http://www.must.edu.

eg

College of Engineering
Mechanical Engineering Department
Desalination Engineering
Dr. Hassan K. Abdulrahim
MULTI STAGE FLASH (MSF)
SYSTEM
Nov. 21, 2017

2
 Assignment
When = 0 all vapors generated in all effects,
other than the first one, are by flashing only.
This is similar to the case of MSF system
using much higher number of stages (not
effects), say 19 stages.
So, repeat example 13, but for 19 effects to
compare it later by MSF system.
Forward feed multi-effect system with regenerative feed heaters.

4
 Multi Stage Flash (MSF) Evolution
In MED, vapor is generated by boiling in
effects and flashing from brine moving from
1st to nth effect due to pressure drops between
effects and become product D when
condensed.
In a typical MED system, (Db)80% and
(Df)20%
Db generated by effects heat transfer surface
areas
5
 Multi Stage Flash (MSF) Evolution
Df condensed on feed preheater (FH) heat
transfer areas
As F/D increases, Df/Db increases.
This requires increase FH heat transfer surface
area and decrease of the effects heat transfer
area.
In MSF system, F/D is increased so that all
generated vapor is by flashing only.

6
7
8
9
10
11
12
 Multi Stage Flash (MSF) Evolution
FH heat transfer areas increased to condense
all released vapor.
The first large unit using this concept (MSF)
built in Kuwait by Westinghouse in 1957 for
D=0.5 MIGD, using 4 stages and PR=3.3
Based on MEB analysis (presented earlier)
with a PR close to but smaller than n.

13
 Multi Stage Flash (MSF) Evolution
Silver filed a patent (British Patent in 1957) for
a MSF process with different analysis than
MED in some respects
PR does not explicitly depend on n as in MED
system.
n is greater than twice the required PR.
In practice, n3 PR
Effects heat transfer surface were eliminated
14
 Multi Stage Flash (MSF) Evolution
In 1958 Silver designed first two units based
on his patent.
First unit in Kuwait, D = 1 MIGD or 4546-
m3/day, and n = 19 stages, GR = 5.8.
Second unit has n = 40, D = 0.5 MIGD, GR =
10.5.
Both units were commissioned with success in
1960.

15
 Multi Stage Flash (MSF) Evolution
Dramatic increase in GR, and simplicity of the
MSF has happened since then.
Unit capacity continuously increasing.
Max. capacity were 7.5 MIGD (1990) and 12
& 17 MIGD in (2000s) and 20 MIGD (2012).
MSF produced more than 80% of desalted
water in GCC (2000).

16
 Multi Stage Flash (MSF) Evolution
MSF process has two types
A. Once-through MSF (OT-MSF) and
B. Recirculation MSF (R-MSF) systems.
R-MSF system most widely used in practice.
MSF plant has two types according to the
condenser tubes arrangement
A. Long Tube Configuration
B. Cross Tube Configuration

17
One of eight MSF units at the Ras Al-Khair plant, Saudi Arabia
(total cost = 1.76 billion US$, capacity/unit = 91,000 ton/d (20
MIGD), $11 M/MIGD, 123 m (length) 33.7 m (width), weight
4150 ton)
18
19
20
21
Long Tube Configuration

22
Arrangements of long tube directions in the MSF stages
23
Cross Tube Configuration

24
Arrangements of cross-tube directions in the MSF stages

25
Isometric views of long-tube arrangements in MSF
stages
26
 Single Stage Flash
F is pre-treated, from tc to t1 in condenser tubes
located at the upper part of flashing chamber,
called a stage here.
F is then heated in Brine Heater (BH) (heat
exchanger) to To (TBT) by condensing S at Ts
F leaves BH at To and Po, enter to 1st flash
chamber (or stage) kept at P1 of saturation
temperature T1 < To.

27
 Single Stage Flash
When F enters the flash chamber it becomes
unstable, part of it is spontaneously vaporized
(i.e. flashed to lower its temperature to T1).
Vapor D generated by flashing flows through
demisters, to separate entrained liquid, and to
condenser tubes to be condense in the product
tray and forms the product.
Heat released by condensing vapor used to heat
F in tubes.

28
29
 Single Stage Flash - Analysis
In brine heater
Qbh = S Ls = F C (To t1)
In flashing chamber
D1L = F C (To T1)
In condenser
D1L = F C (t1 tc)
If S supplied as sat. vapor, and leaves as sat.
liquid, overall energy balance gives
F C tc + S Ls = (F D1) C T1 + D C Tv1

30
 Single Stage Flash - Analysis
The un-flashed brine is rejected back to the sea
as blow down.
Brine blow down B = F D.
Tv1 = T1 T(loss),
T(loss) in stage by BPE, non-equilibrium
losses, and drop in saturation temperature due
DP(losses) in demisters and condenser tube
bundle.

31
 Single Stage Flash - Analysis
Feed Feed
(F, t1) (F, tc)
Steam
(S, Ts)
Distillate
(D, td)
Brine
Heater
(BH)

Brine
Feed (B, Tb)
(F, To)

32
Typical cross-section of a stage in an MSF desalting system
33
 D1.L = F.C.(T0 - T1)
D1.L = F.C.(t1 - tc)
(T0-T1) = (t1 - tc) =DT=Dt
S.L = F.C.(T0 - t1)
S.L = F.C.(T1 - tc)
(T0-t1) = (T1 - tc)

Single-stage flash desalting system and stage temperature profile34

 Single Stage Flash - Analysis
SL F C (T1 tc), heat in = heat out (BH)
DL= F C (To T1), D generated by flashing
DL= F C (t1 tc), condensation heat of D
Then,
F C (To T1) = F C (t1 tc) = F C DT = F C Dt,
or
DT = Dt and
GR = D/S = (To T1)/(T1 tc)

35
 Single Stage Flash - Analysis
D/S = (To T1)/(T1 tc)
= (To T1) / [(T1 t1) + (t1 tc)] < 1
PR = 2330 D/S Ls
F/D = L/[C (To T1)] = L/[C (t1 tc)] = 1/y

36
 Example 1
Data for a single stage MSF system are:
To = 90C (TBT), tc = 30C (SW temp.), (T1 t1)
= 4.2C
Find F/D and D/S
To - tc= (To T1) + (T1 t1) + (t1 tc)
= 2DT + (T1 t1)
60C = 2DT + 4.2, then
DT = 27. 9C,
37
 Example 1
T1= 90 27.9 = 62.1C,
t1= 30 + 27.9 = 57.9C,
D/S = (57.9 30)/(62.1 30) = 0.875, and
F/D = 2330/[4(27.9)] = 19.9 (L = 2330 kJ/kg)
F/D = 19.9 is too large compared to F/D (= 2.5 to
3) for single-effect or MED system when the feed
TDS = 42 g/l and brine blow-down TDS = 70 g/l

38
 Single Stage Flash - Analysis
Brine Heater Heat Transfer Area
S Ls = F C (T0 t1) = Ub Ab (LMTD)b
Ab/D = (F/D) C (T0 t1) / [Ub (LMTD)b]
(LMTD)b=[(T0 t1)/ln[(Ts t1)/(TsT0)]

Ts
To
t1
39
 Single Stage Flash - Analysis
Condenser Heat Transfer Area
D L = Uc Ac (LMTD)c
Ac/D = L/[Uc (LMTD)c]
(LMTD)c= [(Tv1 tc) (Tv1 t1)] / ln [(Tv1 tc) /
(Tv1 t1)]
Tv1

t1
tc
40
Two-Stage Flash System

41
 Two-Stage Flash System
F enters 2nd stage condenser at tc, pre-heated to
t2 and to t1 in 2nd and 1st stages, it enters Bhand
heated from t1 to To by condensing S
It enters 1st stage at P1 (of S.T. T1 < To) as
flashing brine.
D1 flashed from F, (due T drop from To to T1),
condenses on 1st stage condenser outer tubes,
raises feed temp. from t2 to t1

42
 Two-Stage Flash System
Brine (B1 = F D1) and formed distillate D1
proceed to 2nd stage kept at P2 of S.T. T2 < T1.
Flashing brine B1 and D1 suffer pressure drop,
and partially flashed.
Vapor flashed from B1 and D1 condense on 2nd
stage condenser, and heats F from tc to t2.
B2 = F D1 D2 leaves at T2.
D2 is the vapor flashed from B1 only

43
 Two-Stage Flash - Analysis
Brine Heater
Qb = SLs = F C (To t1)
First Stage
D1L = F C (To T1) = F C DT,
D1L = F C (t1 t2) = F C Dt
Second Stage
D2 L = (F D1) C DT
D2 = (F y F) y = F (1 y) y
44
 Two-Stage Flash - Analysis
d1 flashed from D1, does not represent product
d1 L = D1 C (Tv1 Tv2)
d1 = D1 C DT/L,
D2+d1 heats the feed F from t2 to t1
D2 + d1 = (F D1)CDT/L+ D1CDT/L = F C DT/L
Second Stage Condenser
(D1 + d1) L = F C (t2 tc)

45
 Two-Stage Flash - Analysis
(T1 T2) = (t2 tc) = DT
(To T1) = (T1 T2) = DT,
(To T2) = 2 DT
Define: y = C DT/L, then
D1 = F C DT/L = y F
D2 = F (1 y) y
D = D1 + D2

46
 Two-Stage Flash - Analysis
D = y F + F (1 y) y = F [y + y (1 y)]
D = F [1 (1 y)2]
F/D = 1/[1 (1 y)2]
SLs = F C (To t1)
D/S = (D/F)(F/S)
D/S = [1 (1 y)2] L/[C (To t1)]

47
 Example 2
Given data for 2-stage flash system:
Ts = 100C, To = 90C, tc = 30C, Tlosses = 1.2C,
T1 - t1 = 4.2C, Ub = 3 kW/m2C and
Uc = 2.5 kW/m2C
Find F/D, and GR

48
 Answer
Assume (T1 t1) = (T2 t2) = 4.2C
(To tc) = (To T1) + (T1 T2) + (T2 t2) + (t2 tc)
= T + T + (T2 t2) + T
= 3T +(T2 t2)
90 30 = 3T + (T1 t1) = 3T + 4.2,
T = (60 4.2)/3 = 18.6C, and,
t2 = 30 + 18.6 = 48.6, t1 = 48.6 + 18.6 = 67.2C,

49
 Answer

T1 = 90 18.6 = 71.4C, Tv1 = 71.4 1.2 = 70.2C,

y = CDT/L = 0.03193,
F/D = 1/[1 (1 y)2] = 1/[1 (10.03193)2]
= 15.91
D/S = [1 (1 y)2] L / [C(To t1)]
D/S = (1/15.91) 2330 / [4(90 67.2)] = 1.606

50
 Answer
Thus, adding another stage improves the GR
from 0.875 to 1.606, decreases F/D from 19.5
to 15.91
Thus, reduces the energy rejected with the
blow-down brine because its flow rate and
temperature are decreased.

51
END OF LEC. 7
21/11/2017

52
LECTURE 8
28/11/2017

53
 MSF Desalting System
Two types of MSF system are used in practice
Multi Stage Flash with Brine Recirculation (R-MSF)
the mostly used type.
Once Through Multi Stage Flash (OT-MSF).
The first ever designed R-MSF units were built
in Kuwait in 1959, with 1 MIGD unit capacity.
GR = 8, and TBT = 90.5C
MSF unit capacity continues to increase since
1959.
54
OT-MSF

55
R-MSF

56
 OT-MSF Analysis
SW feed F enters last stage (stage n) at a temp. tc,
successively heated in stage condensers to tn, tn-1,
tn-2, and t1 at first stage outlet
F enters the BH at t1, leaves at To (top brine
temperature TBT)
Heat added in BH is Qbh = F C (To t1)
F leaves BH and enters the first stage at a temp. To
> equilibrium temp. of the first stage, T1
To spontaneously drops to T1 due to (or by)
flashing amount of vapor D1, where
D1L= F C (To T1) = F C DT
57
 OT-MSF Analysis
D1 = F C (To T1) = F CDT/L = y F
B1 = F D1 = F y F = F(1 y)
The remaining brine of the amount B1 = (F
D1) enters stage 2 which kept at equilibrium
temp. T2, where T2< T1
Flashing brine temperature T1 drops to T2 due
to (or by) flashing D2
Where D2 L= (F D1)C(T2 T1) = (F D1)CDT
58
 OT-MSF Analysis
D2 = y B1 = (F D1) y = (F y F) y = y F(1 y)
B2 = B1 D2 = F(1 y) F(1 y) y = F(1 y)2
D3 = F y (1 y)2
B3 = F (1 y)3
D4 = F y (1 y)3
B4 = F (1 y)4
Dn = F y (1 y)n-1
Bn = F (1 y)n
D = F Bn = F F(1 y)n
D = F[1 (1 y)n]
59
 OT-MSF Analysis
F enters first stage at temp. To, and leaves last
stage n as brine B = (F D) at temp. Tn
Average mass flow rate of the flashing brine is
[F + (F D)]/2 = F D/2
Heat lost by the average flashing brine is (F
D/2) C (To Tn) is used to evaporate D, or
(F D/2) C (To Tn) = D L, or
F/D = 0.5 + L/C(To Tn)
60
 OT-MSF Analysis
F enters stage 1 with salinity Xf and B leaves
the system with salinity Xb
F Xf = (F D) Xb
F/D = Xb/(Xb Xf)
Heat input in BH
Qbh = F C (To t1) = S L
Overall Energy Balance
S Ls = F C (Tn tc)
61
 OT-MSF Analysis
GR = D/S = (D/F) (F/S)

62
 OT-MSF Analysis
To t1 = (To T1) + (T1 t1) = DT + (T1 t1),
(T1 t1) is called temperature approach.
GR increases with the decrease of DT (or increase
of n), and the decreases of the temperature
approach (T1 t1) of 1st stage.

63
 OT-MSF Analysis
BH Heat Transfer Area
Ts

To

t1

64
 OT-MSF Analysis
For the condenser of any stage i, Aci

65
 OT-MSF Analysis
Total heat transfer area

66
 Example 3
The following data are given for an OT-MSF unit:
The number of stages n=24, D=3.61 MIGD,
seawater temperature tc=26C, steam temperature
Ts=115C, TBT =108C, T24=40.8C, seawater
water salinity Xf=45 g/kg, Ub=2.2 kW/(m2 C),
Uc=2.1 kW/(m2 C), T(loss)=1.3C in the first
stage, and 1.8C in the last stage, and the average
T(loss)=1.55C.
Find the flow and the temperature of the different
streams (feed water, flashing brine, vapor, and
distillate (product) in the stages.
67
 Answer Ex3
1 MIG = 4546 m3,
D = 3.61 MIGD = 3.6145461000/(243600)
= 190 kg/s

68
Answer Ex3

69
Answer Ex3

70
Answer Ex3

71
 Answer Ex3
The brine temperature Tb is calculated by deducting
T=2.8C from To=108C to get T1=105.2C, from
T1 to get T2=102.4C, and so on to Tn=40.8C.
The value Ds is calculated from yF1= 0.004759
1758.58 = 8.37 kg/s, then the feed to the second
stage FD1=1750.22 kg/s, and D2=y(FD1) = 8.33
kg/s, the feed to the third stage FD1D2=1741.89
kg/s, and D3=y(FD1D2)=8.29 kg/s, and so on to
Dn=7.5 kg/s.

72
 Answer Ex3
The salinity X is given first as 45 g/kg, then
the salinity at the first stage exit:

73
Answer Ex3
Results of Example 3

74
 Example 4
Given data for OT-MSF unit:
D = 2 MIGD, n=28, max tc=35C, min tc=18C,
design tc=26C, Xf=45 g/kg, To=110C, Tn=
40C, Cw= 4 kJ/kgC, L=2330 kJ/kg, Sat. steam
temperature Ts=120C, Ls=2202 kJ/kg
Find F, Xb, Qbh, qbh, GR, and PR in summer
and winter.

75
 Answer Ex4
2 MIGD = 2 4546 1000 / (24 3600) =
105.3 kg/s
(To Tn) = (t1 tc)=70C
DT = Dt = 70/28 = 2.5C
t1 = tc + n Dt = 26 + (282.5) = 96C (Design tc)
Sat. steam at 120C, Ls = 2202 kJ/kg
F/D = 0.5 + L/C(To Tn)
F/D = 0.5 + 2330/[4(110 40)] = 8.82

76
 Answer Ex4
F = 8.82105.3 = 929.1 kg/s
Qbh = F C (To t1) = S Ls
Qbh = 929.14 (110 96) =52,030 kW,
Specific energy consumption,
qbh = Qbh /D = 494.11 kJ/kg
S = Qbh/Ls = 52030/2202 = 23.63 kg/s,
GR =105.3/23.63 = 4.46
PR = GR (2330/Ls) = 4.72

77
 Answer Ex4
In Winter, when tc = 18C, t1 = 18 + 70 = 88C,
Qbh = 929.14(110 88) = 81,761 kW,
qbh = 776.5 kJ/kg
S = 81,761/2202 = 37.1 kg/s,
GR = 105.3/37.13 = 2.84
In Summer, when tc = 35C, t1 = 35 + 70 = 105C,
Qbh = 929.14(110 105) = 18,582 kW,
qbh =176.5 kJ/kg
S = 18,582 /2202 = 8.44 kg/s,
GR = 105.3/37.13 = 12.48
78
Calculate Xb, GR and heat rejected to sea by
OT-MSF for tc=18, 26, and 35oC
This main disadvantages of the OT-MSF: Too
much energy is rejected to sea at low tc.
Q (rejected) = F C (Tn tc), Tn = 40C
Q (rejected for tc = 18C) = 81,760 kW
Q (rejected for tc = 26C) = 52,030 kW
Q (rejected for tc = 35C) = 18,582 kW

79
Calculate Xb, GR and heat rejected to sea by
OT-MSF for tc=18, 26, and 35oC
GR = 2.84 for tc = 18C,
GR = 4.46 for tc = 26C,
GR = 12.48 for tc = 35C,
Xb (F D) = Xf F
Xb = 45929.1/(929.1 105.3) = 50.75 g/kg

80
 Assignment-1 (OT-MSF)
An OT-MSF desalting system has the following data:
Desalting capacity is 7.2 MIGD, and To = 111.5C, n = 21, Tn = 38C, Xf = 45 g/kg,
tc = 31C, Ts To = 6.5C. The heating steam enters the brine heater as saturated
vapor and leaves as saturated liquid, an average temperature losses in each sages is
assumed and equal to 1.4C, and the average overall heat transfer coefficient=2.6
kW/(m2C) in condensers and 2.4 kW/(m2C) in brine heater. It is required to:
1. Tabulate the distillate generated and flashing brine in and out for each stage.
2. Tabulate and plot the temperature, salinity, and pressure in each stage.
3. Calculate the average BPE.
4. The total and specific heat transfer areas of the condensers and brine heater.
5. The gain ratio, performance ratio, specific heat input.
6. If the seawater temperature was decreased to 24C and Tn decreased to 35.9C,
recalculate the feed, gain ratio, and performance ratio for the same distilled
water output.

81
Solution

82
83
84
85
86
87
88
89
If seawater temperature tc was decreased
from 31C to 24C and Tn decreased to 35.9C:

This problem shows that when the seawater

temperature tc decreases from 31C to 24C,
the required feed decreases from 3232.6 to
3148 kg/s (2.6%), and the gain ratio decreases
from 9.237 to 5.6 (39%) for the same distilled
water output.

90
 Assignment-2 (OT-MSF)
Calculate the pumping energy required for the OT-MSF unit given in
Assignment -1 provided:
1. The feed, if the pressure drop across the condensers in all stages and brine
heater is equal to 700 kPa,
2. For the blow-down pump, if the required discharge pressure is 200 kPa
3. For the steam condensate if the discharge pressure is 1 MPa,
4. The distillate pump if the discharge pressure is 300 kPa.
5. Total pumping power consumption and specific pumping energy
consumption

Assume reasonable values for the pump and motor efficiencies

91
Solution

92
93
94
95
96
 Recirculation MSF (R-MSF)

HIS: Heat input section (BH)

HRS: Heat recovery section (stage 1 to n-j stages)
HJS: Heat rejection stages (last j stages)
97
 R-MSF Flow-Sheet
The R-MSF has three sections:
Heat input section (HIS): the Brine Heater (BH),
heats the R-stream from t1 to To (TBT)
Heat recovery section (HRS): stage 1 to stage n j
(where n is the total number of stages).
Heat rejection section (HJS): the last j stages, has
(2 to 3) stages.

98
99
HJS of R-MSF

100
 R-MSF Flow-Sheet
The R stream at Tn (taken from last stage) is
successively heated as it enters (n j) HRS
condensers to t1 as it leaves stage 1 condenser.
Stage 1 receives R (from BH at To) as flashing
brine.
R is successively cooled by flashing vapor from
stage 1 to last stage n at Tn.
Cooling water Mc at tc enters stage n condenser,
heated in HJS condensers by condensing vapor,
exits from n j+1 stage at Tn.
101
 R-MSF Flow-Sheet
Part of Mc = feed F is chemically treated and
enters stage n, and the remaining Mc F is
rejected back to sea.
Feed F joins remaining brine in stage n (R D)
and mix together, exits at Tn,
F D rejected to sea as brine blow down, and
R pumped to last HRS stage (n j).
The temperature difference To t1 is called the
terminal temperature difference (TTD).
102
R-MSF Flow-Sheet

Mc

In winter when tc is low, (Mc

F) from stage (n j+1) can be
recirculated with Mc to keep Mc
at Tn at exit to keep constant
temp of cooling SW to HJS all
the year
103
 Temperature profile for R-MSF unit
TS
To
T1
T2
t1
t2
t3

Tn-2
Tn-1
Tn
Tn

tc
104
 Recirculation Arrangements
Two arrangements are used for the pre-treated
feed F to become part of the recirculation stream
1. Mixing before blowdown (MBBL)
2. Blowdown before Mixing (BLBM)

(MBBL) (BLBM) 105

 Recirculation Arrangements

For both arrangements, the mass of salt entered with the

flashing brine in the first stage R Xr is equal that ended
with the flashing brine in the last stage (R D) Xb,
R Xr = (R D) Xb
Xr/Xb = (1 D/R)
R/D = Xb/(Xb Xr)
Xr = Xb(1 D/R) 106
1- Mixing before blowdown

107
 1- Mixing before blowdown
F is introduced to nth stage, mixes with the
remaining flashing brine (R D), so, feed arrived in
last stage is (R D + F) before rejecting blowdown.
Last stage operates under vacuum, so no pump is
required to introduce F to this stage.
Brine blowdown pump dumps (F D) to the sea.
Recirculation pump sucks (R) and deliver it to HRS
last sage (n j) condenser.
There will be some waste in chemicals since part of
the pretreated feed is rejected to sea.
108
2- Blowdown before Mixing

109
 2- Blowdown before Mixing
Blowdown brine in the amount of (F D) is
rejected from nth stage before mixing feed F with
the flashing brine ended in that stage.
Only the required F is treated and no waste from
the feed like in previous case.
Feed can be introduced at the inlet of the
recirculation pump and or small pump can be
used to introduce it at the exit of the
recirculation pump
110
 F/D For Both Cases
Typical value of Xf = 42,000 ppm, Xb = 70,000 ppm,
and assumed R/D = 9.2, what is F/D for the two
methods of recirculation.
For the first case (MBBL):

111
 F/D For Both Cases
For the second case (BLBM):

Ratio of F/D in first arrangement is higher (i.e.

more water to be treated at additional cost) than
in the second arrangement.

112
 R-MSF Analysis
R enters stage 1 for flashing at To, becomes (RD)
at Tn in stage n, average recirculation flow rate is
(R D/2), heat lost is used to flash D, i.e.
(R D/2) C (To Tn) = D L
R/D = 0.5 + L/[C(To Tn)]
Heat gained by R in each HRS condenser is
RCDt, and in each HJS condenser McCDt,
Assuming DT is the same in all stages, heat gain
in HJS is RC(3DT) = Mc C (Tn tc)
See temperature distribution.
113
 R-MSF Analysis
Brine Heater:
Qbh = S Ls = R C (To t1)
S/D = (R/D) C (To t1)/Ls
D/S = (D/R) Ls / [C (To t1)]
D/R = (1 D/2R) [C(To Tn)]/L
D/S = {(1 D/2R)C(To Tn)/L}{Ls/C(To t1)}
D/S = (Ls/L)(1 D/2R)[(To Tn)/(To t1)]
114
 R-MSF Analysis
D/S = (Ls/L)(1 D/2R)[(To Tn)/(To t1)]
D/S = (Ls/L)(1 D/2R)[nDT/[(To T1)+(T1 t1)]
GR = (Ls/L)(1 D/2R) [n / [1 + (T1 t1)/DT]]

D/S increases by increasing n, increasing (To Tn)

and decreasing (T1 t1).
(T1 t1), condenser temperature approach,
decreases by increasing heat transfer area Ac
115
END OF LEC 8
28/11/2017

116
LECTURE 9

117
 R-MSF Analysis
BH Heat Transfer Area
Ts

To

t1

118
 R-MSF Analysis
Condenser Heat Transfer Area in (HRS)

Condenser Heat Transfer Area in (HJS)

119
 Comparison of OT-MSF & R-MSF
Example 4 shows that one of the main
disadvantages of the OT-MSF desalination
system is the drastic reduction of the gain ratio
GR with the decrease of tc.
This overrules the use of this system in single
purpose desalting plant taking its feed water
directly from the sea at relatively low
temperature in winter.

120
 Comparison of OT-MSF & R-MSF
When OT-MSF is used, it would be very inefficient
in winter when seawater temperature tc is low
unless it is combined with condensing steam
turbine and the feed water to the OT-MSF unit is
to be controlled by mixing the cooling water reject
from the power plant condenser with seawater feed
to the unit.

121
 Comparison of OT-MSF & R-MSF
Besides the significant decrease in the gain ratio
when tc is low in winter, the last stage temperature
Tvn becomes low, and gives significant increase in
the vapor specific volume, and thus high vapor
velocity unless the last stages cross section area
is drastically increases, which is not acceptable.

122
 Comparison of OT-MSF & R-MSF
Uses less numbers of pumps in OT-MSF
compared to R-MSF system; only one feed pump
in the OT-MSF while R-MSF has re-circulation,
blow-down, and feed pumps.
But OT-MSF has high F/D ratio, or large amount
of treated feed F.
Largest capacity OT-MSF 2.5 MIGD compared to 20
MIGD for R-MSF.

123
 Comparison of OT-MSF & R-MSF
Low salinity in OT-MSF compared with R-MSF.
In last example Xf = 45, Xb = 50.75 g/kg
In R-MSF range: Xf = 45, Xb = 70, Xr = 63 g/kg
At average T = 75C, X = 50, BPE = 0.7C
At average T = 75C, X = 60, BPE = 1.0C
Since average LMTD = 3.5oC, DBPE/LMTD =
8.5%, allows 8.5% condenser area decrease.

124
 Comparison of OT-MSF & R-MSF
In example 4, GR ranges from 2.84 to 12.48,
depends on tc, while in R-MSF, GR does not
depend on tc, almost constant, say, close to 8.
Another disadvantage of OT-MSF that too much
SW is pretreated, (8.82 D in example 4) compared
to about 3D in R-MSF.
High non-condensing gases in the feed, mainly
oxygen, released in 1st stage, that can cause severe
corrosion.
125
 Comparison of OT-MSF & R-MSF
In OT-MSF, low salinity in 1st stage allows higher
TBT, and thus higher pressure of supply steam to
the BH.
P increase in 1st stage reduces steam required for
ejectors sucking non-condensable gases; where
the non-condensable gases can be vented directly
to atmosphere when stage pressure > Patm

126
 Comparison of OT-MSF & R-MSF
Less equipment used, cooling water pump is
the main pump substitutes recirculation pump
with DP < DP (Rec. pump sucking from low P
of last stage)

127
 Example 5
Given data: R-MSF has n = 24, and j = 3, Tn= 40.5C,
D = 6 MIGD, To = 90.5C, DT are equal in all stage,
DP across Rec. Pump = 700 kPa, Xf = 45g/kg, Xb = 70
g/kg.
Calculate:
GR, PR, R/D, F/D, and pump work

128
 Solution Ex 5
DT = (To Tn)/n = (90.5 40.5)/24 = 2.08C,
DT= Dt
t1= Tn + (n j)Dt = 84.2C.
R/D = 0.5 + 2330/[4(90.5 40.5)] = 12.15
Qd = (12.15)(316)(4)(90.5 84.2) = 97,060 kW
Steam at 100C, Ls = 2257 kJ/kg,
S = 97060/2257 = 43 kg/s, GR = 316/43 = 7.35

129
 Solution Ex 5
PR = (2330/2257)GR = 7.35(2330/2257) = 7.6
Xb (R D) = Xr R
70 (12.15 1) = Xr (12.15), Xr = 64.2 g/kg
Average Xb in stages = 67.1 g/kg
F/D = Xr/(Xr Xf) = 64.2/(64.2 45) = 3.34
The main disadvantage of the R-MSF is the high X in the
stages specially at high T first stage.

130
 Solution Ex 5
Work to Rec. Pump = Q(m3)(DP in kPa)/(pump) =
(12.15316/1000)(700)/0.75 = 3,583 kW
W(pump)/D = 11.34 kJ/kg (3.15 kWh/m3)
All other pumps including cooling water, product, steam
condensate, and chemical pumps consume 25% of rec.
pump work.
For cooling water pump:
Mc = 1800 kg/s, and Mc / D = 5.7, DP = 200 kPa,
Wc = 480 kW, and Wc / D = 1.53 kJ/kg.
Wpump / D 4.5 kWh/m3

131
 MSF Unit Design
The temperature range, TR
The temperature range TR = To tc is one of the most
important operating parameters that greatly affects the
required heat transfer area of the plant, performance ratio PR,
and consequently, the capital and operating costs.
The seawater temperature tc depends on the locality and the
time of the year. In Kuwait, tc varies from 10 to 32C.
The top brine temperature TBT = To is a design parameter,
which depends on the water pretreatment method.
To is limited to 121C for acid treatment, about 110C for
high-temperature additives treatment, and 90.6C for
polyphosphate treatment.

132
 Effect of increasing the TBT
It is well-known that an increase in the TBT has the following advantages:
A. Less heat transfer area are used due to high temperature differences in the
stages. This also increases the heat transfer coefficients, and lowers the
non-equilibrium temperature losses.
B. The increase of To lowers R/D and Mc/D and, consequently, lower
pumping energy and pumps capacity.
C. A smaller vacuum system duty and improved inter-stage brine and
distillate transfer.
However, these advantages with high To are countered by some disadvantages.
A. A high cost of heating steam (higher availability steam is needed).
B. More problems associated with corrosion and thermal expansion.
C. A higher pressures design for the evaporators and recirculation pumps.

133
 Effect of decreasing tc
Since the seawater temperature tc can be as low as 10C, the mass
flow rate of the cooling seawater to the rejection stages must be
decrease in order to attain reasonable flashing brine temperature in the
final stages (Tn).
This can decrease the velocity of the cooling seawater through the
condenser pipes to a velocity lower than the acceptable minimum
(about 1.5 m/s).
It can also decrease the temperature (and consequently, the pressure)
in the final stage and increase the specific volume of the flashing
vapor to an unacceptable limit and unstable the operation.
For this reason, a portion of the rejected seawater can be recirculated
to keep the cooling seawater inlet at a reasonable temperature and
avoid the problems created by a low temperature inlet.

134
Flashing Brine Flow and Vapor Release
Velocity
Stage Width (W)
The flashing brine flow rate (in kg/h) per unit
width (in m) of the stage is called the shell load
(SL).
SL is a design parameter which determines the
width of the stage and, thus, the dimensions and
costs of its shell.
It affects the non-equilibrium losses in the stage.
The unit of SL is expressed in kg/(m h).
SL (in kg/m h) = 380,000 + 65,000D (in MIGD)
135
Flashing Brine Flow and Vapor Release
Velocity
Stage Length (L)
The amount of vapor generated from the flashing
brine depends on its residence time in the stage, or
specifically on the stage length
Other factors affect the choice of the stage length,
are the width of the condenser bundle in a cross-
tube arrangement or the length of the tube bundle
in a long-tube arrangement.
These factors usually give chamber lengths larger
than that required for full equilibration.

136
Flashing Brine Flow and Vapor Release
Velocity
Vapor Velocity and Stage Area
The released flashed vapor velocity Vv in a certain
stage should be kept below certain value to
minimize brine droplets carry-over with the vapor.
In the Kuwaiti specifications, the maximum
permissible velocity is 4 m/s. Thus, the cross-
sectional area of a stage (length width) should be
large enough to give Vv<4.0 m/s.
In recent years, this limiting vapor velocity has
been increased to 6.0 m/s for large units.

137
Flashing Brine Flow and Vapor Release
Velocity
The mass flow rate of the flashed vapor in stage i is
Di = R y (1 y)i1.
The volumetric flow rate of this vapor is
VFi = Di vi
where vi is the specific volume of saturated vapor at Ti.
The released velocity Vv = VFi / (L W) should be
less than the limited vapor velocity.
The value of Vv should be checked, particularly in
the last stages where vi is a maximum to avoid
unacceptable carry-over.

138
 Example 6
R-MSF unit of 6 MIGD capacity has a last stage
width W = 17.6 m and stage length L = 2.98 m. This
unit data give: D = 316 kg/s, R = 3939 kg/s, DT =
2.1, n = 24, and y = 3.6103. Find actual and
recommended SL and Vv
SLactual = 39393600/17.6 = 805.7103 kg/m.h
SLrec= 380,000 + 65,0006 = 770103 kg/m.h
Vv = R y (1 y)23 (vg @ Tn = 40C) / (LW)
= 39390.00360.9219.52/(2.9817.6) = 4.855 m

139
 Example 7
R-MSF unit data are:
TBT = 100oC, Tn = 40oC, tc = 28oC, n = 30, j = 3, D = 315
kg/s, Xb = 72 g/l, Xf = 42 g/l. F enter nth stage after
treatment, before Blowdown rejection (MBBL), SW brine
C = 3.89 kJ/(kgC), vapor L = 2330 kJ/kg, BPE = 1oC,
Find
A. R, F, Mc, and B,
B. Xi and ti at BH entrance,
C. Qbh/D, and Shell Load (SL)

142
 Example 7
Assume that the 29-stage of this MSF unit has:
Uc= 2.1 kW/m2 oC, total T(loss) = 1.6oC, stage W =
condenser tube length = 18 m. Condenser pipes (ID) =
33.6 mm, and (OD) = 36 mm, stage length = 2.2 m.
Calculate for 29th stage: flow rates and X of flashing
brine out of stage, D29, flow velocity inside tubes,
vapor velocity from flashing brine if (vg) = 17.8
m3/kg, CDT/L = 0.00334.
Find work input to R-pump (in kW) if DP across the
pump is7 bar, and it sucks both the recirculation and
blow-down from the last stage, and pump= 0.78.
143
 Solution Ex 7
R/D = 0.5 + 2330 / [3.89 (100 40)] = 10.4829,
R = 10.4829 315 = 3302.1 kg/s
Shell load (SL):
R (in kg/h) / width in m = 3302.1 3600 / 18
SL = 660,420 kg/(h.m)
Recirculation salinity concentration Xr
R Xr = (R D) Xb, and Xr = (R/D 1) Xb
Xr = 72 [1 (1/10.4829)] = 65.13 g/l (salinity at BH
inlet)
144
 Solution Ex 7
Feed (make up) flow rate F:
(R D) 72 + F 42 = (R + F D) 65.13
F 42 = (F D) 65.13,
F/D = 65.13 / (65.13 42) = 2.816
F = 2.816 315 = 886.94 kg/s
Brine blowdown
B = F D = 886.94 315 = 571.94 kg/s
Heat input to brine heater Qbh
DT = (To - Tn )/n = (100-40)/30 = 2.0oC
t1 = Tn + (n-j) DT = 40 + (27 2) = 94 oC, (temperature at BH inlet)
Qbh = 3302.1 3.89 (100 94) = 77,071 kW = 77.07 MW
Qbh/D = qd = 77070 / 315 = 244.67 kJ/kg

145
 Solution Ex 7
Stage 29
Flashing brine in = R (1 y)28 = 3302.1 (1
0.00334)28 = 3006.8 kg/s
D29 = y R = 0.00334 3006.8 =10.043 kg/s
Flashing brine out = 3006.8 10.043 = 2996.75 kg/s
X(flashing brine out) = 3302.1 65.13 / 2996.75 =
71.766 g/l

146
 Solution Ex 7
Vapor velocity:
Volumetric flow rate of D29 = D29 in (kg/s) vg,29
= 10.0417.8 = 178.7 m3/s
Vv = D29 (in m3/s) / (L W)
= 178.70 / (2.2 18) = 4.513 m/s
Flow velocity inside tubes:
Mc C (Tn tc) = j R C DT
Mc 3.89 (40 28) = 3 3302.1 3.89 2
Mc = 1651.05 kg/s
147
 Solution Ex 7
Tv29 = (Tn + DT) T = 40 + 2 1.6 = 40.4C
DtHJS = (Tn tc)/j = (40 28)/3 = 4C, t30 = 28 + 4 =
32C, t29 = 36C and t28 = 32C
Mc C Dt = U A LMTD,
LMTD = Dt / ln(Tv29 t28)/(Tv29 t29) = 6.186C
A = 1651.05 3.89 4/(2.1 6.186) = 1977.6 m2
1977.6 = (OD) L np = (36/1000) 18 np,
np = 971.4, say 972
Where np is the number of pipes

148
 Solution Ex 7
Mc volumetric flow rate (1651.05/1000) = [(/4) (ID)2
np Velocity)
Velocity = 1.65105/[(/4)(33.6/1000)2 972 = 1.915 m/s
Recirculation pump power input Wp
R + B = 3302.1 + 571.94 = 3874 kg/s
Wp = flow (m3/s) DP (kPa)/p
= (3874/1000) (7100) / 0.78 = 3477 kW

149
 Solution Ex 7
To plot the temperature profile in this plant, notice that TBT
= To= 100 oC, Tn = 40oC, tc = 28oC,
n (number of stages) = 30,
j (number of rejection stages) = 3,
T1 = To - DT = 98C, T2 = 96C, T3 = 94C, T4 = 92C, T5 =
90C, T6 = 88C , T7 = 86C, T8 = 84C, T9 = 82C, T10 =
80C, T11 = 78C, T12 = 76C, T13 = 74C, T14 = 72C, T15 =
70C, T16 = 68C, T17 = 66C, T18 = 64C, T19 = 62C, T20 =
60C, T21 = 58C, T22 = 56C, T23 = 54C, T24 = 52C, T25 =
50C, T26 = 48C, T27 = 46C, T28 = 44C, T29 = 42C, and
T30= 40C,

150
 Solution Ex 7
Recirculation brine temp in the condensers.
From n = 1 to 27 (HRS) Dt = 2 oC,
t1 = (272) + 40 = 94oC, t2 = t1 2 = 92 oC, t3 = 90 oC, t4
= 88 oC, t5 = 86 oC, t6 = 84 oC, t7 = 82 oC, t8 = 80 oC, t9 =
78 oC, t10 = 76 oC, t11 = 74 oC, t12 = 72 oC, t13 = 70 oC, t14
= 68 oC, t15 = 66 oC, t16 = 64 oC, t17 = 62 oC, t18 = 60 oC,
t19 = 58 oC, t20 = 56 oC, t21 = 54 oC, t22 = 52 oC, t23 = 50
oC, t = 48 oC, t = 46 oC, t = 44 oC, t = 42 oC.
24 25 26 27
From 28 to 30 (HJS) Dt = 4 oC,
t28 = 40 oC, t29 = 40 4 = 36, t30 = 32, tc = 28 oC.

151
 Assignment -1
This assignment is to investigate the effect of the total number
of stages. It is required to calculate the required heat transfer
surface areas of brine heater and condensers in OT-MSF unit of
7.2 MIGD capacity. In all cases assume the unit have the same
gain ratio, performance ratio, and heating steam flow rates for
the total number of stages, say 18, 21, and 28.
Other given data are: To=111.5C, Tn=38C, Xf=45 g/kg,
TsTo=6.5C, and tc=31C. The heating steam enters the brine
heater as saturated vapor and leaves as saturated liquid, the
average temperature losses in each stage are the same and is
equal to 1.4C, and the average overall heat transfer coefficient
= 2.6 kW/(m2 C) in condensers and 2.4 kW/(m2 C) in brine
heater.

152
END OF LEC 9 AND MSF SYSTEM
5/12/2017

153