Desalination 250 (2010) 729–733

Contents lists available at ScienceDirect

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

Design and optimization of seawater reverse osmosis desalination plants using

special simulation software☆
Marcus Verhuelsdonk, Tony Attenborough, Oliver Lex, Thomas Altmann ⁎
ILF Consulting Engineers, Werner-Eckert-Str.7, 81829 München, Germany

a r t i c l e i n f o a b s t r a c t

Article history: This paper introduces the Integrated process simulation environment (IPSEpro™) software, and its application
Accepted 5 November 2008 to reverse osmosis desalination.
Available online 20 October 2009 The paper introduces the reader to the basic modeling concepts, and how individual process units can be simply
simulated with a graphical, flowsheet style interface.
Keywords: The paper then goes on to describe an example simulation for off design of an integrated pump, membrane rack
Reverse osmosis
and isobaric energy recovery device, investigating the effects of changing water quality, membrane condition
Simulation
Membrane model
and also, the influence of isobaric energy recovery device overflush.
Isobaric energy recovery © 2009 Elsevier B.V. All rights reserved.

1. Introduction 2. Individual components

For effective optimization of the design of seawater desalination
systems using the reverse osmosis process, it is important to consider
the operation of the system not only at the design condition, but at
varying conditions different from the design condition (off design).
For example, a membrane system must be designed to be able to
produce the required quantity of water with the worst combination of
cold water, high salinity and aged/fouled membranes. However, for
much of the time, this system will be operating at a condition very
different from the design condition. In fact, there is a strong possibility
that the design condition will never occur, especially if the speci-
fication has been written to allow for potential deterioration in sea-
water quality over the life of the project.
It is already possible to perform this type of simulation, by making
use of the membrane projection software provided by the membrane
manufacturer, curves from the pump supplier and valve supplier, and
the simulation programs from isobaric energy recovery device sup-
pliers. However, the procedure is somewhat cumbersome, iterative
and time consuming, so that typically, only a limited number of
conditions are considered.
This paper describes the IPSE software by SimTech Simulation
Technology, which enables all of the relevant process units to be
incorporated into a single simulation environment, thereby allowing
rapid and simple simulation.
☆ Presented at the Conference on Membranes in Drinking and Industrial Water
Production, 20–24 October 2008, Toulouse, France.
⁎ Corresponding author. Tel.: +49 89 255 594 400.
E-mail address: thomas.altmann@ilf.com (T. Altmann).
The IPSE (integrated process simulation environment) software
suite enables the user to define simulation equations for different
process modules, and to connect those modules using a graphical
interface.
The software is open ended, which means that the developer can
define any equations he likes to sit behind any particular graphical
symbol.
ILF has been developing modules appropriate to the desalination
processes, including reverse osmosis.
The philosophy behind developing desalination modules in the
IPSE software is to allow simulation of different components in one
simulation environment, thereby not having to transfer data from one
simulation tool to another.
In the following section, some of the most important modules with
respect to an RO system are described.
2.1. Pumps
Pump performance can be simply simulated in IPSE by entering the
pump data into a look-up table. Fig. 1 displays an example look-up
table for a variable speed, RO high pressure feed pump (HPP), based
on Sulzer pump selection tool [1].
The pump curve data sits behind the graphical symbol for a pump
and IPSE uses a bicubic spline to interpolate operating points between
the points entered in the data table.
One of the greatest benefits of the IPSE software is that the user can
decide which parameters should be fixed, and which should be
calculated. For example, in the case of a pump, the user may decide to
define the differential pressure across the pump and the flowrate, and

0011-9164/$ – see front matter © 2009 Elsevier B.V. All rights reserved.
doi:10.1016/j.desal.2008.11.031
730 M. Verhuelsdonk et al. / Desalination 250 (2010) 729–733
Fig. 1. IPSE table — pump height as function of flow and speed.
the program automatically calculates the pump speed. Alternatively,
the user can simply select to fix the speed instead of the flowrate, and
IPSE automatically calculates the pump flowrate for the selected
differential pressure and speed. In addition to calculating the pump
duty point, the pump hydraulic power is calculated, which is then
used by the motor model. Within the motor model, the motor effi-
ciency is defined in a similar look-up table to the pump curve, taking
into account the fact that motor efficiency improves with increasing
motor size. For variable speed pumps, the inverter efficiency is also
input. Thus IPSE automatically calculates the absorbed power
consumption of the pump, taking into account the hydraulic
efficiency, the motor efficiency and the inverter efficiency.
In Fig. 2 below, the flow and pressure drop are set, and the speed is
calculated. To set the speed instead of the flowrate, the user simply
selects the “estimate” button for flow, the “set” button for speed, and
types in the required speed.
Fig. 2. IPSE flowsheet with user interface.
2.2. Control valve
Control valves can be simply simulated in IPSE by entering the
valve Kv against the position data into a look-up table, similar to the
pump look-up tables.
Once the valve data is available, the pump and valve can simply be
connected using the graphical interface. With this arrangement, the
user can define the required flowrate, pump speed and pressure
downstream of the control valve, and IPSE automatically calculates
the valve position. Alternatively, the user can define the pump speed,
downstream pressure and valve position, and the software automat-
ically calculates the flowrate. This facility enables the user to quickly
evaluate the effect of a particular change in valve position on flowrate.
This is a particularly useful facility in evaluating the controllability of a
process with a particular valve.
2.3. Membrane model
It has already been shown above how relatively simple process
modules can be simulated. However, it is also possible to simulate far
more complex process modules, using far more detailed sets of
equations. One example of such a module is the membrane module.
The membrane module represents a single RO membrane element,
and is modeled based on the solution diffusion model. The model
constants can be calibrated against membrane performance projec-
tions from membrane vendor software.
Because IPSE models a single membrane element, it is possible to
combine the elements into any particular process design configura-
tion. In the example below, it can be seen how a typical 7 element
pressure vessel can be represented (Fig. 3). However, it is also simple
to represent a 2 stage system or a split permeate arrangement. In
addition, it is possible to mix different membrane element types in a
single pressure vessel, and even to mix elements from different
membrane manufacturers.
The table below compares the results of the IPSE simulation with
the output from the Hydranautics IMSDesign projection software [2]
for a 7 element system using SWC4+ membrane elements to treat
seawater. Table 1 shows excellent agreement between the two.
The IPSE membrane simulation can be used in the same manner as
the membrane vendor projection software. In other words, the total
permeate flow and recovery can be defined, and IPSE automatically
calculates the required feed pressure. However, there are other
interesting possibilities opened up by IPSE. For example, the recovery
and lead element flux can be fixed, and the maximum permeate flow
for a particular lead element flux is automatically calculated. Alterna-
tively, the feed pressure, recovery and permeate flow can be fixed, and
IPSE automatically calculates the number of pressure vessels.
2.4. Combined pump and membrane model
It has already been shown above that we can fix membrane
recovery and feed pressure to calculate permeate flowrate, and that
for the pump, we can fix speed and pressure to calculate flow. By
combining these two units, we can simply combine the membrane
Fig. 3. RO vessel flowsheet with 7 elements.
 M. Verhuelsdonk et al. / Desalination 250 (2010) 729–733 731

Table 1 rate of high pressure seawater, so some of the feed is used to flush the
Comparison IPSEpro vs. IMSDesign. mixed water into the brine stream. Overflush is defined as
Feed Permeate

IPSE IMSDesign FeedIN  FeedOUT

Overflush½% = 100⋅ :
mg/l mg/l mg/l FeedIN
Ca2+ 445.3 0.76 0.75
Mg2+ 1387.3 2.36 2.35
If overflush is negative, then the high pressure concentrate is
Na+ 11651.2 94.67 94.64
K+ 431.3 4.37 4.38
flushed out into the high pressure feed.
HCO− 3 121.6 1.59 1.60 The benefit of positive overflush is that it reduces the membrane
SO2−
4 2931.6 5.39 5.39 feed salinity. However, the downside is that it increases the feedwater
−
Cl 20913.9 153.13 153.06 requirement, which means that either the membrane recovery must
TDS 37905 263.75 263.70
be increased, or the size of the pre-treatment system must be
increased.
Fig. 5 shows the relationship between mixing and overflush for an
ERI PX220 isobaric energy recovery device (ERD) based on ERI simu-
and pump models. Since the pump flow must be equal to the mem- lation software [4].
brane feed flow, we can fix the membrane recovery and the pump Within IPSE, the user can define the high pressure brine flow,
speed, and IPSE will automatically calculate the membrane feed flow, pressure and quality as well as the feed seawater pressure and quality
pressure and permeate flow. This is a very useful facility which allows to the ERD and the overflush, and it automatically calculates the high
the user to investigate the possibility of increasing the permeate pressure feed and reject brine flowrate, quality and pressure, as well
production when the seawater and membrane conditions are more as the feed seawater flowrate. Alternatively, it is possible to fix the
favourable than the worst case design assumption. Since the software brine discharge pressure instead of the percent overflush, which
also displays the results for individual element flux and recovery, it is enables the user to evaluate the effect of changes in the brine discharge
simple to check that design guideline values are not contravened in system or brine control valve on overall system performance.
these circumstances. The design guideline values can be input in the
simulation platform so that the software comes up with a warning if 2.6. Integrated pump, membrane and energy recovery device
one of the limits is exceeded. This way it is ensured, that during
system optimization, the operating point is always feasible. Using the components described above, it is possible to simulate
the overall pump, membrane and ERD system, as indicated in Fig. 6.
2.5. Isobaric energy recovery devices In this case, only the seawater conditions, the geometrical param-
eters, the product flow and overall recovery are set. The feed pressure,
A particularly useful aspect of the software system is that it is motor power and product quality are all calculated automatically.
possible to integrate an isobaric energy recovery device into the Thus the effect of parameter changes on system performance can be
process simulation. This is especially useful, since the mixing which calculated very simply and quickly.
occurs in the isobaric device affects the feedwater quality to the
membrane, and therefore the performance of the membrane system 3. Case study
and the energy recovery system are not independent. This means that
with conventional simulation using the isobaric equipment supplier's The features and benefits of the IPSE software can be better
simulation software, it is necessary to manually iterate between this appreciated using a case study. In this study, the performance of the
software and the membrane projection software. system at different operating conditions is evaluated, and then the
An isobaric device is simulated as indicated in Fig. 4 below. The key influence of overflush on system performance. The parameters for this
parameters which must be calculated are the mixing flowrate, the study are indicated in Table 2.
leakage and both the low pressure and high pressure drops. A detailed Two different seawater conditions are simulated, representing the
mathematical description has been done by Sanchez et al. [3]. extremes of the expected operating range. These are cold, high salinity
Mixing is defined as the salinity S increase from the low pressure conditions with 20 °C and 41,891 mg/l salinity and warm, low salinity
to the high pressure feed side, caused by a contact between the two conditions with 35 °C and 37,903 mg/l salinity. Both of these con-
streams. ditions have been simulated with new membranes and with five years
old membranes, since aging affects the membrane salt passage and
SFEED;OUT  SFEED;IN permeability.
Mixing½% = 100⋅
SBRINE;IN  SFEED;IN

Mixing can be reduced by the use of overflush. With overflush, the

flowrate of feedwater to the isobaric device is greater than the flow-

Fig. 4. Isobaric device displaying mixing, overflush and leakage. Fig. 5. Correlation: overflush–mixing.
732 M. Verhuelsdonk et al. / Desalination 250 (2010) 729–733

Fig. 6. Complete IPSE flowsheet.

3.1. System performance at different conditions 3.2. Overflush analysis

The system is evaluated at each condition with either a flow As already discussed above, the software allows the designer to
control valve, or with a variable speed high pressure pump. investigate system optimization possibilities which would be very
In each case, the user defines the feedwater quality, pressure and difficult to investigate with conventional simulation tools. One exam-
flowrate, the permeate flowrate and pressure, the number of pressure ple of this is to investigate the impact of varying the overflush rate
vessels, number of PX220 units and the overflush ratio (set to 0%). on the specific energy consumption.
In the case of the variable speed pump, the control valve position is In order to evaluate the impact of varying overflush, the net
set to 100%. In the case of the control valve, the pump speed is fixed at seawater feed flow and the permeate flow are fixed, so that there is no
60 Hz (with 100% inverter efficiency, since there is no inverter), and impact on the size of the pre-treatment system. As the overflush is
IPSE automatically calculates the control valve position, the mem- increased, less feedwater is available to feed the membranes, and it is
brane feed pressure, the ERD feed pressure, the booster pump speed, therefore necessary to increase the membrane recovery (automati-
the brine reject pressure and the permeate quality. In addition, the cally calculated by IPSE). Therefore, there is an increase in membrane
specific energy demand considering the feed pump and the booster feed pressure, which is contrary to the reduction in membrane feed
pump is calculated. The results are presented in Table 3 below. pressure resulting from the lower mixing, and lower membrane feed
It is interesting to see, that in worst case with low temperature and salinity.
high salinity, the power demand with a VFD is higher than with a Table 4 displays the overflush effect on flow and salinity with
control valve. This effect is caused by the 97% VFD efficiency. 20 °C, high salinity and new membranes. It can be seen, that the
From Table 3, the designer can very quickly appreciate the overflush has virtually no effect on the permeate salinity.
required operating range of the pumps and valves. This procedure Without overflush, the recovery is 40.13% (this value is slightly
could also be used with a seasonal seawater quality profile, which higher than the design system recovery of 40% because the water
would then allow the economic benefit of using a variable speed high property functions in IPSE also calculate the impact of water com-
pressure pump to be evaluated. pressibility on density, so the volumetric feed flow at membrane feed
pressure is less than the equivalent volumetric flow for the same mass
of water at ambient pressure).
Table 2 If the overflush is increased to 5%, the feed flow at the ERD
SWRO train details.
decreases to about 16,848 m³/d, and to achieve the required product
Permeate production 12,000 m³/d flow of 12,000 m³/d, the membrane recovery must be increased to
Overall recovery (permeate to overall seawater feed) 40% 41.35%.
Membrane element type Hydranautics SWC4+
This optimization is performed both with a variable speed high
Number of elements/vessel 7
Number of pressure vessels 154 pressure pump and with a control valve. The results of this opti-
Seawater feed pressure 2.0 bar mization using a variable speed pump are shown in Fig. 7 below, and
the results with a control valve are shown in Fig. 8 below.
Fig. 7 shows that using a VFD, there is a minimum energy demand
at about −3% overflush. This effect is caused since the booster
pump needs less power with more overflush because of a decreasing
Table 3
Performance depending on feed temperature and salinity. flowrate, whereas the high pressure pump needs more power. With
increasing overflush, membrane recovery and feed pressure increase.
Temperature °C 35 20
However, the variation in specific energy consumption with overflush
Feed TDS mg/l 37903 41891 is very small, and is much less significant than the variations in
Membrane age years 0 5 0 5

Valve position (open) % 28.38 30.13 31.67 51.38

HPP power (Valve) kWh 1153 1153 1160 1161 Table 4
HPP power (VFD) kWh 945 1012 1068 1186 Overflush effect on performance.
Membrane pressure bar 53.58 57.32 60.64 67.08
HP brine pressure bar 52.32 56.03 59.35 65.77 Overflush [%] − 5.0 0.0 5.0
LP brine pressure bar 1.23 1.23 1.23 1.23 Mixing [%] 7.1 6.0 4.8
Booster pump speed rpm 806.1 810.4 808.8 812.3 Flow [m³/d] ERI HP Feed 18610 17733 16848
Booster pump power kWh 61.04 61.82 62.01 62.62 RO Feed 30784 29901 29017
Permeate TDS mg/l 271.4 399.0 188.6 278.8 Salinity [mg/kg] RO Feed 41939 41766 41579
Spec. energy (HPP Valve) kWh/m³ 2.427 2.430 2.444 2.447 Permeate 186.8 188.9 191.2
Spec. energy (HPP VFD) kWh/m³ 2.011 2.147 2.261 2.497 Recovery [%] Membrane 38.98 40.13 41.35
 M. Verhuelsdonk et al. / Desalination 250 (2010) 729–733
Fig. 7. Specific energy demand with VFD controlled HPP.
specific energy demand due to changing seawater and membrane
conditions.
Interestingly, Fig. 8 shows that there is no optimum overflush, but
that increasing overflush reduces energy consumption. This is because
the higher required membrane feed pressure is provided by opening
the control valve, and the energy consumption of the high pressure
pump is unaltered. However, because of the higher overflush rate,
there is less flow to be pumped by the booster pump, and there is
therefore an energy saving with the booster pump. The extent to
which overflush can be increased is therefore limited to when the
control valve is 100% open.
4. Conclusions
IPSE provides an integrated software platform in which the key
desalination processes can be simulated. The platform has been
modified by ILF for the detailed simulation of reverse osmosis
systems. This allows the user to simply simulate the operation of a
reverse osmosis system design at operating conditions away from the
733
Fig. 8. Specific energy demand with valve controlled HPP.
design point, since the influence of one process module (eg isobaric
energy recovery device) on another process module (eg membrane
performance) can be simulated simply by redefining the new
operating conditions, and running the simulation.
The case studies demonstrate that the integrated process model
can be used for various user defined analyses. Calculations can be
conducted very quickly, even for cases which would require an
iterative approach if conventional methods (eg supplier's projection
software and datasheets) were used.
References
[1] Sulzer Pumps Ltd., Pump selection tool, http://www.sulzerpumps.com/Desktop-
Default.aspx/tabid-1246/.
[2] Hydranautics Corporation, IMSDesign software, http://www.membranes.com/
index.php?pagename=imsdesign.
[3] J.M. Sanchez Sanchez, N. Sanchez Castillo, R. Sanchez Castillo, IDA World congress,
Maspalomas, Gran Canaria, Spain, 2007.
[4] Energy Recovery Inc., ERI SIM V1.2 http://www.energyrecovery.com/tools/px-eri-
sim.php.