ULT – RO 800 GPD

Designing an 800 GPD reverse osmosis (RO) system for Ultratec Water Treatment to handle feed water with a Total Dissolved Solids (TDS) level of 1000 ppm requires careful consideration of various components and design elements. This system must efficiently remove contaminants and deliver high-quality purified water, whether for drinking, industrial processes, or other applications. Key components include membrane selection, high-pressure pumps, pressure vessels, and pre- and post-treatment stages. Ensuring each part of the system is optimized for performance and durability is crucial for achieving desired results and maintaining long-term operational efficiency.

1.1. Water Quality Analysis

Total Dissolved Solids: 1000 ppm is high TDS; this will impact the choice of RO membranes and other system components.
Other Contaminants: If there are other contaminants like chlorine, chloramines, or hard water, additional pretreatment may be necessary.

1.2. Customer Requirement

Understand the use of the purified water (e.g., drinking water, industrial processes) to build the plant accordingly.

1.3. Pre-Treatment

PP Filter: Install a PP filter to prevent fouling and capture particles like sand, dust, and rust.
Activated Carbon Filtration: Use carbon filters to remove chlorine, chloramines, and organic contaminants that can damage RO membranes.

2.1. Water Softening

For hard water, use a softener. If there is no hardness, this stage may not be necessary.

2.2. Adjustment of pH

Adjust the pH if required to prevent membrane scaling and fouling. RO membranes typically perform best within a pH range of 3-11.

2.3. Anti-Scale Dosing

For scaling, use an anti-scalant with a dosing system.

3.1. Membrane Selection

Membrane Selection: Choosing the right membrane is crucial. For an RO system with 800 GPD capacity at 1000 ppm, a high salt rejection membrane like the LG BW8040-400 is ideal.
Capacity: The LG BW8040-400 membrane has a production capacity of 400 GPD, so two membranes in a dual configuration will meet the 800 GPD requirement.
Performance: It efficiently handles brackish water with a TDS level around 1000 ppm.
Filtration: Provides high rejection rates for TDS, ensuring the quality of purified water.

3.2. Pressure Pump

Pressure Pump: Select a high-pressure pump capable of achieving the required pressure, typically between 150-300 psi. For the LG BW8040-400 membranes, consider pumps like the Lowara e-SV or Grundfos CR series.
Lowara: The e-SV series, such as the e-SV 8 or e-SV 15, are designed for high-pressure applications.
Grundfos: The CR series, including models like CR 10 or CR 15, are reliable and efficient for RO systems.

3.3. Pressure Vessel

Pressure Vessel: Choose a vessel compatible with the membranes and capable of withstanding operational pressures. The Protec PX-4040 composite vessel is suitable for the LG BW8040-400 membranes.
Features: Composite materials resistant to corrosion and high pressure, designed for 4-inch diameter membranes, and proper mounting to prevent leaks.

3.4. Flow Rate Calculation

Ensure the design can handle the desired flow rate of 800 GPD by calculating the required flow rates for both feed water and permeate water. With a 50% recovery rate, the feed flow rate should be 1600 GPD.

4.1. Storage Tank

Include a storage tank to store permeate water, sized based on daily usage and peak demand.

4.2. Post-Treatment

Depending on the final use of the water, additional treatment such as UV disinfection or final polishing filters may be necessary.

4.3. Control System

Install a control panel with features like automatic shut-off valves, pressure gauges, flow meters, and a monitoring system for performance and maintenance alerts.

5.1. Maintenance

Design for easy maintenance with accessible filters, membranes, and other components. Provide detailed maintenance schedules.

5.2. Installation and Commissioning

Installation: Follow best practices for secure connections and proper positioning.
Testing: Verify system performance through thorough testing.
Training: Provide training for operators on system use, maintenance, and troubleshooting.

5.3. Operational Considerations

Implement continuous monitoring to track water quality, system performance, and detect any issues early.

5.4. Maintenance Schedule

Establish a regular maintenance schedule for changing pre-filters, cleaning or replacing RO membranes, and checking system components.

For the successful implementation of an 800 GPD RO system utilizing LG BW8040-400 membranes, precise selection and integration of components are paramount. The Protec PX-4040 pressure vessel is ideal for housing these membranes, given its compatibility with the required size and pressure ratings. With two LG BW8040-400 membranes, the system can achieve a total permeate flow rate of 800 GPD, while a recovery rate of 50% necessitates a feed flow rate of 1600 GPD. Choosing an appropriate high-pressure pump, such as the Lowara e-SV or Grundfos CR series, ensures that the system meets operational pressure requirements efficiently. Incorporating a well-sized storage tank, effective post-treatment solutions, and a comprehensive control system will further enhance the system’s performance. Regular maintenance and thorough testing during installation are essential to ensure reliable operation. By addressing these aspects, the RO system will deliver high-quality water consistently, meeting the needs of Ultratec Water Treatment and ensuring optimal performance over its operational life.