Reverse Osmosis System Analysis (ROSA)

Advanced Design
Steven Coker
Dow Water & Process Solutions
RO System Design Webinar Series

Reverse Osmosis Advanced Reverse

System Design Basics RO Webinar Series Speakers: Osmosis System Design

Date & Time Date & Time

Sept 9, 2015 Sept 23, 2015
1-3 pm CDT 1-3 pm CDT

Advanced RO System
ROSA Scott Beardsley & Steven Coker Design with ROSA
System Design Basics
Technical Service Specialists
Date & Time
Date & Time
Sept 30, 2015
Sept 11, 2015
1-3 pm CDT
1-3 pm CDT

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ROSA – Advanced RO Plant Design

• Review of a few ROSA basics

• ROSA procedures for Advanced RO Designs

• Temperature History Effect - SWRO

• Batch Processor Option

• System Optimization – Design Warning Mitigation

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ROSA Basics: Name it and Save it!

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ROSA Basics: Multi-Case File

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ROSA Basics: Manage Case Order

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Overview of Using ROSA

• Enter project information

• Enter feed water data

• If needed, enter pH modification for scale control

• Enter system configuration and select membranes

• Run report

• Evaluate report and iterate to optimize if needed

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Advanced RO System Design Options

Managing Flux Balance

• Stage 1 permeate backpressure
• Stage 2 boost pump
• Multi-element hybrid array
• Internally Staged Design (ISD) array

Managing Permeate Quality

• RO with feed water/permeate blending
• 2 pass RO system
• 2 pass RO system w/ partial 2nd pass
• 2 pass RO system w/ permeate split design

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Balancing Flux with Stage 1 Permeate Pressure

Concentrate

Pump

Concentrate
Throttle Valve

Permeate

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 Stage 1 Permeate Back Pressure

1. Activate Stage 1 by clicking on it

2. Uncheck “Same Back Pressure…”
3. Enter stage 1 back pressure

2 1

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 Stage 1 Permeate Back Pressure - Report

• Stage 1 permeate back pressure is shown in System Details in ROSA report

• Impact of back pressure is seen by comparing stage-wise flux values

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Balancing Flux with Stage 2 Boost Pressure

Concentrate

Pump Boost
Pump
Concentrate

Permeate

Boost pump can be driven electrically

or by energy recovery device.

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Adding Stage 2 Boost Pump

1. Activate Stage 2 by clicking on it

2. Enter stage 2 boost pressure

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Stage 2 Boost Pressure - Report

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Multi-Element Hybrid Array

Concentrate

Feed

Concentrate

Permeate

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Multi-Element Hybrid Array - ROSA

1. Activate stage 1 by clicking on it

2. Uncheck “Use same element in the pass”
3. Select element type for stage 1

3
2

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Multi-Element Hybrid Array - ROSA

1. Activate stage 2 by clicking on it

2. Select element type for stage 2

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Using Multiple Elements in an Array

Increased TH

Increased Alk

Increased TDS

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SWRO Internally Staged Array

Examples of Potential FILMTEC™ ISD Element Loading Options

7,500 gpd 9,000 gpd 11,000 gpd

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Internally Staged Design – Stage 1

To Use ISD Feature:

1. Complete design with single stage array
2 2. Increase number of stages to 2
3. Adjust number of elmts / vessel in stage 1
4. Uncheck “Use same element in the pass”
5. Select element type for stage 1

3
5
4

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Internally Staged Design – Stage 2

To Use ISD Feature:

6. Click on Stage 2 to activate it
7. Set # elmts to total minus # Stg 1 elmts
8. Select element type for stage 2
9. Check ISD box to join vessels
9

7
8

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Internally Staged Design – ROSA Report

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RO with Feed Water Blending

Concentrate

Pump

Concentrate

Blend Water
Final Permeate

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RO with Feed Water Blending

Permeate Flow + Blend Flow = Total Product Flow

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RO with Feed Water Blending – ROSA Report

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 2 Pass RO

Concentrate Recycle
Feed NaOH

Concentrate

Permeate

Permeate

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2 Pass RO – Pass 1

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2 Pass RO – Pass 2

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2 Pass RO – Flow Calculator

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2 Pass RO – Pass 1 ROSA Report

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2 Pass RO – Pass 2 ROSA Report

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2 Pass RO with Partial 2nd Pass

Concentrate Recycle
NaOH

Feed

Concentrate

Pass 1 - SWRO Pass 2 - BWRO Permeate

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2 Pass RO with Partial 2nd Pass

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2 Pass RO with Partial 2nd Pass

Pass 2 Permeate Flow + Blend Flow = Final Permeate Flow

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2 Pass RO with Partial 2nd Pass - ROSA

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2 Pass RO with Partial 2nd Pass - ROSA

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 Split Permeate SWRO with Partial 2 Pass Design

Concentrate Recycle

NaOH

Feed
Rear
Permeate
Concentrate

Front Permeate Final Permeate

• Split permeate SWRO systems withdraw permeate from both ends of the
first pass pressure vessels
• Front permeate is lower in salinity and is directly blended into the final
permeate stream
• Many split permeate SWRO systems use ISD with elements chosen
specifically to reduce front permeate TDS and/or control lead element flux

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Split Permeate SWRO with Partial 2 Pass Design

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Split Permeate SWRO – Flow Calculator

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Split Permeate SWRO – Pass 1 ROSA Report

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Split Permeate SWRO – Pass 2 ROSA Report

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Split Permeate SWRO –Overview ROSA Report

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Temperature History Effect - SWRO designs

• RO operation at elevated temperatures (35ºC and above) causes an

irreversible flow loss.

• Flow loss becomes apparent if the system is later operated at lower

temperatures (20-35ºC).

• This is a phenomenon common to all thin film composite RO

membranes operated under similar conditions.

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 Up’s and Down’s : The Temp. Hysteresis
Simplified model for feed pressure “p” as function of
feed temperature “T” in an RO system

pmax (with hysteresis)

p = f{Tcurrent, Tpast}
pmax (w/o hysteresis)
T, p

p = f{Tcurrent}

Winter Summer Winter Summer

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High Temp. Tests with SWRO elements
10000
Challenge test 1 Challenge test 2 Standard tests Brand A,
(*) (*) product 2
9000 (*)
35 °C, 55 50 °C, 70 bar
Brand A,
bar, 32,000 55,000 mg/L product 2
8000
mg/L
Brand A,
7000 after product 2
Normalized flow (gpd)

1 hour after
~3 days Brand A,
6000 product 2

5000 Brand A,
product 1
4000 Brand A,
product 1
3000 Brand C,
2 product 1
2000
Brand B,
product 1
1000
Brand B,
product 2
0
0 5 10 15 20
(*) Standard test conditions:
Measurement point 25 C, 55 bar, 32,000 mg/L

The hysteresis effect is inherent for all polyamide spiral wound RO modules.

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ROSA – Temperature History Effect

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ROSA – Control Panel: Options

Batch Processor:
allows the software to run
multiple projections
automatically

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Batch Processor

Input Variables
• Flow Factor: Start-up and Long term
• Temperature: Maximum & Minimum and desired number of
intermediate points
• Option to activate the “High Temperature Effect”

Output
• ROSA will generate projections for each temperature at each Flow
Factor indicated
• Projections can be stored in the same folder as the ROSA file
• A summary excel file can be generated as well. The parameters to
be included in this summary are selected by the user

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Batch Processor
1. Go to options>Batch processor once feedwater & design
are defined
2. Input parameters: Indicate
temperature range, FF and “high
temperature effect”

3. Output parameters: Select from

the list those parameters to be
included in the summary table
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Batch Processor Example

Input
Intermediate
Temperature Flow Factor (FF)
points, nº
Minimum Maximum Start up Long term
3
10ºC 30ºC 1 0.75 – 0.65

Note: in case of a two pass system, FF for both passes should be indicated.

Output
The following projections will be generated

10ºC 15ºC 20ºC 25ºC 30ºC

FF 1     
FF 0.7     

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Batch Processor – Output 1
Once all of the projections are finished, the user can save the
results as a summary excel file

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Batch Processor – Output 2
As a result, the user will get all the projections and the summary
excel file
Note: to ensure projections are saved in the same folder as the original
ROSA file  go to options  files and folders and select:
save the output file in the same folder as the input file

ROSA file

Generated
projections

Summary file
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ROSA Report – Warnings!

Designs of systems in excess

of the guidelines results in a
warning on the ROSA Report.

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Warnings and typical solutions –
For one stage systems
Design warning Solutions
Max. element permeate flow exceeded 3, 5, 7, 10

The concentrate flow less than minimum 1, 5, 4 together with 6

The feed flow greater than maximum 2 unless the feed flow is fixed, 3

Maximum feed pressure exceeded 1, 3, 8

Temperature is above acceptable value 9

Max. element recovery exceeded:

• If the problem is encountered in front elements 1, 5, 6, 10
• If the problem is encountered in rear elements 1, 5, 6

Solutions Guide
1 Decrease system recovery
Increase the number of elements Reduce Temp (recommend
6 per PV (keeping the same APF*) 9 customer to reduce temp during
2 Increase system recovery pretreatment).

Reduce average system flux (add

3 membranes, PV) 7 Decrease the number of elements
per PV (keeping the same APF*) 10 Combine two element types: lower
energy elements in rear positions
(ISD configuration)
Reduce number of PV (increasing
4 average system flux)
Install lower energy membranes or
8 ISD with lower energy membranes
Enable a recirculation loop Pass 1 *APF – Average Permeate Flux
5 Conc to Pass 1 Feed (normally not **PV=Pressure vessel
used for SW appl.) 55
 Warnings and typical solutions –
For multi-stage systems
Design warning Solutions
Max. element permeate flow exceeded 3, (5), 6, 10, 13
1, 4, (5), 6, 7, (10 and 11
The concentrate flow less than minimum
only for the 1st stage)

The feed flow greater than maximum in any of the stages 2, 3

Maximum feed pressure exceeded 1, 3, 9
Temperature is above acceptable value 12
Max. element recovery exceeded:
• If the problem is encountered in front elements (front stage/s) 1, (5), 6, 7, 10, 13
• If the problem is encountered in rear elements (rear stage/s) 1, (5), 7

Solutions Guide
1 Decrease system recovery

6 Add backpressure in first and/or 10 Add booster pump in first or second stage
concentrate
2 Increase system recovery second stages permeate streams

3 Increase number of PV (reducing

7 Increase the number of elements per 11 Use a lower active area membrane
element (keeping the same APF)
average system flux) PV (keeping the same APF)

Reduce Temp (recommend customer to

4 Reduce number of PV (increasing
8 Decrease the number of elements per 12 reduce temp during pretreatment).
average system flux) PV (keeping the same APF)

Enable a recirculation loop: Pass Combine two element types: lower energy
5 1 Conc to Pass 1 Feed (normally 9 Install lower energy membranes or 13 elements in second or third stages
ISD with lower energy membranes
not used for SW appl.)
56 *APF – Average Permeate Flux
PV=Pressure Vessel
Further Help –Answer Center

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Questions?

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