Desalination 279 (2011) 2737

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Desalination
j o u r n a l h o m e p a g e : w w w. e l s ev i e r. c o m / l o c a t e / d e s a l

A small scale multi-effect distillation (MED) unit for rural micro enterprises Part II Parametric studies and performance analysis
P.K. Sen a,, Padma Vasudevan Sen b, Anurag Mudgal c, S.N. Singh a
a b c

Dept. of Applied Mechanics, IIT, Delhi, India Center for Rural Development and Technology, IIT, Delhi, India Dept. of Mechanical Engineering, CET, IFTM Campus, Moradabad, India

a r t i c l e

i n f o

a b s t r a c t
The aspects of fabrication, design and operation with design optimization of various components of the small scale multiple effect distillation (MED) unit have been discussed in part I of the paper. The MED system can be operated as n effects + condenser (n + C), where 1 n 9. Extensive experiments were carried out respectively using 9 + C, 6 + C and 3 + C systems. The present part II is devoted to analysis and optimization of the product yield, and economics, based on parametric studies varying the input conditions for all the aforementioned three systems. The most important input parameters for operation of the MED system are the input steam pressure, and the number of effects used. The most important output parameter is the total distillate produced per hour. 2010 Elsevier B.V. All rights reserved.

Article history: Received 27 May 2010 Received in revised form 1 November 2010 Accepted 1 November 2010 Available online 7 December 2010 Keywords: Multiple effect distillation Number of effects Cumulative distillate

1. Introduction In part I, the focus is on design and fabrication. The paper is targeted for the persons who may manufacture small scale MED units in rural areas. Part III looks at the physics of the overall heat transfer coefcient OHTC, based on the analysis of experimental results of different parametric studies. The present part II is targeted for the chief engineer who will inspect the fabricated units as per design considerations elaborated in part I, and train rural artisans to operate and maintain the MED unit. The present part II also has considerable engineering science. For ease of understanding of the present part II, a brief description of the apparatus and its operation, is given using excerpts from part I. The sequence of operation is briey re-capitulated as follows, using excerpts from part I: The main reservoir is lled with the raw feed water that is to be puried, from the overhead tank. This water is pumped, after pressurizing, to the boiler up to a certain desired level which can be monitored in the glass tube indicator in the boiler (usually up to three fourths of the maximum height). The pressurized output water from the pump is also simultaneously fed into the Pressurised Feed Water Pre-heater (PFPH), which is located in the middle section of the boiler assembly (Fig. 1). The economizer

is also lled with the raw feed water from the overhead tank. The boiler is then red with diesel. The initial weight of the diesel tank (20 litre capacity diesel tank is used) is recorded, using a normal horizontal platform weighing machine. Temperatures and pressures at every junction are monitored to achieve smooth performance and correct ow volumes of the uids. It has been observed during experimentation that it takes almost 60 to 70 minutes for the plant to stabilize before the distillate starts trickling out from all the 9 effects and condenser. After the system stabilizes, once again some ner adjustments are made as needed, such as diesel ow rate to the burner, water feed to the boiler and pressurised water pre heater, and feed water rate to all the effects, using appropriate and ner valve adjustments. Once all this is done, the system runs smoothly and only some minor precautions, monitoring, and adjustments, are needed if and when required and the unit can be run continuously for hours together with very little attention. Data are recorded for temperature and pressure at each effect, and for distillate coming out from each effect, which is collected in a measuring ask. The total distillate obtained per unit energy consumed is an effective indicator of the product yield, the efciency of the distillation unit and also indirectly of the economics [1,2]. The energy inputs can be further described in terms of the actual steam input that condenses in the 1st effect and the fuel energy input to raise the steam in the boiler. The actual diesel consumption rate in the boiler burner will give the total energy input. There are heat losses at the burner level, and, heat is used for steam production in the boiler, pre-heating the

Corresponding author. Tel.: +91 11 26591179; fax: +91 11 26581119. E-mail address: pksen@am.iitd.ernet.in (P.K. Sen). 0011-9164/$ see front matter 2010 Elsevier B.V. All rights reserved. doi:10.1016/j.desal.2010.11.005

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P.K. Sen et al. / Desalination 279 (2011) 2737

pressurized water in the PFPH, and pre-heating the non-pressurized raw feed water in the economizer. The steam which reaches the rst effect is taken as the steam input. Both, total energy and input steam have to be optimized for economics. However for optimization of the technological aspects of the system only the total amount of distillate obtained per unit of steam condensed in the 1st effect (performance ratio or PR) needs to be evaluated. Issues related to fuel consumption at the boiler level, including type of fuel used, reduction of heat losses, and other such aspects, have to be considered separately. The MED unit with extendable number of effects with the locations of points at which pressure (P) and temperature (T) have been measured is indicated in Fig. 1. Also given in Fig. 2, is a detailed sketch of a vertical tube evaporator (VTE), which is self explanatory. The MED unit can be operated as an n effects plus condenser (n + C) system. In the present work detailed experiments were done with 9 + C, 6 + C, and 3 + C systems. 2. Selection of parameters for parametric studies The various important parameters which are expected to reect on the performance of the system, PR, are as follows: 1. 2. 3. 4. Feed water ow rate and feed arrangements Top brine temperature (TBT) Number of effects Input steam pressure and temperature.

feed water to be fed in the shell side of the 1st effect has to be based on the following: The feed water has to be at the right temperature, creating the right temperature differential between the tube and shell side lms on the tube wall. This helps to condense the primary steam into distillate while the latent heat of condensation passes through the wall, converting part of the feed water into steam [3]. The optimal feed ow rate was found to be about 100 kg/h, as this amount of feed water ensures integral lm formation on the shell walls of the VTE tubes (see part I, Figs. 9 and 10) avoiding hot spot formation. The ow of 100 kg/h is also appropriate for the feed water to reach saturation temperature on the shell side, by pre-heating by the condensing steam in the tube side. As already discussed in part I, a mixed feed system is found to be a useful system in which forward feed helps in carrying the heat forward from one effect to the other while parallel feed replaces the water removed from the shell side by evaporation. The feed water rate of 100 kg/h in the shell side is about 34 times the steam condensed in the 1st effect. Thus for parametric studies no further changes were made in the feed water ow rate. 2.2. Top brine temperature (TBT) The temperature of input feed water to the rst effect is important for optimizing the heat transfer rate for a given area of the tube surface. The difference in temperature T between the tube and shell side should be kept small to have optimum recovery of distillate in subsequent effects. At the same time T should be sufcient for condensing the steam inside the tubes [3,4]. Ultimately this is controlled by the difference in the initial input steam temperature and

2.1. Feed water ow rate and feed arrangements The MED unit has been designed for converting 30 kg/h of steam into distillate in each effect. To achieve this objective, the amount of

P1, T1

Over head tank

P2, T2

Economizer

P9, T9
P10, T10
C O N D E N S E R

Water pre heater

(PFPH)

T11 T24 VTE 1

T12 VTE 2

T19 VTE 9

T20

R A W F E E D W A T E R

Boiler

T22 T21

Pump

Main reservoir
T23

Distillate tank

Distillate Brine Steam Valve

Mist Eliminator

Steam Feed water

NeedleValve Thermocouple

Fig. 1. Location of points for pressure and temperature measurement in 9 + C units.

P.K. Sen et al. / Desalination 279 (2011) 2737

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Steam chamber

Steam from boiler

Viton rubber seal Feed water chamber

Hot water by forward feed from previous VTE through capillary

Hot water by parallel feed from water pre heater through capillary Fresh steam to next VTE

Fluted vertical tube

Feed water film

Stainless steel rolled wiremesh sheet, along inner length of vertical tube Brine level indicator

Evaporation chamber

Forward feed to next VTE through capillary Distillate level indicator Excess brine if any to main reservoir Distillate chamber
To distillate tank through capillary (Also acts as outlet for noncondensable gases)

Viton rubber seal

Fig. 2. Illustration of water lm formation over full length of tubes.

nal temperature at the condenser. Thus, TBT plays an important role in maintaining T at the minimum possible value [5]. For achieving high TBT, the raw feed water which enters the condenser at room temperature is mixed with other inuents in the main reservoir. Thereafter it is further heated under pressure in the PFPH before being fed into the shell side of the 1st effect. As already described, the maximum TBT is limited to the range of 110112 C due to ease in handling and optimal fuel consumption in the boiler assembly. Hence the parametric studies are effectively done for this range of TBT. 2.3. Number of effects Increase in the number of effects is expected to increase the total distillate obtained. But, optimization of this has to be done in terms of input steam pressure [6]. It may be noted that with an increase in input steam pressure, energy input to the 1st effect would also increase and unless performance ratio (PR) is sufciently high to compensate for this, increasing the number of effects (with increase in capital cost) may not be economically viable. In view of this, the system has been designed with a maximum of ten effects as more than this number of effects leads to the following problems in handling the system. Firstly, the input steam has to be generated at higher pressures and temperatures in the boiler which cannot be done in the present baby boiler used. Secondly the difference between the TBT and the saturation temperature in the rst effect would be higher, requiring a larger length for the pre-heating zone in the evaporator tubes. Also it is not possible to generate very high steam pressure and temperature with a baby boiler of small size. The unit was designed such that the number of effects being operated can be changed from nine downwards up to three effects. It may be noted that a one effect plus condenser system is nothing but simple distillation.

Detailed studies presented are on three selected systems, namely 9 + C, 6 + C, and 3 + C. The trends obtained for these three cases can be interpolated for other combinations as n + C, 1 n 9. 2.4. Input steam pressure and temperature Thus parametric studies were undertaken with primary input steam pressure (temperature), as the most important parameter, which was varied for different experimental runs for the three systems selected. Each system was run for different steam input temperatures and pressures to work out the optimum conditions of operation. The results are presented and analyzed later herein. 3. Measuring devices and range of parameters The input steam temperatures are T1, T2, and T3 to T10 to each VTE, and the feed water or brine temperatures are T11, T12 to T19 for each effect (see Fig. 1). T20 is the temperature of normal raw feed water to the condenser, T21 is the temperature of pre-heated raw water from condenser and T22 the temperature of recycled brine from MED unit coming to main reservoir. T23 is the temperature of mixed feed water in the main reservoir that is to be restricted below 70 C for the safety of pump. T24 is the temperature of feed water that comes out from pressurized feed water pre-heater (PFPH) which goes into the parallel feed line. These temperatures were measured for monitoring heat balance at different stages using PT-100 RTD (resistance temperature device) probes with a least count of 1 C. The location of RTD probes and pressure gauges is indicated in Fig. 1. The pressure of steam (P1 to P10) at different VTEs was measured with a view to oversee proper functioning of the VTEs and to cross check that the measured steam temperatures correspond to the respective saturation pressure, as checked from steam tables. Besides this, forty numbers of pressure gauges are placed in the feed water line (twenty

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P.K. Sen et al. / Desalination 279 (2011) 2737 Table 2 Estimated uncertainties for various parameters. Parameter Pressure Temperature Weight Flow rate of distillate Flow rate of brine Nominal minimum 1 bar 100 C 10 kg 250 mL 500 mL Estimated uncertaintya (%) 5.0 1.0 1.0 4.0 2.0

for parallel feed at two gauges for one effect, and same for forward feed) to allow a calculated xed amount of feed water to each effect as shown in Fig. 1. Ten pressure gauges were placed in the distillate withdrawal line from each effect. Atmospheric pressure was recorded in a Fortin's barometer and room temperature was recorded using mercury in glass thermometer. All the pressures were measured using Bourdon type pressure gauges with a least count of 0.01 to 0.1 bar or kgf/cm2 as per the requirement of measurement of expected pressure ranges at that position. The ow volumes of distilled water and recycled brine were measured volumetrically using a measuring ask. Total dissolved solids (TDS) contents and pH of raw feed water and distilled water, at different stages, were measured by a pen type digital TDS meter and a pH meter. 3.1. Range of data recorded The range in which various measured values were recorded is given here. The primary steam input temperature varied from 123 C to 147 C and corresponding pressure (gauge) values were 1.05 barg to 3.4 barg respectively. The lowest input steam temperature reached in the last effect (condenser) was 100 C. The minimum and maximum volumes of distillate measured volumetrically were 250 mL and 480 mL. The minimum and maximum time duration, for which distillate ow volumes were collected, were 58 s and 450 s. Flow volumes of brine from the last but one effect, and condenser, were recorded in the range of 400 mL to 460 mL and time duration was from 22 s to 27 s. The temperature of raw feed water supplied from the overhead tank was in the range of 23 C to 35 C. The minimum and maximum TDS values recorded in the residual brine were 170 parts per million (ppm) and 260 ppm whereas in the distillate this was around 10 ppm. 4. Uncertainty analysis Due precautions were taken in measuring various parameters like distillate volumes and corresponding time durations, pressure and temperature of steam and brine, at every stage, and also the weight of the diesel tank. However there would be some errors in measurement due to inaccuracies in measuring instruments. Least count of measuring instruments helps in evaluating the measurement uncertainty. The least counts of measuring instruments that have been used are listed in Table 1. The relative uncertainties in quantities were estimated using standard procedures (Nakra and Chaudhry [7]). However the possibilities of errors in measurements have been minimized by taking several observations for the same set of parameters and averaging them to obtain the best estimate of the true value. The estimated uncertainties for various parameters, based on the external estimate of error, are given in Table 2. 5. Experimental results As far as the plant performance is concerned, the cumulative distillate obtained for unit energy consumed will be the indicator of optimality. As discussed earlier, the energy inputs can be further described as the actual steam input that condenses in the 1st effect

a This is the maximum uncertainty percentage, corresponding to the minimum value of the parameter. For higher values of the parameters the uncertainty percentage decreases.

and total fuel energy input to raise steam in the boiler. Measurements were undertaken for varying input steam pressure, which is the main important parameter. The performance of the system has been analyzed and graphs have been plotted using Excel work sheets for calculations of various output quantities. Results are presented for the three selected systems studied, namely, 9 + C, 6 + C, and 3 + C. Six categories of plots have been prepared for analyzing the performance of the system. These are the following.

5.1. Cumulative distillate Effect wise cumulative distillate has been given in this category of graphs. The value of cumulative distillate corresponding to each effect represents the sum of distillate produced up to that effect including its own. This prole also indicates the total distillate produced which value corresponds to the last effect (condenser). All the data points have been normalized with maximum cumulative distillate produced. 5.2. Distillate prole Distillate prole gives distillate produced or steam condensed in each effect. Effect-wise distillate produced for different input steam pressures have been represented in this category of graphs. All the data points have been normalized with maximum distillate produced in the 1st effect irrespective of input steam pressure. To establish the rate of fall at each effect, the fall in distillate at each effect is calculated assuming that the distillate generated in the 1st effect is the same as the designed steam input in the 1st effect, which, for the present system, is 30 kg/h and is taken as Qo. 5.3. Pressure prole Pressure prole gives the steam pressure in each effect. It is evident that steam pressure in the tube side of one effect will be the same as the pressure in the shell side of a previous effect. Data points have been normalized with the pressure of input steam at which maximum cumulative distillate has been achieved, taken as optimum value of pressure. 5.4. Temperature prole Temperature prole gives the temperature of steam available in each effect. Although it is very similar to the pressure proles, since the heat transfer mainly depends on temperature difference, these plots are important. Data points have been normalized with the temperature of input steam at which maximum cumulative distillate have been achieved, taken as optimum value of temperature. Overall heat transfer coefcient (OHTC) will be discussed in greater detail in part III of this series of article.

Table 1 Least counts of measuring instruments. S. no. 1. 2. 3. 4. 5. Parameter Pressure Temperature Time Weight Flow volumes Apparatus used Bourdon tube pressure gauge PT-100 RTD Digital stop watch Weighing machine Measuring jar (500 mL) Least count 0.05 1 C 0.01 s 0.1 kg 10 mL

P.K. Sen et al. / Desalination 279 (2011) 2737 Table 3 Effect wise cumulative distillate for different input steam pressures in 9+C unit. PS1 (barg) 1.8 2.0 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.0 3.1 3.2 3.3 3.4 Q1 (kg/h) 28.0 29.0 29.2 30.0 30.0 30.0 30.0 30.0 30.0 30.0 29.0 29.0 28.0 28.0 CQ2 (kg/h) 52.7 55.0 55.4 56.5 57.0 56.8 56.4 56.0 56.0 56.0 54.0 54.4 52.0 52.0 CQ3 (kg/h) 74.0 77.7 78.6 80.0 80.5 80.7 79.4 79.0 79.3 79.5 76.6 77.1 73.8 73.0 CQ4 (kg/h) 92.0 96.8 98.4 100.0 100.0 101.6 99.4 99.0 99.3 99.5 95.9 96.1 92.2 90.5 CQ5 (kg/h) 105.0 112.4 114.2 116.8 116.1 119.6 116.6 116.0 115.6 115.8 111.9 111.3 107.4 104.5 CQ6 (kg/h) 115.0 124.7 126.6 130.3 129.3 134.6 131.1 130.1 128.6 128.8 124.7 123.4 119.6 115.5 CQ7 (kg/h) 122.0 133.1 135.6 140.3 139.7 146.6 142.7 141.1 138.6 138.8 134.1 132.6 128.6 123.7 CQ8 (kg/h) 127.0 138.4 141.6 147.3 147.2 155.8 151.7 148.9 146.0 145.8 140.6 139.4 134.6 129.4 CQ9 (kg/h) 130.2 141.7 145.5 152.1 152.4 162.6 158.2 154.2 151.3 150.3 144.9 143.5 138.4 132.9

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CQ10 (kg/h) 132.2 143.7 147.9 155.3 155.9 167.3 162.4 157.7 154.7 152.8 147.5 145.9 140.6 134.9

6. Performance of the 9 + C unit Analysis and investigations were done with the 9 + C unit which was selected rst. The unit was operated with input primary steam pressure in the range of 1.8 bar gauge to 3.4 bar gauge with increment of input steam pressure of 0.1 bar. All the readings namely pressure, temperature and distillate produced were measured and recorded at different locations for each input steam pressure. The sum of distillate produced from each effect is the total production, or cumulative distillate produced, at that input steam pressure. This is the indicator of the plant performance. The recorded data are given in Table 3. Values in rst column are input steam pressure given to the 1st effect and values in other columns show cumulative distillate up to that effect. Values given in the last column is the total distillate produced corresponding to each given input steam pressure. 6.1. Effect wise cumulative distillate analysis in 9 + C unit The unit was run at 14 different input steam pressures as shown in Table 3. Selected values are plotted in Fig. 3. At each input pressure the whole set of readings was repeated about four times, and the average

gures were obtained. From the data recorded it is seen that the total production increases as the pressure increases up to a certain limit of 2.5 bar gauge. A further increase in input steam pressure results in reduction of total distillate produced. To understand the variation of distillate clearly, the values are plotted for 8 different input steam pressures. The values have been normalized with the maximum value of distillate of 167 kg/h which is the cumulative distillate produced for an input steam pressure of 2.5 barg. The data points represent values as a fraction of maximum yield of production in any effect. Close observation of Fig. 2 shows that for any given input steam pressure, the distillate obtained in the 1st effect is nearly the same for all input pressures but the cumulative distillate beyond the 1st effect starts to differ. Starting from 1.8 barg input pressure, it is seen that the cumulative distillate, up to each effect number, increases with an increase in inlet pressure up to a pressure of 2.5 barg, and, then decreases with an increase in inlet pressure. The rate of increase of distillate is continuous and is higher in the initial effects and the rate decreases as the effect number increases. Moreover for pressures other than optimal, the cumulative distillate only increases marginally beyond the seventh effect. The percentage increase in distillate at the end of the tenth effect or condenser is 20% more for 2.5 barg inlet

Normalized trend of cumulative distillate for different primary steam pressures in (9+C) unit
Normalized cumulative distillate (Qd/Q) with CQmax
1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 1 2 3 4 5 6 7 8 9 10

Pi= 1.8 bar_g Pi= 2 bar_g Pi= 2.3 bar_g Pi= 2.5 bar_g Pi= 2.8 bar_g Pi= 3 bar_g Pi= 3.2 bar_g Pi= 3.4 bar_g Poly. (Pi= 1.8 bar_g) Poly. (Pi= 2 bar_g) Poly. (Pi= 2.3 bar_g) Poly. (Pi= 2.5 bar_g) Poly. (Pi= 2.8 bar_g) Poly. (Pi= 3 bar_g) Poly. (Pi= 3.2 bar_g) Poly. (Pi= 3.4 bar_g)

Effect Number
Fig. 3. Effect wise cumulative distillate for different input steam pressures in 9 + C unit.

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P.K. Sen et al. / Desalination 279 (2011) 2737

Table 4 Effect wise distillate for different input steam pressures in 9 + C unit. PS1 1.8 2.0 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.0 3.1 3.2 3.3 3.4 Qd1 28.0 29.0 29.2 30.0 30.0 30.0 30.0 30.0 30.0 30.0 29.0 29.0 28.0 28.0 Qd2 24.7 26.0 26.2 26.5 27.0 26.9 26.4 26.0 26.0 26.0 25.0 25.4 24.0 24.0 Qd3 21.3 22.7 23.2 23.5 23.5 23.9 23.0 23.0 23.3 23.5 22.6 22.7 21.8 21.0 Qd4 18.0 19.1 19.8 20.0 19.5 20.9 20.0 20.0 20.0 20.0 19.3 19.0 18.4 17.5 Qd5 13.0 15.6 15.8 16.8 16.1 18.0 17.2 17.0 16.3 16.3 16.0 15.3 15.2 14.0 Qd6 10.0 12.3 12.4 13.5 13.2 15.0 14.5 14.1 13.0 13.0 12.8 12.0 12.2 11.0 Qd7 7.0 8.4 9.0 10.0 10.4 12.0 11.6 11.0 10.0 10.0 9.4 9.3 9.0 8.2 Qd8 5.0 5.3 6.0 7.0 7.5 9.2 9.0 7.8 7.4 7.0 6.5 6.8 6.0 5.7 Qd9 3.2 3.3 3.9 4.8 5.2 6.8 6.5 5.3 5.3 4.5 4.3 4.2 3.8 3.5 Qd(C) 2.0 2.0 2.5 3.2 3.5 4.7 4.2 3.5 3.4 2.5 2.6 2.4 2.2 2.0 Qd(T) 132.2 143.7 147.9 155.3 155.9 167.3 162.4 157.7 154.7 152.8 147.5 146.0 140.6 134.9

then there is no fall in distillate produced for the effect. It is seen that in the pressure range of 2.3 barg to 3.0 barg there is no fall in distillate in the 1st effect and hence it can be assumed that the rst VTE is performing at hundred percent efciency. For pressures above 3.0 barg range, the efciency drops down and can be attributed to the fall in overall heat transfer coefcient for pressures outside the range of 2.3 barg and 3.0 barg which results in reduced formation of distillate. For the other effects it is seen that the fall in distillate is maximum in the 2nd effect and gradually the fall in distillate at each effect is nearly constant irrespective of the upstream pressure except for the lowest pressure. This effect can be attributed to: 1. The amount of steam produced in the preceding effect 2. The temperature difference achieved 3. The inlet pressure at each effect. The combined effect of all this could be related to the reduced OHTC for each effect.

(optimal) pressure with respect to the case for lowest input pressure (1.8 barg). 6.2. Effect wise distillate analysis in 9 + C unit Effect wise distillate produced is given in Table 4 and graphically in Fig. 4 as normalized distillate produced at the end of each effect after normalizing with the maximum value of distillate produced for the optimal case. From Table 4 it can be seen that the maximum distillate is produced at the 1st effect and has a value of 30 kg/h. It is seen that the extent of distillate produced at any effect decreases continuously, with effect number, for any given inlet pressure. The maximum distillate produced at each effect is the highest for 2. barg inlet pressure. Even for this pressure, the amount of distillate produced at the last effect is only about 16% of the distillate produced at the 1st effect. This graph also shows that 2.5 barg inlet pressure is the optimum pressure for the 9 + C unit. 6.3. Effect wise distillate fall analysis in 9 + C unit To understand the rate of fall in distillate at each effect, the fall in distillate at each effect relative to the preceding effect is given in tabular form in Table 5 and graphically in Fig. 5. The system has been designed for condensing 30 kg/h of steam in the 1st effect and this is taken as Qo. If the condensate formed in the 1st effect is equal to this

6.4. Effect wise pressure and temperature analysis in 9 + C unit Effect wise pressures and temperatures measured are given in Tables 6 and 7 for the same set of input steam pressures and the same are presented in graphical form in Figs. 6 and 7 respectively. The pressure and temperature data points have been normalized with their respective optimum values which correspond to the pressure that gives maximum cumulative distillate yield, which for the 9 + C case are respectively 2.5 barg and 139.3 C. Steam fed to rst effect, transfers its heat to feed water of shell side and fresh steam is formed at relatively lower pressure. Magnitude of this fresh steam is observed in terms of pressure and distillate of 2nd effect and same exercise is repeated in the subsequent effects. It is seen that pressure of steam gradually decreases in successive effects. Pressure prole of steam starts with the maximum value in the 1st effect and comes to the minimum value in the last effect or condenser. It can be seen clearly that for the input steam pressures lower than optimum pressure, all data points lie at a lower level than that of the corresponding optimum pressure data points. For the input steam pressures greater than the optimum pressure, the pressure value decreases abruptly from the 1st effect to 2nd effect and comes to a level even lower than that of optimum pressure point in the 2nd effect, and keeps on decreasing in subsequent effects. The variation in pressure and temperature for high inlet pressures shows that the complete system is internally unstable which results in drop of distillate for these

Normalized trend of distillate profile for different primary steam pressures in (9+C) unit
1.0

Normalized distillate with Qmax = 30 kg/hr

0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 1 2 3 4 5 6 7 8

Pi= 1.8 bar_g Pi= 2 bar_g Pi= 2.3 bar_g Pi= 2.5 bar_g Pi= 2.8 bar_g Pi= 3 bar_g Pi= 3.2 bar_g Pi= 3.4 bar_g Poly. (Pi= 1.8 bar_g) Poly. (Pi= 2 bar_g) Poly. (Pi= 2.3 bar_g) Poly. (Pi= 2.5 bar_g) Poly. (Pi= 2.8 bar_g) Poly. (Pi= 3 bar_g) Poly. (Pi= 3.2 bar_g) Poly. (Pi= 3.4 bar_g)

10

Effect Number
Fig. 4. Effect wise distillate for different input steam pressures in 9 + C unit.

P.K. Sen et al. / Desalination 279 (2011) 2737 Table 5 Effect wise distillate fall for different input steam pressures in 9 + C unit. PS1 (barg) 1.8 2.0 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.0 3.1 3.2 3.3 3.4 Q0Q1 (kg/h) 2.0 1.0 0.8 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1.0 1.0 2.0 2.0 Q1Q2 (kg/h) 3.3 3.0 3.0 3.5 3.0 3.1 3.3 4.0 4.0 4.0 4.0 3.6 4.0 4.0 Q2Q3 (kg/h) 3.4 3.3 3.0 3.0 3.5 3.0 3.2 3.0 2.7 2.5 2.4 2.7 2.2 3.0 Q3Q4 (kg/h) 3.3 3.6 3.4 3.5 4.0 3.0 3.2 3.0 3.3 3.5 3.3 3.7 3.4 3.5 Q4Q5 (kg/h) 3.3 3.6 4.0 3.2 3.4 2.9 3.0 3.0 3.7 3.7 3.3 3.8 3.2 3.5 Q5Q6 (kg/h) 3.0 3.3 3.4 3.3 2.9 3.0 3.1 2.9 3.3 3.3 3.2 3.3 3.0 3.0 Q6Q7 (kg/h) 3.0 3.9 3.4 3.5 2.8 3.0 2.9 3.1 3.0 3.0 3.4 2.8 3.2 2.8 Q7Q8 (kg/h) 2.0 3.1 3.0 3.0 2.9 2.8 2.6 3.2 2.6 3.0 2.9 2.5 3.0 2.5 Q8Q9 (kg/h) 1.8 2.0 2.2 2.2 2.3 2.4 2.5 2.5 2.1 2.5 2.2 2.6 2.2 2.2

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Q9Qc (kg/h) 1.2 1.3 1.4 1.6 1.7 2.1 2.3 1.8 1.9 2.0 1.7 1.8 1.6 1.5

Effectwise normalized trend of distillate fall for different primary steam pressures in a (9+C) unit
0.50
Pi= 1.8 bar_g Pi= 2 bar_g Pi= 2.3 bar_g Pi= 2.5 bar_g Pi= 2.8 bar_g Pi= 3 bar_g Pi= 3.2 bar_g Pi= 3.4 bar_g Poly. (Pi= 1.8 bar_g) Poly. (Pi= 2 bar_g) Poly. (Pi= 2.3 bar_g) Poly. (Pi= 2.5 bar_g) Poly. (Pi= 2.8 bar_g) Poly. (Pi= 3 bar_g) Poly. (Pi= 3.2 bar_g) Poly. (Pi= 3.4 bar_g)

Distillate fall normalized with Q max = 30 kg/ h

0.40

0.30

0.20

0.10

0.00 1 2 3 4 5 6 7 8 9 10

Effect Number
Fig. 5. Effect wise fall in distillate for different input steam pressures in 9 + C unit.

pressures. An explanation of this phenomenon is given in part III where the nature of OHTC of the tubes is discussed. The inter effect rate of pressure and temperature falls is minimum for a certain input steam pressure (in the case of 2.5 barg) and this gives a maximum

yield or production. The curve that looks more convex at the top side gives the maximum yield, because it utilizes maximum tube surface area, and more distillate is produced in the initial effects before

Table 6 Effect wise steam pressure for different input steam pressures in 9 + C unit. PS1 1.80 2.00 2.20 2.30 2.40 2.50 2.60 2.70 2.80 3.00 3.10 3.20 3.30 3.40 PS2 1.60 1.80 1.94 2.05 2.20 2.30 2.30 2.30 2.30 2.25 2.25 2.20 2.20 2.15 PS3 1.40 1.53 1.74 1.85 2.00 2.06 2.10 2.05 2.00 2.00 1.90 1.90 1.85 1.80 PS4 1.20 1.33 1.46 1.60 1.75 1.84 1.90 1.85 1.85 1.80 1.75 1.70 1.65 1.65 PS5 1.00 1.11 1.26 1.30 1.50 1.54 1.60 1.50 1.55 1.60 1.60 1.50 1.45 1.45 PS6 0.80 0.87 1.02 1.05 1.25 1.27 1.30 1.20 1.25 1.20 1.20 1.20 1.15 1.15 PS7 0.60 0.66 0.76 0.75 0.95 0.99 0.90 0.80 0.85 0.80 0.80 0.75 0.75 0.70 PS8 0.40 0.46 0.54 0.50 0.60 0.70 0.60 0.65 0.70 0.70 0.65 0.65 0.60 0.60 PS9 0.20 0.23 0.28 0.30 0.30 0.39 0.30 0.40 0.40 0.35 0.35 0.35 0.30 0.30 PSC 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10

Table 7 Effect wise steam temperature for different input steam pressures in 9 + C unit. PS1 TS1 (barg) (C) 1.80 2.00 2.20 2.30 2.40 2.50 2.60 2.70 2.80 3.00 3.10 3.20 3.30 3.40 132.0 134.1 136.0 137.0 138.0 139.3 141.0 141.0 142.0 144.0 145.0 146.0 147.0 148.0 TS2 (C) 129.0 131.4 133.4 134.5 135.5 137.0 138.0 138.0 138.0 138.0 137.0 137.0 137.0 136.0 TS3 (C) 126.0 128.4 130.6 131.5 133.0 134.6 135.0 135.0 135.0 135.0 133.0 134.0 134.0 133.0 TS4 (C) 123.0 125.4 127.6 128.5 130.0 131.7 132.0 132.0 132.0 131.0 130.0 130.0 129.0 130.0 TS5 (C) 120.0 122.0 124.6 124.5 127.0 128.3 129.0 129.0 128.0 127.0 127.0 127.0 126.0 126.0 TS6 (C) 116.0 118.3 120.4 120.5 124.0 124.3 125.0 125.0 124.0 123.0 123.0 123.0 123.0 122.0 TS7 (C) 112.0 114.3 116.0 116.5 119.0 120.3 120.0 120.0 120.0 119.0 118.0 119.0 119.0 118.0 TS8 (C) 108.0 110.1 111.4 112.0 114.0 115.4 115.0 114.0 115.0 115.0 113.0 114.0 114.0 113.0 TS9 (C) 104.0 105.7 106.6 107.0 108.0 109.0 109.0 108.0 109.0 109.0 107.0 108.0 107.0 107.0 TS(C) (C) 100.0 100.4 100.8 101.0 100.5 100.9 101.0 101.0 101.0 100.0 101.0 100.8 100.0 100.0

34

P.K. Sen et al. / Desalination 279 (2011) 2737

Normalized trend of pressure for different primary steam pressures in (9+C) unit
1.5

Normalized pressure with Poptimum = 2.5 bar_g

1.4 1.3 1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 1 2 3 4 5 6 7 8

Pi= 1.8 bar_g Pi= 2 bar_g Pi= 2.3 bar_g Pi= 2.5 bar_g Pi= 2.8 bar_g Pi= 3 bar_g Pi= 3.2 bar_g Pi= 3.4 bar_g Poly. (Pi= 1.8 bar_g) Poly. (Pi= 2 bar_g) Poly. (Pi= 2.3 bar_g) Poly. (Pi= 2.5 bar_g) Poly. (Pi= 2.8 bar_g) Poly. (Pi= 3 bar_g) Poly. (Pi= 3.2 bar_g) Poly. (Pi= 3.4 bar_g)

10

Effect Number
Fig. 6. Effect wise steam pressure prole for different input steam pressures in 9 + C unit.

reaching the last effect. More distillate produced in the initial effects has a multiplying effect in the subsequent effects. All other things being the same, this feature gives greater output for the cumulative distillate. The temperature distribution shown in Fig. 6 also shows similar behaviour, and the temperature at each effect is generally the highest for 2.5 barg inlet (optimal) pressure, as compared to other inlet pressures.

7. Performance of 9 + C unit in terms of primary energy If steam condensed in the 1st effect is considered as energy input for the unit, the 9 + C unit gives the best result with 2.5 bar gauge input primary steam pressure. However it should also be tested in terms of total energy or diesel consumed. Table 8 represents the cumulative distillate produced and diesel consumed for all tested input steam pressures. The data reects that at

the optimum pressure 2.5 barg, the rate of distillate produced per unit diesel consumed is maximum as 38.8 kg. Fig. 8 shows a graphical representation of tabulated data and it can be easily seen that for an optimum pressure of 2.5 barg, the unit gives the best performance. In the graph, the cumulative distillate produced keeps on increasing to its maximum value of 167 kg/h as the primary steam pressure reaches a level of 2.5 bar gauge and as the pressure increases beyond it, cumulative distillate produced keeps on reducing. The corresponding diesel consumption rate varies almost linearly. To maintain a primary steam pressure of 2.5 bar gauge almost 4.3 kg or litres of diesel is required per hour. It is clear that for the steam pressure of 2.5 bar gauge the unit gives a maximum output in terms of distillate produced as well maximum production per unit of diesel consumed. Beyond this pressure, the diesel consumption rate increases while the distillate produced decreases. Below this pressure also, the diesel consumption rate decreases a bit and distillate production also decreases signicantly.

Normalized trend of temperature for different primary steam pressures in (9+C) unit
1.10

Normalized temperature toptimum = 139.3OC

1.05 1.00 0.95 0.90 0.85 0.80 0.75 0.70 0.65 1 2 3 4 5 6 7 8

Pi= 1.8 bar_g Pi= 2 bar_g Pi= 2.3 bar_g Pi= 2.5 bar_g Pi= 2.8 bar_g Pi= 3 bar_g Pi= 3.2 bar_g Pi= 3.4 bar_g Poly. (Pi= 1.8 bar_g) Poly. (Pi= 2 bar_g) Poly. (Pi= 2.3 bar_g) Poly. (Pi= 2.5 bar_g) Poly. (Pi= 2.8 bar_g) Poly. (Pi= 3 bar_g) Poly. (Pi= 3.2 bar_g) Poly. (Pi= 3.4 bar_g)

10

Effect Number
Fig. 7. Effect wise steam temperature for different input steam pressures in 9 + C unit.

P.K. Sen et al. / Desalination 279 (2011) 2737 Table 8 Cumulative distillate produced per unit of diesel for tested pressures. Input steam pressure (barg) 1.8 2.0 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.0 3.1 3.2 3.3 3.4 Cumulative distillate (kg/h) 132 144 148 155 156 167 162 158 155 153 148 146 140 135 Diesel consumption (kg/h) 3.6 3.8 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.8 4.9 5.0 5.1 5.2 Cumulative distillate per unit diesel consumed (kg) 36.7 37.9 37.0 37.8 37.1 38.8 36.8 35.1 33.7 31.9 30.2 29.2 27.5 26.0

35

7.2. Performance of the 3 + C unit For investigation of the 3 + C unit, the rst six effects, were isolated, and input steam was given to the 7th effect of the erstwhile 9 + C unit, which now actually works as the 1st effect of the 3 + C unit. The unit was operated with 11 different input steam pressures ranging from 1.2 barg to 2.2 barg. Data were recorded in the same fashion and similar six plots were prepared for analysis. All the proles show similar trends as these for the 9 + C and 6 + C units, except for changes in corresponding optimal values. Hence the underlying basic physical phenomenon is the same as for the 9 + C and 6 + C units. For different tested pressures, the unit produced 78 to 91 kg/h of total distillate. The 3 + C unit gives an optimum yield at 1.6 barg input pressure as 91 kg/h total distillate. Effect wise pressure and temperature give best proles for the optimum pressure which is 1.6 barg in this case. Maximum OHTC was found to be around 6500 W/m2 C which is less in comparison with the maximum OHTC found for the case of the 9 + C unit and the 6 + C unit. However the maximum value was again found at the optimum pressure. 8. Comparison of the three systems 9 + C, 6 + C and + C For the comparison of all the three systems together, distillate produced per unit of diesel consumed for all input steam test pressures was calculated. This is given in Table 9. A common graph representing all the data points was prepared and shown in Fig. 9. 9. Scaling and corrosion Deposition of scales on the evaporator surface would result in lowering of OHTC. No deposits are expected on the tube side which essentially is in contact with condensing steam. Calcium and Magnesium salts if present in the input water could form scales on the shell side under the high temperature operational regime. This can be avoided by pre-treating the input feed water, either using a soda lime process, or by use of nano ltration. The latter can remove hardness by 70%, and further experiments in this area are underway. However, a nano-ltration unit will increase costs for rural applications. Therefore a soda lime process should be ideal. Under the current studies the TDS was low, about 200 ppm, and within the time frame over which the tests were conducted, there was no scaling. Our

A close observation of Fig. 7 shows that for a range of input primary steam pressure (1.8 barg to 2.6 barg), there is no signicant difference in distillate production per unit of diesel consumed. Distillate production, per hour, for unit diesel consumed varies by only about 2 kg/h rate. This shows the robustness of the unit. 7.1. Performance of the 6 + C unit For investigation of the 6 + C unit, the rst three effects were isolated and input steam was given to the 4th effect of the erstwhile 9 + C unit, which now actually works as the 1st effect of the 6 + C unit. The unit was operated with 13 different input steam pressures ranging from 1.4 barg to 2. barg. Data were recorded in the same fashion and similar six plots were prepared for analysis. All the proles show similar trends as those for the 9 + C unit, except for changes in corresponding optimal values. Hence the underlying basic physical phenomenon is the same as for the 9 + C unit. For different tested pressures, the unit produced 102 to 121 kg/ h of total distillate. The unit gives an optimum yield, at 2 barg input steam pressure, as 121 kg/h of distillate. Maximum OHTC was found to be around 15,000 W/m2 C which is less in comparison with the maximum OHTC found for the case of the 9 + C unit. Maximum OHTC was again found at the optimum pressure.

Distillate produced v/s diesel consumption for different primary steam pressure
180 5.2 5.0 4.8 4.6 4.4 80 60 40 20 0 2.0 2.3 2.7 1.8 1.9 2.1 2.2 2.4 2.5 2.6 2.8 2.9 3.0 3.1 3.2 3.3 3.4 4.2 4.0 3.8 3.6

Distillate produced (Kg/hr)

160 140 120 100

Primary steam pressure (bar gauge)

Distillate produced at different primary steam pressure Cumulative distillate produced per unit diesel consumption Diesel consumed for maintaining different primary steam pressure Poly. (Distillate produced at different primary steam pressure)

Fig. 8. Distillate v/s diesel consumption for different primary steam pressure.

Diesel consumed (kg/hr)

36 Table 9 Distillate produced per hour for unit diesel consumption. Input pressure (9 + C) (barg) 1.8 2.0 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.0 3.1 3.2 3.3 3.4 Distillate per unit diesel (9+ C) in kg/h 36.7 37.9 37.0 37.8 37.1 38.8 36.8 35.1 33.7 31.9 30.2 29.2 27.5 26.0 Input pressure (6 + C) (barg) 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.6 2.7 Distillate per unit diesel (6+C) in kg/h 31.0 31.2 31.3 31.4 31.5 31.6 31.8 30.2 28.8 27.6 26.3 24.7 23.5

P.K. Sen et al. / Desalination 279 (2011) 2737

Input pressure (3 + C) (barg) 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2

Distillate per unit diesel (3+C) in kg/h 25.9 26.3 26.3 26.7 26.8 24.9 23.9 22.7 21.7 20.5 19.5

2. 3.

4.

5. experiments could solve the problems of water treatment in large parts of India, Bangladesh or elsewhere, where contaminants such as arsenic and uoride are present in ppm levels, and are health hazards even at these concentrations. The overall TDS of the raw water is relatively low in these waters. As for corrosion, whatever be the initial TDS, the tube side only contacts condensing steam. In our experiments, no corrosion as an evidence was seen either in the distilled water, or reject water, and, wall components such as aluminium ions were not eluted. Further work is in progress using stainless steel and other materials more resistant to corrosion. Also experiments are underway for periodic ushing of common-salt deposits (which are loose and powdery), when sea-water is used in the apparatus. 10. Conclusions The following conclusions can be made with the data obtained herein: 1. On increasing the input steam pressure, the quantity of distillate produced increases at a slow rate and reaches a respective maxi-

6.

mum value at the optimum pressure corresponding to each n + C unit. This trend is irrespective of the number n of the n + C effects that are operational. On further increase in the input steam pressure, beyond the optimal, the production rate starts falling more sharply. Variation in rate of distillate produced per unit rate of diesel consumed is not very high in a range of pressures just below, and just above, the optimum pressure. In the 9 + C unit this varies from 36.738.8 kg, in the respective pressure ranges 1.82.5 barg. For the 6 + C and 3 + C units this variation is respectively 31.031.8 kg, in the pressure range 1.42. barg for 6 + C, and 25.926.8 kg, in the pressure range of 1.21.6 barg for 3 + C. But these respective gures are not the only index. It must be remembered that at the respective optimal pressure values of 9 + C, 6 + C, and 3 + C units, both the cumulative distillate production and the distillate produced per unit of diesel consumed are maximized. For pressures above optimal, in either of the 9 + C, 6 + C, or 3 + C units, both the cumulative distillate production, and the distillate production per unit of diesel consumed deteriorate. While the unit gives a maximum cumulative distillate production rate on operating at optimum pressure; the system shows an acceptable level of production even at off-optimal steam pressures. For example for the 9 + C unit, the gure for cumulative distillate production varies from 132 to 167 kg/h; for 6 + C unit, it is 102 to 121 kg/h; and for 3 + C unit, it is 71 to 91 kg/h. Among the three systems tested, the 9 + C unit produces best economic results due to the fact that production keeps increasing with an increase in the number of effects and gives a maximum cumulative distillate; and, this occurs at greater energy efciency. A further increase in the number of effects may not be protable with the existing design and boiler, as rate of production and pressure of steam that are needed in the rst effect may stretch the boiler to its limit, with very high requirement of diesel consumption.

However with a higher capacity boiler number of effects may further be increased with modied design of VTEs, with augmented capacity, for handling primary steam ow at rates substantially greater than 30 kg/h. Perhaps the number of stages may be increased by two within the capacity of the existing boiler. But, it is doubtful whether the condensate will be appreciable in the last few stages.

Performance evaluation of three systems

40

Distillate per unit of diesel (kg)

35

30

25

20

15 1.0 1.2 1.6 1.8 2.2 2.4 2.6 3.2 3.4 1.4 2.0 2.8

Primary steam pressure (bar gauge)

9+C unit 6+C unit 3+C Unit Poly. (3+C Unit) Poly. (6+C unit) Poly. (9+C unit)

Fig. 9. Graph showing distillate produced per unit of diesel consumed for all cases.

3.0

3.6

P.K. Sen et al. / Desalination 279 (2011) 2737

37

List of symbols U Overall heat transfer coefcient (OHTC), W/m2 C qd Rate of condensation of steam, kg/h hfg Latent heat of vaporization, kJ/kg T Temperature difference, C P Pressure, bg P Pressure of steam in ith effect, barg T Temperature of steam in ith effect, C Qd Effect wise distillate, kg/h CQ Cumulative distillate, kg/h PS Input steam pressure, bg TS Effect wise steam temperature, bg barg Bar gauge

University, U.K., and IRD-RP02260 Science Bridge project, sponsored by RC-UK and DST India.

References
[1] E.D. Howe, Fundamentals in Water Desalination, Marcel Dekker, Inc0-8247-6200-2, 1974. [2] A. Porteous, Saline Water Distillation Processes, 1st EdLongman UK, London, 19758 150 p. [3] P.K. Sen, P.V. Sen, S.K. Vyas, Water purication by multi-effect distillation for rural drinking water supply, Proceedings of Second International (29th National) Conference on Fluid Mechanics and Fluid Power, IIT Roorkee, December 2 (2002) 982990. [4] A small-scale multiple effect water distillation system (MEWD) for rural sector, International Conference on Mechanical Engineering (ICME2007), Dhaka, December 2007, 20078, Vol. & pp. AM-57. [5] Xu. Li, Shiyong Wang, Shichang Wang, Yuxin Wang, Studies on heat-transfer lm coefcients inside a horizontal tube in falling lm evaporators, Desalination 166 (2004) 215222. [6] S.K. Vyas, (2003), A small scale multiple effect distillation (MED) system for rural drinking water supply, Ph.D. thesis, Department of Applied Mechanics, IIT, Delhi. [7] Nakra B.C., Chaudhry K.K., Instrumentation, Measurement and Analysis, 1st Ed. TMH Publication, 1995.

Acknowledgements Acknowledgement is due to Mr. Sitaram, senior technician. The work was partially funded by three sponsored projects: IRD-RP01892, sponsored by DST, IRD-RP02006, sponsored by EPSRC and Aston