333

6.4.2 Mathematical Model

- The brine temperatures leaving stages 1 and 2, T^ and T2, are calculated from
Eq. (34).
- The seawater temperatures leaving the condensers of the first and second
stages, tx and t2, are determined from Eq. (35). Also, the seawater
temperature leaving the condenser of the last stage, t^, is calculated from Eq.
(35).
- The heat transfer area for the brine preheater (A^), the first stage condenser
(Ac) are calculated from Eqs. (43) and (46), respectively.
- The stage length, width, and cross section areas are determined from Eqs. (54-
56). Also, the height of the brine pool, H, and the gate height for stage i are
obtained from Eqs. (52) and (53).
- The system performance parameters, PR and sA, are calculated from Eqs. (57)
and (58).

The above solution procedure requires specification of the following

variables:
- Total distillate flow rate, M^.
- Total number of stages.
- Feed seawater temperature, Tf.
- Top brine temperature, TQ.
- Steam temperature, Tg.
- Temperature of brine blowdown, T^.
- Intake seawater salt concentration, Xf.
- Heat capacity of liquid streams, Cp.
- Weir friction coefficient, C^.
- Vapor velocity in the last stage, Vy^.
- Brine mass flow rate per stage width, V^.

6.4.3 Case Study

An MSF system with 24 stages is used to produce 7.2 MGD of product

water. The following specifications are made to obtain the system design
parameters and performance characteristics:
- Feed seawater temperature, Tf = 25 ^C.
- Steam temperature, Tg = 116 ^C.
- Top brine temperature, To = 106 ^C.
- Brine temperature in the last stage, T^ = 40 ^C.
- Heat capacity of liquid streams, Cp = 4.18 kJ/kg ^C.
- Salinity of feed seawater, Xf = 42000 ppm.
334 Chapter 6 Multistage Flash Desalination

- Vapor velocity in the last stage, Vv24 = 6 m/s

- Brine mass flow rate per stage width, V^ = 180 kg/ms.
- Weir friction coefficient, C^ = 0.5.

Before proceeding, the product volume flow rate is converted to mass rate
in SI units; this is necessary for solution of the energy balance equations. The
distillate flow rate in kg/s is

7.2rMWioer^ii1^24x3600 rA\\

^ [ d ))[ IMGJJ v«yy

Md =
1 'm ' ^kg^
10^
219.96 v ^ y vm^y

Md = 378.8 kg/s

Calculation of the y ratio from Eq. (36) is preceded by evaluation of T^y and A^^v
The T^v value is

Tav = (To + Tn)/2

= (106+40)/2
= 73«C

At this temperature X^y is equal to 2330.1 kJ/kg from the correlation given in the
appendix. The value of y is calculated

y = Cp AT/^Lav
= (4.18)(2.75)/2330.1
= 4.933x10-3

The feed flow rate is obtained from equation (39)

Mf = M d / ( l - ( l - y ) ^ )
= 378.8/(1 - (1 - 4.933x10-3)24)
= 3384.8 kg/s

Arranging equations (31) and (32) gives the following expression, which is used to
calculate the salinity of the brine blow down

Xb = MfXf/(Mf - M d )
= (3384.8)(42000)/(3384.8 - 378.8)
 6.4.3 Case Study ^^^

= 47292.6 ppm

The flow rate of the blow-down brine is then obtained from the overall balance
given in equation (31)

Mb = M f - M d
= 3384.8 - 378.8
= 3006 kg/s

The temperature drop in each effect is obtained from Eq. (33), where

AT = (To-Tn)/n
= (106 - 40)/24
= 2.75«C

This value is used to calculate the temperatures of the first and second stages, T]^
and T2, where

Ti = To - AT
=: 1 0 6 - 2 . 7 5
= 103.25 oC

As for the second stage temperature it is equal to

T2 = Ti - AT
= 103.25-2.75
= 100.5 oC

Also the temperatures of the seawater leaving the condensers in the first and
second stages are calculated. This is

ti = Tf+nAt
= 25 + (24) (2.75)
= 91«C

and

t2 = t^ - At
= 91-2.75
= 88.25 «C

The steam flow rate is calculated from Eq. (42)

336 Chapter 6 Multistage Flash Desalination

Ms = M f C p ( T o - t i ) / X s
= (3384.8) (4.18) (106 - 91)7(2222.33)
= 95.49 kg/s

The heat transfer area for the brine heater, A^, is calculated from Eq. (43).
This requires calculations of the logarithmic mean temperature difference
(LMTD)b and the overall heat transfer coefficient. The value of (LMTD)}) is
obtained from Eq. (44), which gives

(LMTD)b - (ti - To)/ln((Ts - To)/(Ts - ti))

= (91 - 106)/ln((116 - 106)/(116 - 91))
= 16.37 «C

The overall heat transfer coefficient is obtained from Eq. (45) where

Ub = 1.7194 + 3.2063x10-3 Tg + 1.5971x10-5 (%)^ - 1.9918xlO-7(Ts)3

= 1.7194 + 3.2063x10-3 (116) + 1.5971x10-5 (116)2 - 1.9918x10-^ (116)3
= 2 kW/m2 oC

The brine heater area, A^, is then calculated from Eq. (43)

Ab = MsV(Ub(LMTD)b)
= (95.49)(2222.33)/((2)(16.37))
= 6481.68 m2

The condenser area, A^, is determined for the first stage. This requires
calculations of the vapor condensation temperature, Ty , the logarithmic mean
temperature difference (LMTD)^, and the overall heat transfer coefficient, U^.
The vapor temperature is given by Eq. (49), where

Ty^ = Ti - BPEi - NEAi - AT^^

The boiling point elevation is calculated from the correlation given in the
appendix. This requires calculations of X^, which is obtained in the following
sequence

Di = yMf
= (4.933xl0-3)(3384.8)
= 16.697 kg/s

Bi = M f - D i
6.4.3 Case Study ^^^

= 3384.8 - 16.697
= 3368.1 kg/s

Xi = MfXf/Bi
= (3384.8)(42000)/3368.1
= 42208 ppm

The values of B and C in the correlation for the boiling point elevation are

B = (6.71 + 6.34xl0"^(Ti)+9.74xl0"^(Tif )10"^

= (6.71 + 6.34xl0~^(l03.25)+ 9.74xl0"^(l03.25)^)10~^
= 0.0143

C = (22.238 + 9.59x10"^ ( T I ) + 9.42x10"^ (Ti)^)10"^

= (22.238 + 9.59xl0"^(l03.25)+ 9.42xl0"^(l03.25f )10"^
= 2.423x10"'^

Substituting the values of B and C in the BPE correlation gives

B P E i = X i ( B + (Xi)(C))lO-^
= 42208 (o.0143 + (42208) (2.423x10"'^ ))lO"^
= 1.035 ""C

The non-equilibrium allowance, NEA^, in the first stage is calculated from the
correlation given in the appendix for the MSF system. This involves calculations
of the gate height, GH^, the height of the brine pool. Hi, the stage width, W, the
stage pressure drop, P1-P2, and the brine density. The width of the first stage is
given by

W = Mf/Vb
= 3384.8/180
= 18.8 m

The stage length is calculated for the last stage, where

D24 = 14.9 kg/s

Pvn = 0.0512 kg/m3,

338 Chapter 6 Multistage Flash Desalination

L = Dn/(PvnVvnW)
= 14.9/((0.0512)(6)(18.8))
= 2.58 m

The brine density in the first stage is 1002.413 kg/m^, which is obtained
fi:om the correlation given the appendix at a salinity of 42208 ppm and a
temperature of 103.25 °C. The pressures of the first and second stage are
obtained from the saturation pressure correlations, where, at T^ = 103.25 ^C, P^ =
113.72 kPa, and at T2 = 100.5 ^C, P2 = 103.23 kPa. The resulting gate height in
the first stage, GH^, is calculated from Eq. (52), where

GHi = Mf (2 p^^ APi)(-0-5)/(C^ W)

=(3384.8)((2)(1002.41)(113.72-103.23)xl03)(-0.5)/((o.5)(18.8)
= 0.078 m

It should be noted that the pressure drop in the above equation is in Pa and not
kPa. The corresponding brine pool height is obtained by simply adding 0.2 m to
the value of GH^, or

Hi = 0.278 m

The non-equilibrium allowance is then calculated using the correlation

given in the appendix

NEAi = (0.9784)To (15.7378)^1 (1.3777)Vbxio"6

= (0.9784)(106) (l5.7378)(0-278) (i,3777)(i80xio"6)
= 0.213 oC

The temperature drop in the demister is assumed negligible in comparison

with the values of BPEi and NEAi. Therefore, the vapor temperature in the first
is

Ty^ = Ti - BPEi - N E A i " ATdj

= 103.25-1.035-0.213-0
= 102.002 oC

The vapor temperature, Ty , is used to calculate U^ and (LMTD)^, where

(LMTD)e = (t2-ti)/ln((Tv-ti)/(Tv-t2))
= (2.75)/ln((102.002-91)/(102.002-88.25))
= 12.32 oC
6.4.3 Case Study ^^^

Uc = 1.7194 + 3.2063x10-3 Tv^+ 1.5971x10-5 (Ty^)^ - 1.9918xlO-7(Tv^)3

= 1.7194 + 3.2063x10-3 (101.207) + 1.5971x10-5 (101.207)2
- 1.9918x10-7 (101.207)3
= 2 kW/m2 oC

Ae-MfCp(t2-ti)/(Uc(LMTD)e)
= ((3384.8) (4.18) (97.75-95))/((2) (12.32))
==: 1579 m2

The total heat transfer area is obtained from

A = Ab + n Ac
= 6481.68 + (24) (1579)
= 44377.7 m2

Performance Parameters

Performance Ratio

PR = M^/Mg
= 378.8/95.49
= 3.96

The specific heat transfer area

sA = A/Md
= (44377.7)7378.8
= 117.2 m2/(kg/s)

Solution Summary

Flow Rates

Md = 378.8 kg/s

Mb = 3006 kg/s

Mf= 3384.8 kg/s

Mg = 52.52 kg/s
340 Chapter 6 Multistage Flash Desalination

Heat Transfer Areas

Ab = 6481.68 m2

Ac = 1579 m2

A = 44377.7 m2

Stage Dimensions

W = 18.8 m

L = 2.56 m

GH^ = 0.078 m

Hi = 0.278 m

Performance Parameters

PR = 3.96

sA= 117.2 m2/(kg/s)

Stage Profiles

The MSF-OT simplified model is used to calculate the temperature and

concentration profiles for the 24 stages. The calculations also include the brine
and distillate flow rate, the gate height and the brine level in each stage. In the
following table, the flow rates are in kg/s, the temperature in ^C, the salinity in
ppm, and the height in m.
 341
6.4.3 Case Study

Stage D ED B X T Tf GH H
1 16.70 16.70 3368.1 42208.2 103.25 91 0.078 0.278
2 16.61 33.31 3351.5 42417.5 100.5 88.25 0.081 0.281
3 16.53 49.84 3335.0 42627.7 97.75 85.5 0.084 0.284
4 16.45 66.30 3318.5 42839.1 95 82.75 0.087 0.287
5 16.37 82.67 3302.1 43051.4 92.25 80 0.09 0.29
6 16.29 98.96 3285.8 43264.9 89.5 77.25 0.094 0.294
7 16.21 115.16 3269.6 43479.3 86.75 74.5 0.097 0.297
8 16.13 131.29 3253.5 43694.9 84 71.75 0.101 0.301
9 16.05 147.34 3237.5 43911.5 81.25 69 0.105 0.305
10 15.97 163.31 3221.5 44129.2 78.5 66.25 0.11 0.31
11 15.89 179.21 3205.6 44348.0 75.75 63.5 0.114 0.314
12 15.81 195.02 3189.8 44567.8 73 60.75 0.119 0.319
13 15.74 210.75 3174.0 44788.8 70.25 58 0.124 0.324
14 15.66 226.41 3158.4 45010.8 67.5 55.25 0.13 0.33
15 15.58 241.99 3142.8 45233.9 64.75 52.5 0.136 0.336
16 15.50 257.50 3127.3 45458.2 62 49.75 0.143 0.343
17 15.43 272.92 3111.9 45683.5 59.25 47 0.15 0.35
18 15.35 288.27 3096.5 45910.0 56.5 44.25 0.157 0.357
19 15.28 303.55 3081.3 46137.6 53.75 41.5 0.165 0.365
20 15.20 318.75 3066.1 46366.3 51 38.75 0.175 0.375
21 15.12 333.87 3050.9 46596.2 48.25 36 0.185 0.385
22 15.05 348.92 3035.9 46827.2 45.5 33.25 0.197 0.397
23 14.98 363.90 3020.9 47059.3 42.75 30.5 0.211 0.411
24 14.90 378.80 3006.0 47292.6 40 27.75 0.211 0.411

Problems

Problem 1

An MSF-OT circulation plant has the following design data:

P l a n t capacity: Unknown
Seawater temperature: 32 oC
S e a w a t e r salinity: 49400 p p m
Top brine t e m p e r a t u r e : 100 «C
Performance ratio: 8
N u m b e r of stages: 22
Overall h e a t t r a n s f e r coefficient
in b r i n e h e a t e r : 2 kW/m2 oC
Overall h e a t t r a n s f e r coefficient
in h e a t rejection section: 1.9 kW/m2 oC
Overall h e a t t r a n s f e r coefficient
342 Chapter 6 Multistage Flash Desalination

in heat recovery section: 2.4 kW/m^ oQ

Calculate the following:

- The heating steam flow rate.

- The plant capacity

- The specific heat transfer area

Problem 2

An MSF-OT plant has the following design data:

Plant capacity: Unknown
Top brine temperature: Unknown
Brine flow rate per chamber width: Unknown
Number of stages: 20
Boiling temperature in last stage: 40 ^C
Heat transfer area in the brine heater: 1000 m^
Overall heat transfer coefficient
in all sections: 2.527 kW/m2 oC
Mass flow rate of heating steam: 16.782 kg/s
Heating steam temperature: 120 ^C
Number of tubes in the brine heater: 1000 tube
Specific flow rate of feed water: 8.422
Diameter of tubes used in brine heater: 31.8 mm

Calculate the following:

- The plant performance ratio

- The specific heat transfer area
- The dimensions of stage 7.

Problem 3

An MSF-OT plant has the following design data:

Seawater temperature: 34 ^C
Seawater salinity: 42000 ppm
Top brine temperature: 100 ^C
Temperature in the last stage: 40 ^C
Temperature of heating steam: 110 ^C
Specific flow rate of brine circulation: 8.478
Heat transfer area in the brine heater: 80 m^
Overall heat transfer coefficient
 Problems

in brine heater: 1.5 kW/m^ oC

Calculate the following

- The plant performance ratio

- The terminal temperature difference of the first stage.
- The specific heat transfer area.
- The dimensions of stage 7.

Problem 4

An MSF brine circulation plant has the following design data:

Distillate flow rate: 5000 m^/d

Seawater temperature: 30 ^C
Seawater salinity: 44000 ppm
Top brine temperature: 112^0
Temperature in the last stage: 40 ^C
Temperature of heating steam: 116.7 ^C
Terminal temperature difference: 3 ^C
Number of stages: 20

The overall heat transfer coefficient in the brine heater or the flashing stages is
given by the relation
U==6.5-0.03(115-T)
With U in kW/m2 oQ and T in ^C.

Calculate the following

- Thermodynamic losses in the first stage

- Plant performance ratio
- Brine heater surface area
- Flow rate of feed water.

Also, calculate the following parameters for stage number 5

- Boiling point elevation.

- Gate height
- Liquid level
- Demister temperature loss
- Stage height
- Stage length
- Preheater surface area.
344 Chapter 6 Multistage Flash Desalination

Problem 5

An MSF-OT plant has the following design data:

Distillate flow rate: 22750 m3/d

Seawater temperature: 28 oC
Seawater salinity: 45000 ppm
Top brine temperature: 90 oC
Temperature in the last stage: 40 oC
Temperature of heating steam: 100 oC
Terminal temperature difference: 3«C
Number of heat rejection stages: 3
Number of heat recovery stages: 25
Width of stage 10: 16 m
Length of stage 10: 3.5 m

Calculate the following

The temperature profile of flashing brine

The temperature profile of seawater flowing in the preheaters
The flow rates of heating steam, feed water, and brine blowdown.
The pressure in stages 9,10, and 11.
The distillate product in stage 10.
The vapor velocity in stage 10.