Lenntech bv

[email protected]
www.lenntech.com
Tel. +31-15-261.09.00
Fax. +31-15-261.62.89

Flow Configuration

There are several flow configurations for RO that allow the user to get the most
out of the system. This paper will cover a few of the techniques used in RO
design to optimize system performance.

These techniques include the use of concentrate staging and concentrate

recirculation to increase recovery, permeate staging to attain ultrapure standards
of separation, and permate throttling and interstage boosting to manipulate the
flow distribution between stages.

SYSTEM COMPONENTS

RO systems consist of the following basic components:

• Feed water supply unit

• Pretreatment system
• High pressure pumping unit
• Membrane element assembly unit
• Instrumentation and control system
• Permeate treatment and storage unit
• Cleaning unit

The membrane assembly unit (RO block) consists of a stand supporting the
pressure vessels, interconnecting piping, and feed, permeate and concentrate
manifolds. Membrane elements are installed in the pressure vessels. The
pressure vessel has permeate ports on each end, located in center of the end
plate, and feed and concentrate ports, located on the opposite ends of the
vessel. Each pressure vessel may contain from one to seven membrane
elements connected in series.

Page 1 of 8 01/23/01
 Permeate Brine seal Interconnector End plate
port

Concen-
trate port
Membrane Membrane Membrane
element element element

Feed port
Pressure vessel

Pressure vessel with three membrane elements

As shown above, the permeate tube of the first and the last element is connected
to the end plates of the pressure vessel. Permeate tubes of elements in the
pressure vessel are connected to each other using interconnectors. On one side
of each membrane element there is a brine seal, which closes the passage
between outside rim of the element and inside wall of the pressure vessel. This
seal prevents feed water from bypassing the membrane module, and forces it to
flow through the feed channels of the element.

As feed water flows through each subsequent membrane element, part of the
feed volume is removed as permeate. The salt concentration of the remaining
feed water increases along the pressure vessel. Permeate tubes conduct the
permeate from all connected elements. The collected permeate has the lowest
salinity at the feed end of the pressure vessel, and increases gradually in the
direction of the concentrate flow.

CONCENTRATE STAGING and PYRAMID DESIGN

A system is divided into groups of pressure vessels, called concentrate stages. In

each stage pressure vessels are connected in parallel, with respect to the
direction of the feed/concentrate flow. The number of pressure vessels in each
subsequent stage decreases in the direction of the feed flow, usually in the ratio
of 2:1, as shown below.

Page 2 of 8 01/23/01
 Permeate

Pressure vessel,
PG 1st stage

Pressure vessel,
1st stage
Feed
Pressure vessel,
1st stage

Pressure vessel,
1st stage

Pressure vessel,
2nd stage

Pressure vessel,
2nd stage
PG

Concentrate

Flow diagram of a two stage RO system

Thus, one can visualise that the flow of feed water through the pressure vessels
of a system resembles a pyramid structure: a high volume of feed water flows in
at the base of pyramid, and a relatively small volume of concentrate leaves at the
top. The decreasing number of parallel pressure vessels from stage to stage
compensates for the decreasing volume of feed flow, which is continuously being
partially converted to permeate. The permeate of all pressure vessels in each
stage, is combined together into a common permeate manifold.

The objective of the taper configuration of pressure vessels is to maintain a

similar feed/concentrate flow rate per vessel through the length of the system
and to maintain feed/concentrate flow within the limits specified for a given type
of membrane element. Very high flow through a pressure vessel will result in a
high pressure drop and possible structural damage of the element. Very low flow
will not provide sufficient turbulence, and may result in excessive salt
concentration at the membrane surface. For a given RO unit, the number of
concentrate stages will depend on the permeate recovery ratio and the number
of membrane elements per pressure vessel. In order to avoid excessive
concentration polarization at the membrane surface, the recovery rate per
individual membrane element should not exceed 18%. It is common engineering
practice to design brackish RO systems so that the average recovery rate per 40
inch long membrane element will be about 9%. Accordingly, the number of

Page 3 of 8 01/23/01
concentrate stages for an RO unit having 6 elements per pressure vessel would
be two for recovery rates over 60%, and three for recovery rates over 75%. With
pressure vessels containing seven elements, a two stage configuration would be
sufficient for recovery rates up to 85%.

CONCENTRATE RECIRCULATION

The simplest membrane element assembly consists of one pressure vessel,

containing one membrane element. Such a configuration, used in a very small
systems, can operate at a limited permeate recovery ratio, usually about 15%. In
order to increase the overall system recovery ratio and still maintain an
acceptable concentrate flow, a part of the concentrate stream is returned to the
suction of the high pressure pump. The concentrate recycling configuration,
shown below, is used mainly in a very small RO units. An advantage of such a
design is the compact size of the RO unit. The disadvantage of concentrate
recirculation design is related to the need for a larger feed pump to handle higher
feed flow. Accordingly, the power consumption is relatively higher than that
required in a multistage configuration. Due to blending of the feed with the
concentrate stream, the average feed salinity is increased. Therefore, both the
feed pressure and the permeate salinity are higher as well.

PG

PG

Flow diagram of a single stage RO unit with concentrate recirculation

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CONCENTRATE STAGING

A commercial RO unit usually consists of single pump and a multistage array of

pressure vessels. A simplified block diagram of a two stage RO unit is shown on
the next page.

The concentrate from the first stage becomes the feed to the second stage; this
is what is meant by the term "concentrate staging." The flows and pressures in
the multistage unit are controlled with the feed and concentrate valves. The feed
valve, after the high pressure pump, controls feed flow to the unit. The
concentrate valve, at the outlet of RO block, controls the feed pressure.
112 gpm 150 gpm
204 psi 25.4 m3/hr 34.0 m3/hr
14.1 bar

PG

200 gpm 38 gpm

45.4 m3/hr 8.6 m3/hr
179 psi
12.4 bar

PG

PG

50gpm 154 psi

11.3 m3/hr 10.6 bar

Flow diagram of a two stage RO system

FLOW DISTRIBUTION

In some cases it is necessary to equilibrate permeate flow between stages i.e.

decrease permeate flow from the first stage and increase permeate flow from the
last stage. This can be accomplished in one of two design configurations. One
solution is to install a valve on the permeate line from the first stage, as shown.

Page 5 of 8 01/23/01
By throttling this valve, permeate back pressure will increase, reducing net
driving pressure and reducing permeate flux from the first stage. The differential
permeate flux is produced from the second stage by operating the RO unit at a
higher feed pressure.

50 psi 101 gpm 150 gpm

PG 3.4 bar 22.9m3/hr 34 m3/hr
236 psi
16.3 bar

PG

200 gpm 49 gpm

45.4 m3/hr 11.1 m3/hr

210 psi
PG 14.5 bar

PG

50gpm 182 psi

11.3 m3/hr 12.6 bar

Flow diagram of a two stage RO system with permeate throttling

The other solution is to install a booster pump on the concentrate line between
the first and the second stage, as diagrammed below. The booster pump will
increase feed pressure to the second stage resulting in higher permeate flow.
The advantage of the permeate throttling design is simplicity of the RO unit and
low capital cost. However, this design results in additional power losses due to
permeate throttling and higher power consumption. The interstage pump design
requires modification of the interstage manifold and an additional pumping unit.
The investment cost is higher than in the first design, but the power consumption
is lower.

Page 6 of 8 01/23/01
 101 gpm 150 gpm
22.9 m3/hr 34.0 m3/hr
186 psi
12.8 bar

PG

200 gpm 49 gpm

45.4m3/hr 11.1 m3/hr

210 psi
14.5 bar

160 psi PG
11.0 bar

PG

PG

50gpm 182 psi

11.3 m3/hr 12.6 bar

Flow diagram of a two stage RO system with interstage pump

PERMEATE STAGING

For some applications, the single pass RO system may not be capable of
producing permeate water of a required salinity. Such conditions may be
encountered in two types of RO applications:

• Seawater RO systems, which operate on a very high salinity feed

water, at high recovery ratio and/or at high feed water temperature.

• Brackish RO applications which require very low salinity permeate

such supply of makeup water for pressure boilers or production of rinse
water for microelectronics applications.

To achieve an additional reduction in permeate salinity, the permeate water

produced in the first pass is desalted again in a second RO system. This
configuration is called a two pass design, or "permeate staging." Depending on
quality requirements, all or part of the first pass permeate volume is desalted
again in the second pass system. The system configuration is known as a
complete or partial two pass system depending on whether all of the permeate is
fed to the second pass or not.

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The first pass permeate is a very clean water. It contains very low concentrations
of suspended particles and dissolved salts; therefore, it does not require any
significant pretreatment. The second pass system can operate at a relatively high
average permeate flux and high recovery rate. The common design parameters
for the second pass RO unit are average flux rate of 20 gfd and recovery rate of
85% - 90%. In a two pass system, the permeate from the first pass flows through
a storage tank or is fed directly to the suction of the second pass high pressure
pump. There are number of possible configuration of the two pass RO units. One
configuration, which is a partial two pass system, shown here, splits the
permeate from the first pass into two streams.

Flow diagram of a partial two pass RO system

One stream is processed by the second pass unit, and is then combined with the
unprocessed part of the permeate from the first pass. Provided that the partial
second pass system can produce the required permeate quality, this
configuration results in smaller capital and operating costs, as well as higher
combined permeate recovery rate (utilization of the feed water), compared to a
complete two pass system.

It is a common procedure in a two pass systems to return concentrate from the

second pass unit to the suction of the high pressure pump of the first pass unit.
The dissolved salts concentration in the concentrate from the second pass is
usually lower the concentration of the feed to the first pass unit. Therefore,
blending feed water with the second pass concentrate reduces slightly the
salinity of the feed, and increases the overall utilization of the feed water.

Page 8 of 8 01/23/01
Lenntech bv
[email protected]
www.lenntech.com
Tel. +31-15-261.09.00
Fax. +31-15-261.62.89

RO Sizing

The approximate system size (the number of membrane elements and pressure
tubes) required to produce a quantity of product water (permeate) may be
determined by the following steps:

a. Select the membrane type and corresponding model number.

b. Select the flux rate (GFD) according to expected feed water quality.
c. Divide the desired plant capacity by the design flux rate and by
membrane element surface area (the membrane area is listed in the
element specification sheet).
d. Divide total number of elements by the number of elements per
pressure vessel. Round result up to the nearest integer.
e. Select the appropriate array to achieve the desired percentage
recovery. Increase number of pressure vessels if necessary.

The RODESIGN program displays the recommended pump pressure in addition

to the calculated feed pressure. The recommended pump pressure is higher than
the feed pressure by 10% of Net Driving Pressure + 3 psi (0.2 bar) for entry
loses. This safety margin should usually be sufficient. Alternatively, a safety
margin of 10% should be used for system design whenever the fouling rate
cannot be predicted. A design should include as a contingency a number of
elements 10% higher than calculated by the computer program. Alternatively, the
feed pressure should be specified as required for the given product flow with
90% of the calculated membrane elements.

A NOTE OF CAUTION TO THE DESIGNER:

The RODESIGN program only projects RO system performance from a user

controlled set of data input and design decisions. The program does not judge
whether a system design is realistic or optimized for a given set of conditions. It
is the user's responsibility to review and judge the system design based on the
anticipated or existing pretreatment, reasonable design guidelines, and
experience. The user is strongly recommended to review all RO system designs
with the HYDRANAUTICS Technical Support Group or a HYDRANAUTICS
Technical Sales Representative.

Page 1 of 1 01/23/01
Lenntech bv
[email protected]
www.lenntech.com
Tel. +31-15-261.09.00
Fax. +31-15-261.62.89

Hydranautics Design Limits

The Following System Design Limits should be observed when designing a Reverse
Osmosis system.

Average flux rates and expected % decrease in flux per year:

Water Type SDI Flux % Flux Decline/year
Surface water (SDI 2 - 4) 8 - 14 GFD 7.3 - 9.9
Well water (SDI < 2) 14 - 18 GFD 4.4 - 7.3
RO Permeate (SDI < 1) 20 - 30 GFD 2.3 - 4.4

Expected % Salt Passage Increase per year:

MembraneType Abbreviation % SP Increase/year
Cellulosic membrane CAB1, CAB2, CAB3 17 - 33

Composite Membrane
Brackish, Low Pressure ESPA1, ESPA2, ESPA3 3 -- 17
Brackish, High Rejection CPA2, CPA3, CPA4 3 -- 17
Low Fouling LFC1, LFC2 3 -- 17
Seawater SWC1, SWC2, SWC3 3 -- 17
Softening, PolyVinyl Deriv. PVD1, ESNA1, ESNA2 3 -- 17

Maximum Feed Flow and Minimum Concentrate Flow Rates per Vessel:
Membrane Diameter (in) Max (GPM) Max (m3/hr) Min (GPM) Min (m3/hr)
4 16 3.6 3 0.7
6 30 8.8 7 1.6
8 75 17.0 12 2.7
8.5 85 19.3 14 3.2

Saturation Limits for Sparingly Soluble Salts in the Concentrate:

Salt Saturation %
CaSO4 230
SrSO4 800
BaSO4 6000
SiO2 100

Limits of Saturation Indices (Langelier and Stiff & Davis Saturation Indices):
Condition* LSI Value
LSI and SDSI without scale inhibitor < -0.2
LSI & SDSI with SHMP < 0.5
LSI & SDSI with organic scale inhibitor < 1.8

Page 1 of 1 01/23/01
Hydranautics are the most common Membranes.
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Lenntech bv
Rotterdamseweg 402m
2629HH Delft
The Netherlands
[email protected]
www.lenntech.com
Tel. +31-15-261.09.00
Fax. +31-15-261.62.89