Optimization of LNG Cold Energy Utilization via Power Generation, Refrigeration, and Air Separation

Natural gas is conventionally transported in its liquid form or Liquid Natural Gas (LNG). It is then transported using cryogenic insulated LNG tankers. At receiving terminals, LNG is regasified prior to distributing it through gas distribution system. Seawater has been used as the heat source, which leads to vast amount of cold energy discarded into the water. This work presents the use of LNG cold energy around Melaka Refining Company (MRC). The cold energy is utilized in power generation, propylene refrigeration cycle, and air separation plants. These systems are designed and simulated using a commercial process simulation software. Capital cost (CAPEX) function and revenues of each system are further developed as a function of LNG flowrates. These developed correlations are then used in an optimization problem to seek for the most profitable scenario. The results show that utilizing LNG for air separation unit yields the highest profit compared to power generation and refrigeration plants.

Development of An Integrated Surface and Sub-Surface Simulation Model in A Single Simulation Platform

An integrated model between surface and sub-surface is typically done by interconnecting many process modelling platforms. PROSPER and GAP are the common steady state modelling platforms for sub-surface while VMGSim and HYSYS are typical steady state surface modelling platforms. A major issue of using multiple simulation platforms is the compatibility of thermodynamic physical properties calculations among the platforms. This situation makes the simulations difficult to converge to a consistent thermo physical properties values. This is due to different interaction parameters applied in each platform that impact flashing and the physical property values even though the same property package such as Peng Robinson is used. To overcome this convergence problem, a single simulation platform within iCON (PETRONAS’s standard process simulation software, co-developed with VMG-Schlumberger) has been developed. This allows the use of one thermodynamic package across the integrated model. PROSPER sub-surface pressure-flow relationship results were automatically correlated and connected to surface models within the iCON environment. This integrated model was validated with data from operations and yielded about 1.23% average error tolerance. Based on this validated model, an optimization envelope can be developed with all possible well lineup configurations. This envelope covers set points for the operations where CAPEX free optimization can readily be applied.

Finned spacer for efficient membrane fouling control in produced water filtration

Membrane based technologies are highly reliable for water and wastewater treatment, including for removal of total oil and grease from produced water. However, performances of the pressure driven processes are highly restricted by membrane fouling and the application of traditional air bubbling system is limited by their low shear stress due to poor contacts with the membrane surface. This study develops and assesses a novel finned spacer, placed in between vertical panel, for membrane fouling control in submerged plate-and-frame module system for real produced water filtration. Results show that permeability of the panel is enhanced by 87% from 201 to 381 L/(m² h bar). The spacer system can be operated in switching mode to accommodate two-sided panel aeration. This leads to panel permeability increment by 22% higher than the conventional vertical system. The mechanisms of finned spacer in encouraging the flow trajectory was proven by visual observation and flow simulation. The fins alter the air bubbles flow trajectory toward the membrane surface to effectively scour-off the foulant. Overall results demonstrate the efficacy of the developed spacer in projecting the air bubble trajectory toward the membrane surface and thus significantly enhances membrane panel productivity.

Two-way switch: Maximizing productivity of tilted panel in membrane bioreactor

Membrane fouling is a major challenge in membrane bioreactors (MBRs) and its effective handling is the key to improve their competitiveness. Tilting panel system offers significant improvements for fouling control but is strictly limited to one-sided panel. In this study, we assess a two-way switch tilting panel system that enables two-sided membranes and project its implications on performance and energy footprint. Results show that tilting a panel improves permeance by up to 20% to reach a plateau flux thanks to better contacts between air bubbles and the membrane surface to scour-off the foulant. A plateau permeance could be achieved at aeration rate of as low as 0.90 l min^-1, a condition untenable by vertical panel even at twice of the aeration rate. Switching at short periods (<5min) can maintain the hydraulic performance as in no-switch (static system), enables application of a two-sided switching panel. A comparison of vertical panel under 1.80 l min^-1 aeration rate with a switching panel at a half of the rate, switched at 1 min period shows ≈10% higher permeance of the later. Since periodic switching consumes a very low energy (0.55% of the total of 0.276 kWh m^-3), with reduction of aeration by 50%, the switching tilted panel offers 41% more energy efficient than a referenced full-scale MBR (0.390 kWh m^-3). Overall results are very compelling and highly attractive for significant improvements of MBR technologies.

Tackling membrane fouling in microalgae filtration using nylon 6,6 nanofiber membrane

Microalgae technology, if managed properly, has promising roles in solving food-water-energy nexus. The Achilles' heel is, however, to lower the costs associated with cultivation and harvesting. As a favorable technique, application of membrane process is strongly limited by membrane fouling. This study evaluates performance of nylon 6,6 nanofiber membrane (NFM) to a conventional polyvinylidene fluoride phase inverted membrane (PVDF PIM) for filtration of Chlorella vulgaris. Results show that nylon 6,6 NFM is superhydrophilic, has higher size of pore opening (0.22 vs 0.18 μm) and higher surface pore density (23 vs 18 pores/μm²) leading to higher permeance (1018 vs 493 L/m²hbar) and better fouling resistant. Such advantages help to outperform the filterability of PVDF PIM by showing much higher steady-state permeance (286 vs 120 L/m²hbar), with comparable biomass retention. In addition, unlike for PVDF PIM, imposing longer relaxation cycles further enhances the performance of the NFM (i.e., 178 L/m²hbar for 0.5 min and 236 L/m²hbar for 5 min). Overall findings confirm the advantages of nylon 6,6 NFM over the PVDF PIM. Such advantages can help to reduce required membrane area and specific aeration demand by enabling higher flux and lowering aeration rate. Nevertheless, developments of nylon 6,6 NFM material with respect to its intrinsic properties, mechanical strength and operational conditions of the panel can still be explored to enhance its competitiveness as a promising fouling resistant membrane material for microalgae filtration.

Tilted membrane panel: A new module concept to maximize the impact of air bubbles for membrane fouling control in microalgae harvesting

Microalgae harvesting using membrane technology is challenging because of its high fouling propensity. As an established fouling mitigation technique, efficacy of air bubbles can be improved by maximizing the impact of shear-rates in scouring foulant. In this study, it is achieved by tilting the membrane panel. We investigate the effect of tilting angle, switching period as well as aeration rate during microalgal broth filtration. Results show that higher tilting angles (up to 20°) improve permeability of up to 2.7 times of the vertical panel. In addition, operating a one-sided panel is better than a two-sided panel, in which the later involved switching mode. One-sided membrane panel only require a half of area, yet its performance is comparable with of a large-scale module. This tilted panel can lead to significant membrane cost reductions and eventually improves the competitiveness of membrane technology for microalgae harvesting application.

A novel In-situ Enzymatic Cleaning Method for Reducing Membrane Fouling in Membrane Bioreactors (MBRs)

A novel in-situ enzymatic cleaning method was developed for fouling control in membrane bioreactors (MBRs). It is achieved by bringing the required enzymes near the membrane surface by pulling the enzymes to a magnetic membrane (MM) surface by means of magnetic forces, exactly where the cleaning is required. To achieve this, the enzyme was coupled to a magnetic nanoparticle (MNP) and the membrane it self was loaded with MNP. The magnetic activity was turned by means of an external permanent magnet. The effectiveness of concept was tested in a submerged membrane filtration using the model enzyme-substrate of Bacillus subitilis xylanase-arabinoxylan. The MM had almost similar properties compared to the unloaded ones, except for its well distributed MNPs. The enzyme was stable during coupling conditions and the presence of coupling could be detected using a high-performance anion-exchange chromatography (HPAEC) analysis and Fourier transform infrared spectroscopy (FTIR). The system facilitated an in-situ enzymatic cleaning and could be effectively applied for control fouling in membrane bioreactors (MBRs).

Role of transparent exopolymer particles on membrane fouling in a full-scale ultrafiltration plant: feed parameter analysis and membrane autopsy

Ultrafiltration (UF) is widely used for water purification, but membrane fouling remains an important issue. In this study, the role of transparent exopolymer particles (TEPs), recently put forward as possible major foulants, was investigated in the fouling process of a full-scale UF installation. Algae, TEPs and other parameters in the UF feed were monitored and correlated during an 8 months long full-scale operation. Results revealed a complex fouling mechanism involving interactions mainly between algae, Fe (flocculant) and TEPs. Algae related parameters rather that TEP concentrations correlated stronger with irreversible fouling rates, suggesting that the overall role of TEPs in membrane fouling seems limited for this application. Finally, membrane autopsy showed the formation of a thick Fe-rich fouling layer on top of the fouled membranes, which could mostly be removed via cleaning-in-place. It remained partly irremovable in the form of some Fe-organic complexes.

Membrane technology in microalgae cultivation and harvesting: a review

Membrane processes have long been applied in different stages of microalgae cultivation and processing. These processes include microfiltration, ultrafiltration, dialysis, forward osmosis, membrane contactors and membrane spargers. They are implemented in many combinations, both as a standalone and as a coupled system (in membrane biomass retention photobioreactors (BR-MPBRs) or membrane carbonation photobioreactors (C-MPBRs). To provide sufficient background on these applications, an overview of membrane materials and membrane processes of interest in microalgae cultivation and processing is provided in this work first. Afterwards, discussion about specific aspects of membrane applications in microbial cultivation and harvesting is provided, including membrane fouling. Many of the membrane processes were shown to be promising options in microalgae cultivation. Yet, significant process optimizations are still required when they are applied to enable microalgae biomass bulk production to become competitive as a raw material for biofuel production. Recent developments of the coupled systems (BR-MPBR and C-MPBR) bring significant promises to improve the volumetric productivity of a cultivation system and the efficiency of inorganic carbon capture, respectively.

Membrane photobioreactors for integrated microalgae cultivation and nutrient remediation of membrane bioreactors effluent

The feasibility of a new concept of wastewater treatment by combining a membrane bioreactor (MBR) and a microalgae membrane photobioreactor (MPBR) is assessed in this study. In this system, the organic carbon present in wastewater is expected to be fully oxidized in the MBR, while the nutrients are removed via the subsequent MPBR treatment. The effluent of a lab-scale MBR was fed into a PBR and a MPBR which served as growing medium for Chlorella vulgaris. The MPBRs demonstrated their superiority by limiting the algae wash-out, thus increasing the allowable optimum dilution rate (Dopt). At these corresponding Dopt values, 3.5 and 2 times higher biomass concentrations and volumetric productivities respectively were achieved by the MPBR. It is also possible to run the MPBR at still higher biomass concentration, thus enabling a smaller footprint and higher nutrient removal efficiency. However, reduced nutrient removal efficiencies were found to be one possible drawback.

Coupled cultivation and pre-harvesting of microalgae in a membrane photobioreactor (MPBR)

A new and effective concept is proposed for microalgae cultivation and pre-harvesting using a membrane photobioreactor (MPBR), in which the bioreactor is coupled to membrane filtration by cultivating Chlorella vulgaris. A basic simulation was first performed to understand the behavior of the hybrid system. The effectiveness of the MPBR for cultivation and pre-harvesting was proven. The membrane completely retained the biomass, which then was partly recycled into the bioreactor to maintain a high biomass concentration, thus enhancing flexibility and robustness of the system. The MPBR can operate at both higher dilution and higher growth rates, resulting in a 9× higher biomass productivity. In addition, pre-harvesting can be achieved by applying variable concentration factors in the filtration stage. The membrane permeate was recycled to the reactor as feed medium without affecting the algae growth, which offers a substantial reduction of 77% in the water footprint.

Impact of changes in broth composition on Chlorella vulgaris cultivation in a membrane photobioreactor (MPBR) with permeate recycle

A membrane photobioreactor (MPBR) is a proven and very useful concept in which microalgae can be simultaneously cultivated and pre-harvested. However, the behavior with respect to accumulation of algogenic organic matter, including transparent exopolymeric particles (TEPs), counter ions and unassimilated nutrients due to the recycling of the medium is still unclear, even though the understanding of this behavior is essential for the optimization of microalgae processing. Therefore, the dynamics of these compounds, especially TEPs, during coupled cultivation and harvesting of Chlorella vulgaris in an MPBR with permeate recycle are addressed in this study. Results show that TEPs are secreted during algae cell growth, and that their presence is thus inevitable. In the system with permeate recycle, substances such as counter ions and unassimilated nutrients get accumulated in the system. This was proven to limit the algae growth, together with the occurrence of bioflocculation due to an increasing broth pH.

Harvesting microalgal biomass using a magnetically induced membrane vibration (MMV) system: filtration performance and energy consumption

This study was performed to investigate the effectiveness of submerged microfiltration to harvest both a marine diatom Phaeodactylum tricornutum and a Chlorella vulgaris in a recently developed magnetically induced membrane vibrating (MMV) system. We assess the filtration performance by conducting the improved flux step method (IFM), fed-batch concentration filtrations and membrane fouling autopsy using two lab-made membranes with different porosity. The full-scale energy consumption was also estimated. Overall results suggest that the MMV offers a good fouling control and the process was proven to be economically attractive. By combining the membrane filtration (15× concentration) with centrifugation to reach a final concentration of 25% w/v, the energy consumption to harvest P. tricornutum and C. vulgaris was, respectively, as low as 0.84 and 0.77kWh/m(3), corresponding to 1.46 and 1.39 kWh/kg of the harvested biomass.

Role of transparent exopolymeric particles in membrane fouling: Chlorella vulgaris broth filtration

Recent reports show strong evidence for the involvement of transparent exopolymer particles (TEPs), mainly produced by microalgae in natural environments, in membrane fouling in a wide range of membrane filtration processes. The objective of this study is to fundamentally investigate the direct role of TEPs on membrane fouling by using different Chlorella vulgaris broth solutions and different fractions of such broth (the soluble and bound fractions, the cells separated from these fractions and the cells with their bound sugars, separated from the soluble fraction) as filtration feed. The relation between the feed properties and their filterability over three membranes was determined. Scanning electron microscopy and light microscopy showed that the foulant types differed for each broth fraction and confirmed the role of TEPs in the fouling of microfiltration membranes. In addition, this study contributes to the role of TEPs in the filtration of microalgae cultivated for commercial reasons.

Direct sewage up-concentration by submerged aerated and vibrated membranes

Membrane filtration is a promising technology for realising the so-called ZeroWasteWater concept, i.e. the wastewater can be up-concentrated and the retentate can sequentially be sent to a bioreactor (e.g., for energy production) while the permeate is aimed for reuse. In the present study, aerated and novel vibrated membrane filtration systems were evaluated as possible techniques for both energy and water recovery through the up-concentration of sewage from a municipal wastewater treatment plant. The lab-scale experiments proved the clear advantage of vibrated membrane filtration over the aerated system, considering both the filtration performance (fouling control) and energy usage. Both microfiltration systems were found efficient in up-concentrating the COD, but not the nitrogen nor the phosphorus. The semi-continuous pilot-scale experiment could not confirm the usefulness of the process which was due to both fast in situ microbial COD degradation and fast particulate COD settling in the feed tank.

Harvesting microalgal biomass using submerged microfiltration membranes

This study was performed to investigate the applicability of submerged microfiltration as a first step of up-concentration for harvesting both a freshwater green algae species Chlorella vulgaris and a marine diatom Phaeodactylum tricornutum using three lab-made membranes with different porosity. The filtration performance was assessed by conducting the improved flux step method (IFM) and batch up-concentration filtrations. The fouling autopsy of the membranes was performed by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX) and Fourier transform infrared spectroscopy (FTIR). The cost analysis was estimated based on the data of a related full-scale submerged membrane bioreactor (MBR). Overall results suggest that submerged microfiltration for algal harvesting is economically feasible. The IFM results indicate a low degree of fouling, comparable to the one obtained for a submerged MBR. By combining the submerged microfiltration with centrifugation to reach a final concentration of 22% w/v, the energy consumption to dewater C. vulgaris and P. tricornutum is 0.84 kW h/m(3) and 0.91 kW h/m(3), respectively.