ࡱ> giftbjbj /V <<ZZZ@v\Z5^0000   5555555$7h:;5u     ;5005!&!&!& 005!& 5!&!&r0T10TP 055050:;a#`:;1:;1d  !&     ;5;5$`   5    :;         < \: MARINE FRESH WATER GENERATOR PROCESS OPTIMIZATION Predrag Kralj, associate professor, Ph.D., BME Faculty of Maritime Studies, University of Rijeka Studentska 2 Phone: +385 51 338 411 Mobile: +385 91 538 83 98 E-mail:  HYPERLINK "mailto:pkralj@pfri.hr" pkralj@pfri.hr Dragan Martinovi, professor, Ph.D., BME Faculty of Maritime Studies, University of Rijeka Studentska 2 Phone: +385 51 338 411 Mobile: +385 98 656 755 E-mail:  HYPERLINK "mailto:dragec@pfri.hr" dragec@pfri.hr Mato Tudor, professor, Ph.D., BEE Faculty of Maritime Studies, University of Rijeka Studentska 2 Phone: +385 51 338 411 Mobile: +385 99 685 82 98 E-mail:  HYPERLINK "mailto:tudor@pfri.hr" tudor@pfri.hr Summary The introductory part of this paper offers an overview of approaches to the management of marine fresh water generator and points out the most important factors that influence the processes. The second chapter deals with operation and overhaul times influenced by evaporation intensity. Comparison is made of two modes of operation, and simple calculation assuming days in voyage and hours necessary for overhaul is also made. Third chapter gives an insight to the optimal management system for one single-stage unit. The suggested management system is based upon the energy balance equation also given in the chapter. In the fourth chapter analysis of most important operational values is made. The changes recorded on the six channel plotter are used to evaluate the suggested management system. The paper gives an example of optimal management system for the single stage fresh water generator and suggests further research. Key words: energy balance, management system, marine fresh water generator, optimization INTRODUCTION Although the process of fresh water production by distillation method is well known and analyzed in the scientific journals, significance of the distillation plant on board ship gives an opportunity for further improvement [1, 2]. Scientific results could be used to improve the management system and, as a consequence to reduce the price of the produced water or to improve its quality or both. Since on board ships waste heat is mainly used with the exception of small consumption of the electric energy for the sea water and distillate pumps, the price of production is the price of crew members working hours consumed for occasional cleaning and the price of expendable material used for cleaning [1, 2]. Used material is mainly acid solution used to dissolve scale created on the evaporator surfaces during operation hours. The efficient management system [3, 9, 10] of the distillation process should increase the maximum continuous capacity and to decrease operation costs. It would be time consuming to engage engine room officer to manage the process of distillation, so it is clear a management system has to be implemented to achieve those tasks. The process analysis, the analysis of thermodynamic parameters, the analysis of measured and regulated values [1, 2, 3, 4, 9, 10] point out the following: although the evaporator heat inlet and the condenser heat outlet change in time, by fixing the regulating valves position both of them could be considered constant with the above presumption the quantity of produced vapor and consequently of produced distillate depends mainly on pressure changes in the vessel, i. e. upper and lower values of pressure switch that opens and closes the vacuum breaking valve almost every measured parameter shows sinusoidal change exactly in accordance with the change of pressure, or precisely vacuum in the vessel, but some show deterioration with operating hours both short and long term changes in the process affect the quantity and quality of the distillate. The managing algorithm should use above listed facts, but much more, especially fault propagation through the process [11, 12, 13, 14]. HOW THE OVERHAUL TIME AFFECTS THE CAPACITY The diagram shown on graph 1 represents the changes in the capacity of the plant with the operating hours and the capacity maximum set point. The diagram stands for the single stage vacuum plant that could be found on almost every ship having diesel engine propulsion. There are three important elements such plants have: evaporator, demister and condenser, and several auxiliary elements or subsystems: brine rejection, vacuum management and distillate collection including the salinity check. Some technological differences are possible. Occasionally, plants could have only one ejector instead of two, while in some cases sea water is preheated being the condensers cooling fluid. On the steam turbine propulsion ships not vacuum, but low or even medium pressure plants are used. In case large capacities are needed multistage plants are used. Those differences dont change the process basics. Graph 1 The capacity and the operation hours of the distillation plant dependence The qualitative changes shown on the figure perhaps aren't precise enough, but for the exact quantitative relations waste number of ship plants should be analyzed. Nevertheless the validity of obtained data could be questionable, because it depends on a number of factors. On the period during which desired and set plants capacity is decreased to the lowest one, the one that still satisfies actual consumption, following factors are of importance: construction characteristics of the evaporator and condenser and their condition according to the exploitation, surrounding condition, i. e. sea water temperature, heat inlet and outlet settings, vacuum settings in the vessel and other. The longitude of the nonoperational period is affected by the scale thickness on evaporator surfaces, the quantity and concentration of acid solution applied, capability and training of crew members and other. The nonoperational periods during sailing through contaminated coastal waters are not considered, but the periods necessary for scale removal from heating surfaces are. With all restrictions diagram on fig. 1 has, it could be useful for certain distillation process management system functions considerations. The diagram shows two distinct modes of operation: first, when lowest capacity is set, and second, when maximum obtainable capacity for given surrounding conditions and plants operating condition is set. In both scenarios there is a small drop in capacity caused by scale formation on the heating surfaces, the difference being faster scale formation in the second scenario. Why scale is formatted faster and earlier? Faster means that its thickness is increased faster, while earlier means at a lower point of a vertical channel. In the second scenario more heat is introduced in the process of evaporation or a high vacuum is created in the vessel, hence the temperature of sea water undergoing process of evaporation is higher, vapor bubbles are created on lower position in the evaporator channel, more vapor bubbles are created usually combining in a few larger ones, a very narrow brine layer with increased salinity remains on the surface wall [1- 8, 15]. Because of several reasons mentioned earlier in the paper, it's impossible to predict exact number of operating hours, but from marine practice its known that in tropical environment having higher temperatures where larger amount of water is consumed and obviously higher production is needed, evaporator surfaces have to be cleaned every 48 to 72 hours, while in moderate climates this should be done only every few days. Hence, although the increase in evaporation results with immediate increase of distillate production, because of often stoppages needed for cleaning the evaporator surfaces, the process production is in fact decreased. Sometimes the maximum production is necessary, but in most of cases more meaningful is that long term, process production that calculates both the production and stoppage periods. Several practical situations will be compared. Fresh water generator with maximum capacity of 22 t/h is selected for analysis. The minimum capacity that satisfies ships need is 18 t/h. Assumed voyage time on open sea is 10 days or 240 hours. In the first case operation starts with maximum capacity, it drops to minimum allowable capacity during 48 hours, and stoppage for cleaning that lasts for 6 hours follows. The second case starts with 21 t/h, it drops to minimum during 56 hours, and a stoppage for 4 hours follows. In the third case operation starts with 20 t/h, it drops to minimum during 76 hours, followed by stoppage of 3 hours, while in the last case operation starts with 19 t/h and stoppage time is 2 hours. Operations in every case are repeated until expiration of voyage time, because the plant is stopped during sail through contaminated waters. Results of this simple analysis are shown on graph 2. For starting and operating conditions during 10 days voyage the highest process capacity is accomplished with the lowest starting capacity of 19 t/h and the operation period of nearly 10 days and the lowest with the highest starting capacity. Graph 2 The plant's process capacities for different starting and operating conditions Increase in heat inlet and vacuum in the vessel results with increase in evaporation and plant's capacity. The reduction of those parameters results with decrease in capacity. It seems the first mode of operation is better, but from earlier analysis its obvious that this isnt so. Furthermore, the increase of vacuum in the vessel will positively affect the evaporation but it will diminish the condensation process taking place in the same vessel. Another setback is creation of brine droplets and their separation from fresh water molecules. Its well known that separator operates poorly when large number of small droplets is created, meaning that the quality of distillate is decreased. In modern fresh water generator types corrugated plates are used for both evaporators and condensers, but even more, plates are made in one piece. When combined with rubber gaskets evaporator, demister and condenser channels are created, as schematically shown on figure 1. The type of exchanger surfaces wouldnt in any way affect the processes mentioned before. Besides technical layout of the plant and its piping, the figure shows inlet and outlet signals of the management unit. Main influence on the evaporation process has heating fluid flow through the evaporator and the vacuum in the vessel. Management unit measures the pressure and temperature in the vessel and of the casing respectively, and the distillates salinity. In accordance with measured values and logic implemented the unit will act on by-pass valve 1 and vacuum breaker valve 3. Figure 1 Single stage vacuum fresh water generator and management system THE MANAGEMENT SYSTEM FOR OPTIMAL PROCESS Let's repeat the reasoning from before. The main effects on the distillation process have: heating fluid flow through the evaporator and cooling fluid flow through the condenser, both of them affected by heat transfer coefficients that are deteriorating with operation hours, the temperature differences between the fluids in those heat exchangers, and the pressure in the vessel. If maximum cooling fluid flow through the condenser and proper vacuum ejector operation is assumed, the utmost effect would have the temperature difference between the cooling sea water, having the surrounding temperature or being slightly preheated, and the fresh water saturation temperature depending on the pressure in the vessel. There is no objective reason to reduce the cooling water flow, except there is a problem of low flow through the main engine fresh water cooler. The presence of non-condensable gases in the vessel would reduce the condensing effect, and they are removed by the ejector. The temperature difference between the heating fluid and the heated sea water is most important parameter for evaporator performance, but not the only one. For practical reasons one could assume certain temperature values. The maximum temperature in the process is the temperature of the heating fluid, being the high temperature main engine cooling water, and is determined by the regulating equipment of the system. Usually that is 80(C. The lowest temperature of the process is the sea water inlet temperature, and for 80 up to 90% of the ships it varies from 10 to 20(C. The empirical Antoines equation could be used to determine saturation temperature of the liquid according to the pressure. When condensation and evaporation values are compared the second one is slightly higher, because its sea water. A term boiling point elevation (BPE) is used, and it represents the increase of sea water saturation temperature over fresh water saturation temperature for the same pressure. Since evaporator and condenser temperature differences, i. e. (Tevap i (Tcond, are together with the respective flows, main heat exchange generators, it is clear the effect of evaporation would be increased, and the intensity of condensation decreased with decrease of the pressure in the vessel. It should be possible to determine for every surrounding temperature the optimal pressure in the vessel, although there will be a small oscillation of pressure in accordance with the pressure management system. The total energy balance equation for the plant given on fig. 4 is  EMBED Equation.3  (1) The values in the expression (1) from the left to the right are: (Qheat/HT heat inlet introduced in the process with main engine high temperature cooling water, USW inlet sea water internal energy, (Qcond heat rejected from the process by condenser's cooling sea water, Ubrine rejected brine internal energy, Udest produced distillate internal energy, Ugas internal energy of non-condensable gases removed from vessel, Qrad heat radiation losses to the surrounding (engine room), mcas mass of the plant's casing; ccas specific heat of the casing material; (tcas the temperature change of the casing itself. A heat introduced in the vessel with the air that enters after vacuum breaker valve opens could be neglected. In comparison with the other values, the last two on the left side of the equation are of lower magnitude, and as such could also be neglected. During the beginning of the operation heat introduced in the process is higher than the heat removed from it, resulting with increase of casing temperature. The casing temperature would asymptotically approach the upper limit. After stationary condition has been reached, there would be only small disturbances caused by surrounding temperature changes, management system characteristics etc. The expressions (1) simplification gives an insight of possible simpler and cost efficient management system application. The precision in main parameters regulation would in the same time not be lost and the quality of produced distillate would not deteriorate. The simplification results with:  EMBED Equation.3  ,(2)where K is a constant including physical values of casing material, and (E is a difference of heat inlet and outlet of the process. SIMULATION OF THE DISTILLATION PROCESS Value of (E changes with transient outer and inner conditions: heating fluid flow is constant in time according to the regulating by-pass valve position, but temperature varies according to the main engine power and the characteristics of the system that regulates the temperature, the heat transfer coefficient changes in time due to the scale formation in particular sea water flow should be considered as constant, but its temperature changes with the movement of the ship the same stands for condensers cooling sea water but, moreover heat transfer coefficient also changes in accordance with non-condensable gases or other impurities presence heat rejection with brine removed from the vessel depends on first condition and the evaporation intensity heat rejection from the process with amount of distillate discharged also depends on the evaporation intensity. Simulation was carried over on the model in every respect similar to the one shown on fig. 1. The key values have been measured and recorded. Recorded values are given on graph 3. Six channel plotter was used. The changes are recorded during 20 minutes period (from 32nd till 52nd minute of operation). During that period the position of the by-pass regulating valve was gradually changed. Vertical lines mark the moment when the valve position was in fact changed. Following parameters were recorded: light purple represents inlet sea water salinity (its constant during the recording time), ocher represents the salinity of the rejected brine, green represents the distillate salinity, purple represents the amount of produced distillate, blue represents the (absolute) pressure in the vessel and black represents the temperature of discharged distillate. The sinusoidal change of every measured parameter could clearly be seen, except inlet sea water salinity. From the plants operation explanation presented before, the generator of those sinusoidal changes is vacuum breaker valve, i. e. changes of the pressure in the vessel. The trigger points of the vacuum breaker valve are 91% of vacuum or 0,09 bar of absolute pressure when it closes and 92% of vacuum or 0,08 bar of absolute pressure when it opens. When vacuum breaker valve opens there is a sudden rise of absolute pressure in the vessel and, after it closes, the pressure slowly decreases. Other dependable parameters follow the same change. Another major influence has change in position of the heating fluid by-pass valve. The vertical lines show the moment of change in the valve position, i. e. the valve was slightly closed, resulting with the increase of heating fluid inlet. The curves show slight increase of brines salinity and temperature, while at the same time there is a sudden increase of distillate production, and unfortunately its salinity. Graph 3 The diagram of measured parameter changes [1, 2] CONCLUSION Of every changeable parameter affecting the plants operation, especially the distillate production and salinity, the most important are heating fluid flow to the evaporator and the vacuum in the vessel. If proper operation of the vacuum management system is assumed the value of the vacuum would change between two set limits, the pressure would have a sinusoidal change and every dependable parameter would change accordingly. It is clear the major increase of distillate production can be accomplished with increase of heating fluid flow to the evaporator. Unfortunately, the consequence of such operation is distillate of higher salinity. The energy balance analysis shows the dependence between energy of the process and temperature of plants casing. In accordance with the expression a simpler and cost effective management system and advanced information algorithm could be implemented without losing necessary distillate capacity or increasing its salinity. Other mathematical models should be used to verify that increase of heating fluid causes faster scale formation, increases the operation costs due to crew members working hours an due to material expenses, and in consequence reduces the process capacity of the plant. Also, a model of scale formation dependence on heating fluid and evaporating brine temperatures should be designed in order to determine the optimal process procedures. REFERENCES [1] Kralj, P. : Fresh Water Generator Model, Ph. D. Thesis, The Faculty of Maritime Studies University of Rijeka, Rijeka, 2012. [2] Kralj, P., Martinovi, D., Tudor, M.: Analysis of thermodynamic and technological basics of the marine fresh water generator model, Desal. Water Treat. 95 (2017) pp. 180-185 [3] Kralj, P.: Prijedlog sustava upravljanja vakuumskog generatora slatke vode, Zbornik radova Pomorskog fakulteta, Rijeka, god. 10 (1996), pp. 83-90 [4] Lior, N.: Measurements and Control in Water Desalination, Amsterdam, Elsevier, 1986. [5] Martinovi, D. - Tireli, E.  Kralj, P.: Stanje i razvoj integralnog upravljanja brodom, Zbornik radova Meunarodnog znanstveno-stru nog simpozija o prometnim znanostima, Portoro~, 1997., pp. 129-134 [6] Miloaevi, `.  Kralj, P.: Simplified Mathematical Model of Vaporization in a Fresh Water Vacuum Distillation Generator, Proceedings from the Symposium "Energy and Environment", Opatija, 1996., pp. 237-244 [7] Miloaevi `.  Kralj, P.: Vacuum distillation fresh water generator application on board ship, ELMAR  98, Zadar, 1998., pp. 196-200 [8] Miloaevi, `.  Kralj, P.: Vacuum distillation fresh water generator application, Seventh International Expert Meeting - Power engineering, Maribor, Slovenia, 1998., pp. 75-82 [9] Tomas, V.,45WYd    8 < R > @ n ɸx_x_H_xx_x_H_xx,h+hUh0JCJOJQJ^JaJmH sH 1jh+hUhCJOJQJU^JaJmH sH (h+hUhCJOJQJ^JaJmH sH (h+hUhCJOJQJ^JaJmH sH +h+hUh5CJOJQJ^JaJmH sH  h+hKCJOJQJ^JaJ#h+h<)5CJ(OJQJ^JaJ(#h+h)*5CJOJQJ^JaJ#h+h<9I5CJOJQJ^JaJ45d R . 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CJOJQJ^JaJmH sH DDEE;E@~̦ЦҦЮ{jj h+hCJOJQJ^JaJhLCJOJQJ]^JaJ#h+h\? CJOJQJ]^JaJ#h+hCJOJQJ]^JaJh CJOJQJ]^JaJU h+h CJOJQJ^JaJ h h CJOJQJ^JaJ hmlCh CJOJQJ^JaJh CJOJQJ^JaJ$ Vlahini, I., Martinovi, D.: Implementation of the Fault Detection and Isolation Method into the Control System, ISEP 99, Ljubljana 1999. [10] Tomas, V.  Kralj, P.  Tudor, M.: A modern freshwater generator processes control system, ELMAR  98, Zadar, 1998., pp. 226-229 [11] Tudor, M.: O pouzdanosti brodskih sustava, Pomorstvo, Vol. 17, 2003, pp. 11-20 [12] Tudor, M.: Analiza pojave kvarova kod brodskih sustava, Pomorstvo, Vol. 15, 2001, pp. 97-103 [13] Tudor, M., Bukaa, A., Kralj, P.: Odr~avanje brodskih sustava, Pomorstvo, Vol. 18, 2004, pp. 29-42 [14] Tudor, M. - Kralj, P.: Utjecaj rizika kvara na ra unalni odabir pristupa odr~avanju brodskih sustava, Pomorstvo, Rijeka, Godina 14 (2000), pp. 43-52 [15] VDI Heat Atlas, 2. English ed., Dsseldorf, VDI Verlag, 1991. 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