The effect of natural organic matter on ultrafiltration and reverse osmosis membrane performance at Komati Power Station

Abstract

Komati Power Station has installed a membrane plant consisting of ultrafiltration, double pass reverse osmosis and continuous electro-deionisation to treat cooling tower blowdowns in order to produce demineralised water and to conduct sidestream chemistry control of the cooling water circuit. This plant has replaced the existing ion-exchange plant that was used for the production of demineralised water and thus serves to reduce the loading of mobile salts in the ash dam (90% reduction) by eliminating regeneration effluent from the ion-exchange plant. Due to oil contamination in the cooling water circuit (when oil from oil coolers leaks into the cooling water), the membrane plant was also designed to operate on raw water from either the Nooigdedacht or the Vygeboom Dam or a blend of both dams. This is considered to be an emergency intervention under abnormal conditions to prevent possible irreversible fouling of the membranes due to oil in the cooling water. The Nooigtedach Dam water contains high concentrations of organic matter and is also enriched with nutrients due to raw sewage influent into the Dam water. This poses a challenge with regard to treatment of the high fouling feed water on the membrane plant. Natural organic matter in water has the ability to foul reverse osmosis membranes. This adversely affects the operation of the reverse osmosis process. However, very little information is available regarding the fouling characteristics of natural organic material in the raw and cooling water at Komati Power Station for the reverse osmosis membranes. Therefore, a pilot study was undertaken to determine the influence of natural organic matter on membrane fouling, to optimise the process for the removal of natural organic matter and to assess the ability of two different reverse osmosis membranes to effectively treat the high fouling feed water at Komati Power Station. The ability of a polyethersulphone hollow-fibre ultrafiltration membrane system was first evaluated to remove natural organic matter in the feedwater, by conducting pilot tests, initially without coagulation of the raw water and thereafter with in-line coagulation for organics removal. Jar tests were conducted in the laboratory to determine the most suitable coagulant and dosage for turbidity and natural organic matter removal. Various coagulants were tested and, based on the results of the jar tests, a coagulant (U3000) was identified based on optimal removal of both total organic carbon and turbidity at a dosing level of 20 mg/L. During the operation of the ultrafiltration pilot plant, permeate flow; feed pressure and feed temperature were monitored. Performance of the ultrafiltration membrane was monitored in terms of flux versus time for operation with and without a coagulation process. The results indicated that there was very little total organic carbon removal (maximum removal of 4%) without coagulation and a slight decrease in flux. The flux declined as a result of fouling but could be recovered by performing hydraulic backwashes and CEB procedures. Permeate flux, however, could be maintained at about 90 Lmh (from 642 hours of operation). Since most of the organics passed through the ultrafiltration membrane, it was concluded that the loss in flux was due to colloidal fouling of the membrane. This was observed when the operation was carried out using raw water as feed as well as when cooling water was used. The total organic carbon removal increased to 30% when the plant was operated with inline coagulation. The flux remained relatively stable during the first 600 hours of operation and only decreased significantly during the last 200 hours of operation as a result of fouling. The reduction in flux prior to cleaning was less than the 15% (maximum flux decline of 9.9% during the test period) which is acceptable according to the industry norm of 15%. It appeared that flux could be maintained at around 90 Lmh which was about the same as when no coagulant was applied. The 30% total organic carbon reduction that was obtained was not sufficient to reduce the organics to the level of 6mg/L dissolved organic carbon that was specified by the membrane manufacturer for the standard brackish water reverse osmosis membrane. Two reverse osmosis membranes – the standard brackish water reverse osmosis membrane (BW30-2540) and the extra-low-fouling membrane (BW30XFR-2540) – were assessed in terms of their ability to remove dissolved organic carbon, ease of cleaning of the membrane and the ability to recover flux after cleaning. This was done to establish which membrane is more suited to Komati’s high-fouling feedwater. The evaluation of the performance of the two reverse osmosis membranes was conducted using pre-treated water (filtered water after in-line coagulation, anti-scalant and biocide dosing) as well as using water that was not pre-treated. During operation (under both conditions), the normalised permeate flux, conductivity, dissolved organic carbon and organics absorbing at UV254 were monitored. It was established that in terms of flux decline that the extra low-fouling membrane gave slightly superior performance to that of the standard membrane, achieving longer production runs (up to 5 days compared with 3 days achieved by the standard brackish water membrane) without requiring chemical cleaning. The low fouling membrane achieved better CWF recovery after the cleaning cycles (81.26% Lmh of the virgin membrane on the occasions when there was flux loss) compared to the standard membrane (restored to 77.35% of CWF of the virgin membrane) when using untreated feed water. This performance improved when pre-treated feed water was used and the low fouling membrane’s CWF regained after the CIP was 95.89% which was within the industry norm of a flux recovery of 95%, indicating that the CIP had been effective. It was determined that the TOC rejection of the low-fouling membrane was higher (average TOC rejection of 97%, maximum TOC rejection of 99%) than that of the standard membrane (average TOC rejection of 95.3%, maximum TOC rejection of 97%). Preliminary efforts to optimize the pre-treatment for organics removal in order to reduce organic loading for the RO membranes confirmed that the use of granular activated carbon and use of an organic scavenger resin might not be economically feasible due to the relatively quick TOC breakthrough (8910BV, approximately 18000BV and less than 18000BV for the Filtrasorb 300, Filtrasorb 400 and organic scavenger resin, respectively). Although further investigations should still be conducted, the preliminary results indicate that it would be beneficial to also identify other options that can be further investigated for optimization of organics removal at Komati Power Station. Decline in the normalised flux as well as the evidence of biofouling were witnessed during the pilot operation suggesting that the membranes were fouled. Autopsies were performed on both membranes to identify foulants responsible for the decline in flux that was observed during the pilot study. The results did not indicate an organic foulant on the membrane surface. Biofouling should however, be monitored in the main plant as this was suspected to have resulted in the flux decline during the pilot study. The low fouling membrane demonstrated a better capability to treat the Komati raw and cooling water and would be expected to achieve lower operating costs for the plant (CIP costs and membrane replacement costs) while achieving better organics removal and it is therefore recommended that the low-fouling membranes be used at Komati Power Station as they are superior to the standard membrane and the cost of the low-fouling membranes is comparable to that of the standard membrane. While this would provide somewhat better performance than that obtained with the standard brackish water membranes, it is proposed that further investigation into pre-treatment optimization for organics removal as well as more efficient cleaning solutions be investigated to improve the performance and economics of the main water treatment plant at Komati power Station.