energy and exergy analysis of a once through multi stage flash desalination...

133 THE INTERNATIONAL JOURNAL OF ENGINEERING AND INFORMATION TECHNOLOGY (IJEIT), VOL.6, NO.2,2020

www.ijeit.misuratau.edu.ly ISSN 2410-4256 Paper ID: EN114

Energy and Exergy Analysis of a Once

Through Multi Stage Flash Desalination Unit

at Variable Operational Temperatures

Jamal S. Yassin

University of Misurata/Mechanical Engineering Department, Misurata, Libya [email protected]

Abstract— This paper is to investigate the exergy and energy

analysis of the once through multi stage flash (OT-MSF)

desalination unit at variable operational temperatures. Here

the study is carried out theoretically by developing a

computer package using visual basic 6 as a tool to encode

the program. This program contains input and output pages

where many variables can be studied such as feed water,

final stage and heating steam temperatures as well as

heating steam and distillate mass flow rates with other

variables to study the exergy and energy analysis for each

stage of the unit and for the whole system as a single unit.

The performance parameters considered here are the

performance ratio (PR), the exergetic efficiency and the

specific heat transfer area (sA). The results obtained have

shown a clear influence of the feed water and last stage

temperatures, in which the performance ratio and the

exergetic efficiencies are increased by increasing feed water

temperature and decreased by increasing last stage

temperature. At feed water temperature 30 oC the

performance ratio obtained is 15 and the exergetic efficiency

is 52 % for the OT-MSF unit.

Index Terms: once through, temperatures, specific area,

exergetic efficiency, performance ratio.

I. INTRODUCTION

ater is the life, and there is no life without water,

which is unfortunately decreasing rapidly in many

places due to extensive consumption , rising of

population, increasing standards of living,

industrialization, and in some instances, wasteful water

use and management policies. Nowadays, around 1.7

billion people have shortage for accessing to water,

particularly in the developing countries, especially in

Middle East, South Asia and Africa. The shortage in the

drinking water contributes in 70-80% of diseases in

around 90 developing countries[1].

So the decreasing of water resources and steadily rising

water demand drive us towards new approaches for safe

and reliable water supply for the municipal, agricultural

and industrial sectors. One solution for fresh water

provision is sea water desalination using any

conventional or renewable source of energy.The

continual research and development of desalination

processes have resulted in a variety of commercial

desalination methods. These processes are classified into

major desalination processes that include multi stage

flash, multi effect, vapor compression and reverse

osmosis desalination; while the minor processes include

solar humidification, freezing and electrodialysis

desalination [1].The primary desalination methods used

are multi-stage flash distillation (MSF) that

constitutes44% of the installed world capacity and

reverse osmosis (RO) that constitutes 42%. Therefore,

these two methods constitute about 86% of the total

world capacity. The remaining 14% is made up of

electrodialysis (6%), vapor compression VC (4%) and

multiple effect distillation ME(4%) [2]. These

desalination technologies are energy consuming , and a

comparison of the idealized and actual processes shows

that the actual energy cost of desalination is much higher

than the cost under ideal operation. This corresponds to a

second law efficiency of under 20% and points out that

there are tremendous opportunities in both the MSF and

RO plants for improvements. The first step in any

improvement or enhancement project is diagnostics, and

the most powerful diagnostics tool in thermodynamics is

second law analysis [3].

The second law of thermodynamics (exergy analysis)

becomes further appreciated to measure the performance

of the desalination systems. Exergy analysis interprets for

the obtainable forms of energy in the system streams and

energy supply with a reference environment and

recognizes the major losses of energy/exergy destruction.

This helps in evolving an effective desalination processes

by reducing the hidden losses [4]. However, many

investigations have been conducted in this topic for

processes improvements.

W

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Received 9 Mar, 2020; revised 1 May, 2020; accepted 2 May, 2020.

Available online 3 May, 2020.

Jamal S. Yassin/ Energy and Exergy Analysis of a Once Through Multi Stage Flash Desalination Unit at Variable Operational Temperatures 134


Veera Gnaneswar Gude investigated the exergy

analysis of the desalination processes to evaluate the

thermodynamic efficiency of major components and

process streams and identifies suitable operating

conditions to minimize exergy destruction. Well-

established MSF, MED, MED-TVC, RO, solar

distillation, and membrane distillation technologies were

discussed with case studies to illustrate the exergy

performances [5].

Isa, et al., studied the exergy analysis of an optimized

MSF distillation plant based on the latest published

thermodynamics properties of water and seawater

software of the Massachusetts Institute of Technology by

using design and optimized plant operation data. Exergy

flow rates are evaluated throughout the plant and the

exergy flow diagram is prepared in both cases. The rates

of exergy destruction and their percentages are indicated

on the diagram so that the locations of each exergy

destruction can easily be identified. The study concludes

that as a result of an optimization, making the MSFD unit

once-through cooling system to recirculating type by

using cooling tower system, the unit's exergy destruction

pattern changes meaningfully [6].

A.M.K. El-Ghonemy studied the performance of the

seawater multi-stage flash (MSF) desalination plant that

is currently under operation in Al-Khafji operations plant

located in Saudi Arabia (KSA). The objective is to

present field results of this MSF plant operation in order

to measure and evaluate the performance at 70% and

100% capacity during summer (case-1) and winter (case-

2) operation. The results showed that, for the same plant

output, the main cooling water flow rates is decreased

from 47.1% to 20.1% for case-1 and case-2 respectively,

which in turns directly reduces the pumping power by the

same ratio. Consequently, running the large scale thermal

desalination MSF plant in cold regions is more economic

than hot regions for pumping power energy saving

considerations[7].

Nafey et al., presented the design and thermoeconomic

analysis of a proposed multi stage flash-thermal vapor

compression MSF-TVC system. The proposed MSF-

TVC system is analyzed and investigated under different

operating conditions by using the thermoeconomic

methodology. The comparison between the proposed

MSF-TVC system and the conventional MSF system

showed that the gain ratio of the MSF-TVC system is

96% higher than that of the conventional MSF brine

circulation plant. The heat transfer area of the MSF-TVC

is 52 % higher than the conventional MSF. The exergetic

efficiency of the MSF-TVC system is 46 % higher than

that of the MSF system. The unit product cost of the

MSF-TVC system is 19 % lower than that of the

conventional brine circulation multi stage flash (MSF-

BR) system[8].

Adel K. El-Feky in his study focused on the analysis of

the energy and exergy of MSF and MVC units. The

exergy losses due to irreversibility for the subsystems of

the units are evaluated, the specific exergy losses of the

MSF unit is at the range of 63 kJ/kg. The exergy

destruction in heat recovery and heat rejection sections,

brine heater and all the other systems are calculated, these

values are 61, 17, 10, and 12% respectively. The study

showed that, the second law efficiencies of the MSF unit

is around 4 % and for the MVC is around 7%, so these

law efficiencies clarify that there are many ways to

improve the plant performance by reducing the highest

exergy destruction through these systems [1].

Ezzeghni, et al. carried out the exergy analysis of a

brine mixing once through multi stage flash MSF-BM

desalination plant to identify the component that has the

largest exergy destruction. The MSF-BM desalination

plant is located at 30 km north-west of Tripoli the capital

of Libya. Exergy flow rates are estimated all over the

plant and exergy flow diagram is prepared. The results of

the exergy analysis show that the multi-stage flash unit,

pumps and motors are the major sites of highest exergy

destruction, where 61.48 % of the entire input exergy

took place in the MSF unit, and 19.8 % happens in the

pumps and motors [4].

However, this study is conducted to investigate the

exergy analysis of the MSF desalination plant at different

hypothetical operational parameters such as feed water

temperature, steam temperature and brine temperature

with some other variables. In this case a computer

software using visual basic language has been developed

to perform the analysis through the stages of the MSF

desalination unit.

II. ENERGY ANALYSIS OF THE MSF

UNIT

The MSF unit is one of the thermal technologies which

depends on evaporation and condensation techniques in

each stage and it operates at progressively lower

pressures, as water boils at lower temperatures, Figure 1.

For this technique, the feed water is heated under

sufficiently high pressure to prevent boiling, until it

reaches the first “flash chamber.” In the first flash

chamber (stage), the pressure is released and sudden

evaporation or “flashing” takes place. This flashing of a

small portion of the feed continues in each successive

stage, because the pressure in each is lower.

Figure 1. Multi Stage Flash Desalination Unit [10]

Thus, this design offers the benefit of heat recovery.

That is, the feed water passing through the heat

exchanger in the upper section of the flash chamber gains

heat as it condenses the vapor to distillate. Two distinct

sections of each stage are the flashing chamber (where

the vapors are produced) and the condensing section

(where the vapors are condensed) [9].

An essential step in MSF distillation is to maintain the

flashing process for a longer period of time without the

addition of any external heat. Therefore, for this reason,

the temperature and pressure of every stage are stabilized



at a lower value than during the previous stage. In the

final stage, the temperature of brine and condensate is

same as the inlet temperature [10].

There are two main layouts for the MSF process. The

first is the once-through (MSF-OT) system and the

second is the brine circulation system.

A. Assumptions of the energy analysis

The assumptions used to develop the energy analysis

of the MSF-OT process include the following:

Steady state operation, which is the industry

standard. Although, system operation may

experience seasonal temperature variations of

the intake seawater, but, such variations are slow

and the system parameters are adjusted

accordingly. Another factor that may change the

system characteristics is the tube fouling, which

results in the increase of the thermal resistance

for heat transfer. This problem is encountered

through the use of on-line ball cleaning system

or tube acid cleaning, which restores conditions

to near clean operation.

Heat losses to the surroundings are negligible.

This assumption is valid, since, the surface to

volume ratio of the MSF plants is very small.

Also, the temperature of the low temperature

stage is very close to the ambient temperature,

which reduces the rate of heat transfer to the

surroundings.

Equal heat transfer area in each flashing stage in

the heat recovery section.

Equal heat transfer area in each flashing stage in

the heat rejection section.

The heat capacities for feed seawater, brine, and

distillate product depend on temperature and

composition.

The overall heat transfer coefficients in the

evaporators depends on the following

parameters:

Flow rate of the condensing vapor.

Flow rate of the brine inside the condenser

tubes.

Temperatures of the condensing vapor and the

brine.

Physical properties of the condensing vapor

and the brine, which includes thermal

conductivity, viscosity, density, and specific

heat.

The tube material, diameter, and wall

thickness.

The fouling resistance.

The percentage of the non-condensable gases.

The overall heat transfer coefficient is the sum

of the thermal resistances expressed in terms of

the inside and outside heat transfer coefficient,

the fouling resistance, and the thermal resistance

of the condenser tube.

The latent heat of formed/condensed vapor

depends on temperature.

Thermodynamic losses include the boiling point

elevation (BPE), the non-equilibrium allowance

(NEA), and demister losses (Tp).

The distillate product is salt free [11].

B. Elements of the energy analysis

The energy analysis of the MSF-OT process is

based on the following elements:

- Overall material balance.

- Stages and condensers temperature profiles.

- Stage material and salt balance.

- Condensers and brine heater heat transfer area.

- Stage dimensions.

- Performance parameters [12].

Figure 2. OT-MSF Flashing Stage Variables [12]

C. Mathematical modeling of the energy analysis

According to Figure. 2 the overall material balance

equations is given by

(1)

Where M is the mass flow rate and the subscript b, d,

and defines the brine, distillate, and feed.The overall salt

balance is given by

(2)

Where X is the salt concentration.

The temperature distribution in the MSF-OT system is

defined in terms of four temperatures; these are the

temperatures of the steam, Ts, the brine leaving the

preheater (top brine temperature), To, the brine leaving

the last stage, Tn, and the feed seawater, Tf. A linear

profile for the temperature is assumed for the flashing

brine and the seawater flowing inside the condenser

tubes.

The temperature drop per stage, ΔT, is obtained from

the relation

(3)

Where n is the number of stages

Then the general expression for the temperature of

stage j is

(4)

By neglecting heat transfer losses in each stage the

feed water temperature increment stays the same and is

equal to that of the brine temperature drop, thus:



Then

(5)

Stage Material and Salt Balance

The amount of flashing vapor formed in each stage

obtained by conservation of energy within the stage,

where the latent consumed by the flashing vapor is set

equal to the decrease in the brine sensible heat. This is

(6)

Where y is the specific ratio of sensible heat and latent

heat and is given by:

(7)

In this equation λav is the latent heat and is calculated

at average temperature , thus:

(8)

The general form for the total summation of the

distillate formed in all stages, Md is given by

(9)

The flow rate of the brine stream leaving stage (j) is

given by

(10)

The salt concentration in the brine stream leaving stage

jis given by

(11)

The flow rate of the heating steam, Ms is obtained the

energy balance equation for the brine heater, where

(12)

Brine Heater and Condensers Heat Transfer Areas

The brine heater area is given by

(13)

Where LMTD is the log mean temperature difference

of the brine heater and is given by:

(14)

Also Ub is the overall heat transfer coefficient of the

brine heater at steam temperature and is calculated at the

following correlation [12]:

(15)

The heat transfer area for the condenser in each stage is

assumed equal. Therefore, the calculated heat transfer

area for the first stage is used to obtain the total heat

transfer area in the plant. The condenser heat transfer area

in the first stage is obtained from

(16)

Where Uc is the overall heat transfer coefficient of the

condenser and is calculated at the condensing vapor

temperature (Tv) as follows [12]:

(17)

The condensing vapor temperature in the first stage is

given by:

(18)

In the above equations (BPE) is the boiling point

elevation, (NEA) is the non- equilibrium allowance and

( ) is the temperature drop in the demister.Boiling

point elevation (BPE) is function of salt concentration X

and temperature T, and can be obtained from the

following correlation [12]:

(19)

Where

While non-equilibrium allowance (NEA) is given by:

Where NEA10 is obtained from:

Where H is the gate height and Vb is the brine mass

velocity per chamber width. Then the total heat transfer

in the plant is obtained by summing the heat transfer area

for all condensers and the brine heater, thus:

(20)

Stage Dimensions

Calculations of the stage dimensions include the gate

height, the height of the brine pool, the stage width, and

the stage length. The length of all stages is set equal to

the length of the last stage and the width of all stages is

set equal to the width of the first stage. The height of the

brine pool must be higher than the gate height, this is

necessary to prevent bypass of the vapors between

stages(vapor blow through). The gate height (GH) is

obtained in terms of the stage pressure drop (AP), the

brine density (ρbi), the weir friction coefficient (Cd), the

stage width (W), and the feed flow rate (Mf). For stage j

the gate height is:

(21)



The brine pool height is set higher than the gate height

by 0.2 m from designers experience [12].

(22)

Where

and

(23)

Where Pj and Pj+1 are the pressures in stages j and

j+1, and Vbis the brine mass velocity per chamber width.

The length of the last stage is determined as a function of

the vapor flow rate, Dn, the vapor density, ρvn., the vapor

allowable velocity, Vvn, and the stage width, W.

(24)

The cross section area for each stage, As is then

calculated

(25)

Performance Parameters The system performance parameters are defined by the

thermal performance ratio, PR and the specific heat

transfer area, sA. The performance ratio is the defined as

the amount of distillate product produced per unit mass of

the heating steam. This is

(26)

The specific heat transfer area is defined as;

(27)

III. EXERGY ANALYSIS OF THE MSF UNIT

The impetus for new tools for a comprehensive and

accurate analysis of industrial and energy utilization

systems comes from the need for sustainable

development that could be impeded by exhausting energy

sources and deteriorating environment. Exergy evaluation

provides insight to achieve highest technological

efficiency at the lowest cost while meeting the social and

legal conditions. Exergy analysis is generally carried

through various stages of process development including

design phase and when evaluating economic feasibility of

a system. It is very critical in estimating the process

economics, natural resource utilization and environmental

impacts of a system because exergy performance depends

on the environmental conditions (temperature and

pressure) [13].

Exergy analysis identifies pathways to increase energy

efficiency in a system, which benefits the environment by

avoiding excess energy use, associated resource

consumption, and environmental pollution. Improving

energy efficiency increases both economic and

environmental benefits [14].

The difference between energy and exergy in any

system is that the first is conserved while the second is

not conserved unless in reversible processes which is

ideal case. Exergy is that part of energy that can be

transformed into other forms of energy. It is the

maximum theoretical work obtainable from an overall

system consisting of a system and the environment as the

system comes into equilibrium with the environment

(passes to the dead state)[15].

Different forms of energy flows are utilized in

desalination processes which include kinetic, potential,

heat, mechanical, electrical, chemical, and radiation

energies, as shown in Figure. 3 [16]. According to this

figure there are two forms of exergy: physical

(mechanical and thermo-mechanical) and chemical

(reactions and separations).

Figure 3. Types of Exergy

Thermal desalination processes account for the heat

and mass balances thus involving all forms of exergy, but

the dominant is the thermo-mechanical and the others are

very small which can be neglected, and this what is

considered in the current analysis of the MSF unit. In

this unit in each stage there is a phase change process

with evaporation and condensation as shown in Figure. 4

[5].

Figure 4. Concept of Phase Change Desalination

According to the control volume of this process the

general formula of the rate of exergy transfer is given

by: [15].

At steady state, dEcv/dt = dVcv/dt =0, giving the steady-

state exergy rate balance

In the above equations (e) is the specific flow exergy

and is given by

(28)



Where the last two terms are the kinetic energy and

potential energy, which are almost equal in the inlet and

outlet of the stage, thus their differences can be neglected

in the analysis, so the equation becomes:

(29)

Where h0 and s0 are the enthalpy and entropy of the

stream at the dead state (ambient conditions). In the MSF

process, the streams are pure water, seawater, and heating

steam. To find the specific flow exergy of the stream the

correlations suggested by Sharqawy et al. [17] for the

thermo-physical properties of the saline water are used.

For a given set of operating conditions and the

corresponding properties of the working fluid, the rates of

exergy destruction and exergy loss for each component of

the process can be computed from the above equations.

The following measures can now be defined to assess the

thermodynamic performance of the components of a

system and the entire system [18]:

Exergy destruction ratio for component c of the

system, yD,c:

Exergy destruction ratio for complete system,yD:

Exergy loss ratio for the complete system, yL:

Exergetic efficiency, ψ:

(30)

The exergy destruction rate (irreversibility) is related

to the entropy generation rate by the Gouy–Stodola

equation as follows:

yD= T0 × Sgen (31)

IV. RESULTS AND DISCUSSION

The current study about OT-MSF desalination unit is

carried out theoretically by developing a software

program using visual basic 6 with many pages to input

the influential parameters on the performance of this unit

and get output required results. These parameters are the

feed water temperature (Tf), number of stages, last stage

temperature (Tn), total distillate flow rate (Md) and the

heating steam temperature (Ts). The resulted performance

parameters are the performance ratio (PR), the stage and

unit exergetic efficiencies, and the total specific heat

transfer area. Due to change of temperatures during flow

from one stage to another the physical properties of the

saline water such as specific heat, density and salinity

have been considered variable and function of

temperatures, as well as the distillate water. In all cases

two variables, such as feed water temperature (Tf) and

last stage temperature (Tn), are depicted simultaneously

as family curves to infer their influence on the

performance parameters.

Figure. 5 shows the influence of feed water

temperature and the last stage temperature on the

performance ratio which indicates about the thermal

energy used to produce the fresh water. The values of the

both temperatures are selected within the ranges of

operation that could be applied on the unit, which are

helpful in designing the unit. By fixing the value of

temperature at the last stage (Tn) it is noticed that the

performance ratio increases as feed water temperature

increases, while the opposite happened with the

increasing of (Tn). This means that by using preheaters to

raise the temperature of the feed water from any source of

heat such as condensation heat or solar energy will

improve the performance of the OT-MSF desalination

unit. In the other hand this ratio drops with increasing the

heating steam temperature (Ts) at a certain last stage

temperature (Tn) as shown in Figure.6, this due to the

increasing in the heating energy needed to raise the

temperature of the heating steam.

Figure 5. Performance ratio vs. Feed Water Temperature and Last Stage

Temperature.

Figure 6. Performance Ratio vs. Feed Water Temperature and Heating

Steam Temperature.

The other important parameter is the exergetic

efficiency which determines the causes of losses and how

we can improve the performance of the system. Here in

Figure.7 at a certain number of stages this parameter

increases with Tf and drops with Tn this due to the

decrease of the total exergy destruction of the all stages

with the feed temperature, which improves the stage

exergetic efficiency as shown in Figure. 8. The total

exergy destruction is the summation of all exergy

destructions of the stages, and it is the difference between

the inflow and outflow exergies of the stages. While by

increasing the last stage temperature Tn this efficiency



goes down, due to increase in the exergy destruction of

the last stage.

Figure 7. Unit Exergetic Efficiency vs. Feed Water Temperature and

Last Stage Temperature.

Figure 8. Stage Exergetic Efficiency vs. Feed Water Temperature and

Last Stage Temperature.

Also it is noticed that the unit exergetic efficiency goes

down by increasing the number of stages at a certain feed

water temperature as shown in Figure. 9, and by

increasing(Ts) as shown in Fig. 10. This means that there

should be an optimum case to design the unit by selecting

the proper parameters according to the productivity

needed and the operational conditions.

Figure 9. Unit Exergetic Efficiency vs. Stage Number and Feed Water

Temperature.

Figure 10. Unit Exergetic Efficiency vs. Feed Water Temperature and

Heating Steam Temperature.

The total specific heat transfer area is very important

factor in designing the desalination unit, and it is the

summation of the condensation areas of the all stages

with respect to the fresh water productivity. Here we see

that this parameter influences with the operational

temperatures, where it increases with (Tf) and decreases

with (Tn) as shown in Figure. 11 , and with (Ts) as shown

in Figure.12. So in this case we have to choose the

optimum condition suitable to give the higher

productivity at a minimum heating transfer area.

Figure 11. Total Specific Area vs. Feed Water Temperature and Last

Stage Temperature.

Figure 12. Total Specific Area vs. Feed Water Temperature and Heating

Steam Temperature.

V. CONCLUSIONS

From the results obtained in this study about the

exergy and energy analysis of the OT-MSF desalination

unit, which is carried theoretically, one can conclude the

following:

1. The performance ratio (PR) of the unit has been

influenced by the operation temperatures, where

it is increased by increasing the feed water

temperature (Tf), and goes down by increasing

the heating steam temperature (Ts) and last stage

temperature (Tn).This means that the operation

process of the unit should be set at an optimum

case to get the higher productivity.

2. The exergetic efficiency of the stages or of the

unit get improved also by increasing the feed

water temperature (Tf), while get dropped by

increasing the heating steam temperature (Ts)

and the last stage temperature (Tn), which

influences on the value of the performance ratio

as discussed in the previous point. The lower

exergetic efficiency means more exergy

destruction and higher energy losses, which



reflects badly on the economic aspect of the

desalination process.

3. The total specific heat transfer area of the unit

increases with the feed water temperature

sharply at low values of the last stage

temperature, and smoothly at higher

temperatures. Thus due to the difference

between these two temperatures, if it is small

this means that we need more areas, and if it is

large we need less areas. Although the

productivity will be higher at large areas, it is

not preferred unless we make compromise with

other variables such as steam heating

temperature to find the best performance.

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