A new one-dimensional predictive model for spiral wound modules (SWMs) applied to reverse osmosis membrane systems is developed by incorporating a detailed description of the geometric features of SWMs and considering flow in two directions. The proposed model is found to capture existing experimental data well, with similar accuracy to the widely-used plate model in which the SWM is assumed to consist of multiple thin rectangular channels. However, physical parameters that should in principle be model-independent, such as membrane permeability, are found to differ significantly depending on which model is used, when the same data sets are used for parameter estimation. Conversely, when using the same physical parameter values in both models, the water recovery predicted by the plate-like model is 12–20% higher than that predicted by the spiral model. This discrepancy is due to differences in the description of geometric features, in particular the active membrane area and the variable channel heights through the module, which impact on predicted performance and energy consumption. A number of design variables – the number of membrane leaves, membrane dimensions, centre pipe radius and the height of feed and permeate channels – are varied and their effects on performance, energy consumption and calculated module size are analysed. The proposed spiral model provides valuable insights into the effects of complex geometry on the performance of the SWM as well as of the overall system, at a low computational cost
Empirical correlations for mass transfer coefficient and friction factor are often used in process models for reverse osmosis (RO) membrane systems. These usually involve four dimensionless groups, namely Reynolds number (Re), Sherwood number (Sh), friction factor (f), and Schmidt number (Sc), with the associated coefficients and exponents being obtained by fitting to experimental data. However, the range of geometric and operating conditions covered by the experiments is often limited. In this study, new dimensionless correlations for concentration polarization (CP) modulus and friction factor are presented, which are obtained by dimensional analysis and using simulation data from computational fluid dynamics (CFD). Two-dimensional CFD simulations are performed on three configurations of spacer-filled channels with 76 combinations of operating and geometric conditions for each configuration, covering a broad range of conditions encountered in RO membrane systems. Results obtained with the new correlations are compared with those from existing correlations in the literature. There is good consistency in the predicted CP with mean discrepancies less than 6%, but larger discrepancies for pressure gradient are found among the various friction factor correlations. Furthermore, the new correlations are implemented in a process model with six spiral wound modules in series and the predicted recovery, pressure drop, and specific energy consumption are compared with a reference case obtained by ROSA (Reverse Osmosis System Analysis, The Dow Chemical Company). Differences in predicted recovery and pressure drop are up to 5% and 83%, respectively, highlighting the need for careful selection of correlations when using predictive models in process design. Compared to existing mass transfer correlations, a distinct advantage of our correlations for CP modulus is that they can be directly used to estimate the impact of permeate flux on CP at a membrane surface without having to resort to the film theory.
30 August 2020 in International Journal for Numerical Methods in Biomedical Engineering