ROSA 7.

0
Training

Eduard Gasia & Justyna Warczok

Technical Service
Dow Water & Process Solutions

Index
1. Input data for analysis
2. Plant Design using ROSA 7.0
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis
3. Example

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 Index
1. Input data for analysis
2. Plant Design using ROSA 7.0
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis
3. Example

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Input data for analysis

1. Feed water data:
 Feed water type: Seawater, bore hole, surface supply, tertiary effluent, RO
permeate.
 RO pre-treatment: Conventional pretreatment, MF or UF pretreatment
 Water composition: Answer Center: 2307

2. Permeate / Feed flow / Recovery

3. Operating temperature range (maximum and
minimum temperature)
4. Permeate quality requirements, e.g. TDS < 70 ppm,
SiO2 < 0.05 ppm
5. Focus on CAPEX or OPEX

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 Focus on capital or operation costs
5. Focus on CAPEX or OPEX
Focus on minimizing capital costs (CAPEX):
Implications:
 Maximize system flux
 Minimize number of elements and vessels
Focus on minimizing operational costs (OPEX):
Implications:
 Lower system flux
 Higher number of elements and vessels
 Prefer low energy membranes

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Index
1. Input data for analysis
2. Plant Design using ROSA 7.0
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis
3. Example

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 Plant Design using ROSA
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis

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Plant Design using ROSA

 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis

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 ROSA – Control Panel: File

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ROSA – Control Panel: User data

Database can be updated using Database switching

tool

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 ROSA – Control Panel: User data

When first opened it shows where the ROSA files are

stored by default
Can be changed according to the personal
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ROSA – Control Panel: User data

User Data Settings – stores introduced and selected

information

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 ROSA – Control Panel: Help

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ROSA – Project description

Project basic
information

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 ROSA – Limiting Scenarios

We should consider the two limiting

scenarios:
A) Highest T + Highest FF (short term
conditions) + Highest feed TDS
Worst scenario in terms of salt passage
and hydraulics of the system
(highest flow rate in first elements)
B) Lowest T + Lowest FF (long term conditions)
+ Highest feed TDS
Worst scenario in terms of energy
demand (useful for sizing the high
pressure pump)

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ROSA – Fouling Factors

Fouling Factor Concept:
 FF = 1.0 Nominal element flow performance according
to specification
 FF = 0.80 80% of nominal element flow performance
Fouling Factor
+ 3 years (fouling + 3 years (fouling
Membrane Start up
excluded) included)
WRU 0.95 0.80 0.65 – 0.55
BW 0.95 0.80 0.75 – 0.65
SW 0.90 0.80 0.70 – 0.65
Long term FF (+ 3 years) depends strongly on:
 Temperature, raw water source, pre-treatment, feed pressure, etc.

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 ROSA – User Defined
Pre-stage Pressure Drop

Pre-stage Pressure Drop

(ΔP) can be defined
If the specific ΔP is not
known, leave the default
value

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Plant Design using ROSA

 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis

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 ROSA – Introducing Feed water analysis
Introduce the water analysis data
Choose Feed water type
1. Check the box: Specify individual solutes
2. Introduce the concentrations

Introduce the T and pH

Cations and Anions

should be balanced

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Choosing Feed Water Type

Feed water type Description
RO Permeate SDI<1 Very-low-salinity, high-purity waters (HPW) coming from
the first RO systems (double-pass RO system) or the
polishing stage in ultrapure water (UPW) systems with TDS
up to 50 mg/L.
Well Water SDI<3 Water from a ground source that has been accessed via well.
Usually, has low fouling potential.
Surface Supply SDI<3 Water from rivers, river estuaries and lakes. In most cases it
has high TSS, NOM, BOD and colloids. Frequently, surface
Surface Supply SDI<5 water quality varies seasonally.
Tertiary Effluent Industrial and municipal wastewaters have a wide variety of
(Microfiltration) SDI<3 organic and inorganic constituents. Some types of organic
Tertiary Effluent components may adversely affect RO/NF membranes,
(Conventional) SDI<5 inducing severe flow loss and/or membrane degradation
(organic fouling).
Seawater (Well/MF) SDI<3 Well -water from a beach well with any type of pre-treatment
MF –Seawater any type with Microfiltration/Ultrafiltration as a
pre-treatment
Seawater (Open Intake) SDI<5 Open intake seawater with conventional pre-treatment
12/22/2009 • For more information refer to Answer Center answer 209 20

10
 Choosing Feed Water Type
SDI specification Description
SDI<1 RO permeate

SDI<3 Before RO very good pre-treatment is used: Microfiltration,

Ultrafiltration
SDI<5 Conventional pre-treatment is used before RO.

SDI Calculation
 ti 
1  
% P30  t f 
SDI T    100
T T
Where:
%P30 – percent @ 30 psi feed pressure
T – total elapsed flow time
ti – initial time required to collect 500 ml sample
tf – time required to collect 500 ml sample after
test time T

12/22/2009 • For more information refer to Answer Center answer 209 21

ROSA – Saving the Water Profile

Previous water profiles can be loaded

Current water profile can be

added to the library

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 ROSA – Temperature History Effect

Only for SWRO cases

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Temperature History Effect -SWRO designs

 RO operation at elevated temperatures (35ºC and above) causes an
irreversible flow loss that becomes apparent if the system is later
operated at lower temperatures (20-35ºC).
 This is a phenomenon common to all thin film composite RO membranes
operated under similar conditions.
 The reduction of permeate flow is usually a combination of both elevated
pressure and temperature and the effect is strongest when elevated
temperature and pressure occur simultaneously.
 While a number of factors impact this permeate flow loss, the major
factors are believed to be:
• Compaction of the microporous polysulfone layer which decreases membrane
permeability. Long recognized but not well quantified.
• Intrusion of the membrane composite into the permeate carrier, leading to increased
permeate-side pressure drop. This is a function of temperature and pressure, as well
as spacer geometry and strength of the composite membrane.
 Due to the relatively low pressure in brackish water applications, the
performance impact of elevated temperature is much lower compared to
seawater conditions.

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 Plant Design using ROSA
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis

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ROSA – Scaling information

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 Plant Design using ROSA
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis

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ROSA - Introduction of known data

To introduce the Flow and Recovery data:
1. Double click on any of the boxes:
Permeate Flow, Recovery, Feed Flow or
Permeate Flux
2. Pop-up window will appear
3. Specify two parameters to be
introduced by checking the Specify box
4. Introduce the data
5. Click on Recalculate
6. Click on Accept Changes and Close

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 Main components of a membrane system

One or more pressure vessel(s) containing

one or more membrane elements
Feed
Water Permeate line

Pump
Concentrate line

Main components:
pump(s), pipes, pressure vessel(s), membrane element(s)

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Main components of a membrane system

Serial arrangement of membrane elements in a pressure vessel

RO FILMTEC™
element

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 ROSA – Membrane Element Selection

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Membrane Element Selection

Select the membrane element type
According to:
i. System capacity
ii. Feed water TDS
iii. Feed water fouling potential
iv. Required product water quality and
Energy requirements

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 Membrane Element Selection
i. According to System capacity
 Element diameter for system capacity of about
2.5” < 200 l/h
4.0” < 2.3 m3/h
8.0” > 2.3 m3/h
 Element length
Standard: 40” (1016 mm)
For small compact systems: 21” or 14”

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Membrane Element Selection

ii. According to Feed water TDS (Rules of thumb)

< 1000 mg/l NF270, NF90, XLE, LE, LP, TW30, BW30

< 10 000 mg/l BW30

10 000 - 30 000 mg/l SW30XLE, SW30ULE

30 000 - 50 000 mg/l SW30HR, SW30XHR, SW30HRLE, SW30XLE

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 Membrane Element Selection
iii. According to Feed water fouling potential
 Standard feed spacer thickness: 28 mil
 Feed spacer thickness for feeds with increased
fouling potential: 34 mil used in BW30-400/34i,
BW30-365, BW30XFR-400/34i, BW30-365-FR,
SW30HR-370/34i
 Fouling resistant BW membrane for biofouling
prevention - used in BW30XFR-400/34i, BW30-365-
FR

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Membrane Element Selection

iv. According to Required product water quality and
Energy requirements
Higher salt Lower feed
passage NF270 pressure
NF200
NF90
XLE
LE
BW30 / TW30
BW30XFR
BW30HR
SW30ULE
SW30XLE
Lower Salt SW30HR / SW30HR LE Higher feed
passage SW30XHR pressure

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 ROSA – Configuration design

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Configuration - Single vessel system

One pressure vessel containing one or
100 m3/day
more membrane elements
Feed
Water Permeate line
50 m3/day

Pump
Concentrate line

50 m3/day
Permeate Flow
Recovery   50%
Feed Flow
 For low flow rate
 For low system recovery

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 Configuration - Single stage system
Pressure vessels in parallel with common feed,
concentrate and permeate connections
50 m3/day
100 m3/day
Concentrate

Pump

 For higher permeate flow rates

 For modest system recovery Permeate
 Typical in seawater desalination Permeate Flow
Recovery   50%
Feed Flow

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Configuration - Multistage
Two stage system

Concentrate

Pump

Concentrate

Permeate

 Use for higher recovery

 Typical 75% recovery with 6-element vessels

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 Configuration - Multistage
Three Stage System
Permeate: 50 m3/day per PV

Feed: Permeate: 50 m3/day per PV

400 m3/day
Permeate: 50 m3/day

Pump
Concentrate

Permeate
Permeate Flow 200  100  50
Recovery    85%
Feed Flow 400
Use for higher recovery
Typical 85% recovery with 6-elements vessels
Up to 90% depending on the feed water quality

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Configuration – Number of stages selection

Number of serial element positions should be higher for

 Higher system recovery

 Higher fouling tendency of the feed water

Number of stages depends on

 Number of serial element positions

 Number of elements per pressure vessel

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 Configuration – Number of stages selection
N u m b e r o f s ta g e s o f a b r a c k is h w a te r s ys te m

S ys te m N u m b e r o f s e ria l N u m b e r o f s ta g e s
R e co very (% ) e le m e n t p o s itio n s ( 6 -e le m e n t ve s s e ls )
40 – 60 6 1
70 – 80 12 2
85 – 90 18 3

Number of stages of a sea water system

Number of stages Number of stages Number of stages

System Number of serial (6-element (7-element (8-element
Recovery (%) element positions vessels) vessels) vessels)
35 - 40 6 1 1 -
45 7 - 12 2 1 1
50 8 - 12 2 2 1
55 – 60 12 - 14 2 2 -

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Configuration – Concentrate recycle

 Way to increase recovery by recirculating reject to increase
feed flow
 Typical for special / waste water applications
 Typical for single vessel systems

Concentrate

Pump

Recycle

Permeate

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 Configuration – Internally Staged Design
 Principle: Elements with the lowest production and highest
rejection in the first positions and elements with the highest
production in the rear positions of the vessel
 Advantages vs. conventional configuration
• Better hydraulics resulting in lower flux in the front modules:
o Lower fouling potential -> lower energy required
o Less cleaning needed -> longer membrane life
• Lower energy requirement for a given production and/or higher
production for a given pressure due to the use of high flow elements
in the rear positions

Internally Staged Design (ISD)

Conventional

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Configuration – Internally Staged Design

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 Configuration – Internally Staged Design

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Configuration – Double pass

 Permeate from first array goes into another array
 Use when standard permeate quality is not sufficient
 For high purity applications
 Sometimes part of first pass permeate is blended with the second pass
permeate stream: second pass size can be reduced.
(First pass permeate blending)
Feed Pass 1 Pass 2
Water Final Permeate

Concentrate
Pump (drain)

Concentrate
(sidestream)

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 Double pass with permeate split-stream
To the second pass goes only the permeate produced by the
first pass rear elements.

Front Rear
Permeate Permeate
Feed Concentrate

Front Permeate

Rear
Feed
Permeate
Pass 1 Pass 2
Pump

Concentrate (drain)
Final Permeate

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Double pass with permeate split-stream

 Rule 1: The permeate quality produced by the front elements of the
pressure vessel is always better than the quality of the permeate
produced by the rear elements.
¿Why?

39181 44164 49422 54700 59700 64178 68000

Salinity gradient in the feed water channel (ppm)

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 Double pass with permeate split-stream
 Rule 2: Elements in front position in the pressure vessel produce
more permeate than the rear position elements.
¿Why?

39181 44164 49422 54700 59700 64178 68000

Salinity gradient in the feed water channel (ppm)

61.6 61.3 61 60.8 60.6 60.4 60.3

Pressure gradient in the feed channel (bar)

Higher Salinity Higher Osmotic Pressure Lower Production

Lower Feed Pressure Lower Production

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Permeate Split

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 Permeate Split

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Nº of Elements per Pressure Vessel Selection

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 Nº of Elements per Pressure Vessel Selection
Number of elements per vessel
Large 8-inch systems
 Benefits of vessels for 7 to 8 elements:
• lower capital costs
• higher recovery possible with same number of stages
 Benefits of vessels for 6 and less elements:
• less pressure drop
• better cleaning results
• more compact
• more stages for better hydraulic design

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Nº of elements selection: Average system flux

Select the design flux (f) based on
• pilot data
• customer experience
• typical design fluxes according to
the feed source found in System
Design Guidelines
• CAPEX or OPEX focus

QP
NE 
f  SE
NE: number of elements
QP: design permeate flow rate of system
f: flux
SE: active membrane area of the selected
element
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 System design guidelines
Each element in a system should operate within
certain limits
 To minimize concentration polarization:
• permeate flow rate below upper limit
• element recovery below upper limit
• concentrate flow rate above lower limit
 To avoid physical damage:
• feed flow rate below upper limit
• pressure drop below upper limit
• feed pressure below upper limit

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System design guidelines

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 Multistage systems: Staging ratio calculation
R Staging ratio
NV(i)
R NV(i) Number of vessels in stage i
NV(i  1) NV(i +1) Number of vessels in stage (i +1)

1
 1 n Y System recovery (fraction)
R   n Number stages
 (1 - Y) 
Calculate number of vessels of first stage NV(1)
NV
NV(1)  For 2 stage system
1  R -1

NV
NV(1) 
1  R  R -2
-1 For 3 stage system

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Multistage systems: Staging ratio calculation

Typical staging ratio:

1.5 sea water systems

with 6-element vessels
2 brackish water systems
with 6-element vessels
3 2nd pass RO systems

The active stage/Pass is highlighted

Click on the system configuration to
move from one stage to another

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 Multistage systems: Balance the permeate flow
rate
 Permeate flow rate per element decreases from the feed end
to the concentrate end of the system because of
• Pressure drop in the feed/concentrate channels
• Increasing osmotic pressure of the feed/concentrate

 Imbalance of permeate flow rate predominant with

• High system recovery
• High feed salinity
• Low pressure membranes
• High water temperature
• New membranes

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Multistage systems: Balance the permeate flow

rate
 Why balance the permeate flow rate?
• Avoid excessive flux of lead elements
• Reduce fouling rate of first stage
• Make better use of tail end membranes
• Reduce number of elements
• Improve product water quality

 Methods to balance the permeate flow rate

• Boosting the feed pressure between stages
• Permeate backpressure to first stage only
• Membranes with lower water permeability in lead positions -
membranes with higher water permeability in tail positions

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 Plant Design using ROSA
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis

12/22/2009 63

Example - ROSA Report

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 Example - ROSA Report

Designs of systems in
excess of the guidelines
results in a warning on the
ROSA Report.

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Warnings and typical solutions – For one stage systems

Design warning Solutions
Max. element permeate flow exceeded 3, 5, 7, 9, 11
The concentrate flow less than minimum 1, 4, 5, 7
The feed flow greater than maximum 2, 3
Maximum feed pressure exceeded 1, 3, 8
Temperature is above acceptable value 10
Max. element recovery exceeded:
• If the problem is encountered in front elements 1, 5, 6, 11
• If the problem is encountered in rear elements 1, 5, 6

Solutions Guide
1 Decrease system recovery Increase the number of Use a lower active area
6 elements per PV (keeping the 9 membrane element (keeping
Increase system recovery
2 same ASF) the same ASF)
Increase number of PV Decrease the number of Reduce Temp (recommend
3 (reducing average system flux)
7 elements per PV (keeping the 10 customer to reduce temp during
same ASF) pretreatment).
Reduce number of PV
4 (increasing average system flux)
Install lower energy Combine two element types:
Enable a recirculation loop 8 membranes or ISD with lower 11 lower energy elements in rear
5 Pass 1 Conc to Pass 1 Feed energy membranes positions (ISD configuration)
(normally not used for SW appl.)
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 Warnings and typical solutions – For multistage systems
Design warning Solutions
Max. element permeate flow exceeded 3, (5), 6, 8, 10, 11, 13
The concentrate flow less than minimum 1, 4, (5), 6, 10
The feed flow greater than maximum in any of the stages 2, 3
Maximum feed pressure exceeded 1, 3, 9
Temperature is above acceptable value 12

Max. element recovery exceeded:

• If the problem is encountered in front elements (front stage/s) 1, (5), 6, 7, 10, 13
• If the problem is encountered in rear elements (rear stage/s) 1, (5), 7

Solutions Guide
1 Decrease system recovery 10 Add booster pump in first or
Add backpressure in first and/or
6 second stage concentrate
2 Increase system recovery second stages permeate streams

Increase the number of elements

11 Use a lower active area membrane
element (keeping the same ASF)
3 Increase number of PV
(reducing average system flux)
7 per PV (keeping the same ASF)
Reduce Temp (recommend customer
Decrease the number of elements 12 to reduce temp during pretreatment).
4 Reduce number of PV
(increasing average system flux)
8 per PV (keeping the same ASF)
Combine two element types: lower
Enable a recirculation loop:
9
Install lower energy membranes or
ISD with lower energy membranes
13 energy elements in second or third
5 Pass 1 Conc to Pass 1 Feed
(normally not used for SW appl.)
stages
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ROSA – Checking Second Limiting

Scenario: Lowest T + Lowest FF
• Example: Lowest T= 16 ºC, low fouling factor

First add a new case, the

previous data will be copied
automatically

To change from one case to

another we can use 3 ways:
1.Click on the drop-down list
2.Move the cursor on the bar
3.Click next to the number
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 Plant Design using ROSA
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis

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Cost Analysis - Element Value

Analysis (EVA)
 The Element Value Analysis (EVA) tool has been added to ROSA
to allow for a snapshot economic comparison of different
elements operating in the same system under the same
operating parameters.
 While RO system modeling software historically provides a
snapshot comparison of the performance parameters such as
feed pressure and permeate quality, EVA provides an added
dimension allowing the system designer to also evaluate the
impact of product selection on the lifetime operational cost of
the system.
 There are a significant number of cost factors outside of RO
element selection; EVA is a comparison tool only and is not a
guarantee of actual capital or operating costs.

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 ROSA – Cost Analysis

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Index
1. Input data for analysis
2. Plant Design using ROSA 7.0
 Project Information
 Feedwater Data
 Scaling Information
 System Configuration
 Report
 Cost Analysis
3. Example

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 Example - Data for projection
1. Water analysis
IONS Concentration [ppm] 2. Feed:
Barium 0.14
Boron 0.153
• Well water
Zinc 0.006 • pre-filtered to 3μm
Fluoride 0.5
• TDS=1290 ppm
Chloride 34.29
Calcium
Potassium
9.55
0.97
3. Permeate Flow:
Magnesium 7.2 • 92.89 m3/h
Manganese 0.002
Sodium 328 4. Recovery: 87%
Nitrate 2.6
Aluminium 0.001
5. Temperature: 16 and 20ºC
Iron 0.0121
Sulphate 15.8
6. Permeate quality:
Carbonate 0.22
Bicarbonate 871 • TDS < 50 ppm
Silica 15
CO2 363.3 7. Focus on OPEX
Strontium 10
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Example - Membrane Element Selection

According to:
i. System capacity: permeate flow 92.89m3/h, than for flows >
2.3 m3/h the element diameter should be 8.0”

ii. Feed water TDS: TDS=1290 ppm very close to 1000 ppm,
then we can try LE membrane element or in case the permeate
quality is not met try BW30

iii. Feed water fouling potential: well water, conventional pre-

treatment, doesn’t have high biological fouling potential

iv. Required product water quality: conductivity <100 μS/cm

we should meet the quality with LE

v. Energy requirements: LE has lower energy requirements,

than BW30 – we should choose LE

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 Example - ROSA - Introduction of known data
• Worst scenario in terms of salt passage and hydraulics of the system (High
Temperature + High Fouling Factor):

In our example:
Permeate Flow 92.89 m3/h
In our example we have Brackish Recovery 87%
water, therefore we choose 0.95

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Example - Configuration Selection

We should choose two stage system – since high recovery
is required

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 Example - ROSA Report

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Example - ROSA Report

Designs of systems in
excess of the guidelines
results in a warning on the
ROSA Report.

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 Example - ROSA permeate flow balancing
 By adding some back pressure, the first stage will produce less.

De-select the ¨Same back

pressure¨ icon
Introduce the Back
pressure value in the Back
Pressure box

Back pressure valve

12/22/2009 79

Example - ROSA Report

Back Pressure is added to
the Feed Pressure

Water quality with TDS <50 ppm

No design warnings

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 Thank you for your attention!
For more information please visit our web site:
http://www.dow.com/liquidseps/index.htm

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