NEW COST EFFECTIVE ANTISCALANT SOLUTION FOR MED

DESALINATION UNITS WORKING IN SEVERE CONDITIONS

Authors: Daniele Ciferri

Italmatch Chemicals, Italy, [email protected]

Mohamed Khafagy
Italmatch Chemicals, UAE, [email protected]

Mohamed Adel
Italmatch Chemicals, KSA, [email protected]

Marino Mastria
Italmatch Chemicals, Italy, [email protected]

Presenter: Daniele Ciferri

Global technical development manager, Italmatch chemicals, Italy

ABSTRACT SUMMARY

The correct control of the inorganic scale in multi effect thermal desalination units can be achieved by the
application of proper antiscalant agent combined with correct operative approach of the desalination unit.
In MED thermal desalination units, inorganic fouling can predominantly accumulate across the tube
bundle section and through the sea water spray nozzles, producing performance decay and deficiency of
distillate production.
The prevention of fouling phenomena is achieved by the application of suitable antiscalant agent, able to
hinder the first crystalline nucleation phase, promotes the distortion of the crystalline inorganic lattice and
deny the solids particle’s agglomeration by providing efficient dispersion action.
New Albrivap® 141 technology has been specifically designed for MED desalination units, which can
potentially work in severe working conditions.
Laboratory performance tests results of new Albrivap® 141 antiscalant solution in comparison with others
antiscalants chemistries validated this new technology as promising candidate able to control scale
formation at low dosing rate and high temperature, which extend MED equipment cleaning cycle time. In
particular, the new Albrivap® antiscalant solution can extensively inhibits the CaCO3, CaSO4 and
Mg(OH)2 and equally provides superior dispersant capabilities.
As second step, the Albrivap® 141 antiscalant has been applied in MED pilot units, which operated at
higher temperature respect to standard conditions of MED distillation units (TBT=85°C). The excellent
laboratory performance results have confirmed by the pilot plant MED trial. The analysis of the fouling
factor and heat coefficient transfer continuously recorded during the whole test period confirmed the
superior effectiveness of this new Albrivap® antiscalant chemical solutions.

The International Desalination Association Conference 2019 Action4Good, Santa Margherita, Italy
REF: IDA19A4G-000001_Ciferri
I. INTRODUCTION

The correct selection and application of proper antiscalant agent in multi effect distillation thermal plant
(MED) is a vital aspect to assure safe and efficient operation of the evaporator. The inorganic scale
formation across the MED tube bundles drastically reduce the heat coefficient transfer, which leads to un-
expected plant shut down and consequent planning of cleaning activity to restore the initial thermal
evaporator performance.
Antiscalant agents are widely used in MED/MED-TVC applications to interfere the inorganic crystal
growth at different stages. It can act according to different inhibition mechanisms, such as threshold,
crystal distortion, or dispersion effects.
The new developed Albrivap® 141 is a cost effective solution specifically designed by Italmatch research
& development applicative center, which drastically delays the precipitation of CaCO3, Mg(OH)2, CaSO4
deposition in MED industrial operative conditions and prevents the solid fine particles agglomeration.
The scale inhibition performance of Albrivap® 141 has been carefully evaluated by laboratory applicative
tests in comparison with others antiscalants benchmarks chemistries currently applied in industrial MED
plants.
Albrivap®141 antiscalant product has tested in MED-TVC pilot plant unit operating at top brine
temperature (TBT) of 85°C, for a period time of 2 months.

II. RESEARCH OBJECTIVES

Different antiscalant chemistries are nowadays applied to control the precipitation of inorganic scale in
MED, MED-TVC desalination units.
The research of this paper has the objective to identify a cost-effective antiscalant solution designed to
work under MED/MED-TVC conditions with the property to provide high dispersancy effectiveness and
control of the most common scale issues encountered in during MED operation.
As final objective, the efficacy of the new Albrivap® 141 solution has assessed in MED-TVC pilot
application, which works at higher top brine temperature (85°C) respect to standard industrial MED-TVC
applications (60°C – 70°C)
To validate the performance of Albrivap® 141, heat coefficient transfer and fouling factor calculation
have carefully performed and monitored during the whole trial period.

The International Desalination Association Conference 2019 Action4Good, Santa Margherita, Italy
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III. EXPERIMENTAL:

The performance of Albrivap® 141 antiscalant has tested in laboratory in comparison with benchmark
products by using different protocol methods and it has validated in real MED-TVC pilot plant.

3.1 Laboratory performance tests:

The antiscalant inhibition performance of Albrivap® 141, has evaluated by different laboratory test
protocol methods, specifically designed to evaluate:

✓ Dispersant capability Vs silts, clays and CaCO3 inorganic crystals

✓ Scale inhibition performance Vs CaCO3, CaSO4 and Mg(OH)2.

Tests results has been compared with benchmark antiscalant products, currently applied in the market.

3.2 MED-TVC, pilot plant trial:

Albrivap® 141 has tested in MED-TVC pilot unit located at the Desalination Technologies Research
Institute (DTRI), Saline Water Conversion Corporation (SWCC), Jubail in the Kingdom of Saudi Arabia
(KSA) on the Arabian Gulf, operating at TBT of 85°C with brine sea water in the range of 62 – 65 g/l. The
distillation production capacity of MED pilot plant is 1 m3/h, and make up sea water of 3.2 m3/h.
Make up sea water is pretreated through decarbonator and deaerator unit. Before the decarbonator the sea
water is preheated by plate heat exchanger, which exchanges heat with distillate stream.
After deaerator the sea water flow is splitted in two separated streams in which recover heat from distillate
cooler and brine cooler. In this way the brine temperature is maintained at a temperature less than allowed
standard temperature.
In such way the brine water is discharged at temperature less than +10°C of natural sea water temperature
and distillate temperature in the range of 35°C.
The MED unit received steam from a steam header coming from the boiler room, The boiler is operating
with a pressure of 12 bar with capacity of 2,000 Kg/hr.
The MED-TVC plant has 4 effects with tray spray feed system and contains two passes. The tubes in the
evaporator are 3.6 m in length, 18.88 mm in diameter and 0.7 mm in thickness. Tubes are arranged in
triangular pattern and distance of the tube are 9.5 mm. First pass has 100 tubes and second pass has 13
tubes, with 16 rows and 2 rows, respectively (figure 1).

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REF: IDA19A4G-000001_Ciferri
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 Figure1, Two pass arrangement of the tube bundles.

The vapour produced in the first effect is recovered in the second effect; the same vapor produced in the
second effect is used in the third effect and so on.
The vapor produced in the fourth effect is condensed in the condenser together with all the other
condensate stream, pumped by distillate pump.
All evaporator stages are equipped with non-condensable gases vent ejector. To enhance the MED
performance, the TVC entrains vapor from the 4th effect and mixed it with steam supplied from boiler.
The ratio of blow down is controlled by level valve control bar.

Figure 2, MED-TVC schematic representation

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REF: IDA19A4G-000001_Ciferri
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Albrivap® 141 has initially dosed at 4 ppm, then it has reduced to 2 ppm for all the rest of the trial.
During the tests temperature profile of TBT, feed, make up sea water, steam and vapor in each effect was
constantly monitored.
Indeed, flow rate of brine, feed, make and distillate was constantly monitored during the time, together
with related TDS water values.
Performance ratio (PR) and gained output ratio (GOR) has also calculated during the all period of the trial.
The performance of Albrivap® 141 antiscalant has evaluated by monitoring the following parameters:

a) First effect heat transfer coefficient (HTC) Vs Time

b) First effect fouling factor (FF) Vs Time
c) Visual inspection of the thermal desalination unit.

The International Desalination Association Conference 2019 Action4Good, Santa Margherita, Italy
REF: IDA19A4G-000001_Ciferri
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IV. RESULTS

4.1 Laboratory test results, Albrivap® 141 Vs Benchmarks.

Laboratory performance tests conducted on Albrivap® 141 demonstrate the antiscalant performance
properties reported in below figures. Benchmark products used for comparison are commercial
antiscalants products based on phosphonates and polymeric chemistries.

✓ Dispersant inhibition properties in clay, kaolin.

Albrivap® 141 provides premium dispersant properties. In comparison with others benchmark products,
Albrivap® 141 has comparable dispersant properties respect to Benchmark 2, and enhanced dispersant
properties respect to Benchmark 1 (figure 3).

Figure 3, % Efficiency silt and clay Vs Blank

✓ Calcium sulfate inhibition performance test.

Tests results demonstrated that Albrivap® 141 inhibits CaSO4 precipitation, with superior performance
respect to reference benchmarks (figure 2). In comparison with Benchmark 2 (antiscalant product with
premium dispersant capability), Albrivap® 141 provides improved CaSO4 inhibition performance.
Calcium sulfate inhibition performance has reported in figure n.4.

The International Desalination Association Conference 2019 Action4Good, Santa Margherita, Italy
REF: IDA19A4G-000001_Ciferri
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 Figure 4, calcium sulfate inhibition test results.

✓ Calcium carbonate inhibition performance test.

Calcium carbonate tests results demonstrated that Albrivap® 141 product provides effective calcium
carbonate inhibition performance. In comparison with Benchmark 1 & 2, Albrivap® 141 provide enhanced
CaCO3 inhibition performance.

Figure 5, calcium carbonate inhibition results

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REF: IDA19A4G-000001_Ciferri
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4.2 MED-TVC pilot trial with Albrivap® 141

Operative parameters of MED-TVC desalination units were carefully monitored during the entire trial
period, with the objective to closely assess the performance of Albrivap® 141 antiscalant.
Sea water temperature was carefully controlled, and it fluctuates between 26°C and 28°C, as reported in
figure n.6.

Figure 6, Sea water Temperature Vs time

Steam temperature and vapor of the first, second, third and fourth effect was constantly monitored.
In specific following trend has observed (figure 7):

Figure 7, Steam and Vapour temperature in each effect Vs time

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The top brine temperature has constantly controlled in the range of 84°C – 85°C, as reported in figure
n.8.

Figure 8, Top brine temperature Vs time

Sea water make up and brine conductivity has monitored during the entire trial period. Specifically, the
make up conductivity fluctuate in the range of 60-62 mS/cm, while the brine conductivity is in the range
of 80-82 mS/cm.
The conductivity of the distillate fluctuates in the range of 4-5 S/cm (see figure 9)

Figure 9, Make up, brine and distillate conductivity Vs time

From conductivity results of make-up sea water and brine water, concentration factor has calculated.
According to this, it is fluctuated in the range of 1.29 and 1.39 (Figure n.10).

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REF: IDA19A4G-000001_Ciferri
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 Figure 10, Concentration factor Vs time

Steam flow rate has been continuously monitored and it was in the range of 240 – 290 Kg/h.

Figure 11, Steam Flow Vs Time

Distillate production flow rate has monitored in the range of 1.1 – 1.3 m3/h (See figure 10).

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 Figure 12, Distillate flow rate Vs time

Gained output ratio (GOR) has calculated as ratio between distillate flow rate and steam flow.
GOR has kept in the ratio of 3.9-4.3.

Figure 13, Flow rate of feed, make up, brine ad distillate Vs time

Heat transfer coefficient for the first effect has calculated starting from the collected operative data. No
significant decline of HTC has observed during the trial period.

The International Desalination Association Conference 2019 Action4Good, Santa Margherita, Italy
REF: IDA19A4G-000001_Ciferri
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 4000
Dose rate = 4 ppm Dose rate = 2 ppm
3500
U (W/m^2/˚C)

3000

2500

2000
0 200 400 600 800 1000 1200 1400 1600
Time (hr)

E1 24hr mov avg

Figure 14, calculated Heat coefficient transfer (HTC) Vs Time

No significant increasing of the calculated fouling factor has observed during the trial period with
Albrivap® 141 treatment. Extrapolated equation of the line is: FF=3E-09t-7E-07 (Figure 13).
Indeed, Albrivap® 141 dosing rate has drastically reduced from 4 ppm to 2 ppm. After dosing rate
optimization, it has not observed any deviation of fouling factor or heat coefficient transfer. This confirms
that even reduction of -50% of antiscalant dosing rate did not affect final antiscalant performance.

Dose rate = 4 ppm Dose rate = 2 ppm

1,0E-04
FF (m^2.˚C/W)

5,0E-05
FF = 3E-09t - 7E-07

0,0E+00

-5,0E-05
0 200 400 600 800 1000 1200 1400 1600
Time (hr)

E1 Design value: 0.0001 24hr mov avg

Figure 15, Calculated fouling factor (FF) Vs time

At the end of two months trial, the pilot plant unit has shut down and visual inspection has performed.

The International Desalination Association Conference 2019 Action4Good, Santa Margherita, Italy
REF: IDA19A4G-000001_Ciferri
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 Figure 26, A) Pre-test visual inspection of first effect B) Post-test visual inspection of first effect

Figure 17, Post-test visual inspection of first effect

Figure 18, Post-test visual inspection of first effect

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V. CONCLUSIONS.

The New Albrivap® 141 has been designed with the objective to provide an enhanced cost/effective
antiscalant solution for MED/MED-TVC units.
Laboratory performance tests demonstrated the effectiveness of Albrivap® 141 antiscalant solution.
Combined with excellent dispersant capability, Albrivap® 141 provides excellent CaCO3 and CaSO4
inhibition performance.
Albrivap® 141 has tested in pilot plant trial for 2 months at dosing rate of 4 ppm and then optimized at 2
ppm at TBT of 85°C.
All operative parameters have been carefully controlled. MED-TVC pilot plant performance (Heat
coefficient transfer, HTC, fouling factor, FF, gained output ratio, GOR) has carefully monitored.
GOR has maintained constant with no deviation in reference to the design values.
HTC and FF parameters were stable for all the trial period. Indeed, after optimization of Albrivap 141
dosing rate (from 4ppm to 2 ppm), it was not observed any variation of HTC and FF performance
indicators.

Visual inspection confirmed that the MED-TVC pilot unit was completely free of scale, as confirmed by
fouling factor and heat coefficient transfer results.
Albrivap® is commercially approved product to be used in MED-TVC industrial plant as a sustainable
antiscalant cost/effective solution to be used in MED, and MED/TVC distillation units.

The International Desalination Association Conference 2019 Action4Good, Santa Margherita, Italy
REF: IDA19A4G-000001_Ciferri
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