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Keywords: In this paper, thermo-economic evaluation of hybrid solar-conventional energy supply in a zero liquid discharge
Thermo-economic plant has been conducted. The zero liquid discharge plant includes a brine concentrator and a crystallizer. Brine
Hybrid solar-conventional energy supply concentrator and crystallizer utilize falling film and forced circulation evaporators respectively. The plant was
Wastewater treatment studied thermo-economically in capital of Iran, Tehran city weather conditions. The plant performance and
Brine concentrator
economics were investigated in four design (winter, spring, summer and autumn design) conditions based on the
Crystallizer
Zero liquid discharge plant
seasonal weather data and compared with the conventional energy supply system. It was concluded that the
design proposed based on average weather conditions shows no economic advantage over the conventional
design; due to accounting for financial aids and subsides for the fuel cost at 0.05 $/m3, affecting the steam and
water costs. However, a parametric study demonstrated that if the financial aids associated with the fuel are
disregarded, it will have a pronounced effect on the cost of steam and produced water.
1. Introduction East [7]. Accordingly, a lot of researches have been carried out on using
solar energy for desalination.
Today, the need for recycling industrial wastewater is one of the Shaobo et al. [8] provided an improved MSF design based on
most important problems in society; and due to the faster growing “Pinch” technology. Sharaf et al. [9] studied two configuration of multi
population, and subsequently, the growing industries, it is deemed even effect distillation-vapor compression in both economic and thermo-
more necessary [1]. In addition to environmental problems and water dynamic aspects. Their studies showed that for a 4545 m3/day design,
shortage, energy is considered another important reason in industrial water would be priced at 2.1 and 1.5 $/m3 for multi effect distillation-
wastewater management [2]. Therefore, thermodynamic study and thermal vapor compression (MED-TVC), and multi effect distillation-
economic analysis of water and power cogeneration plants in the scope mechanical vapor compression (MED-MVC), respectively. Palenzuela
of industrial wastewater can demonstrate the feasibility of different et al. [10] studies different configuration of parabolic trough solar
methods to resolve the aforementioned issues [3]. One of the solutions power plants with distillers designs in arid environments. In one of the
to water scarcity is recycling and concentration of the industrial was- designs, they used a low-temperature distiller in the place of the con-
tewater. Desalination is the process to remove the dissolved salts to denser in a solar power plant, and studied the optimization of this de-
produce fresh water. Multi-effect distillation (MED) and multistage sign by evaluating the turbine discharge. Bataineh [11] studied the
flash distillation (MSF) are among the most important processes to yearly operation of a MED-MVC in Jordan. He demonstrated that
produce fresh water. Although desalination processes have succeeded highest efficiency of the system is achieved by placing the collectors
in slightly improving the water scarcity problem, they require ex- towards south, and solar fraction change has negligible variation in
pensive investments due to their high energy consumption [4]. Because saturated vapor production. Delgado et al. [12] demonstrated in their
of the rising fuel costs, environmental contaminant and greenhouse gas thermoeconomic study of a solar powered reverse osmosis and MED-
emission, using fossil fuels to setup the aforementioned processes are TVC seawater desalination plant, that highest system efficiency is
not efficient options [5]. Regarding the problems with fossil fuels, re- achieved when the reverse osmosis unit is connected to the local power
newable energy resources seem like an appropriate alternative [6]. grid. Kouta et al. [13] provided an entropy, exergy, and cost analyses of
Among renewable energy resources, using solar energy has a lot of a solar driven cogeneration systems using supercritical CO2 Brayton
advantages, especially in areas with high sunlight, such as the Middle cycles and multiple effect evaporation with a thermal vapor
⁎
Corresponding author.
E-mail address: jafarian@modares.ac.ir (A. Jafarian).
https://doi.org/10.1016/j.enconman.2019.03.059
Received 20 December 2018; Received in revised form 18 March 2019; Accepted 19 March 2019
Available online 27 March 2019
0196-8904/ © 2019 Elsevier Ltd. All rights reserved.
A. Najafi, et al. Energy Conversion and Management 188 (2019) 276–295
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A. Najafi, et al. Energy Conversion and Management 188 (2019) 276–295
compression (MEE-TVC) desalination system. The study was performed could be reduced by 33% (from 17.5 to 11.7 h), whereby the LCOE and
for the regeneration and recompression of supercritical CO2 Brayton LPSP decreases by almost 5% and increased from 1.02% to 7.17%, re-
cycles with two thermal energy storage (TES). The studies showed that spectively. Rashid et al. [20] conducted a dynamic simulation of
80% and 0.3% of total entropy are generated by solar tower and TES, 100 MW solar and natural gas hybrid power plant in its nominal con-
respectively. Ayman et al. [14] studied a solar desalination system dition, integrated by parabolic trough collector (PTC). The results de-
composed of evaporation chamber, air-cooled condenser and condenser monstrated that the hybridization of the power plant with dispatchable
receiver, in terms of exergetic performance, the results of this research energy resource can be improved reliability of solar power production
can be attributed to a 27% increase in the productivity and 25% in- and increased thermal efficiency from 15.2% to 26.13% annually. The
crease in energy efficiency of the desalination plant with a 12% im- potential environmental impact of two kind of 100 kW power plant:
provement in the absorption of basin base. It is also determined that photovoltaic plant and hybrid solar-gas turbine system, was studied by
with 75% reduction in the heat loss from the bath base, the exergy Magrassi et al. [21]. The study showed greenhouse gas emission of
efficiency and production increases by 152% and 87% respectively. photovoltaic plant and hybrid solar-gas turbine system was 0.043 kg/
Mohammadi et al. [15] thermodynamically analyzed different config- kWh and 0.236 kg/kWh respectively. The study also showed that
urations of integrated cogeneration of electricity, fresh water and technological improvements could further reduce greenhouse gas
cooling. The result of this study showed the configurations extracting emissions, higher receiver outlet temperatures and consequently save
their required motive vapor at a lower pressure and temperature were fuel reached. Large-scale solar heating plants for district heating net-
more effective. In power and cooling cogeneration plant, supplying works integrated with flat plate and PTCs was investigated by Tian
electricity to compression cooling was less efficient than all single, et al. [22]. In this study a generic method to optimize the hybrid solar
double and triple effects absorption chillers. Alhaj et al. [16] studied district heating plant with respect to levelized cost of heat (LCOH) was
energy efficiency of an optimized MED process, driven by vapor at 70 °C introduced. This method can help engineers on design and control of
and 0.3 bar, which was integrated with a linear Fresnel collector. Re- such plant. It was clarified that using solar collectors can reduce LCOH
ducing 59% of equivalent mechanical energy of the optimized MED by 5–9%. A cogenerative plant that a solar field (SF) combined with gas
plant compared to existing commercial installations with thermal vapor and steam turbine system evaluated from exergoeconomic and ex-
compression and using 1 m2 of solar linear Fresnel collector for pro- ergoenvironmental aspect by Cavalcanti [23]. Based on this research, in
ducing 8.6 m3 of fresh water per year were the most important results of the exergoeconomic aspect, a 4.2% increase the net produced electricity
this study. Thermo-economic evaluation of a concentrated solar power and 2.6% increase of average cost rate per exergy unit of electricity was
plant integrated with desalination cycles and absorption refrigeration achieved by using SF. The influence of using SF in the plant, in the
were investigated by Mehrpooya et al [17]. The results of the study exergoenvironmental aspect can denote reusing 3.8% and 9.8% about
showed around 86% of the total exergy destruction rate of plant be- average specific environmental impact per exergy unit of electricity and
longed to the heat exchangers and desalination cycles. The overall ex- specific environmental impact per exergy unit of electricity produced at
ergy and thermal efficiency of the plant were 66.05% and 80.70% re- the turbine, respectively. In other study, Cavalcanti et al. [24] ther-
spectively. The economic analysis showed that the proposed integrated modynamically analyzed a SF combined with Rankine engine for gen-
structure had a payback period (PBP) of 5.738 years and a net annual erating power. The specific exergy cost analysis was carried out for the
profit of 6.828 million dollars per year. Sadi and Arabkoohsar [18] si- plant on March, June, September and December 21th from 7 am to
mulated a 10 MW hybrid solar-concentrating waste incineration power 4 pm in Natal, Brazil. The ratio of the advantageous solar flux, the daily
plant for a case study in Denmark. During this research they showed average values of collector efficiencies, the specific cost per exergy unit
that the hybrid system can increase the solar fraction and utilized more of the generated power and other heat rates were presented in this
waste incinerators to generate electricity. Using this plant reduced 8000 study. These items can be valuable in the operating variables optimi-
tons of carbon dioxide resulted emission per month. Also, the overall zation, design and guide to take the better decision of investment. As-
efficiency of the plant was reached 24%. Bravo and Friedrich [19] kari and Ameri [25] conducted a feasibility study on a multistage dis-
provided a two-stage optimization in which a multi-objective opera- tiller utilizing a thermocompressor on a SF combined with Fresnel
tional optimization was used to supply the operational information to a collectors. They concluded that, considering the solar fraction of
multi-objective design optimization. The epsilon constraint method and 67.77% and without using thermal storage, water production cost
the scalarisation method were used for balancing the trade-off between (3.32 $/m3) is higher than common multistage distillers utilizing fossil
financial and technical performance. Both method had same result but fuels. They carried out a sensitivity analysis in another paper, coming to
scalarisation method was much faster than the epsilon constraint the conclusion that for a cogeneration water and power plant, water
method. Using the methods, it was shown that both, the levelized cost and power costs are dependent to solar collector and energy storage
of electricity (LCOE) and the loss of power supply probability (LPSP) of costs, respectively; with land and fuel costs having negligible effects.
the concentrating solar power (CSP) plant can be enhanced by its hy- They also claimed that by doubling the size of the design, water cost can
bridization with a photovoltaic power plant. Whereas the LPSP was be reduced by 27.33% [26]. In recent years, the decline of water
reduced by 90% and the LCOE decreased by 5.6%. Despite this the TES sources and strict regulations on industrial wastewater effluents,
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A. Najafi, et al. Energy Conversion and Management 188 (2019) 276–295
changed focus to zero liquid discharge (ZLD). This process results in weather data and compared with the conventional energy supply
more fresh water and less brine production [27]. A lot of researches system. As mentioned before, few works has thermo-economically
have been carried out on ZLD due to the importance of fresh water studied such a proposed plant configuration. Evaluation of the cost of
production. Sobhani et al. [28] studied the energy footprint of a mod- water and economic sensitivity analysis to investigate the influence of
ular process in a pellet reactor to reduce hardness and improving the fuel cost on proposed plant feasibility as well as effect of the plant on
ZLD process. Koppol et al. [29] provided an approach based on a reducing environmental impacts by carbon dioxide and nitric oxide are
mathematical program to analysis the feasibility of ZLD in different main contribution of this research.
industries. Kumar et al. [30] provided a steady state simulation of a
multistage evaporator and its related topics using MATLAB. Farahbod 2. Process description
et al. [31] conducted an experimental study on a forced circulation
evaporator in a ZLD process. In this study, they investigated factors According to Fig. 1, condensate is pumped through vacuum PTCs
affecting system function, such as heat exchanger temperature, cooling arranged in a North-South direction, in a once-through sequence, by the
fluid flow rate and size distribution of salt crystals. Vinshu et al. [32] pump. Sun rays are focused by the apertures in the collectors, gradually
studied a few different methods of achieving ZLD. They compared the heating and increasing the temperature of fluid passing through. Taking
different properties of a few composite samples, namely color, pH, the length and surface area of the collectors, the amount of sun beam's
amount of sulfates and hardness. rays, and other climate conditions, steam as a working fluid is dis-
Most literature in the field of water production is subject to the use charged from the collectors with a quality between 0 and 1. According
of a MED system, in some of which solar energy is used to lunch a to this quality and unit demand to saturated vapor, the following pro-
desalination process. In fact, the main purpose is to produce freshwater cesses take place.
from seawater and evaluate it from different aspects, such as economics
and thermodynamics. In the present work, focus is on an industrial 1. When the sun doesn’t provide enough solar energy for the water to
wastewater treatment (WWT) plant, which includes a brine con- reach the saturated conditions required by the unit at its operational
centrator (BC) and a forced circulation crystallizer (FCC). These kinds pressure, since the quality is lower than one, the discharged satu-
of plants are generally installed inland to manage the wastewater de- rated steam enters a separator, so that its separated liquid passes
livered from industries. Here the main challenge is supplying the mo- through the boiler to be evaporated, and mixed with the produced
tive energy. Thus, the proposed energy supplying plant performance vapor.
and its economics are investigated in four design (winter, spring, 2. During night and at times of the day that the solar energy is not
summer and autumn design) conditions based on the seasonal Tehran efficiently available, the water is directly supplied to the boiler to
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reach the aforementioned conditions. part of this water is used by the steam generator unit.
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Table 1
The equations associated with the energy supply unit of the solar wastewater treatment unit.
Definition Equation Number
ṁ 2di
Wetp =
2 2 −1
⎛ πdi ⎞ ⎛ x 1−x⎞
ß⎜ +
4 ⎟ ⎜ ρg ρl ⎟
⎝ ⎠ ⎝ ⎠
2
⎛ ⎞
⎜ ṁ ⎟
Frtp = gdi ⎜ −1 ⎟
πd 2
⎜⎜ gdi i ⎛⎜ x + 1 − x ⎞⎟ ⎟⎟
4 ρ ρl
⎝ ⎝ g ⎠ ⎠
Solar thermal energy absorbed in absorber tube sol
Qa = Isol W Δzηop αa τc (9)
Optical efficiency ηop = F0 (β ) ρref εsh εtr εge εda εun (10)
Solar thermal energy absorbed in glass cover Qcsol = Isol W Δzηop αc (11)
Radiative heat transfer coefficient rad
hamb = σεc (Tc2 + 2
Tsky )(Tc + Tsky ) (12)
Convective heat transfer coefficient 1 (13)
⎧ kair Γ Re Γ2 Pr 3 Reair ≠ 0
⎪ Do 1 air air
⎪ 2
⎪ ⎛ ⎞
⎪
conv ⎜ ⎟
hamb =
⎨ kair ⎜ 0.387Raair1.6 ⎟
⎪ Do ⎜0.6 + 8 ⎟ Reair = 0
⎪ ⎜ ⎛
9 27
⎞ ⎟
⎪ 0.559 ⎞ 16
⎜⎜ ⎜1 + ⎛ ⎜ ⎟ ⎟
⎟
⎪ ⎜ ⎝ Prair ⎠ ⎟ ⎟
⎩ ⎝ ⎝ ⎠ ⎠
Sky temperature 1.5
Tsky = 0.0552Tamb (14)
Radiative heat losses to ambient rad = πD Δzh rad (T − T )
Qamb o (15)
amb c sky
Convective heat losses to ambient conv = πD Δzh rad (T − T
Qamb o amb) (16)
amb c
Radiative heat transfer coefficient between absorber tube and glass cover (T 2 + Ta2 )(Tc + Ta ) (17)
harad
−c = σ c1 (1 − εc ) d o
+
εa εc Di
Convective heat transfer coefficient between absorber tube and glass cover Pr Ra 0.25 (18)
⎧ 2.425k ⎛ anu anu ⎞
⎪ ⎝ 0.861 + Pr ⎠
Panu > 1 [torr ]
⎪ 5
3 4
⎪ ⎛
d 5
⎞
⎪ ⎜1 + ⎜⎛ o ⎟⎞ ⎟
D
haconv
−c =
⎜
⎝
⎝ i⎠ ⎟
⎠
⎨
⎪ kstd
Panu ⩽ 1 [torr ]
⎪ Ta + Tc d
⎪d (9γ − 5) ⎛ o + 1⎞ ⎜ ⎟
2 ⎝ Di
⎪ o ln ⎛ Di ⎞ + 2.331 × 10−20
⎜ ⎟
⎠
⎩ 2 ⎝ do ⎠ 2(1 + γ ) Panu δ2
Radiative heat losses between absorber tube and glass cover Qarad rad (T − T )
= πdo Δzhamb a c
(19)
−c
Convective heat losses between absorber tube and glass cover Qaconv rad
− c = πd o Δzhamb (Ta − Tc )
(20)
Single-phase heat transfer coefficient between absorber tube and fluid k (21)
⎧
⎪ 4.367 di Ref < 2300
hfconv =
⎨ k
⎪ 0.023 Ref0.8 Pr f0.4 Ref ⩾ 2300
⎩ di
Two-phase heat transfer coefficient between absorber tube and fluid hfconv =
k
0.023 Ref0.8 Pr f0.4 (Ω CoΩ 2 (25 Frsp )Ω 5 +Ω BoΩ 4 ) (22)
di 1 3
2
0.5 ⎛ ⎞ Qconv
1 − x 0.8 ρg ṁ f
Co = ( ) x
⎛ ⎞
⎝ ρl ⎠
, Frsp = gdi ⎜
⎜ gdi ρl πdi
2
⎟
⎟
, Bo =
ṁ (Hg − Hl )
⎝ 4 ⎠
(continued on next page)
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Table 1 (continued)
Table 2
Physical and geometrical properties of IST parabolic solar collectors.
Parameter value Parameter value Parameter Value
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considering the fluid’s velocity range, is of forced convective type. The The boiler will evaporate the liquid part of the fluid discharged from
heat transfer coefficient can be in either a single phase or two phase the collectors. In case DNI of sun amounts to approximately zero, the
condition (which is a result of fluid temperature rising and entering the boiler provides the entire energy required by the wastewater con-
saturated area and forming the conditions for convective and nucleate centrator unit. Eq. (26) calculates the heat required from the boiler and
boiling). Therefore, Eqs. (21) and (22) are used for the single phase [46] ηB indicates boiler efficiency. The boiler was chosen regarding the
and two phase [47] conditions, respectively. The values of the constant maximum capacity required by the wastewater concentrator unit, equal
Ω i used in Eq. (22) are presented in Table 3. to 2000 kW.
In the case that Frsp of the flow is bigger than 0.04, Ω 5 is set as Considering the operating pressure (600 kPa, gage), Eqs. (27) to
zero. Considering the equations used to obtain the heat transfer coef- (29) are applied to obtain the vapor-water separator used in the energy
ficient between the absorber tube and the working fluid, it is possible to supply unit.
calculate the thermal energy received by the fluid through Eq. (23)
4ṁ g
[39]. D∗ = ρl − ρg
πρg k ′
ρg
(27)
3.1.5. Conductive heat transfer in the glass cover and the absorber tube
walls L
As depicted in Fig. 2, Fourier transform is used to calculate the L∗ = D∗ ⎛ ∗ ⎞
⎜ ⎟
⎝ D∗ ⎠recomended (28)
conductive heat transfer along each collector (Eqs. (24) and (25)) [33].
D 2
vol = 2π ⎛ ∗ ⎞ L∗
3.1.6. Solar collector equations solution algorithm ⎝2 ⎠ (29)
An iterative developed MATLAB code is used to solve Eqs. (1) to (5)
after their discretization based on Ref. [48]. Fig. 3 shows the algorithm where L∗, D∗ and vol are height, diameter and volume of cylindrical
used for the aforementioned equations. In this algorithm, after speci-
L
separator respectively. D∗ ( ) and k ′ are set as 3 and 2 m per
∗ recomended
fying the initial conditions, geometrical and optical properties, weather second, respectively[49]. The details of the separator design are pro-
conditions such as amount of DNI, wind speed, ambient temperature, vided in Ref. [50].
and other parameters involved with the problem, the desired tem-
perature distribution for the absorber tube temperature and the glass 3.3. Wastewater treatment unit
cover, temperature, pressure and fluid mass flow rate are set, and fi-
nally the fluid continuity, momentum and energy equations are solved The equations governing the WWT unit for the BC and FCC are quiet
along the tube. The new acquired temperature values of the fluid are similar.
used to calculate source terms for the absorber tube energy equation, Generally, the equations governing each part of the WWT unit are
and start the solution of the absorber tube energy equation. After the grouped in three categories; mass, energy and concentration equations.
solution of this equation, new temperature distribution for the absorber The equations include these equipment: Effects (containing evaporator
tube is acquired, and is utilized to update the glass cover source terms and separator), thermocompressor, preheater, centrifuge (present in
and solve its energy equation and obtain its new temperature dis- FCC part), and condenser. In addition, a few other quantitative equa-
tribution. Now, this process is repeated until the temperature calcula- tions are used for thermodynamic analysis along with the aforemen-
tion error satisfies an acceptable limit. In that case, the solution for a tioned equations; all of which are presented in Table 4.
time step is halted, and the solution for the next time step is started. Equations (30) to (33) represent the governing equations of the heat
transfer effects. Eqs. (30) and (31) denote, the mass and concentration
3.2. Boiler and separator equations of fluid flow inside evaporator tubes, respectively. In Eq.
(30), Ψ and rFCC function, indicate the position of returned liquor from
As the sun cannot output the same thermal power throughout a day, the pusher centrifuge to the effect and the existence of forced circula-
this design considers a boiler schematic of which is provided in Fig. 1. tion crystallizer. Eq. (32) governs the vapor inside of the shell. In these
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A. Najafi, et al. Energy Conversion and Management 188 (2019) 276–295
Table 4
The equations used in the simulation of wastewater treatment unit.
Component Equation type Equation Number
i-th Effect Mass ṁ Bi− 1 + rFCC Ψ(i) ṁ liq = ṁ Vi + ṁ Bi , i = 2, ...,N Tube Side (30)
Ψ(i) =
1
0 { i=N
i≠N
ṁ Salt =
ṁ Feed XFeed
For FCC (47)
XSalt
Temperature distribution of effects ΔT = ∑ ΔT i + BPEBi , i = 1, …, N (48)
i
ΔT i = TSi − TBi
BPEBi = TBi − TVi
i )2 2 3
R¯ (TB ⎛ ⎛ X Bi ⎞ i
1 ⎛ XB ⎞
i
1 ⎛ XB ⎞ ⎞
BPEBi = VHF ⎜⎜ 1 − Xi ⎟ + ⎜ ⎟ + ⎜ ⎟
⎟
MWcry H ifg 2 1 − Xi 3 1 − Xi
sl ⎝⎝ B⎠ ⎝ B⎠ ⎝ B⎠ ⎠
Equations related to heat exchanger Surface ṁ Si H ifg = U iAi ΔT i (49)
sl
1 (do∗ / di∗ ) dout ln(do∗ / di∗ ) 1
= + +R+ , i = 1, …, N
Ui i
hinner 2kw i
houter
equations, ṁ Bi , ṁ liq , ṁ Vi and X are mass flow rate of brine, returned li- supplied from the cooling tower to condense vapor from the last effect.
quor from the pusher centrifuge, produced vapor in the i-th effect and In Eqs. (39) and (40), ṁ Distillate and ṁ CLT represent the cooling water and
concentration. In the Eq. (32), ṁ Si and ṁ FPHi
show the inlet steam flow to the total amount of produced water, respectively.
the effect shell and preheater respectively. ṁ Di is the total amount of Pusher centrifuge is used to remove the emerged salt crystals. Its
produced water from the i-th effect. The H symbol represents the flow governing equations are conservation of mass, energy, and concentra-
of the enthalpy in Eq. (33). tion, which are presented by Eqs. (41), (42) and (43), respectively. In
Eqs. (34), (35) and (36) show the governing equations of mass, these equations, ṁ Salt is the value of crystal salts present in the inlet feed
energy, and auxiliary equation of designing the thermocompressor re- and ηSLS =0.85, is the separation efficiency of pusher centrifuges. In Eq.
spectively. In these equations, ṁ mot , ṁ suc and ṁ disch are mass flow rate of (43), Xsat N
is the concentration of solution, in saturation state of the N-th
motive steam, suction and discharge of the thermocamposor. ER re- effect.
presents thermocompressor Entrainment Ratio in Eq. (36), obtained by To close the thermodynamic equations governing the WWT, we
using experimental data from Ref. [51]. need a number of general equations that are presented in Eqs. (44) to
The governing equations for preheaters include the mass equations (47). Additionally to calculate the enthalpy flows, the temperatures of
of the tube and shell side (Eq. (37)) and the equation of energy trans- flow streams are calculated by Eq. (48). In the relations of Eq. (48),
i
ferred from the shell side to the heat exchanger tubes (Eq. (38)). In H fg sl
, TBi , TVi and TSi are vaporization heat, temperature of brine, vapor
these equations, ṁ FC , HSi − HDi , ΔHFi and ΔHFC are the mass flow rate of and steam which enter to the i-th effect, respectively. An important
intake feed passed through the preheaters, evaporation enthalpy, in- parameter in WWT unit is the boiling point elevation (BPE), which is
creasing the feed enthalpy in the i-th preheater and preheater of the the temperature difference between the generated vapor and re-
condenser. circulating brine, and can climb up to 20 °C at higher concentrations.
Similar to the preheaters, Eqs. (39) and (40) are represented for This can negatively affect investment and operational costs. Eq. (48)
mass and energy governing equations of condenser, but coolant water is governs this phenomenon, where VHF is Vent Hoff coefficient and
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A. Najafi, et al. Energy Conversion and Management 188 (2019) 276–295
MWcry is the molar weight of crystal. [AF × Ccapital + CO & M + CMaterial + Celectrical ]WWT
LCOW =
As mentioned fluid flows as a falling film in the BC evaporator TVW
tubes, while it is in the FCC evaporator tubes of forced circulation type. [AF × Ccapital + CO & M + Celectrical ]SF
+
Therefore, total heat transfer coefficient of each part is different. Heat TVW
transfer coefficient in the falling film tube side (htsi ) is calculated [AF × Ccapital + CO & M + Cfuel + Celectrical ]Boiler
through an equation from Ref. [52]. The heat transfer coefficient (hssi ) of +
TVW
the shell side in both of the systems, preheater, and condenser is cal- [CInsurance + Cpersonal + CContingency ]overall
culated based on Ref. [53]. The tube side heat transfer coefficient in all +
TVW (50)
of the heat exchangers (except for the BC tubes with falling film) is
calculated by Eq. (21). [AF × Ccapital + CO & M + Celectrical ]SF
The calculations on heat transfer surfaces are done by Eq. (49). The LCOS =
TMS
first phrase of this equation shows heat transfer from the shell side to [AF × Ccapital + CO & M + Cfuel + Celectrical ]Boiler
the tubes side; where the latent heat energy of vaporization on the +
TMS
vapor side evaporates a percentage of the recirculating flow inside the [CInsurance + Cpersonal + CContingency ]overall
tubes. Total heat transfer coefficient is calculated in the second phrase; +
TMS (51)
the first term of which is heat resistance of the tube side with the heat
transfer coefficient (hinner ) being calculated based on the flow regime. AF in the Eq. (50) and (51) represents amortization factor and can
The second, third, and the fourth phrases of this equation indicate wall be obtained through Eq. (52).
heat resistance, fouling resistance, and convective thermal resistance of J ( J + 1)np
the shell side, respectively. AF =
( J + 1)np − 1 (52)
where J and np stand for nominal interest rate and plant lifetime, re-
3.4. Validation spectively. In this paper nominal interest rate and plant lifetime are 5%
and 20 years, respectively.
The accuracy of the PTC and WWT simulation codes is evaluated by Another important factor used in the economic evaluation of dif-
the results provided in Refs. [54] and [55] (Darwish study) respec- ferent projects, is the PBP, acquired by setting the Net Present Value
tively. As Fig. 4 demonstrates a good agreement between results of the (NPV) to zero, and finding a suitable Np from Eq. (53).
simulation and the experimental work (maximum error of 2, 7 and Np
GI
3.3% for temperature, pressure along the PTC and gain output ratio NPV = ∑ (1 + J )nk
− ∑ Ccapital
(GOR) of WWT) is observed. Furthermore, in this diagram, results of the nk = 1 (53)
present have been compared against the simulation results proposed by
This plant is intended to have five personnel, two for energy supply
Sagharchiha [56].
unit and three for WWT unit. Therefore, personnel cost calculation is
considered by setting a monthly salary of 450 $ for each personnel.
Insurance and unanticipated costs are to 0.005 and 0.05 of the initial
3.5. Economic analysis
capital cost. The land cost to construct the SF and the WWT unit is
considered zero. The costs related to BC and FCC of the WWT unit are
One of the important viewpoints on the execution of a plan is its
accounted for based on the experience of the authors at Fanniroo Co.
economic outlook; here it is analyzed by reviewing the cost of the
[58]. Refs. [59] and [60] are used to calculate the costs associated with
generated water and steam in the hybrid energy supply unit. Levelized
the SF and boiler respectively. All the aforementioned expenses are
cost of water (LCOW) and levelized cost of steam (LCOS) are respec-
provided in Table 5 [59–62].
tively used to estimate the costs of water and steam in the WWT unit.
This method considers all the CAPEX (capital expenditures) and OPEX
3.6. Fuel and pollutants
(operating expenses) of every component of the system and calculated
the water and steam costs by Eqs. (50) and (51), respectively [57].
One of the most important factors in analyzing hybrid energy supply
projects is studying the environmental effects such as pollutant
(A) Validation of for Parabolic trough collector simulation (B) Validation of wastewater treatment unit
results simulation results
Fig. 4. Validation of hybrid solar-conventional wastewater treatment plant simulation results.
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Table 5
Solar wastewater treatment unit expenses.
Wastewater treatment unit BC FCC BC FCC
emissions, especially greenhouse gases and economic evaluation based dimensions and varieties. Among them, vacuum tube collectors have
on the financial support and subsides. These types of support are given lowest thermal loss compared to other collectors due to the presence of
out by the government through bonuses or periodic extra financial vacuum between the glass cover and the absorber tube [66]. Hence IST
payments based on the amount of reduced pollutants in an operational type of these collectors was used in this design. Collector and WWT unit
cycle of the complex. On the other hand, using clean solar energy not properties and other relevant parameters are presented in Table 2.
only reduces environmental pollutants, it also cuts back on fuel con- Working fluid thermodynamic properties are calculated by REFPROP
sumption and provides a solution to fight the fossil fuel shortage in the [67].
not too distant future. Therefore, the fuel mass required by the energy In the following, the thermodynamic and economic analysis results,
supply unit is necessary to estimate the amount of pollutants; which can along with the amount of reduced pollutants are represented.
be acquired by Eq. (54). Fig. 6 shows the percentage of variation in discharge pressure of the
solar collectors proportional to operational pressure of BC and FCC
TIME
Mfuel = QBoiler thermocompressors of the WWT unit in different months of the year.
LHV (54)
The highest value is 1.64% for the spring design in the second half of
In the equation above LHV stands for Lower Heating Value of the July with the highest DNI and ambient temperature. Based on minor
fuel, and equals 3600 [kJ/m3] for the natural gas of Tehran, Iran [63]. changes of ΔP throughout the entire year, it should be acknowledged
Pd
In this equation, TIME represents the operation cycle of boiler. Exact that the summer design shows the lowest yearly average (0.32%) and
fuel analysis is presented in Table 6. best performance in providing the thermocompressor operational
The program Chemkin is used to calculate the amount of fuel pressure compared to the other three hybrid design scenarios.
combustion products in the boiler [64], the results including exact Hence, the motive steam pressure range of the WWT unit thermo-
contribution of each combustion product is presented in Table 6. compressors would be about 6.9–7.1 bar. The aforementioned differ-
ences results in differences in compression ratio and expansion ratio
4. Results equal to: 2.10–2.14 and 40.70 to 41.76, respectively, which will con-
sequently slightly affect thermocompressor suction. Therefore, no sig-
The design and numerical simulation of the solar WWT unit in nificant variations will occur in the total performance of the WWT unit.
Tehran (35.44 N, 51.30 E) is based on typical meteorological year Although the overall pressure variations are negligible, the gradients of
(TMY) of the city [65]. To this aim, each month of the year is divided to pressure variations for spring design are far more than that of the au-
first and second halves, and in each half, average ambient temperature, tumn and summer, which peak from July to October.
wind speed, and DNI is calculated, and presented in diagrams (A), (B) Reaching the operating WWT unit thermocompressor motive steam
and (C) in Fig. 5. Taking averages of each of these parameters in a pressure (saturated temperature at 600 kPa, gage), requires choosing a
season of a year is carried out similarly; and its values provided in suitable collector surface area and creating enough pressure along the
Fig. 7. For a WWT unit, SF area and intake pressure of the pump tasked line in accordance to the working fluid mass flow rate; climate condi-
with pumping the water into the collectors is computed based on the tions, specially DNI which has direct effect on reaching this tempera-
developed computer program for each of the calculated seasonal ture. Higher dependence of temperature to operating parameters
averages, and its results also included in Table 7. The Characteristics of compared to pressure, generally necessitates higher temperature fluc-
each of the WWT unit are presented in Table 7. Regarding the para- tuations compared to pressure in the discharged fluid from the PTCs.
meters presented in Table 7, for BC and FCC, the steam conditions re- The provided diagram in Fig. 7 showing the difference percentage be-
quired by the WWT are determined. Solar collectors have different tween this temperature and design temperature provided in Table 7
Table 6
Percentage of volume fractions of natural gas constituents and its combustion products.
Natural gas combinations
C3H8 1.74 C2H6 4.70 C5H12 i-pentane 0.13 CO2 0.05
C6H14 n-hexane 0.08 C4H10 n-butane 0.42 CH4 87.7 N2 4.70
C4H10 Iso-butane 0.37 C5H10 n-pentene 0.10 C5H12 n-pentane 0.10
Fuel products
CO 2.65 CO2 8.48 H2O 18.67 NO 0.05
N2 68.77 Others 2.24
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(A) Monthly changes in wind speed (B) Monthly changes in ambient temperature
compared to yearly design temperature proves this fact. The values throughout the months of the year are depicted in Fig. 8. This para-
presented in this diagram indicate that the four design scenarios pro- meter in addition to expressing the flow rate of steam discharged from
posed for the energy supply unit properly provide the temperature the PTCs, defines the rate of boiler usage against the SF in the hours
conditions for the motive steam. The summer design with the lowest when DNI value is decent (maximum 8 h in a day). Thus, lower quality
heat transfer area and the winter design with the highest collector value indicates higher boiler usage contribution compared to the PTCs
surface area showed the lowest and the highest fluctuations, respec- of SF.
tively. The average annual variations of temperature in Fig. 7 for For example, due to the decrease in DNI in colder months of the year
spring, summer, autumn and winter design are 0.327%, 0.321%, (January and February) working fluid quality of the four design sce-
0.411% and 0.875%, respectively. narios drops. This trend can be seen in Fig. 9, where the highest amount
Working fluid steam quality is the most important and fundamental of solar fraction in all of the designs is about 34% for the hot months of
parameters in designing a hybrid energy supply unit. Its changes the year, and the lowest happens in the first half of January for the
Table 7
Design parameters for winter, spring, summer and autumn.
Solar field Characteristics
Season W Tamb [°C] m Pin [kPa] ASF [m2] Td [K ] Pd [kPa]
DNI ⎡ 2 ⎤ Vwind ⎡ ⎤
⎣m ⎦ ⎣s⎦
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summer design. Another point deducted from comparing the DNI According to the gradient of these designs, it is possible to say that the
Figure diagram and discharged steam quality based on the summer, autumn design showed the least fluctuations after the summer design.
autumn and spring design is that the trend of changes in quality and Fig. 11 depicts the trend of change for the PTC efficiency, provided
DNI are completely proportional to each other while steam quality is according to Eq. (55). This diagram expresses the percentage of solar
lower than one, and appears to be independent of other atmospheric energy received by the collectors used to increase the fluid temperature.
conditions such as wind speed, and ambient temperature. This con- The diagram takes the effects of atmospheric conditions, and optical
formity seems more pronounced for the summer design compared to parameters associated with the collector and mirror manufacturing si-
the other designs. By comparing the DNI and quality diagram, it is multaneously. By comparing the results acquired for the PTCs, it is
concluded that with an increase of 58.25% of DNI from first half of concluded that in the cold months of the year, decreasing the heat
February to first half of June, 71.5%, 53.9%, 43.7%, and 5.64% in- transfer area of the collectors from the winter design to the summer
crease in the steam quality occur for summer, autumn, spring and design, causes the efficiency of the collectors to drop by 1%; however,
winter design. increasing ambient temperature and DNI, reduces this difference to
The diagram presented in Fig. 10 shows the percentage of unused zero, making the efficiency of all four collector design essentially
intended collector surface area for each design in different months of identical. On the other hand, studying this parameter separately for
the year. Based on this diagram, unused percentage is the lowest in the each collector, results in calculating a zero to five percent difference in
summer design, and the highest in the winter design. Unused area efficiency according to atmospheric conditions.
percentage increases sharply in the hot seasons of the year so much, so
ṁ mot (Hout − Hin )SF
that in the first half of July, it reaches 65, 47, 40, and 20% for the ηSF =
Qasol (55)
winter, spring, autumn, and summer designs, respectively. During the
winter, due to the sharp decline of DNI, the need for more surface area Fig. 12 demonstrates the trend of change in the two hot (June 21th)
is profoundly felt, causing the unused area to reach approximately zero. and cold (January 14th) days of the year throughout a day-night cycle.
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Fig. 8. Changes in steam quality discharged from the absorber tubes of the parabolic trough collectors.
This figure illustrates the changes in the thermal energy supplied by the costs.
boiler needed for the production of water by the WWT unit for all four By considering natural gas and electricity costs as 0.05 $/m3 and
hybrid design scenarios in accordance to the changes in atmospheric 0.02 $/kWh respectively, and the capital and operational costs pre-
conditions. This trend indicates that even in cold days, in the hours with sented in Table 5, the cost of water, steam, PBP and internal rate of
more favorable DNI the winter design requires lower boiler assistance return of the capital are calculated and presented in Table 8 considering
compared to the other designs due to its larger surface area; so that linear depreciation.
during some sunny hours of the day, its need for boiler is 2.3 times Since the cost of produced water and produced steam is evaluated
lower than the other designs. Comparing the design of autumn and by Eqs. (50), (51) and the mentioned equations in Table 5 is directly
spring for a period of 8 h (8 am to 16 pm on January 14th) in terms of proportional to the level of SF area, this leads to higher costs for water
heat energy supply, it is concluded that in spring design, greater and steam. By comparing the spring and summer designs while taking
thermal energy of 88 kW is required. All four designs demonstrate si- the values presented in Table 8 into account, it is concluded that by
milar performance in reducing boiler usage and consequently fuel increasing the capital and operational costs by 14 and 4% respectively,
consumption in hot days of the year. Since hot days of the year receive steam costs and consequently water costs rise by 17.5 and 7% respec-
more sunlight throughout the day, hybrid designs provide most of the tively.
energy used by the WWT unit. In the aforementioned conditions, the changes in operational and
In this section, each of the proposed hybrid design scenarios and a capital costs of the hybrid designs has little effect on the PBP and in-
conventional design where a boiler is tasked with providing the entire ternal rate of return (IRR) when compared with each other.
energy requirement of the WWT unit throughout the day are econom- Based on the PBP and the water and steam costs of the hybrid de-
ically analyzed. Afterwards, the sensitivity of water and steam cost of signs reported in Table 8 compared to the conventional design, it is
each of these designs is studied in relation to the capital and operational concluded that the design proposed based on average atmospheric
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Fig. 10. Amount of unused heat transfer surface area for each design.
conditions has no economic advantage over the conventional design; autumn design could be suggested as a proper scenario, although no
due to accounting for financial aids and subsides for the fuel cost at significant difference was observed between autumn and spring design
0.05 $/m3, affecting the final calculation of steam and water costs. If scenarios.
the financial aids associated with the fuel are disregarded, it will have a According to this diagram, while natural gas cost is set to 0.05 $/m3,
pronounced effect on determining the cost of water and steam. Fig. 13 the share of the boiler in the design equals 28.45%; by increasing the
illustrates this issue. fuel cost to 0.25 $/m3 this share increases significantly to 66%, taking a
Comparative evaluation of four investigated scenarios revealed that significant share of the water cost, while the WWT unit accounts for
considering indicators such as minimum changes of steam pressure and about one third of the water cost. On the other hand, the role of the PTC
temperature at wastewater treatment plant inlet, and economics, becomes more significant due to their lack of need for fuel, and as
summer design sounds more superior; however winter design demon- shown in Fig. 14, reduces overall water and steam costs compare to
strates a better stable performance while considering the produced conventional design. At a fuel cost of 0.05 $/m3, using hybrid design
steam quality and active available solar heat transfer surface and re- the contribution of WWT unit cost in water cost can be reduced from
duction of gases pollutants. To take use of both summer and winter 45.5% to about 36–41%, while rising fuel cost to 0.25 $/m3, the con-
design advantages one might consider autumn and spring design sce- tribution of WWT unit for all design scenarios would be almost
narios. Economic evaluation showed that autumn design is the second 21–24.5%. According to Fig. 13, increasing fuel cost, reduces the con-
rank after summer design from the plant IRR point of view. Considering tribution of other costs. For example, for conventional and hybrid
other indicators as showed in different figures it was realized that au- spring design, this reduction is about 13.65% and 11.13% respectively.
tumn design displays a proper performance. For example the minimum The changes in the economy between the different hybrid designs
variation of steam temperature and pressure at the WWT plant inlet as can be entirely affiliated with the difference in surface area due to the
well as the minimum unused heat transfer area is for autumn. Hence high dependence of SF expenses on the surface area of the collectors.
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Fig. 12. Hourly variations in weather conditions and thermal energy supplied by the boiler in a cold and a hot day of the year for all four hybrid design scenarios.
Therefore, as evident in Fig. 14, by increasing the fuel cost, the summer on the cost of water in each design. The effect of changes in electricity
design and the winter design will each prorate the produced water and costs in the cost of steam is very insignificant. For the unit studied in
steam costs at 0.11 $/m3 and 0.17 $/m3 fuel costs, respectively. It is this paper, boiler capital cost compared to its yearly fuel cost is con-
deducted from the figure above that at fuel costs higher than 0.1 $/m3, sidered negligible, so much so that as seen in the Fig. 15, the sensitivity
hybrid designs become economically feasible. Another important result of water and steam costs is essentially inconsiderable to boiler cost. The
which is concluded from Fig. 14, is that LCOW and LCOS of conven- only difference between the sensitivity analyses of the hybrid designs is
tional design cross and overcome the hybrid one at a same cost of fuel. related to their SF. The winter design shows higher sensitivity due to
It means that as predicted before LCOW mostly follows the motive having a larger collector surface area.
energy cost. In addition to the study on sensitivity of the solar WWT unit to
Due to the possibility of variations in the costs of equipment, elec- parameters such as cost and expenses, the sensitivity of this unit to the
tricity and fuel, it is important to analyze the sensitivity of steam and interest rate and its lifetime is discussed as well. The results are de-
water costs to these changes. It is important to note that while ana- picted as contours based on the two parameters mentioned in Fig. 16.
lyzing the sensitivity of water and steam costs to one parameter, other According to the contours in the Fig. 16, it is concluded that for the
parameters should remain constant. solar and the conventional WWT units, the cost of water is more de-
Fig. 15 displays the sensitivity analysis of water and steam costs to pendent on changes in the rate of interest against changes in plan life
all each of the four hybrid designs in proportion to an increase in any of time. In fact, the conventional design has lower expenses for the interest
the expenses listed in Table 5. It is concluded from the results of this rate and plan life time in the intended life cycle range compared to the
analysis that the cost of water for all of these designs has the highest hybrid designs; but due to the presence of numerous gradients in its
sensitivity to changes in WWT unit and least sensitivity to changes in contour, it is deduced that its cost changes have a lot of fluctuations.
boiler expenses; the sensitivity of the cost of water to SF expenses in the While by adding the SF and operating the hybrid energy supply unit,
displayed range takes the second rank. By increasing the size of the SF these fluctuations are reduced; in such a way that the cost of water for
from summer design to winter design, the sensitivity of water and steam the autumn design in 20–35 years lifetime, and 4–8% interest rate has
costs to heat transfer surface area, increases compared to fuel cost, significantly fewer fluctuations compared to the conventional design for
electrical and boiler costs. This diagram demonstrates that changes in the same range. The Fig. 16 indicates that by increasing the lifetime of
electricity costs have the lower effect compared to changes in fuel costs the plant at low interest rates, lower water costs are obtainable.
Table 8
Economic parameters, the fuel saving and pollutant reduction value.
Parameter Conventional design Winter design Spring design Summer design Autumn design
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Fig. 13. The contribution of solar wastewater treatment plant components in cost of water based on 0.05 $/m3 and 0.25 $/m3 fuel cost.
The use of solar energy in hybrid design scenarios results in lower conventional energy supply plant in a ZLD WWT plant, was considered.
fuel consumption and consequently lower pollutants (NO and CO2) The investigation was conducted based on mean seasonal climate of
emission from burning natural gas in the boiler. The amount of re- Tehran (Iran) in four different scenario designs; winter, spring, summer
duction in the emission of these destructive gases and fuel consumption and autumn. The performance and sensitivity of all the scenarios were
due to the use of each of the hybrid design scenarios compared to the studied. Thermodynamic analysis revealed that variations of the tem-
conventional design are provided in Table 8. The highest and lowest perature and pressure are negligible at the inlet of thermocompressor.
values belong to the winter and summer designs, respectively, while the Quality was considered as ones of the main parameters to indicate the
spring design shows better performance in this matter compared to the contribution of conventional boiler during solar times. Studies showed
autumn design. Fig. 17 indicates that in the 20 years lifetime of the that in winter design, averagely up to 34% of solar energy contributes
solar WWT unit, between 1500 and 1750 tons less pollutants is pro- to producing water, however around 60% of heat transfer surface area
duced compared to the conventional WWT unit. Employing winter, remain unused in some hot seasons.
spring, summer and autumn design scenarios, approximately 40, 39, 35 The hourly analysis indicated that on 21th June, in all hybrid design
and 38% of fuel saving is occurred annually. scenarios, the amount of heat energy supply by boiler is reduced si-
milarly, but on a cold day (14th January), the amount of heat energy
supply by boiler in sunny hours varies depending on the amount of
5. Conclusion thermal surface of each design and the reduction of DNI. While the
summer design uses about 17 to 33% of the sun's energy and it uses
In this paper, Thermo-economic evaluation of a hybrid solar-
Fig. 14. Changes in water and steam costs against increasing fuel cost.
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almost all of its thermal surface in all seasons. impact on water costs in all hybrid designs. The effect of electricity
Based on economic analysis performed in each of the four hybrid costs on LCOS changes is negligible. For hybrid solar-conventional en-
design scenarios, it was found that the payback period and water cost ergy supply in a WWT plant and conventional WWT unit, water cost
for all different scenarios were roughly the same, about 9–10 years, and changes were more dependent on changes in interest rates versus
4–5.5 $/m3 respectively. These values for conventional design were changes in plant lifetime. The conventional design for a given range for
7.7 years and 3.5 $/m3, respectively. As the fuel cost rises up to more the interest rate and lifetime of the collection is less expensive than
than 0.1 $/m3 the hybrid design gets superior. The LCOW of all design hybrid configurations, although with increasing lifetime at a low in-
is most sensitive to the WWT unit cost rather than energy supplying terest rate, lower costs for water in hybrid configurations can be
plant. Changes in the cost of electricity versus fuel cost changes had less achieved. By using winter, spring, summer and autumn designs,
Fig. 16. Sensitivity analysis based on simultaneous changes in interest rate and life cycle.
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