Reverse Osmosis Process I

Reverse
Osmosis
Process - I
Date
Agenda
• RO Basics
• RO Management
• Nalco Products & Services
• Applications in the Steel Industry
• Case Histories
Confidential Ecolab Content – Do not copy or duplicate

RO Basics - Industrial RO Systems
100 GPM
200 GPM
CW make-up water system at a Steel Plant
Cross-Flow Filtration
FEED PERMEATE
Flow Control Valve
CONCENTRATE
(REJECT
WASTE)
Permeate and Recovery
• Definition of Recovery
– Recovery describes how much of the feed water passes
through the membrane to become “product” or “permeate.”
– Expressed in terms of percent of feed.
– Typical recovery ranges from 50% to 85%.
– Higher recovery means less wastewater.
– Set by designer.
FEED PERMEATE
CONCENTRATE
Recovery
75% RECOVERY
FEED PRODUCT
100 gpm 75 gpm
25 gpm
REJECT
Recovery
75% RECOVERY
FEED PRODUCT
100 gpm 75 gpm
25 gpm
REJECT
RECOVERY is set by the designer
Rejection
• Definition of Rejection
– Rejection describes the amount of a feed water species that
is “retained” or “rejected” by the membrane…stays in feed
water.
– Expressed in percent of feed water concentration.
– Higher rejection means “cleaner” product.
– Property of the membrane
FEED PERMEATE
CONCENTRATE

Rejection
Typical
Type of Rejection
Example
Species
TFC (%)
Multi-valent
Ca2+, Mg2+ 98 – 99+
ion
Mono-valent
Na+, Cl- 96 - 99
ion
Gas O2, CO2, Cl2 0

Rejection
75% RECOVERY
98% REJECTION = 2% PASSAGE
FEED PRODUCT
100 gpm 75 gpm
100 ppm 2 ppm
25 gpm
REJECT
REJECTION is a property of the membrane

Rejection
CONCENTRATION FACTOR:
FEED gpm / REJECT gpm = CF
FEED PERMEATE
CONCENTRATE

Rejection
75% RECOVERY
FEED PRODUCT
100 gpm 75 gpm
100 ppm 2 ppm
25 gpm
FEED / REJECT = CF
REJECT
100 gpm / 25 gpm = 4

Rejection
80% RECOVERY
FEED PRODUCT
100 gpm 50 gpm
100 ppm REJECT 2 ppm
50 gpm
480 ppm
Concentration Factor = 5

Concentration Factor
RECOVERY CF
50% 2
75% 4
80% 5
83% 6
87.5% 8

Pressure Vessel
Pressure vessels hold the membrane modules.
• Designed to contain pressurized feed

water and reject
• Pressure Housing Materials are
Fiberglass or Stainless steel

Pressure Vessel
MULTI-ELEMENT PRESSURE VESSEL
Product
[Permeate]
Feed Concentrate
[Reject]
Contains 1, 3, 4, 6, or 7 modules in series

Inside a Pressure Vessel
2.4 gpm
20 gpm
10 ppm
1,000 ppm
2.1 gpm 10.7 gpm
11 ppm 1.8 gpm 13.37 ppm
17.6
gpm 13 ppm 1.6 gpm
1,136 14 ppm
ppm
15.4 gpm
1.5 gpm
1,291 ppm
17 ppm
13.6 gpm
1467 ppm
1.3 gpm
12.0 gpm 19 ppm
1,667 ppm
10.55 gpm
1,894 ppm
9.28 gpm
2,152 ppm

Pressure vessel
Stages
SINGLE STAGE RO SYSTEM
TRAIN #1
FEED
PERMEATE
HIGH
PRESSURE
PUMP
TRAIN #2 BRINE
VESSEL
ELEMENTS
Pressure Vessel
MORE MODULES IN SERIES

= HIGHER WATER RECOVERY
(= LESS WASTE WATER)
= LOWER PRODUCT QUALITY
Hydraulics
Bulk flow
Bulk flow
Bulk flow
Bulk flow
Bulk flow
Boundry layer
Reverse Osmosis Skid
RO Skids typically have three major components

plus controls.
CARTRIDGE
PRESSURE
FILTER HIGH-PRESSURE
VESSELS
FEED PUMP
FEED PRODUCT
TO WASTE
Multi Stage Centrifugal Pump
RO Skids typically have two or three chemical

injection points.
CARTRIDGE
PRESSURE
pH Adjustment FILTER HIGH-PRESSURE
VESSELS
FEED PUMP
Scale inhibitor
De-chlorination
FEED PRODUCT
TO WASTE
TYPICAL RO SKID
Controls
Cartridge Pressure
filter vessels
Feed pump
Industrial RO system
Stages &
Arrays
Bahrain - 2013
Stages
RO PRESSURE VESSEL ARRANGEMENT

STAGE 1 STAGE 2
PRODUCT
FEED
REJECT
Stages
STAGE 1 STAGE 2
PRODUCT
FEED
REJECT
THE REJECT FROM STAGE 1 BECOMES

THE FEED STAGE 2
Stages
• ADVANTAGE
– Higher recovery = less waste
• DISADVANTAGE
– Lower product quality

Multiple Passes
TWO PASS SYSTEM
PASS 1 PASS 2
PERMEATE 1 FINAL
FEED PERMEATE
REJECT RECYCLE
REJECT
THE PERMEATE FROM PASS 1 BECOMES THE FEED PASS 2
Multiple Passes
• ADVANTAGE
– Polishing
– Higher product quality
• DISADVANTAGE
– Lower recovery

Membrane
Fouling
Bahrain - 2013
Tight Spacing
Rough Surface
Salt Concentration in the Boundary
Layer
Poor Permeate Quality
Low Water Production
FOULING
Membrane Damage
Frequent Cleaning
Poor Permeate Quality
Foulant Distribution Globally
Other
CaSO4
CaCO3 14%
3%
4%
Organic
Ca3(PO4)2 50%
4%
Al2O3
5%
SiO2
13%
Fe2O3
7%
Membrane
Offering
Bahrain - 2013
Scale Control
• Prevent scaling
– Industry leading antiscalants
• PC-191T, PC-510T, PC-504T, PC-1850T, PC-1638T, PC-1020T , PC-1522T
, PC-161T
– Automation to insure antiscalant is always present, at the right
concentration
• 3D TRASAR for RO
– Extensive experience in scaling prevention
• Accurate and detailed water analysis
• Trusted and tested dosing models for antiscalants

Components of RO TRASAR®
Control
Monitor
Auto-tuning
PID controller
In-line
fluorometer
Traced Digital dosing
antiscalant pump
Implementing RO TRASAR®
Operating “In Control”
Monitor Assess Control
– Install online – Collect data over a – Install

fluorometer 4 week period, controller,
observe variability connect dosing
– Switch to “T” pump
version of – Address issues
antiscalant causing excessive – Tune controller,
variability begin automatic
– (Install operation
external – Collect data over a
alarm) 2 week period to – Analyze data
verify “In control” monthly to
operation insure stable
operation
Particulate
Removal
Bahrain - 2013
Generic system flow chart
Multi Media
Filter (MMF)
Raw Water
Cartridge RO
Filter System
Detectable
Coagulant
SDI
Turbidity
Field test results – Steel Plant
SDI decrease after coagulant-aid dosing

Reverse
Osmosis
Process
Bahrain - 2013
Biological fouling control
• Bugs are a fact of life ….. real question is how to minimize their
effect
– Don’t
• feed them
• permit immigration
• give them places to live
• let them get too numerous
– Do
• kill them whenever you can
• remove the traces they leave behind

Biological fouling control
• Manage biofouling
– Non oxidizing biocides
• PC-11
• PC-56
– Development of customized bio-control programs
– Pretreatment review to identify opportunities for improvement

Cleaners
Bahrain - 2013
Cleaners
• Effective cleaners for many foulants

– Biological fouling
• PC-98 plus, PC-67, PC-40, PC-33
– Mineral scaling
• PC-87, PC-77
– Insoluble scale
• PC-77, PC-67, PC-33, PC-42
– Colloidal fouling
• PC-98, PC-67

Diagnostic
Pen Trasar for
RO
Bahrain - 2013
Diagnostic TRASAR 3D TRASAR for RO Extra Benefit
Diagnostics How is this possible?
• Verify recovery • Water transport through

• Detect membrane failure convection
• Detect mechanical problems • Salt transport through
• Troubleshooting diffusion
• Calibration • Tracer transport through
…LEAKS
Diagnostic 3D TRASAR for RO
• If you see traced material in the

• Diagnostics permeate you know there is a
– Detect membrane failure leak …
– Detect mechanical problems and you can track it down!
– Troubleshooting • Verify that the system is operating
according to design specs –
– Calibration obtain inter-stage flow rates by
sampling the reject and
completing a mass balance for
the tracer
• Make sure you are running at the

right recovery
• Complete a mass balance and

Handheld verify the operation of your flow
fluorometer meters
Autopsy
Bahrain - 2013
Autopsy report
Autopsy report
• Most comprehensive report in the industry

• Clear guidance to what caused the fouling and how to prevent it
• Specific cleaning recommendations

Nalco RO
24/7
Bahrain - 2013
Standard Normalization
Standard Normalization
Enhanced Normalization
Enhanced Normalization with Performance Reports
PermaFloc PermaTreat PermaClean
reduce colloidal prevent scaling, reduce restore performance
fouling cleaning frequency
Media Filter Cartridge RO System

Filter
SDI
Monitor
Coagulant-aid Chlorine
treatment Monitor
Autopsy
RO TRASAR
ORP
antiscalant
Monitor
monitoring, alarm and
RO optimizer
control
Local support – Global expertise
• Access to membrane expertise

– Troubleshooting to identify and remedy poor performance and
potential risks
– Institute “Best Practices”
– Review operating data
• System services
– Total system audits
• Survey
• Autopsy
• Water analysis
• Design analysis
– Operational support and assistance

Why is Reverse Osmosis used in the Steel Industry…..
• Produces consistent, high-quality water at the lowest possible

operating cost
• Maximizes the water produced for every pound of acid and caustic
used to regenerate and neutralize the IX system
• Minimizes the wastewater generation
• Bottom line: minimizes $ / 1,000 gallons

Where is Reverse Osmosis used in the Steel Industry?
• Steam cycle, boiler make-up

• Condensate polishing
• Cooling water make-up
• Waste water recycle
• Pretreatment to further polishing
– Ion Exchange (softening & demineralization)
– Electro deionization (EDI)

How Reverse Osmosis is used in the Steel Industry
• Water treatment process using membranes to remove:

– Salts
– Organics
– Inorganics
• Critical to cooling system – avoid scale formation / deposition.
• Critical for boiler feed water quality – High COC, low energy
wastage.
• Reduce the water consumption per MT of steel produced.

ROI Savings
Bahrain - 2013
Why is Reverse Osmosis used in the Steel Industry…..
• Produces consistent, high-quality water at the lowest possible operating

cost
• Maximizes the water produced for every pound of acid and caustic used
to regenerate and neutralize the IX system
• Minimizes the wastewater generation
• Bottom line: minimizes $ / 1,000 gallons

Where is Reverse Osmosis used in the steel Industry
• Steam cycle, boiler make-up

• Condensate polishing
• Cooling water make-up
• Waste water recycle
• Pretreatment to further polishing
– Ion Exchange (softening & demineralization)
– Electro deionization (EDI)

How Reverse Osmosis is used in the Steel Industry
• Water treatment process using membranes to remove:

– Salts
– Organics
– Inorganics
• Critical to cooling system – avoid scale formation / deposition.
• Critical for boiler feed water quality – High COC, low energy
wastage.
• Reduce the water consumption per MT of steel produced.

RO can only meet it’s full ROI if
• Salt removal is > 96% (ideally 98%)

• System is operated as designed recovery
• Membranes are clean
– Perform cleaning no more than 4 x year
• Membrane life > 3 years (ideally > 5)
• Antiscalant must be effectively controlled to avoid scaling and
fouling
Not meeting these best practices costs $$$’s

RO can only meet it’s full ROI if
• Salt removal is > 96% (ideally 98%)

• System is operated as designed
• Membranes are clean
– Perform cleaning no more than 4 x year
• Membrane life > 3 years (ideally > 5)
• Antiscalant must be effectively controlled to avoid scaling and
fouling
Not meeting these best practices costs $$$’s

The Situation
RO installed to improve plant performance
RO Symptoms Cause Effect
Design criteria
• Permeate quality
• Permeate quantity
• Feed flow rate
• Feed water quality
• Budgeted operating costs
The Problem
• Poor permeate quality

• Low water production
• Unbudgeted membrane replacement
• Frequent membrane cleaning
• Unexpected shutdown
• Short DI runs
The Cause
Membrane Fouling, Scaling , Damage due to:

• Poor chemical dosage control
• Lack of accurate operating data
• Poor response to changing operating
parameters
• Ineffective/poorly operated pretreatment
• Lack of operator training/time
These “causes” have Implications

The Effect
• Operating budget exceeded

• Production goals threatened
• High DI regeneration costs
• Mobile RO/DI trailers needed
These “Effects” create certain Needs

SPIN sell Membrane Chemicals
Situation Problems Implications Need
• Perform system audit

• Review operating data
• Talk to operators

• Compare what you find with best

practices

• Show the consequence if operation continues

as is
• Quantify cost consequence of operating as is
vs. your recommendation (best practice)

Show the Need
• Operating according to “Best practices” will help the customer

make more money
– Higher output
– Less downtime
• Operating according to “Best practices” will save the customer
money
($ Current operating costs - $ Best practice operating costs)
= $ Saved
– Operating costs to consider
• Chemicals cost • Water cost
• Cleaning costs • Energy Cost
• Membrane replacement costs • Labor cost

Show the Need
(example)
• Fouled membranes cost money!

(100 GPM base case)
– Membrane cleaning = $ 1,000/week
– Membrane replacement due to irreversible fouling or damage = $
20,000
– Production loss due to high salt passage and /or loss of flow = $
70,000/day at 40% rated capacity (sea water RO )
– Rental of mobile trailer = $5-10,000/month

Show the Need
• Operating “out of control” will foul your membranes

– Too much antiscalant – chemical fouling
– Not enough antiscalant - scaling
– Inadequate pre-treatment – biological fouling, mechanical fouling,
chemical fouling

Nalco can meet the need

• Tried and true Chemicals & Product Innovation
• System assessment

Nalco can meet the need

– Troubleshooting to identify and remedy poor performance and
potential risks
– Best Practices
– Scheduled system “tune-up”
– Proven Chemicals & Product Innovation
– Antiscalants, Biocides, Cleaners
– Pretreatment
– Advanced technology for monitoring and control
– System assessment
– Survey
– Autopsy
– Water analysis
– Design analysis
– Total Cost of Operation Gap Analysis for Best practices vs. Actual to
reduce costs

Proven Chemicals & Product Innovation
PermaFloc to reduce PermaTreat to prevent scaling, PermaClean to restore

colloidal fouling biofouling & membrane oxidation performance
Cartridge Filter
Media Filter
RO optimizer 3DT FM chemical control Membrane Autopsy

Proven Chemicals
• Scale inhibitors
• Membrane cleaners
• Biocides
• Pretreatment chemicals

Product Innovation RO TRASAR®
Before RO TRASAR® After RO TRASAR®
Nalco is the only supplier that can monitor

and control antiscalant dosage

Scale control is a key issue for
cost-effective RO performance
RO
Performance
Microbial Fouling
Membrane Automation
Chemicals control + Monitoring + Alerting

91
Case study -Tata Steel – Jamshedpur Complex
Project: RO-MB Flow rate: 175 m3/hr

Case study -Tata Steel – Jamshedpur Complex
• System : Filters --- RO plant ----- MB

• RO-DM water is supplied to Power house -5 with < 0.1 conductivity &
less than 10 ppb silica.
• The major concern was membrane fouling due to Bio fouling & scaling.
This reduced the RO recovery from 75 % to 55 %.
• The RO plat is treated by Nalco from last 5 years with Nalco Antiscalant &
online biocide dosing with PC-11.
• Nalco treatment could able to save USD 15 M till date because of Water
& energy saving.

Jindal steel Limited Vashind
• Project: Integrated steel plant with ZLD system

for waste water treatment
• Project Scope:
– RO Chemical treatment & service contract for
waste water RO system
• Plant Capacity:
– Pre treatment clarifier and filters 300 m3/day
• Savings :
– Customer saved appx. 109,500 m3 water/ annum
by implementing Nalco treatment and best
practices

Jindal Steel Limited Scheme

Reverse Osmosis Process I

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Reverse

Confidential Ecolab Content – Do not copy or duplicate

Flow Control Valve

Confidential Ecolab Content – Do not copy or duplicate

Gas O2, CO2, Cl2 0

Confidential Ecolab Content – Do not copy or duplicate

Confidential Ecolab Content – Do not copy or duplicate

Confidential Ecolab Content – Do not copy or duplicate

Confidential Ecolab Content – Do not copy or duplicate

100 gpm 50 gpm

100 ppm REJECT 2 ppm

Confidential Ecolab Content – Do not copy or duplicate

Confidential Ecolab Content – Do not copy or duplicate

Pressure vessels hold the membrane modules.

• Designed to contain pressurized feed

Confidential Ecolab Content – Do not copy or duplicate

MULTI-ELEMENT PRESSURE VESSEL

Contains 1, 3, 4, 6, or 7 modules in series

Confidential Ecolab Content – Do not copy or duplicate

Confidential Ecolab Content – Do not copy or duplicate

SINGLE STAGE RO SYSTEM

MORE MODULES IN SERIES

RO Skids typically have three major components

RO Skids typically have two or three chemical

RO PRESSURE VESSEL ARRANGEMENT

THE REJECT FROM STAGE 1 BECOMES

Confidential Ecolab Content – Do not copy or duplicate

TWO PASS SYSTEM

Confidential Ecolab Content – Do not copy or duplicate

Low Water Production

Foulant Distribution Globally

Confidential Ecolab Content – Do not copy or duplicate

Operating “In Control”

Monitor Assess Control

– Install online – Collect data over a – Install

SDI decrease after coagulant-aid dosing

Confidential Ecolab Content – Do not copy or duplicate

Confidential Ecolab Content – Do not copy or duplicate

• Effective cleaners for many foulants

Confidential Ecolab Content – Do not copy or duplicate

Diagnostics How is this possible?

• Verify recovery • Water transport through

• If you see traced material in the

• Make sure you are running at the

• Complete a mass balance and

• Most comprehensive report in the industry

Confidential Ecolab Content – Do not copy or duplicate

Media Filter Cartridge RO System

• Access to membrane expertise

Confidential Ecolab Content – Do not copy or duplicate

• Produces consistent, high-quality water at the lowest possible

• Minimizes the wastewater generation

• Bottom line: minimizes $ / 1,000 gallons

Confidential Ecolab Content – Do not copy or duplicate

• Steam cycle, boiler make-up

Confidential Ecolab Content – Do not copy or duplicate

• Water treatment process using membranes to remove:

Confidential Ecolab Content – Do not copy or duplicate

• Produces consistent, high-quality water at the lowest possible operating

• Minimizes the wastewater generation

• Bottom line: minimizes $ / 1,000 gallons

Confidential Ecolab Content – Do not copy or duplicate

• Steam cycle, boiler make-up

Confidential Ecolab Content – Do not copy or duplicate