of 2 and 4 o C, respectively. Both figures reveal that increasing
number of stages while keeping top brine temperature constant such as lines AC & BD,
results in an increase of both performance ratio and specific condensing area and a
decrease of exergy losses. Increase of number of stages will decrease temperature drop
per stage which will reduce the irreversibility of the system due to the reduction in
condenser and flash exergy losses and results in an improved thermal performance.
Increase of performance ratio will reduce steam consumption and consequently
minimize operating cost while increase in surface area results in an increase of capital
expenditure. Therefore, optimum performance ratio (i.e. that of lowest production cost
of water which is site specific) has to be determined by making cost tradeoffs between
the cost of process energy and capital cost of the process.

Conversely, increasing top brine temperature while keeping number of stages constant
(lines such as AB and CD) will increase the performance ratio and decrease the
specific condensing area but its net effect on exergy destruction is not significant.
Within the selected range of number of stages and top brine temperature, the simulation
analysis revealed the dependence of exergy losses on number of stages is more
appreciable than that due to variation of top brine temperature.

CONCLUSIONS

1. Performance and operation of a 22-stage MSF distiller is simulated. An operating

envelope with specific boundary conditions is generated and presented to describe
the distiller possible operating conditions.

2. A one year operation data is used to carry out an energy/exergy thermal analysis
of the whole distiller as well as the major subsystems. Dependence of
performance ratio, heat transfer coefficients and exergy losses on the most
important operation parameters, is discussed.

3. A detailed parametric study is carried out. The impact of number of stages and
top brine temperature on performance ratio, exergy losses and specific condensing
area is presented in the form of grid network.
Table 1 : Design Characteristics of the Selected Distiller (winter conditions) at low
(L) and high temperature operation (HTO).

Parameter LTO (90.6 HTO (112.8

C) C)
Product water flow m3 /Hr 987 1184
Recycle brine flow m3 /Hr 10817 9556
Makeup flow m3 /Hr 2923.55 3504.5
3
Blow down flow m /Hr 1936.55 2320.5
Sea water to rejection m3 /Hr 6996 7130
Tube side velocity m/s 1.98 1.58
2 o
Brine heater heat transfer coefficient W/m C 2257 2182
Fouling allowance m2 o C/W 0.000176 0.000176
Heat recovery and brine heater
Performance ratio kg/1000 kJ 3.44 4.08

Table 2 : Comparison of design and simulated parameters of the selected distiller

(winter conditions) at low (L) and high temperature operation (HTO).

Parameter LTO (90.6 o C) HTO (112.8 o C)

Design Simulated Diff. Design Simulated Diff.
Set product (t/hr) 987 987 0.0% 1184 1184 0.0%
Flow (t/hr) 10817 10733.6 0.77% 9556 9348.1 2.17%
Recycle Conc. Ppm 63700 63461 0.37% 61400 61508 0.17%
Steam to brine heater 126.77 126.64 0.1% 131.417 132,09 -
(t/Hr ) 0.51%
PR ( kg /1000 kJ ) 3.44 3.448 -0.23 % 4.08 4.074 0.14%
Total surface 88459.6 79672.2 9.93% 88459.6 83798.6 5.2%
2
Area requirements m (available) (available)

ACKNOWLEDGEMENT

The authors gratefully acknowledge the help and useful discussion provided by Mr.
Abdul Salam Al-Mobayed and Anwar Ehsan of Al-Jubail Plants.
 9.6
112.8 C A
9.4 109 C Brine Conc.
112.8 C B
Ratio
Performance Ratio (kg / 2326 kJ)

TBT=112.8 C 106 C
9.2 1.4
C" 102 C
9
109 C 100 C 1.25
98 C
8.8 106 C
96 C 1.325
8.6 102 C 94 C

100 C 92 C
8.4
98 C
96 C D 90 C
8.2
94 C 90 C
8 92 C E
90 C
7.8 F

7.5 8 8.5 9 9.5 10 10.5 11 11.5

Recycle to Distillate Ratio

Figure 1 :Operating Analysis of a 22-stage MSF distiller.

5000

Simulated UD Simulated Uc
Overall Heat Transfer

4000
Coeff.(kW/m2 K)

3000

2000

1000
0 2 4 6 8 10 12 14 16 18 20

0.2
Fouling Factor(m K/kW)

0.16
Simulated FF FF(design)
2

0.12

0.08

0.04

0
0 2 4 6 8 10 12 14 16 18 20
Recovery Stage Number

Figure 2 : Variation of Heat Transfer Coefficient and Fouling Factor with Recovery Stage Number
 Acid Cleaning
120
e
100

Temperature
80

( C )
TBT Flash Range

60

o 40

20

6 0.8

5 Fouled HTC of Brine Heater Fouling F. of Brine Heaterd

Factor(m K/kW)
Brine Heater

0.6
(kW/m K )

Fouling
OHTC
2

2
3 0.4

2
0.2
1

0 0

6 1

5 Av. HTC of H.Recovery Sec. Av. Fouling F. of H.Rec. Sec. c

0.8

Fouling Factor
(kW/m K)
Heat Rec.

(m K/kW)
0.6
2
OHTC

3
0.4
2

2
0.2
1

0 0

10 b
(kg/2326 kJ)

9
PR

8 Simulated Plant

70
a

60

50
Exergy Destruction

40
(kJ/kg)

30
Dest. In B/H Dest in Recov.

Dest. In Rejec. Wasted in leaving Stream

20
Wested in Ejector Total Losses

10

0
0

20

40

60

80

100

120

140

160

180

200

220

240

260

280

300

320

340

360

Days

Figure 3: Operation Performance of MSF Distiller

 110 400

40 C
32 36

Condensing Area, m /(kg/s)

28 350
24
100 D

2
40
Number of Stages
20 36
16 32 300
A 28
24
90 20
TBT, o C 250
16 90
B 100
Number of Stages
80 16 112 200
120
A 20
Exergy Losses, kJ/kg

150
20 B
70 24

24 o
28 100
28 TBT C 32
32 36
60 36
40
40 D 50
C

50 0

6 7 8 9 10 11 12 13 14
P e r f o r m a n c e R a t i o , k g / 2 3 2 6 kJ

Figure 4: Dependence of Performance Ratio, Exergy Losses and Specific

Condensing Area on TBT and Number of Stages

/(kg/s)
130 230
40 C
32 36
28
24

2
20 210

Condensing Area, m
120 40
D
40
32 36
Number of Stages 16
28 190
110 A
24 C

20
170

100 A
B
16 Stages 16 TBT, o C
150
90
Exergy Losses, kJ/kg

Number of Stages
100
90 20 20 112
120 130
24

28 24
32
80 28
36 110
40 32
36
C D
40
70 90

3 4 5 6 7 8 9 10 11 12 13 14

Performance Ratio, kg/2326 kJ

Figure 5: Dependence of Performance Ratio, Exergy Losses and Specific

Condensing Area on TBT and Number of Stages
REFERENCES

1. 1998 IDA Worldwide Desalting Plants Inventory, (1998),

Report. 15, June, Prepared and published by Wangnick Consulting GmBH.

2. Wade, N.M., (1992), Technical and economic evaluation of distillation and

reverse osmosis desalination processes,
Regional Water Desalination Symposium, Al-Ain, United Arab Emirates, Vol. 2,
637-660.

3. Morris, R.M., (1992), The development of the multistage flash distillation

process,
Symposium, Al-Ain, United Arab Emirates, 15-17, Nov., 881-890.

4. Darwish, M.A., El-Refaee, N.M. and Abdel-Jawad, M., (1995), Developments in

Multistage Flash Desalting System, Desalination, 100, 35-64.

5. El-Saie, M.H.A., (1992), Technical developments of the MSF desalination

process and its prospects for the future,
Regional Water Desalination Symposium, Al-Ain, United Arab Emirates, 15-17,
Nov., Vol. 2, 579-595.

6. Darwish, M.A., (1995), Desalination Process: A technical comparison,

Proceedings of IDA World Congress on Desalination and Water Science, Abu
Dhabi, Nov. 18-24, 149-162.

7. Darwish, M.A., (1991), Thermal analysis of multistage flash desalting system,

Desalination, 59-79.

8. El-Dessouky, H. and Bingulac, S., (1996), Solving equations simulating the

steady-state behavior of the multistage flash desalination process, Desalination,
107, 171-193.

9. El-Dessouky, H., Alatiqi, I. and Ettouney, H., (1998), Process synthesis: The
multistage flash desalination system, Desalination, 115, 155-179.

10. Hamed, O.A., amamiri, A.M. Z., Aly, S. and Lior, N., (1996), Thermal
performance and exergy analysis of thermal vapor compression desalination
system, J. of Energy Convers. Mgmt, Vol. 37, No. 4.,. 379-387.

11. Darwish, M.A., Al-Najem, N. M. and Al-Ahmed, M.S., (1993), Second law
analysis of recirculating multistage flash desalting system, Desalination, 89, pp.
289-309.

12. El-Nasher, A.M., (1994), An MSF Evaporator for the UANW 9 and 10 power
station. Design Considerations based on energy and exergy, Desalination, 97, pp.
253-279.

13. Hamed, O.A., Al-Sofi, M. AK., Imam, M., Mustafa, G.M., Bamardouf, K. and Al-
Washmi, H., (1999), Thermal performance of MSF distillation plants in Saudi
 Arabia, Proceedings of IDA World Congress on Desalination, San Diego, USA,
107-119.

14. Al-Najem, N. M., Darwish, M.A. and Youssef, F.A., (1997), Thermovapor
compression desalter: energy and availability analyses of single and multi-effect
systems, Desalination, 110, pp. 223-238.

15. Al-Sofi, M. AK, (1984), Fuel & Chemical Consumption in MSF-BTG Dual
Purpose Plants, 6th Arab Energy Conference, Algere, Al-Geria,

16. Al-Sofi, M.AK.,et al., (1987), MSF Operation Modes & Antiscalant Dose Rate
Optimization, 3rd IDA Conference, Canne, France.

17. Al-Mudaiheem, et al, (1991), MSF Design Configuration in SWCC along the Gulf
Coast, 5th IDA Conference, Washington, DC, USA.

18. Hornburg, C.D., and Watson, B.M., (1993), Operational optimization of MSF
systems, Desalination, 92, 333-351.

19. Hussain, A., Woldai, A., Al-Radif, A., Kesou, A., Borsani, R., Sultan, H. and
Deshpandey, P.B., (1994), Modeling and simulation of a multistage flash (MSF)
desalination plant, Desalination, 97, pp. 555-586.

20. Rautenbach, R. and Schafer, S., (1997), Calculation of stagewise fouling factors
from process data of large MSF distillers, Proceedings of IDA World Congress,
Madrid,. Vol. 1, 165-177.