Mega-ton Water System

(1)

Dr. Masaru Kurihara

Senior Scientific Director, “Mega-ton Water System”

of FIRST Project (FY2010-2013)

(Fellow, Toray Industries, Inc.)

“Mega-ton Water System”

January 14

th

_{, 2015}

Large Scale Desalination System for

21 st

_{Century Key Technology with Low Energy and}

Low Environmental impact

SWPF

CWC Technical Seminars

–Session 3

(2)

Urbanization is Progressing

1970/

145 2025/

668 2011/

449 Year and Number of Cities for Urban

Agglomerations of

1 million Inhabitants or more

Authority: “World Urbanization Prospects”, The 2011

Revision by United Nations

47%

53%

Coastal city

Inland city

(3)

World Population (million)

Water Use in the World (km

3 _/year)

World Urbanization Prospects, The 2011 Revision, United Nations

WORLD WATER RESOURCES AND THEIR USE a joint SHI/UNESCO product

It is necessary to install more than fifty million m

3 _/d

Water plants every year.

World Population Prospects and Dynamics of Water

Use by Kind of Economic Activity

(4)

0 10,000,000

20,000,000

30,000,000

40,000,000

50,000,000

60,000,000

19

6

0

19

6

2

19

6

4

196

6

19

6

8

19

7

0

19

7

2

19

7

4

19

7

6

19

7

8

19

8

0

19

8

2

19

8

4

19

8

6

198

8

19

9

0

19

9

2

19

9

4

199

6

19

9

8

20

0

20

0

2

20

0

4

20

0

6

20

0

8

20

1

0

20

1

2

20

1

4 MED

MSF

RO

1

st

generation

2

nd

generation

3

rd

generation

Number of Plants

14,000

2,000

Growth rate 25%

Desalination is approved as a national

project by JFK (1961)

Online Capacity m

3

_/d

(Cumulative)

Toray has created under DesalData 2014/GWI/IDA Desalination Plants Inventory

History of Desalination Plant

Shifting from Distillation to Reverse Osmosis

4 RO

(5)

100 1,000

10,000

100,000

1,000,000

1960

1970

1980

1990

2000

2010

2020

Desalination

Reclamation

Target

1,000,000m

3 _/d

Trend of Largest Plant

Industrial

Water

Daily Life

Water

Agricultural

Water

Soreq

Magtaa

Melbourne

Sulaibiya

Hadera

Ashkelon

Tuaspring

Technological development for 1,000,000 m

3 _{/day plant is required}

Soreq

Changes in RO plant scale

5

(6)

New Energy and Industrial

Technology Development

Organization

(NEDO)

Japan Society for the

Promotion of Science

(JSPS)

“Mega-ton Water System”

Research Organization

Overall

Management

Council for Science &

Technology Policy/Cabinet

Office, Government of Japan

International

Experts

Recommendation

Dr. Masaru Kurihara

Senior Scientific Director of

“Mega-ton Water System”

Research Support

Contracts

University: 11

Company: 17

Others: 2

Registered Researcher: 140

Research Scheme & Organization

Duration: FY2009-FY2013 (4years)

Kickoff Meeting

：

June 11, 2010

For sustainable management of water environment and for low-carbon path, all-Japan

team members are working together to develop Key 21st century water treatment

technologies and contribute to global water issues.

6 Budget

(7)

7 1. Energy Reduction

---“20-30% less Energy”

2. Low Environmental Impact

---“No or Minimum Chemical”

3. Low Water Production Cost

--“Reduction by Half”

Sustainable Desalination and Reclamation

(8)

8 RO Technology

Brine Discharge

Pressure Energy

Recovery (ERD)



Fossil Fuels



Nuclear



Renewable Sources

Wind

Hydroelectric,

Solar

Biomass

Geothermal

Tidal

For the Sustainable Desalination

Pressure Retarded

Osmosis (PRO)

Desalination

Drainage

No or minimum

Chemical Process

Energy Reduction

“

_{Mega-ton Water System”}

Conservation of

Energy Resources

Reduction of

Marine Pollution

Seawater RO

System

Energy

Resources

Subject-1

Subject-2

Subject-3

Used as

Electrical Energy

(9)

Seawater

Treated Water

Concentrated Seawater

Seawater RO System

Wastewater

Treatment System

Municipal

Water

Wastewater

_Treatment

Water Cycle in Mega-ton Water System

9 Pressure Retarded

Osmosis (PRO) System

Intake

Pre-treatment

Reverse Osmosis

Membrane

(10)

High Efficiency, Large

Size Element, Module

Intake Technology

Highly Efficient

Energy Recovery

Environmental Friendly

SWRO System

Pressure Retarded

Osmosis (PRO)

Highly Durable

Low Cost Pipes

Core Technology

System Technology

Pursuit of ultimate technology

Pursuit of future essential technology

1-1 1-2 1-3 1-4 1-5 2-2 2-3

1,000,000m

3 _/d

SWRO System

Optimization of

Mega-ton scale SWRO Plant

2-1

：

Sub

：

Main

Resource Reproductive

Sewage Integrated

Membrane System

2-2

100,000m

3 _/d

Waste Water

Treatment System

Output

Theme

Mission

FIRST Program: Mega-ton Water System

Mission & Output

Low cost

Energy Reduction

(Energy

Production )

Low

Environmental

Impact

10

(11)

Seawater

Low Pressure

Multi-stage High Recovery

SWRO System

Bio-Friendly

Pre-treatment

PRO

Municipal

Water

(12)

Polyamide Composite RO Membrane

Structure of polyamide composite RO membrane

Interfacial polycondensation

Polyamide

Thin layer

Amine

Acid

halide

Membrane surface

Protuberance

structure

Separating layer

Support layer

Substrate

Cross-linked aromatic

polyamide, 0.2µm

Poly sulfone,

60µm

Non-woven fabric,

150µm

Organic Layer

Aqueous Layer

Supposed chemical structure

Insoluble to any solvent

(13)

Elemental mapping by STEM-EELS

Prepared by Pretreatment to

keep wet condition

【SEM観察】

（

N

-

S

-

O）

Polymer

Substrate

【SEM】

_【TEM】

Innovative Low Pressure

Seawater RO membrane

1.Protuberance” Structure

with

Leading-Edge method

13 Target of High Efficiency Membrane

( for Reduction of Energy Consumption )

(1) Fine Structural Analyses of

Functional Layer in RO membrane

(a) Pore Size Estimation

(b) Precise Estimation of the

“protuberance” structure

(2) Innovative Low Pressure

Seawater RO membrane

Schematic diagram of

water permeation

Permeate

H２O H２O H２O H２O H２O H２O H２O H２O H２O H２O H２O NaCl

NaCl _NaCl_NaCl

NaCl NaCl NaCl

(14)

Energy Reduction

Low Pressure Seawater RO membrane will contribute to Large

Energy Reduction of the System

Comparison of High and Low Pressure Desalination

R

ej

ec

tion

（％）

Conventional

High Pressure

RO membrane

99.9

99.5

99.0 7.5 7.0 6.5 6.0 5.5 5.0 4.5

High Pressure

Desalination

Low Pressure

Desalination

Operation Pressure for Energy Saving (MPa @ 1.0m

3

_/m

2

_/d)

Low Pressure Seawater RO

membrane

measured

value

99.8 Innovative Low Pressure

Seawater RO membrane

14 R

ej

ec

tion

(%

)

(15)

LMS/ Megaton

Process

New ERD

Brine

RO/ LMS Megaton Process

ERD

Brine

RO/ Conventional Process

Conventional

Process

Seawater

Low Pressure Multi-stage Seawater RO System

(LMS)

Product

UF

Seawater

UF

Product

Advantages of LMS/ Megaton Process



Energy Reduction (20%) is possible due to Low Pressure Operation.



Water Production Cost Reduction(50%) and Footprint reduction is possible

due to High Recovery Operation (up to 65%).

1

2

1 TDS 35,000 mg/l

TDS 35,000 mg/l

15

1

2 Low Pressure Seawater

RO Element

(16)

8.0

7.5

7.0

6.5

6.0

5.5

5.0

4.5

4.0

3.5

3.0

2.5 Seawater Concentration (TDS %)

Pressu

re

(MPa)

Conventional

Mega-ton

Membrane

Eff. Press.

30%

down

Conventional

3.5 4.5 5.5 6.5 7.5 8.5 9.5

Eff. Press.

50%

down

One Stage

Two Stage

Low Pressure

Two Stage

Mega-ton

Membrane

Rec=45%

Rec=60%

16 Pressure Reduction by LMS Process

(17)

Low Pressure Multi-stage

High Recovery RO System

Conventional system

High pressure pomp

１ train

５ trains

Capacity 100,000 m

3

_/d

17 30% footprint reduction

will be possible due to High

Recovery Operation (up to 65%)

UF RO ERD High pressure pomp UF RO ERD Intake pump Intake pump

Low Pressure 2-stage

High Recovery

(18)

18 Image of New ERD installation for a Mega-ton

Seawater RO plant

New ERD

Ideal ERD

New ERD

Conventional ERD

with Over-Flush

Conventional ERD

without Over-Flush

Energy Recovery

Effectiveness

100 %

98.3 %

96.4 %

Mixing

0.0 %

1.3 %

2.5 %

6.0 %

Over-Flush

0.0 %

5.0 %

0.0 %

Normalized S.E.C.

for RO core process

1.000

1.025

1.059

1.069 Suitability for large-scaled

〇

△

Impact on plant Specific Energy

Consumption (S.E.C.)



Piston-less



No-leakage



Low Brine/Seawater Mixing



Flexible Control



Quiet Operation

Characteristic Feature of

Next-Generation ERD

(Single stage RO, Recovery=45%, Feed TDS=4%)

(19)

19 Durable Resin Piping System

Resin Piping System

Conventional Piping

SCH80

Components

PP+FRP

SDSS

Durability

(Safety Factor)

6~8MPa

(4.0)

6~8MPa

Size

Up to 300A

-

Weight 100A*5m

45kg

115kg

Cost Reduction

30% OFF

-

Comparison with SDSS



No Corrosion in Seawater Condition



Suitable for High Pressure Applications in

SWRO Plants



Lightweight & Easy to Handle

Feature of

Durable Resin Piping and Fittings

Prefabricated Resin Piping

(made by Asahi)

(20)

Solution

②

③



It was verified that continuous

chlorination/de-chlorination will be the

trigger of biofouling.



Novel index BFI was established for RO

monitoring.

①

Re-examination of bacteria quantification method

②

Verification of hypothesis

③

Establishment of biofouling risk predictive index.

Research problem related

to

_biofouling

Influence of chemical addition was

verified and biofouling risk predictive

index was established.

Selection of proper detection method is

important.

Sterilization effect of low concentration

chlorination is limited.

Solution

①

Classical method

（

Plate count method

）

Fluorescence

Microscopic observation



Detection sensitivity can be increased 100

times by direct count by fluorescence

microscopic observation



Only about 30% of live marine bacteria

were sterilized by chlorination.

100 1,000 10,000 100,000 1,000,000 海水塩素殺菌海水 100 1,000 10,000 100,000 1,000,000 海水塩素殺菌海水菌数（ ce ll s/m l ）菌数（ ce ll s/m l ）生菌数全菌数（生菌+死菌）生菌数（細部まで健全）生菌数（呼吸活性あり）

20 Clarification of the influence of

chlorination/de-chlorination on biofouling

Differential Pressure ATP BFI Cell d ensit y [cell s/ml] C ell d en sit y [ cells/m l] Raw Chlorinated seawater seawater Raw Chlorinated seawater seawater

Colony forming cell

Total cell

Membrane undamaged cell Respiratory active cell

(21)

BFRI

● High

● Moderate ● Low

Categorization of Seawater Quality based on Mega-ton Water System Bio-Fouling

Risk Index “BFRI”

Conventional

Filtration Process

HP Pump

RO

BFRI : Low

BFRI : Moderate

BFRI : High

No Chemical

No or Minimum

Chemical

Seawater

HP Pump

RO

Biodegradable

Filtration Process

Seawater Quality

0

500 1000

0

5

10

15

20

25 Biodegradable Filtration Process Pilot Test Results

Time

Bio

-fo

uling

on

RO

me

mbra

ne

Clear seawater

Necessary Pretreatment Process can be estimated by Mega-ton Water System “

BFRI

”

Non-Chemical Process

(Pretreatment Process Design Concept)

Pretreatment Process Design Concept

(22)

PRO system

PRO Unit

Treated Waste

Water

Fresh Water

Brine

UF Treated

Water

UF-Unit

LRO-Unit

Pump Effluent Tank Release

Turbine & Generator

To Effluent Tank Press Exchanger

Membrane

Module

PRO Unit

Treated Waste

Water

Fresh Water

Brine

UF Treated

Water

UF-Unit

LRO-Unit

Pump Effluent Tank Release

Turbine & Generator

To Effluent Tank Press Exchanger

Membrane

Module

LRO-Unit

UF-Unit

Outline of PRO system

PRO Unit in Prototype PRO System

(23)

Seawater

Pretreatment

PRO

Product

SWRO Brine

MBR + RO

Draw solution: 460 m

3

_{/d of SWRO brine}

Feed water: 420 m

3

_{/d of treated sewage}

PRO membrane:10-inch hollow fiber x 8 pcs.

Fukuoka Prototype PRO Plant

The world highest power density of

13 W/m

2 _{at 7% Seawater RO Brine}

_{has been achieved.}

Pressure Retarded Osmosis (PRO)

Energy Reduction by Seawater RO Brine PRO System

Process

Seawater

Conc. (%)

Brine Conc.

(%)

Specific Electric Consumption (SEC) kWh/m

3

without PRO

With PRO

Reduction Rate

Conventional (R=45%)

3.5

6.4

3.75 -

-

Mega-ton (R=65%)

10

3

2.7 10%

23 

Energy Reduction is 10% by PRO System.

(24)

Proposal of “Mega-ton Water System”

Low Pressure Seawater RO Element

Next-Generation ERD

New High Pressure Resin Pipes

Low pressure Multi-stage Inter-boosted System (

LMS

) with High

Recovery

Chemical-Free Seawater RO Plant Intake & Pre-treatment System

(

Non-Chemical

)

Pressure Retarded Osmosis (

PRO

) System



Materials &

Equipment

Integration of Advanced Device and Advanced System Technology



System

4

5

1

2

3

1

2 ₃

4

5

6

24

(25)

0.0

1.0

2.0

3.0

4.0

5.0 Conventional

0.1MCMD (R=45%)

Conventional 1 MCMD

(R=45%)

Mega-ton LMIS 1

MCMD (R=65%)

SE

C (Spec

ifi

c

Energy

Cons

umpti

on

(kW

h/m

3

)

Others

RO

>20%

Energy Reduction by Megaton Water System

25 Conventional

Process

Conventional

Process

LMS Process with

Mega-ton

Technologies

Capacity

100,000 m

3 _/d

_{1,000,000 m}

3 _/d

_{1,000,000 m}

3 _/d

Recovery

45%

65%

Seawater Concentration=TDS 3.5%

(26)

Conventional

0.1MCMD

Conventional 1MCMD

Mega-ton Water

System 1MCMD

Capital

50%

35%

25%

O&M

14%

10%

7%

Power

37%

26%

20%

0%

20%

40%

60%

80%

100%

120%

W

at

er

Pr

odu

ctio

n

C

os

t

Br

eak

d

own

Capital

O&M

Power

50%

30%

Reduction of Water Production Cost

26 Conventional

Process

Conventional

Process with

Large-scale

Technologies

LMS Process

with Mega-ton

Technologies

Capacity

100,000 m

3 _/d

_{1,000,000 m}

3 _/d

_{1,000,000 m}

3 _/d

Recovery

45%

65%

This figure presents an example of FS cost estimation for

a 1,000,000 m

3

_{/day seawater RO desalination project.}

Seawater TDS=3.5%,

(27)

4. “Mega-ton Water System” technologies are also applicable to

Small Size

Decentralized Systems

and conventional plants

as Retrofit

along with

the ultra-large system under the concept of resilient economy

1. “Mega-ton Water System” is a project by the state support of Japan

to develop mega-scale seawater desalination plant system

technologies necessary in the 21st century

2. Mission and Progress by “Mega-ton Water System”

1) Energy Reduction

--- “20-30% less Energy”

2) Low Environmental Impact

--- “No or Minimum Chemical”

3) Low Water Production Cost

--- “Reduction by Half”

3. Output of “Mega-ton Water System”

i. Low Pressure Seawater RO Element, Large Size Hollow Fiber RO Element

ii.Next-Generation ERD

iii.New High Pressure Resin Pipes

i. Mega-ton Scale Desalination RO Plant System with “LMIS” Process

ii.Chemical-Free Seawater RO Plant Intake & Pre-treatment System

iii.Seawater RO Brine PRO System



Materials and

Equipment



System

“Mega-ton Water System” will help realize

the Global Water Solutions

27

(28)

Acknowledgement

This research is granted

by the Japan Society for the Promotion of Science (JSPS)

through

the “Funding Program for World-Leading Innovative R&D

on Science and Technology (FIRST Program)”

initiated

by the Council for Science and Technology Policy (CSTP).