Multistage Flash Distillation Process

Dr. Khawla Al-Shayji

Kuwait University
College of Engineering
Chemical Engineering Dep.

Contents

Ü Flash Desalination Processes

Ü Single Stage Flashing (SSF)
Ü Once Through Multistage Flashing (MSF-OT)
Ü Multistage Flashing with Brine Circulation (MSF)
Ü Specifications of the MSF process
Ü Long & Cross Tube Configurations
Ü Venting Lines
Ü Demisters
Ü Brine Weirs
Ü Effect of Operational Parameters

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 MSF Developments

Ü Increasing the unit capacity from 454.6 m3/d to 32,000 m3/d. Larger units
with a capacity of 57,734 m3/d are operational in UAE.
Ü Optimizing the number of stage to 24 and a thermal performance ratio of 8.
Ü Decreasing the specific power consumption from 25-70 kW/m3 to 4-10
kW/m3.
Ü Use of efficient antiscalent and on-line ball cleaning allowed continuous
online operation for more than 2 years, without the need for complete shut
down.
Ü Decreasing the specific equipment size.
Ü Reducing the number of stand-by units.
Ü Minimizing and simplifying control units.
Ü Extensive training programs.
Ü Developing accurate and advanced models capable of various tasks, which
include process design, rating, evaluation of process economics,
optimization, process dynamics, and system control

Single Stage Flashing

Non-Condensable Gases

Condenser
Tubes Intake Seawater,
Cooling Seawater,
Mcw +Mf, Xf, Tcw
Mcw, Xf, T1
Distillate Product, Md, Tv
Heating
Steam, Ms, Ts Distillate Tray

Demister
Flashed off Vapor
Steam
Reject Brine,
condensate,
Mb, Tb, Xb
Ms, Ts Feed
Seawater, Mf, Brine Pool
Xf, To

2
 Temperature Profiles

Brine Heater Feed Preheater

TTDh
Heating
Top Brine Steam, Ts To Flashing
Temperature, To brine

DTs
Vapor
TTDc Rejected Brine, Tb
Seawater temperature, Tv
Entering the DT!
T1 T1
Brine Heater, Tb1
Feed Seawater, Tcw

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 Once-through
2 sections

Once Through MSF

Heat input Heat Recovery

Section Section

Distillate Condenser
Demister
Trays Tubes
Intake
Seawater
Mf
Heating
Steam Distillate
Ms 1 2 3 2 2 2 24 Md
1 2 3
Brine
Brine Blow-
Unevaporated
Heater Condensate Brine down
Mb

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 MSF-OT Temperature Profile

Heat Steam
Stage n
Temperature, Ts Stage 1

Top Brine
Temperature, To
Flashing brine

Temperature of
Unevaporated Rejected
brine entering the brine, Tn
brine heater, T1

Seawater, Tcw
Unevaporated
Brine Brine
Heater

Once Through MSF

v Found on a very limited scale.

v The process is formed of the flashing stages and the brine heater.
v Other process units include the intake system, pretreatment units, pumping station,
and ejectors
v The feed seawater flows through the condenser tubes, where it absorbs the latent
heat of condensation from the flashing vapor formed in each stage.
v This heat recovery process improves the overall system efficiency.
v The feed seawater leaving the preheaters in the flashing stages has a temperature
lower than the top brine temperature by 5-10 oC.
v The feed seawater is heated to the top brine temperature in the brine heater.
v Brine flashing takes place in the flashing chambers, where small amounts of
distillate are formed in each stage with simultaneous increase in the brine salinity
and decrease in its flow rate.

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 Drawbacks of MSF-OT

v Absence of control system on the temperature of the feed seawater.

v Reduce the thermal performance ratio to low values of 3 as the seawater
temperature drops from 25 oC (summer) to 15 oC (winter).
v Maintaining the thermal performance ratio at a value of 8 would require
decrease in the brine blowdown temperature, which is associated with
drastic increase in the stage dimensions (to limit the vapor velocity to 4
m/s).
v The flow rate ratio of the feed to product in the MSF-OT process is
approximately 10:1. On the other hand, this ratio in the brine circulation
MSF is 2.5:1. This increases the MSF-OT consumption rate scale and foam
control chemicals.
v Irrespective of the MSF-OT drawbacks, its use can be prove useful
especially in equatorial regions, where the seawater temperature remains
nearly constant throughout the year.
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MERITS of MSF-OT

v Optimum for equatorial regions with feed seawater constant at 28 oC all

year.

v Reduction in the number of pumping units (MSF-OT has pumps for feed
seawater, distillate product, and brine reject) and (MSF has additional
pumps for brine recycle and cooling seawater).

v Reduction in the number of pumps would reduce the number plant trips
caused to the pumping units (50% of all MSF plant trips).

v Elimination of the temperature control loop, piping, and valves placed on

the intake seawater.

v Low brine salinity 36,000-45,000 ppm should affect the consumption rate
of the antiscalent.
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6
 MERITS of MSF-OT

v Lower boiling point elevation, which would increase the flashing vapor
temperature and consequently the feed seawater temperature entering the
brine heater.

v Other factors to be taken into considerations:

v The performance ratio of the MSF-OT is similar to the MSF.
v The capacity of the MSF-OT is similar to the MSF.
v The specific heat transfer area (defined as the total heat transfer area
per unit product flow rate) of MSF-OT is similar to the MSF.

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Recirculating Brine
3 sections

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Brine Heater (BH):

Recirculating brine temperature is raised to the
top brine temperature

Heat Recovery Section (HRS):

Heat released by condensation is used to heat
the recirculating brine flow

Heat Rejection Section (HJS):

Uses the heat released during condensation to
preheat the feed and Reject energy into the
supplementary cooling seawater

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 MSF Brine Circulation

Heat Recovery Heat

Heat input
Section Rejection
Section
Section

Cooling
Seawater Cooling Seawater
Distillate Mcw Recycle Winter
Trays Temperature
Condenser Water Control
Tubes Boxes
Demister
Intake
Seawater
Mf +Mcw
Heating
Steam
Ms Distillate
1 2 3 1 20 21 2 2 24 Product
9 2 3 Md

Brine
Feed Pool
Condensate Brine Feed
Brine Brine Blow-down
Recycle Seawater Mb
Mr Mf

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MSF Temperature Profiles

Heat Steam
Stage 1 Stage n-3 Stage n
Temperature, Ts

Top Brine Flashing brine

Temperature, To

Temperature of
unevaporated Rejected
brine entering brine, Tn
the brine heater,
t1 Unevaporated
Brine
Seawater, Tcw

Heat
Heat Recovery Rejection
Section (n-j) Section (j)
Brine
Heater

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 Brine Circulation MSF

Ü The process is formed of brine heater and flashing stages of the heat
rejection and heat recovery sections.

Ü The intake seawater stream flows in the condenser tubes of the heat
rejection section.

Ü The warm stream of intake seawater is divided into two parts: the first is
the cooling seawater (Mcw), which is rejected back to the sea and the
second is the feed seawater (Mf), which is deaerated, chemically treated
and then fed to the brine pool of the last flashing stage in the heat rejection
section.

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Brine Circulation MSF

Ü The brine recycle stream (Mr) is extracted from the brine pool of the last
stage in the heat rejection section and is introduced into the condenser tubes
of the last stage in the heat recovery section.

Ü The temperature of the brine recycle is increased inside the condenser tubes
in the heat rejection section to a temperature 5-10 oC lower than the top
brine temperature.

Ü The brine recycle stream is heated to the top brine temperature in the brine
heater, where its value depends on the type of chemicals used to control the
scale formation.

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 Brine Circulation MSF

Ü The hot brine enters the flashing stages in the heat recovery section and
then in the heat rejection section, where a small amount of fresh water
vapor is formed by brine flashing in each stage.

Ü The flashing process takes place due to the decrease in the stage saturation
temperature that causes reduction in the stage pressure.

Ü The condensed fresh water vapor outside the condenser tubes accumulates
across the stages and forms the distillate product stream.

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Brine Circulation MSF

Ü The flashing process and vapor formation is limited by increase in the

specific vapor volume at lower temperatures and difficulties encountered
for operation at low pressures. Common practice limits the temperature of
the last stage to range of 30 to 40 oC, for winter and summer operation,
respectively.

Ü In MSF, most of the flashing stages operate at temperatures below 100 oC

and have vacuum pressure.

Ü This increases the possibilities of in-leakage of the outside air. Also, trace
amounts of dissolved gases in the flashing brine, which are not removed in
the deaerator or formed by decomposition of CaHCO3.

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 Brine Circulation MSF

Ü Presence of non-condensable gases result in severe reduction in the heat

transfer rates within the chamber, increase of the tendency for corrosion,
and reduction of the flashing rates.

Ü Proper venting of non-condensable gases is necessary to enhance the

flashing process and to improve the system efficiency.

Ü Treatment of the intake seawater (Mf+Mcw) is limited to simple screening

and filtration. On the other hand, treatment of the makeup seawater is more
extensive and it includes dearation and addition of chemicals to control
scaling and foaming.

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Long Tube Configuration

Demister
Condenser
Tubes

Distillate
Side
Walls

Brine

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Long Tube Configuration

v Tubes are aligned in the same direction as the brine flow.

v A single tube can span more than one stage. In practice, available long tube
configurations are limited a maximum length of 28 m, which encompass on
average 8-10 flashing stages.

v Fouling, blocking, and scaling of a single tube have a strong impact on the
system performance, since; loss of a single tube implies reduction of the
heat transfer in 8-10 stages for the lost tube.

v Tube removal is not simple task. Also, conventional mechanical cleaning,

blasting, would require specially designed equipment.

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 Long Tube Configuration
v Expansion consideration for long tubes requires special consideration in
stage design.

v Vapor leakage between stages is a serious problem that needs special

consideration in design, installation, and during maintenance and cleaning
procedures.

v The main advantage for the long tube configuration is the reduction of the
tube pressure drop by a factor of 25-30%. This reduces the associated
pumping power.

v The long tube configuration can be thought as the optimum choice for
plants with capacities higher than 50,000 m3/d.
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Long Tube Configuration

v Long tube configuration eliminates the water boxes on both sides of the
flashing chamber, which is found in the cross tube configuration.

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 Demister Height above Brine Surface
(0.3-0.5m above Foam Surface)
Small brine particle will travel with the vapor while large
once fall back into the brine

Ü Function of:
S Violence of flashing
S Vapor release rate

Ü Problems
S Flood and corrode the demisters
S Contaminate the distillate
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Demisters
Construction Materials
v Metal, fiberglass, plastics or polymers such as polypropylene or Teflon.

v Commercial alloys have been developed specifically for construction of

wire mesh demisters, which provide three to five times the service lives of
the traditional materials.

v Also, alloy wires offer improved service depending on the temperature and
acid concentration of the gas stream.

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 Brine Weirs

a Stage b Stage Vapor

Vapor
(i+1) (i+1)
Stage (i) Stage (i)
Adjustable Adjustable
Area Area

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Brine Weirs

Ü Provide stable operation at large load variation of 60-120% of the full

load. The upper load is limited by the maximum pump capacity, maximum
brine velocity in the tubes, erosion of mechanical parts, demister flooding.
The minimum load is limited by minimum brine level that generate vapor
lock between stages, minimum brine velocity inside the tubes,

Ü Maintain the minimum/optimum brine level throughout the stages. This is

necessary to reduce the head loss caused by higher brine levels, which
would reduce flashing rate, increase pressure drop, increase entrainment
rate, and reduce the stage temperature.

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 Brine Weirs

Ü Provide vapor lock between stages to prevent vapor blow through across
the stages. The liquid level is adjusted to 0.1-0.2 m higher than the gate
height and the gate height varies between 0.2-0.3 m, however; adjustments
might be necessary to prevent blow through and control of the liquid level
within the stages.

Ü Provide sufficient turbulence that allow for liquid mixing and flashing from
the brine pool.

Ü Controls the brine flow path and rate per unit width of the flashing
chamber. This has a strong effect on the flashing rate of distillate product

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 Stage Stage
(i) (i+1)
Adjusta
ble Area
H2
V
H3
H1 Hw
H
H
c 4
o

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Summary

v Flashing stage is the heart of the MSF process and its performance is
affected by the design of:
v Demister
v Tube bundle
v Venting lines
v Demister
v Weir

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Effect of Operational Parameters

Ü Top Brine Temperature

Ü Shell Pressure
Ü Vapor Velocity
Ü Brine Velocity
Ü Make-up Flowrate
Ü Steam Flowrate and Temperature
Ü Cooling Seawater Flowrate and temperature
Ü Recirculating Brine Flowrate

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 Operating Conditions

! Top Brine Temperature, 90-120 oC.

! Operating range of the antiscalent additives.

! Lower specific heat transfer area.
! Lower flow rates of the intake seawater and brine circulation
! Lower flow rates of antiscalent.
! Lower pumping power.
! Use high pressure heating steam.
! Higher rates of corrosion, release rates of non-condensable gases, and
thermal expansion

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Operating Conditions

¨ Vapor Velocity

¨ Limited to a maximum value of 4 m/s, to avoid entrainment of brine

droplets and reduction of the product quality.

¨ Higher vapor velocities result in re-entrainment of the brine droplets

which accumulates in the demister pad.

¨ In the heat rejection section, the low stage temperature reduces the
pressure and increases the specific volume. As a result, the vapor
velocity is the highest among all stages.

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 Operating Conditions

q Brine Tube Velocity

q Increase the heat transfer coefficient.

q Reduce fouling rates.

q High velocities increase pressure drop and pumping power.

q Tube fouling reduces the net flow area and result in higher brine
velocity.

q Limits 4 m/s in 90/10 Cu/Ni and 5 m/s in 70/30 Cu/Ni, practical limits
are within 1.5-2.3 m/s.

q Titanium and high steel alloys have higher limit of 20 m/s.

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Operating Conditions

Ü Recirculating Brine Flowrate / MR

S A direct effect on MD and thermal efficiency

S Determine the brine flow velocity

□ Lower limit Influence the degree of fouling
□ Upper limit Contaminate the distillate &
Errosion

S Adjust brine orifice

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 Recirculating
Brine Pump

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Evaporator Stages

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 Discharge Line

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Flash Champer

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 Flash Box

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Last Stage

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Condenser Tubes

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 Advantages
Ü PR not directly connected to the No. of stages.

Ü Can be constructed in very large capacities

Ü Boiling does not take place on the tube surface.

Ü Very pure product water is obtained

Ü Scale prevention is less hazardous because threshold

chemicals are extensively used

Ü Plenty of operational experience

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Disadvantages
Ü Performance ratio limited. Upper temperature is limited to 121
oC

Ü Low heat transfer coefficient. Therefore, heat transfer surface

requirement are greater than in the ME process.

Ü Cannot operate below 60% of design capacity

Ü Slow start up. Requires considerable care

Ü Leaks in tubes can cause serous product contamination

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 Cont.

Ü Large amount of seawater required compared to the

production. Large pumping power required.

Ü Very large intake structure required sue to large requirement

of seawater

Ü Large capital cost

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