Optimization of Operating Parameters of MSF Desalination Plants

Authors: Prof. Ibrahim S. Al-Mutaz and Eng. Abdullah M. Al-Namlah

Presenter: Prof. Ibrahim S. Al-Mutaz

Abstract

A dual purpose desalination plant consists mainly of three interacting systems; the steam generating
plant, the turbine-generator system and the desalination process. High temperature and high pressure
steam (500 oC and 87 atm) is often produced. Maximum power can be obtained by complete
condensation of this steam using condensing turbine. The maximum allowable temperature in
desalination plant is usually restricted (114-121 oC for acid treatment plant, 88-91 oC for additive
treatment plant). Usually backpressure turbine is used to provide suitable stream for the desalination
plant within the restricted temperature range. As this exhausted temperature increases water production
increases while the generated power is decreased significantly. Backpressure turbines give lower power
to water ratio (high water demand) and they are also characterized by high thermal efficiencies. On the
other hand, the extraction turbine is preferred for satisfying low power-to-water requirements. In Saudi
Arabia Saline Water Conversion Corporation (SWCC) large MSF plants operate using either
backpressure or extraction condensing turbine schemes.

This paper aims to study the operating parameters of the dual-purpose MSF desalination plants to find
the optimum operation of dual-purpose MSF desalination plants. This aim will be accomplished by
seeking an optimum operation of the dual-purpose MSF desalination plants. Major operating parameters
will be traced.

International Desalination Association World Congress: SP05-068 1

I. INTRODUCTION
Most of the potable water and electricity in the Arabian Gulf countries are produced by cogeneration
plants associated with seawater multi-stage flash (MSF) desalination plants. MSF desalination plants
need mainly thermal energy, which is convenient to be supplied by low- or medium-pressure steam
(sub-atmospheric or below 3 bars, respectively). MSF plants need also secondary and tertiary
mechanical energy for pumping and maintaining vacuum, which is normally supplied by electricity (and
possibly, for gas pumping, by high- or medium-pressure steam). In efficient MSF plants it is equivalent
to about 8.1 kWh (±15%) per m3[1]. The additional secondary and tertiary mechanical and electrical
energies are equivalent to 2.5-4.5 kWh per m3 for MSF plants.

The steam source for MSF desalination plants can be a dedicated or non-dedicated (co-generation) plant.
The former provides energy exclusively for the desalination process and water is the only product out of
the complex. The latter provides only part of its energy to the desalination process, and the rest of the
energy is used to generate electricity. The efficiency of the low- or medium-pressure steam is usually
measured by:
- The ratio between the amounts of water produced per unit mass of dry saturated steam supplied
to the system. This is known as the gain output ratio (GOR);
- The amount of product water in kilograms (kg) per one million Joules of low-temperature heat
supplied to the system. This is known as the performance ratio (PR).

Typical GOR values for large-scale commercial MSF plants range between 8 and 10 kg/kg with PR
between 3.5 and 4.5 kg/MJ. The GOR value of 8 is a very common figure for MSF plants operating at
top brine temperature (TBT) of approximately 91°C. As the TBT is increased GOR and PR are expected
to increase for the same plant.

The efficiency of the utilization of low-temperature heat consumption in an MSF plant depends on the
following:

- The maximum temperature reached by the brine, the top brine temperature (TBT): This depends
on the scale prevention technique, seawater salt concentration and nature of dissolved salts.
- The temperature at which excess heat is rejected from the system: This is limited by the cooling
water inlet temperature and the absolute pressure maintained in the last stage.
- The number of stages of the system: Theoretically the actual number of stages is not important in
determining the MSF efficiency. However, the number of stages determines the total heat
exchange area required. Large number of stages results in a decrease in the total heat exchange
area per stage leading to an increase in the stage efficiency. Hence a better plant performance.
The number of stages increases with increasing gain ratios, but also depends on the plant's
capacity. The capital cost is the main limiting factor in determining number of stages.
- Salt concentration in the flashing brine: Obviously, this depends on the intake seawater salt
concentration.
- Geometrical configuration of the flashing stages: This has a direct influence on non-equilibrium
losses, pressure drop losses and heat dissipation losses.
- Construction material and design configuration of the heat exchanger device inside the stages
and the heat input section: This has direct influence on heat transfer losses and efficiency.

In Saudi Arabia all Saline Water Conversion Corporation (SWCC) large MSF plants operate within the
context of dual-purpose facilities for the simultaneous production of power and water [2]. Such co-
generation arrangement uses either backpressure turbine (steam from the low-pressure end of a steam

International Desalination Association World Congress: SP05-068 2

turbine) or extraction condensing turbine (also called pass-out steam turbine). In extraction steam
turbine, steam is taken partway along a steam turbine to serve a requirement for a particular pressure, the
balance remaining in the turbine to the exhaust stage to generate more power. Co-generation cycles
which were used in SWCC MSF desalination plant till 1982 were employing extraction condensing
turbines with a power to water ratio ranging between 10.2 to 17.5 MW/migd as shown in Table 1 [2].
From 1983 onwards backpressure turbines were used in all new co-generation plants.

Backpressure turbines give lower power to water ratio (high water demand) and they are also
characterized by high thermal efficiencies. They make the best use of low-grade heat that would
otherwise be rejected by the power generating plant cycle. On the other hand, extraction turbines permit
a control on the steam that flow through the turbine to allow generation of additional power during
periods of low water demand. Between the power only output of a condensing steam turbine and the
power and steam combination of a backpressure steam turbine essentially any ratio of power to heat
output can be supplied.

TABLE 1. POWER PRODUCTION SYSTEMS FOR SAUDI MSF DESALINATION PLANTS

Extraction Condensing Turbine Commissioning (MW/migd) Back Pressure Turbine Commissioning (MW/migd)
Date Date
Jeddah II 1978 10.2 Jubail II 1983 6.8
Jeddah III 1979 15.3 Khafji-II 1986 8.1
Jeddah IV 1981 14.7 Shoaiba I 1989 6.2
Yanbu -I 1981 17.5 Shuqaiq 1989 5.9
Al-Khobar-II 1982 16.8 Al-Khobar-III 2000 9.5
Jubail I 1982 13.8 Yanbu-II 2000 3.0
Shoaiba-II 2000 6.0

II. MSF MATHEMATICAL FORMULATION

The steady-state mathematical model of the multistage flash desalination process is illustrated in Figure
1. It has been developed using the following simplification assumptions [3,4]:
- Distillate from any stage is salt free.
- Heat of mixing is negligible.
- Negligible heat losses.
- There is no entrainment of mist by the flashed vapor.
- The condensate produced in the brine heater is not subcooled.

Figure 1: Simplified Schematic Diagram of MSF Desalination Plant.

International Desalination Association World Congress: SP05-068 3

Model equations constituted of set of mass and energy balances, which are given in the following sub-
sections; stages, brine heater, splitter and mixer. Definitions of variables are given at the end.

(a) stage number j , 1≤ j ≤( NR+NJ), of the heat recovery or rejection section as shown in Figure 2.

Figure 2: Representation of j-th stage in MSF plant.

Enthalpy balance of flashing brine:

Bj-1 hBj-1 = Bj hBj + (Bj-1- Bj) hVj (1)

Overall mass balance:

Bj-1 + Dj-1 = Bj + Dj (2)

Salt mass balance:

Bj-1 CBj-1 = Bj CBj (3)

Overall enthalpy balance:

WSRj (TFj – TFj+1 ) = Dj-1 SDj-1 ( TDj-1 – T*) + Bj-1 SBj-1 ( TBj-1 – T*) +
_ Dj SDj ( TDj – T*) + Bj SBj ( TBj– T*) (4)

for heat rejection section, W is replaced by WS.

Heat transfer equation:

WSRj (TFj – TFj+1 ) = Uj Aj [(TFj – TFj+1 ) / ln((TDj - TFj+1) / (TDj - TFj))] (5)

Where Uj is the overall heat transfer coefficient at stage j. It can be given as function of the following
parameters:
Uj = Ø ( W, TFj , TFj+1 , TDj , Dij , Doj , ƒj ) (6)

Distillate and flashing brine temperature correlation:

TBj = TDj + θj + εj + ∆j (7)

where θ , εj , and ∆ are boiling point elevation at stage j, non-equilibrium allowance at stage j and
temperature loss at stage j, respectively.

Distillate and flashed steam temperatures correlation:

TSj = TDj + ∆j (8)

Stage pressure evaluation:

International Desalination Association World Congress: SP05-068 4

log10 Pc / Pj = X / TSj [(a + bX + Cx3) / (1+ dX)] (9)

where Pj is the j-th stage pressure; a = 3.2437814; b = 5.86826 × 10-3 ; c = 1,1702379 × 10-8 ; d =
2.1878462 × 10-3 ; X = Tc –TSj ; Pc = 218.167 atm ; and Tc = 647.27 K are the critical pressure and
temperature of water, respectively.

(b)Brine heater
Overall mass balance:
Bo = W (10)

Salt mass balance:

CBo = CR (11)

Overall enthalpy balance:

WSRH (TBo – TFI) = WSTEAM λS (12)
Where λS is the latent heat of steam in the brine heater.

Heat transfer equation:

WSRH (TBo–TFI) = UH AH [(TBo–TFI)/ln((TSTEAM–TFI))/(TSTEAM – TBo))] (13)

Where UH is the brine heater heat transfer coefficient. It can be given as function of the following
parameters:
UH = Ø (W, TBo, TFI, TSTEAM, DiH , DoH , ƒH ) (14)

(c) Splitters
Blowdown splitter:
BD = BN – R (16)

Make-up seawater splitter:

SW = WS – F (17)

Reject seawater splitter:

SW = S + CW (18)

(d) Mixers
- Make-up seawater/recycle brine mixer
Overall mass balance:
W= R + F (19)

Salt mass balance:

RCBN + FCF = WCR (20)

Overall enthalpy balance:

Whw = RhR + FhF (21)

- Sea water mixer, Overall mass balance:

WS = S + WT (22)

International Desalination Association World Congress: SP05-068 5

Overall enthalpy balance:
WS hWS = ShS + WT hWT (23)

III. OPTIMIZATION CASE STUDY

The design and operating data of Shoaiba-I MSF desalination plant in Saudi Arabia as shown in Table 2
were used to validate the steady state model described early [5]. Figure 3 shows the procedure used in
solving the model.

Table 2: Input Data for Shoaiba-I MSF Desalination Plant

General Information
- Type of plant: Brine recycle-cross tube
- Plant feed: Seawater, 45 g/kg, 33 oC
- Steam temperature: 100 oC
- Number of recovery stages: 16
- Number of rejection stages: 3
-Total number of stages: 19

Tube Characteristics
Out Side Tube Tube Stage Heat Fouling
Plant Section Diameter, m Length, m Width, m transfer Factor, m2
Area, m2 K/kcal
Brine Heater 0.00256 15.1 - 3096 1.86x10-4
Heat Recovery
0.00256 15.1 15.1 4805 1.40x10-4
Section
Heat Rejection
0.00260 15.0 15.0 3096 2.33x10-5
Section
Flow Rates
Seawater feed, WT: 9313200 kg/h
Rejected seawater flow rate, CW: 6616800 kg/h
Reject seawater recycle, S: 0
Recycle stream, R: 8913600 kg/h

Shoaiba phase one power and desalination plant was commissioned on 1988 by Hanjung; a partnership
between Bechtel and Doosan with a production rate 40 mgd of distillate water and 325 MW of electric
power. Five boilers and five turbine generator units with associated equipment were used to generate the
required power. The power station is composed of five adjacent and essentially independent power plant
units. Each of five steam turbine generators is connected with a boiler to form a power station. Two
desalination units are connected to each steam generator on the exhaust steam side. The steam turbine
generators with all their auxiliaries are installed in turbine halls, longitudinally in services.

The simulated results for Shoaiba-I MSF desalination plant are given in Table 3. The obtained results
were in good agreement with the actual plant data [5]. The estimated performance ratio of the plant
(GOR) was about 8.34.

International Desalination Association World Congress: SP05-068 6

 * given :
WT, CW, S, R, TSTEAM, TSEA, CF. 1
* knowing: P1.
*Calculate :TS.

*use equ(20) to calculate hf

* initial guess Cbc .

* initial guess TF * rejection

* for 1st stage calculations section
calculations
* use equ(8) to calculate TD . * use equ(25) calculate hf

No
* initial guess TBO * hf equ(20) =hf
equ(25) ?

* initial guess TB Yes

No
* Repeat for all stages in the
* TB satisfy equ(7)?
rejection section

Yes
* initial guess TF1

No
* Cbc satisfy
No equ(19)?
* TF1 satisfy
equ(13)?
Yes

Yes
* mathematical model
* initial guess TF2
is satisfies
No
* TF2 satisfy
equ(13)?
* Calculate GOR

Yes
No
* TBo satisfy equ(4)?

Yes

* use equ(12) to calculate, Wsteam.

*use equ(2) to calculate D

* Repeat for all stages in the

recovery section

1 Figure 3: Solution Sequences of Model Equations

International Desalination Association World Congress: SP05-068 7

 Table 3: Simulation Results for Shoaiba-I MSF Desalination Plant

Flow rates and Concentrations

Blow down (BD) = 1714582.80 kg/h
Steam (Wsteam) = 117360.30 kg/h

Recovery Section
Stage B D Cb TB TD TF
1 11552404.0 54864 0.063357 87.19 86.51 84.32
2 11497540.0 109728 0.063659 84.58 83.45 81.44
3 11442676.0 164592 0.063964 81.95 80.81 78.72
4 11387812.0 219456 0.064272 79.29 78.15 76.00
5 11332948.0 274320 0.064584 76.61 75.46 73.25
6 11278084.0 329184 0.064898 73.91 72.75 70.49
7 11223220.0 384048 0.065215 71.19 70.01 67.71
8 11168356.0 438912 0.065535 68.45 67.25 64.91
9 11113492.0 493776 0.065859 65.68 64.47 62.09
10 11058628.0 548640 0.066185 62.89 61.65 59.25
11 11003764.0 603504 0.066515 60.08 58.81 56.39
12 10948900.0 658368 0.066848 57.24 55.94 53.51
13 10894036.0 713232 0.067185 54.38 53.04 50.61
14 10839172.0 768096 0.067525 51.50 50.11 47.69
15 10784308.0 822960 0.067868 48.59 47.15 44.75
16 10729444.0 877824 0.068215 45.66 44.15 41.79

Rejection Section
Stage B D Cb TB TD TF
17 10695640.0 911628.00 0.067485 43.84 42.31 40.10
18 10661836.0 945432.00 0.067698 42.01 40.43 37.82
19 10628032.0 979236.00 0.067914 40.17 38.54 35.53

Figures 4 and 5 show the flow rate trends and the temperature profile along the MSF stages. Also the
developed steady state model was used to study the operating parameters of the dual-purpose MSF
desalination plants to trace their effect on the operation of the plant. The following operating parameters
were allowed to change and the obtained GOR values were reordered:
- intake seawater temperature
- intake seawater flow rate
- steam temperature
- rejected brine flow rate
- recycle brine flow rate

for constant production rate and fixed rejected brine salinity and temperate of 70,000 ppm and 40 oC,
respectively. This is done to simulate actual plant location and co-up with the environmental constrains
[6]. Top brine temperature (TBT) has a pronounce effect on the distillate production which was kept

International Desalination Association World Congress: SP05-068 8

constant. So TBT was unchanged. The maximum permissible value of TBT is practically determined by
the type of scale inhibitor added to the intake seawater.

11600000 1000000 90

11400000 800000 80

Flashing Brine
11200000 600000 70
Flashing Brine, Kg/h

Temperture, oC
Distillate, Kg/h
11000000 400000 60

flashing brine
distillate
coolant

10800000 200000 50

Distillate

10600000 0
40

0 4 8 12 16
0 4 8 12 16
Number of Stages Number of Stages

Figure 4: Flow rates of flashing brine and distillate Figure 5: Temperature profile along the MSF
along the MSF stages stages

Intake seawater temperature had minor effect on the plant performance. It was allowed to change from
the current value of 33 oC to 15 oC to reflect the winter situation. Almost no changes in GOR were
found. This is in agreement with other findings [4]. Figures 6-9 show the effect of the other operating
parameters on the plant performance (GOR), mainly seawater feed flow rate, steam temperature,
rejected brine flow rate and recycle brine flow rate.

Seawater feed flow rate governs velocities in the heat rejection section and affect the heat transfer. An
increase in the seawater feed flow rate would basically decrease the GOR as shown in figure 6.
Increasing the steam temperature yield an increase in the steam flow rate [3]. If the production rate was
kept constant then a decrease in the GOR would be expected as shown in figure 7.

The increase in the rejected brine flow rate reduces the amount of makeup or feed seawater flow rate [7].
This in turn reduces the brine level in the last stage and would improve the flashing efficiency. As a
result GOR increasing as illustrated in figure 8. On the other hand, brine recirculation flow affects the
brine levels in each flashing chamber and the steam consumption at fixed top brine temperature [8]. The
higher the recycle brine flow rate the shorter the resident time and the higher the brine level in the stages
which turn to give lower flashing efficiencies; i.e. lower distillate production which yields lower GOR
as shown in figure 9.

International Desalination Association World Congress: SP05-068 9

 9.2 8.4

8.36

8.8

8.32
GOR

GOR
8.4 8.28

8.24

8.2

7.6 8.16
7000000 8000000 9000000 10000000 11000000 92 96 100 104 108 112
Seawater Feed, Kg/h Steam Temperture, oC

Figure 6: Plot of GOR vs. Seawater Feed Flow Rate. Figure 7: Plot of GOR vs. Steam Temperature.

8.8 9

8.8

8.6

8.6
GOR
GOR

8.4 8.4

8.2

8.2

8 7.8

5600000 6000000 6400000 6800000 7200000 7600000 8000000 7000000 8000000 9000000 10000000 11000000
Recyle Stream, Kg/h
Rejected Flowrate, Kg/h

Figure 8: Plot of GOR vs. Rejected Brine Flow Rate. Figure 9: Plot of GOR vs. Recycle Stream Flow Rate.

International Desalination Association World Congress: SP05-068 10

IV. CONCLUSIONS

Optimum operation of the dual-purpose MSF desalination plants depends on the well understanding of
the variation of the major operating parameters of the plant. Steady sate modeling of MSF desalination
plant reveals that seawater feed flow rate, steam temperature, rejected brine flow rate and recycle brine
flow rate are among the major plant parameters whose effect on the plant performance should be traced.
For realistic situation constant production rate and fixed rejected brine salinity and temperate were used
in this study. The optimum values of the operating parameters can be found at higher plant performance.
Detailed discussions of the effect of each parameter on the plant performance were given. This insight
for sure will help operators to seek the optimum operation of the plant.

List of symbols
AH Heat transfer area of the brine heater
Aj Heat transfer area of stage j
BD Blowdown mass flow rate
Bj Flashing brine mass flow rate leaving stage j
Bo Flashing brine mass flow rate leaving the brine heater
CBj Salt concentration in the flashing brine leaving stage j
CBo Salt concentration in the flashing brine leaving the brine heater
CF Feed seawater salt concentration
CR Salt concentration in the cooling brine to the recovery section
CW Rejected seawater mass flow rate
D iH Internal diameter of brine heater tubes
D oH External diameter of brine heater tubes
Dj Distillate flow rate leaving stage j
D ij Internal diameter of tubes at stage j
D oj External diameter of tubes at stage j
F Make-up seawater mass flow rate
ƒH Brine heater fouling factor
ƒj Fouling factor at stage j
h Specific enthalpy
hBj Specific enthalpy of flashing brine at stage j
hVj Specific enthalpy of flashing vapor at stage j
Hj Height of brine pool at stage j
LH Length of brine heater tubes
Lj Length of tubes at stage j
N Total number of stages, N=NR+NJ
NJ Number of stages in the heat rejection section
NR Number of stages in the heat recovery section
Pj Pressure at stage j
Pc Critical pressure
R Recycle stream mass flow rate
Ro Brine density
S Reject seawater recycle mass flow rate
SBj Heat capacity of flashing brine leaving stage j
Sd Heat capacity of pure water
SDj Heat capacity of distillate leaving stage j
SRH Heat capacity of brine in the brine heater
SRj Heat capacity of cooling brine leaving stage j
SW Mass flow rate to the reject seawater splitter

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T Temperature
TB Boiling temperature of pure water
TBo Temperature of flashing brine leaving the brine heater
TBj Temperature of flashing brine leaving stage j
TDj Temperature of distillate leaving stage j
TFj Temperature of cooling brine leaving stage j
TSj Temperature of flashed vapor at stage j
TSEA Seawater temperature
TSTEAM Steam temperature
TW Temperature of the cooling brine to the heat recovery section
TWS Temperature of seawater to the heat rejection section
UH Overall heat transfer coefficient at the brine heater
Uj Overall heat transfer coefficient at stage j
Vj Flashed vapor mass flow rate at stage j
W Cooling brine mass flow rate to the heat recovery section
wj Width of stage j
WS Seawater mass flow rate to the heat rejection section
WSTEAM Steam mass flow rate
WT Seawater mass flow rate

Greek letters Subscripts and superscripts

∆j Temperature loss at stage j H Brine heater
εj Non-equilibrium allowance at stage j j Stage index
θj Boiling point elevation at stage j * Reference value
λS Latent heat of steam to the brine heater

REFERENCES
1 I. S. Al-Mutaz, “Energy Conservation in Seawater Desalination Plants”, the First Saudi
Symposium on Energy, Utilization and Conservation, King Abdulaziz University, Jeddah, Saudi
Arabia, March 4-7, 1990.
2 O. A. Hamed et.al, “SWCC MSF Desalination Plants - Current Status and Future Prospects”, 3rd
Acquired Experience Symposium, Saline Water Conversion Corporation, Al-Jubail, Saudi
Arabia, 4-6 Feb. 2002.
3 M. Rosso et al, “Modeling Multistage Flash Desalination Plants”, Second Annual Meeting of the
European Desalination Society (EDS) on Desalination and the Environment, Genoa, Italy,
October 20–23, 1996.
4 M. Morbidelli et al, “Dynamic Modeling of Multistage Flash Desalination Plants”, Desalination
127, 207-218, 2000.
5 M. A. Al-Osaimi, “Simulation of MSF Desalination Plant: Shoaiba Phase One and Phase Two”,
Master Thesis, Department of Mechanical Engineering, University of Glasgow, Scotland,
September 1997.
6 I. S. Al-Mutaz and A. M. Al-Namlah, “Characteristics of Dual Purpose MSF Desalination
Plants”, Desalination 166, 287-294, 2004.
7 I. Alatigi et al, “Measurements of Dynamic Behavior of a Multistage Flash Water Desalination
System”, Desalination 160, 233-251, 2004.
8 A. Ismail, “Control of Multi-Stage Flash Desalination Plants: A survey”, Desalination, 116, 145-
155, 1998.

International Desalination Association World Congress: SP05-068 12