CEDT workshop

Seawater by RO method in the kingdom of - The past, the present and the future

Dr. Nobuya Fujiwara Vice President , JDA (Japan Desalination Association) Director, IDA (International Desalination Association) To create new thing , learn by studying the past

When discussing the future, I would like to share our past and present experience. The present The present

)) 30, 000, 000 /d

3 Evaporating Method RO Method 25,000,000 city (m aa

20,000,000 ation Cap ation nn 15,000,000

led Desali 10,,,000,000

5,000,000 obal Instal obal ll G 0 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 Year The present - Major Seawater RO Plants in G .C .C

As of July 2008

No. Country Location Capacity(m3/d) Start Membrane 1 Saudi Arabia Shuqaiq 240,000 （2010） TOYOBO Largest 2 Saudi Arabia Rabigh 218,000 2008 TOYOBO in GCC G C C 3 UAE Fujairah 170,475 2003 Hydranautics 4 Saudi Arabia Shoaiba 150,000 （2009） Toray 5 SdiAbiSaudi Arabia YbYanbu 128,000 1998 TOYOBO 6 Saudi Arabia 113,600 1989 TOYOBO 7 UAE Dubai 100,000 2005 Dow 8 Saudi Arabia Al 66,660 2000 Others Biofouling 2007 TOYOBO N o B io f o u lin g 24,240 2000 Toray 9 Saudi Arabia 50,400 2006 TOYOBO 10 Bahrain Ad Dur 45,500 1989 Others Biofouling 2005 TOYOBO N o B io f o u lin g Seawater RO desalination plants using TOYOBO membrane

2,,,000,000 。

1,800,000 /day) 3 1,,,600,000 mm 1,400,000

ction ( 1,,,200,000 uu 1,000,000 Expected Shuqaiq

r prod 800,000 Ragigh 600,000 Jubail Ad Dur

ly wate 400,000 Yanbu(RC) Existing Dai 200,000

0 2000 2002 2004 2006 2008 2010 2012 Year The past The past

R&D subject

- To prove the reliability of the RO method

- To eliminate bio-fouling The past

In the early 1980s, Seawater desalination by RO method was regarded as an unreliable and high cost system.

The RO method was adopted only as small-scale equipment. The past Demonstration Unit of Seawater RO Saudi Arabia Red Sea : Jeddah Arabian Gulf :Al Year 1981 - 1982

Toyobo made a demonstration unit and b rought it i nt o KSA . The long-term test proved the RO method was a reliable system. The Past - Major Seawater Desalination plants using TOYOBO membr ane

Haql Year 1980 - 1999 - 4,400m3/day - Start 1989

Duba - 4,400m3/day - Start 1989

Yanbu - 128,000m3/day - Start 1998

Jeddah - 113,600m3/day - Star t 1989,1994 The Past - Major Seawater Desalination plants using TOYOBO membr ane

Jeddah（Saudi Arabia ） - 113,600m3/day - Start 1989,1994

Yanbu (Saudi Arabia)

- 128,000m3/day - Start 1998 The past Jeddah RO Plant phase 2 (15MGPD)

Differential Pressure was stable in low level . Avail abilit y i s Once a year Citric acid cleaning was enough more than 99%

100 80 Feed Pressure & Temperature 60 40 20

5.0 50 4.0 Differential Pressure Citric Acid Cleaning 3.0 2.0 1.0

Mar 94 Sep 94 Mar 95 Sep 95 Mar 96 Sep 96 Mar 97 Sep 97 Mar 98 Sep 98 Mar 99 The past Jeddah RO Plant phase 2 (15MGPD)

Permeate TDS stayed below Total shut down time due to 500mg/l without the membrane membrane is only 100hours replacement in 5 years. in 5years.

Feed TDS: 43,300mg/l , Feed Temp.: 24-35 deg.C 60,000 Production 58,000 56,000 54,000 52,000 50,000 Product TDS 1500 1000 500

Mar 94 Sep 94 Mar 95 Sep 95 Mar 96 Sep 96 Mar 97 Sep 97 Mar 98 Sep 98 Mar 99 The Past - Major Seawater Desalination plants using TOYOBO membr ane

The reliabilityyp of the seawater desalination plant which uses the Toyobo membrane was proved. Location Capacity (m3/d) 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 Ohi 4,000 Average Membrane life : 7.2 years (Japan) Jeddah PhaseⅠ 56,800 7.2 years (Saudi Arabia) Duba 4,400 11.2 years (Saudi Arabia) Haql4,400 11.2 years (Saudi Arabia) Ikata 2,400 7.8 years (Japan) Jeddah PhaseⅡ 56, 800 9.0 years (Saudi Arabia) Yanbu 128,000 More than 6 years (Saudi Arabia) - Average membrane life is more than 7years. - All plants in the above table have open sea intake. The past Year 2000-2007 Bio-fouling Serious bio-fouling problems occurred in some plants using pol yamide memb ranes which do not have chlorine tolerance.

Plant MMtateri ilal TblTrouble Temporary Countermeasure Ad Dur Diff. P Frequent C.C. (Bahrain) Polyamide Production ((everyevery 2-2-33 w) Permeate TDS Al J ub ail Diff. P FtCCFrequent C.C. ((KSA)KSA) Polyamide Production ((everyevery 3-3-66w)w) Permeate TDS Eliminate Bio-fouling

Polyamide membrane doesn't have chlorine resistance. - easy to occur biobio--foulingfouling problems TOYOBO membrane(CTA) has superior resistance to chlorine. - There is no room for Biofouling Eliminate Bio-fouling

TOYOBO membrane(CTA) Polyamide membrane

No bio-fouling Severe bio-fouling by chlorine injection Growth Rate of Bacteria The result of the growth test of the bacteria that inhabit Red Sea

1.E+06106 y = 8.3X103 e0.17x R2 = 0.99 ml)

// 5 1.E+0510 y = 1.4X102 e0.22x [Growth rate prediction] 2 4 R = 0.75 1.E+0410 nts (CFU N=No x exp(0.22 x (th-6)) uu （exponential regression)

3 1.E+0310 N = Bacteria Counts (CFU/ml) teria Co teria cc Lag Phase Logarithmic Phase No = Initial Bacteria Counts (CFU/ml) th = time(hr) 1.E+02102 Initial counts:104 CFU/ml level 3 Total Ba Initial counts:10 CFU/ml level 1 1.E+0110 0 3 6 9 12 15 18 21 24 GthTiiSt(h)Growth Time in Seawater (hr) Sterilization of Bacteria by chorine Usiiing incub bdbihihbidated bacteria that inhabit Red Sea

1.E+06106 Residual Chlorine: 0.5mg/l Delayed Chick-Watson model Residual Chlorine: 0.2mg/l /ml) 1E+051.E+055

UU 10 0 if t  t , Initial counts:105 CFU/ml level lag 3 , Initial counts:10 CFU/ml level ln(N / N0 )   kCt  kCt if 1.E+044 lag t  tlag nts (CF 10 uu K = inactivated rate constant 3 1.E+0310 C = concentration of disinfectant

cteria Co cteria Tlag = time of lagpg phase

2 Detection limit : 20 CFU/ml 1.E+0210

Total Ba Tlag=10 min 1 1.E+0110 0 102030405060 Time aft er I nj ecti on of Chl ori ne ( mi n) Sterilizat io n o f Bacte ria by c ho rine

0 10^3 CFU/ml, 0.2mg/l 10^3 CFU/ml, 0.5mg/l 10^5 CFU/ml, 0.2mg/l 10^5 CFU/ml, 0.5mg/l -2

線形

) -4 [Sterilization rate prediction] 0 y = -0.99x R2 = 0.79 ln(N / N0 )  0.99C tr ln(N/N -6 （exponential regression)

-8 N = Bacteria Counts (CFU/ml) No = Initial Bacteria Counts ((/)CFU/ml) -10 C = concentration of disinfectant

024681012tr = t-tlag

Ctr ((gmg/l x min) ) Required Chlorine Injection time per day Based(iihliji)dd on ICI (intermittent chlorine Injection) mode - Combination of Growth rate prediction and Sterilization prediction 100 C=0.2mg/l 90 C=0.3mg/l y (min)

aa C=0.4mg/l 80 C=0.5mg/l 70 ln(2.62N0 ) ime per d t  10 TT 60 0.99C 50 0.99ln(2.62N ) C  0

Injection 40

ee t 10 30 C=Chlorine Concentration (mg/l) 20 t=Injection time (min) d Chlorin ee 10

Requir 0 1.00E+011 1.00E+022 1.00E+03 1.00E+04 1.00E+05 1.00E+06 10 10 103 104 105 106 TTtlBotal Bact eri a C ount s of fR Raw S eawat er (CFU/ (CFU/l)ml) Joint research in cooperation with plant owners - to solve the bio -fouling problems

Ad Dur（Bahrain)

Test Period : year 2001-2003 Al Jubail（Saudi Arabia)

Test Period : year 2004-2005 Eliminating Bio-Bio-foulingfouling by TOYOBO Membrane - Rehabilitation of Ad Dur Plant ( 45,000m3/day)

Polyamide membrane requires chemical cleaning every 2-3 weeks due to bio-fouling even with UF pretreatment. TOYOBO requires C.C. once per year thanks to Chlorine injection. Change of Differential Pressure 450450 Feed SDI < 3 400400 350350 re [kPa] uu 300300 250250 Chemical Cleaning tial press

nn 200200

150150 Differe 100100 TOYOBOToyobo Test data PolyamideDupont (Stand-by membrane Train) 5050

00 00 20 40 40 60 60 80 80 100 100 120 120 140 140 160 160 180 180 200 200 ElapseElapsedd Ti metime (d[day]ay ) Eliminating Bio-Bio-foulingfouling by TOYOBO Membrane - Severe bio -fouling at Al Jubail plant ( 90,900m3/day)

Chem ica l Clean ing for Sp ira l Wound mem brane was carried out 14times during 14,000hrs(19months) due to biofouling.

Chemical Cleaning

“ComparisonComparison of the performance of hollow fine fiber and spiral -wound membranes in the Al-Jubail SWRO desalination plant”, Abdul Salam Al-Mobayed et al, Desalination 178(2005)273-286 Eliminating Bio-Bio-foulingfouling by TOYOBO Membrane - Severe Bio -fouling at Al Jubail plant ( 90,900m3/day)

In the field testing, TOYOBO RO module achieves significantly higher performance and efficiencyyy by using Arabian Gulf Seawater source, known for its high salinity and high potential of biological growth at Al-Jubail plant location. Joint research in cooperation with plant owners - to solve the bio -fouling problems

Ad Dur（Bahrain)

Test Period : year 2001-2003 Year 2005 (replaced by TOYOBO) Al Jubail（Saudi Arabia)

Test Period : year 2004-2005 Year 2007 (replaced by TOYOBO) The Past - Major Seawater Desalination plants using TOYOBO membr ane

Tanajib Haql Year 2000 - 2007 - 6,000m3/day - 4,400m3/day - Start 2001 - Start 1989

Al Jubail Duba - 66 ,700m3/day - 4,400m3/day (90,900m3/day) - Start 1989 - Start 2007

Bahrain Yanbu - 45,500m3/day - 128,000m3/day - Start 2005 - Start 1998 Solution provider Others → TOYOBO Yanbu - 50,400m3/day - Start 2006

Jeddah - 113,600m3/day - Star t 1989,1994 Al Birk - 2,200m3/day - Start 2001 The past

- The reliability of the seawater RO was proved

- Bio-fouling problem was solved The present

R&D subject

- To develop a large-sized RO module The present

The current growth of larger desalination plants based on the RO method have demanded greater economical efficiency.

1) The number of modules is reduced by about 50% 2) The volume of installation space for the RO racks reduced up to 30% 3) The RO system construction cost can be reduced. *High class stainless steel costs for feed and brine piping can be reduced up to 70% Comparison between Both Open Ended (BOE) and Single Open Ended (SOE)

・SOE (conventional）: Permea te pressure (bore sid e) will increase in longer holl ow fiber ・BOE（new）: the channel length of the permeated water becomes half, and flow pressure loss is reduced. Feed Seawater Hollow Fiber

JW  A(P   )  A(PF  PP )  ( F   P ) SOE structure

Permeate

BOE structure Jvj

ΔZ do di z Comparison between Both Open Ended (BOE) and Single Open Ended (SOE)

10 10 8 8 6 6 [m/s] [m/s] 7 7 0 0 11 4 11 4 x x v 2 v 2 J J 0 0 3 3 a] a] PP PP 2 2 [M [M π π - - P P 1 1 - P - P F F P PP 0 0 3 3

2 2 MPa] MPa] [[

[ P 1 P

P 1 P

0 0 0 0.5 1 1.5 0 0.5 1 1.5 Open中空糸長手方向 Z [m] Close Open中空糸長手方向 Z [m] Open End SOESOE End End BOE End Design of a LargeLarge--sizedsized RO Module for Seawater Desalination

Relationshippgp between element length and permeate water flow rate in BOE and SOE element

(DO=0.28m, PF=5.5MPa, CF=35kg/m3, RC=30%, T=25 deg.C) 80 70 60 BOE 50 /d] 3

mm 40 [ P

Q 30 SOE 20 10 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 L [m] Design of a LargeLarge--sizedsized RO Module for Seawater Desalination

Relationship between element length and volume efficiency of module in BOE and SOE

(DO=0.28m, PF=5.5MPa, CF=35kg/m3, RC=30%, T=25 deg.C) Optimum 300 ] 3 mm BOE 200 /d) / 3 m [(

MO SOE 100 V //

P Q

0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 L [m] LargeLarge--sizedsized RO Module for Seawater Desalination

New (BOE) size: 11 inch X 4.5m production:100m3/d

Conventional (SOE) size: 11 inch X 3m production: 50m3/d The Present - Major Seawater Desalination plant using TOYOBO membr ane

Rabigg(h (Saudi Arabia )

- 218,000m3/day - Start 2008 The Present - Major Seawater Desalination plants using TOYOBO membr ane

Tanajib Haql - 6,000m3/day - 4,400m3/day - Start 2001 - Start 1989

Al Jubail Duba - 66 ,700m3/day - 4,400m3/day (90,900m3/day) - Start 1989 - Start 2007

Bahrain Yanbu - 45,500m3/day - 128,000m3/day - Start 2005 - Start 1998 Solution provider Others → TOYOBO Yanbu - 50,400m3/day - Start 2006

Rabigh - 218,000m3//yday - Start 2008 Shuqaiq(Saud Arabia） Jeddah - 240,000m3/day - 113,600m3/day - Start 2010 - Star t 1989,1994 Al Birk - 2,200m3/day - Start 2001 The pppast & present

Year 1980 - 2008

- The reliability of the seawater RO was proved

- Bio-fouling problem was solved

- Large-sized RO module was developed The future Enlargement - High-pressure pump - Energy recovery equipment (PX,DWEER) - 16-inch RO modules Environment - Simulation about diffusion of brine Natural power sources - Solar cell power generation - Windmill Membrane filtration pretreatment - CtCost re dtiduction JDA (Japan Desalination Association)

Ace Water Treatment Co., Ltd. Mitsubishi Rayon Engineering Co., Ltd. Asahi Kasei Chemicals Corporation Mitsui Bussan Plant & Project Corporation DMW Corporation Nihon-netlon Co., Ltd. Dow Chemical Japan Limited Nitto Denko Corporation Ebara Corporation Sasakura Engineering Co.,Ltd Fujikasui Engineering Co., Ltd. Suido Kiko Kaisha, Ltd. Hitachi Plant Technologies, Ltd. Sumitomo Corporation Hitachi Zosen Corporation Tokyo Polymer Co., Ltd. Itochu Corporation Tokyo Printing Ink Mfg. Co., Ltd. KbtKubota C orpora tion TIdiIToray Industries, Inc. Kyowa Kako Co., Ltd. Toyobo Co., Ltd. Mitsubishi Heavy Industries , Ltd . Water Re -use P romotion Center

The present - Seawater RO membranes in Saudi Arabia

Plant capacity : more than 30,000m3/day

Toray 18% TOYOBO 82%

IDA Worldwide Desalting Plants Inventory and others The Past - Major Seawater Desalination plants using TOYOBO membr ane 3030MGPD(MGPD(113113,,600600mm3/day) Jeddah RO Plants Phase 1 Phase 2 Product Flow Rate more than 56,8000m3/day More than 56,800m3/day Membrane Guarantee － 5 year （10%／year replacement） Seawater TDS 43,300mg/l. 43,300mg/l RO Module TOYOBO HM10255: 1480pcs. TOYOBO HM10255 :1480pcs. Owner SWCC, KSA SWCC, KSA Constructor/Consultan MHI / Bechtel MHI Start-up April, 1989 March, 1994

ly 33 tt MCF DMF RO Module id lant FeCl rine ermitten cc uu tt oo Open Sea A Chl

Intake Coag SBS(In ) P P Intake Pond Filtered Water Tank H.P Pump Product Water Tank