1. Case Basic Information
1.1 Company Overview
Hella Water Treatment Equipment Technology Co., Ltd. is a leading provider of energy-saving solutions for RO water treatment plants, specializing in high-efficiency energy recovery devices (ERD) with national invention patents. Based in China, the company focuses on reducing energy consumption in seawater desalination, wastewater reuse, and brackish water desalination projects. Its ERD products integrate advanced technology, corrosion resistance, and high recovery efficiency, serving global industrial and municipal RO systems. For more reverse osmosis system solutions, visit [reverse osmosis].
1.2 Project Background
This project involves supplying energy recovery devices for large-scale RO plants (e.g., seawater desalination or industrial wastewater reuse) to address high energy consumption from high-pressure pumps. The ERD system is designed to recover energy from high-pressure concentrated brine (a byproduct of RO desalination) and reuse it to pre-pressurize raw water, significantly reducing the load on high-pressure pumps. The project delivers 2 sets of ERD systems (each with a design flow of 250m³/h), composed of 3 IPX-85 energy recovery devices per set (83.3m³/h per device).
1.3 RO Plant Basic Parameters
| Parameter | Specification |
|---|---|
| Raw Water Type | Seawater/brackish water (TDS ~37,500 mg/L) |
| RO System Inlet Flow | 417 m³/h |
| Concentrated Brine Flow | 250 m³/h |
| Pure Water Output | 167 m³/h |
| RO Operating Pressure | 60-63 bar |
| Operating Temperature | 25℃ |
2. Core Pain Points and Requirements of the Project
2.1 RO Plant Energy Pain Points
- High Energy Consumption: RO high-pressure pumps consume substantial power (shaft power ~430.86 kW) to overcome osmotic pressure, accounting for 50-70% of total RO plant energy use.
- Wasted Energy in Brine: High-pressure concentrated brine (60 bar) discharges directly, wasting valuable hydraulic energy.
- Operational Cost Burden: Rising energy prices increase long-term operational costs for large-scale RO plants.
- Corrosion Risk: High-salinity brine requires ERD materials with strong corrosion resistance to ensure durability.
2.2 Project Operation Requirements
- Energy Saving Efficiency: ERD efficiency ≥95% to reduce RO system energy consumption per ton of water to ≤3 kWh/m³.
- Flow Capacity: Single ERD flow ≥80 m³/h; total system flow 250 m³/h per set.
- Corrosion Resistance: Materials (SS2507, HDPE) withstand high-salinity (37,500 mg/L TDS) and high-pressure (60 bar) environments.
- Stability: Long-term operational stability with ≤3% volume mixing between raw water and brine.
- Compatibility: Seamless integration with existing RO systems (high-pressure pumps, security filters, membranes).
- Environmental Compliance: Reduce carbon dioxide emissions by ≥3,000 tons/year.
3. Hella Water Customized Solutions
3.1 System Model and Core Configuration
Hella Water provides the IPX-85 High-Efficiency Energy Recovery Device System, consisting of modular ERD units, supporting pipelines, and control cabinets. The detailed configuration is as follows:
| No. | Part Name | Description |
|---|---|---|
| 1 | Energy Recovery Devices | 6 IPX-85 units (3 per 250m³/h set), single flow 83.3 m³/h, efficiency 95.5% |
| 2 | Piping System | SS2507 high-pressure pipes (1000PSI, 8” interface) + HDPE low-pressure pipes (DN200) |
| 3 | Supporting Components | Anti-corrosion brackets, copy hub, flanges (1.0MPa), control valves |
| 4 | Control System | SS316 stainless steel control cabinet (shared by 6 units), pressure sensors |
| 5 | Lubrication System | Lubrication flow 1.2 m³/h per device (1.44% of concentrated water flow) |
3.2 Key Technical Parameters of IPX-85 ERD
| Parameter | Specification |
|---|---|
| Single Device Flow Rate | 83.3 m³/h |
| System Flow Rate (per set) | 250 m³/h |
| Operating Pressure Range | 59-63 bar |
| Energy Recovery Efficiency | 95.5% |
| Volume Mixing Rate | ≤3% |
| High-Pressure Side Differential Pressure | ≤1.0 bar |
| Material | High-pressure parts: SS2507; Low-pressure parts: HDPE |
| Single Unit Weight | 1,750 kg |
| Gross Weight (2 sets) | 7,000 kg |
| Power Consumption | 3.0 kW (system total) |
3.3 Working Principle and Integration
3.3.1 Energy Recovery Mechanism
- High-pressure concentrated brine (60 bar) from the RO membrane enters the ERD, transferring hydraulic energy to low-pressure raw water (2.5 bar) via a piston or rotary mechanism.
- Pre-pressurized raw water (59 bar) is sent to the high-pressure pump, reducing the pump’s required pressure boost (from 2.5 bar to 63 bar instead of 0 to 63 bar).
- Energy from brine is recovered instead of being wasted as heat or pressure, cutting high-pressure pump energy use.
3.3.2 RO System Integration Process
Raw Water Tank → Raw Water Pump → Security Filter → ERD (Pre-pressurization) → High-Pressure Pump → RO Membrane → Pure Water Output→ Concentrated Brine → ERD (Energy Recovery) → Low-Pressure Outlet (Discharge/Treatment)
For more industrial water filtration solutions, visit [industrial water filtration].
4. Project Effect Verification
4.1 Energy Saving Performance
| Indicator | Before ERD Installation | After ERD Installation | Improvement |
|---|---|---|---|
| High-Pressure Pump Shaft Power | 430.86 kW | Reduced by 582.79 kW (net saving) | – |
| RO Energy Consumption per Ton of Water | ~6.7 kWh/m³ | 2.86 kWh/m³ | ≥57% reduction |
| Carbon Dioxide Emissions | – | 3,016.47 tons/year reduction | – |
| Concentrate Energy Recovery Efficiency | – | 96.92% | – |
4.2 Operational Stability
- Mixing Control: Volume mixing between raw water and brine ≤3%, ensuring no impact on RO membrane performance.
- Corrosion Resistance: SS2507 and HDPE materials show no corrosion after 12-month operation in high-salinity environments.
- Continuous Operation: 72-hour continuous test confirms stable flow and pressure, no downtime or performance degradation.
4.3 Case Validation
Successfully deployed in 20,000 tons/day coking wastewater reuse projects and 200 tons/hour containerized seawater desalination systems. Customers report 50-60% energy savings for RO processes, with payback periods of 1-2 years. For desalination projects, visit [desalination].
5. Case Corresponding Product Quotation Description
5.1 Main Equipment Quotation
| Item | Model | Qty | Unit Price (USD) | Total Price (USD) | Description |
|---|---|---|---|---|---|
| 250m³/h Energy Recovery System (per set) | IPX-85 | 2 | 150,000 | 300,000 | Each set includes 3 IPX-85 devices, piping, brackets, and shared control cabinet |
5.2 Terms & Conditions
| Term Type | Details |
|---|---|
| Quotation Validity | 30 working days from the date of quotation |
| Payment Term | T/T: 50% deposit, 45% before shipping, 5% after 1-year warranty |
| Shipping Terms | FOB Shanghai, China |
| Lead Time | Customization and production: 45 days from deposit receipt |
| Warranty | 12 months from delivery; free repair/replacement for non-human-induced failures |
| Installation & Training | Free online technical support; on-site installation/training available at additional cost |
5.3 Annual Operating Cost
| Item | Specification | Annual Cost (USD) |
|---|---|---|
| Lubrication Fluid | 1.2 m³/h × 8,000 hours/year × USD20/L | ~19,200 |
| Electricity Consumption | 3.0 kW × 8,000 hours/year × USD0.15/kWh | ~3,600 |
| Maintenance & Spare Parts | Routine inspection and wear parts | ~5,000 |
| Total Annual Operating Cost | – | ~27,800 |
6. Common Questions (FAQ)
6.1 Performance and Energy Saving
Q1: How much energy can the IPX-85 ERD save for an RO plant?A1: It reduces RO energy consumption per ton of water to 2.86 kWh/m³, achieving ≥57% energy savings compared to systems without ERD. For a 250m³/h RO plant, annual electricity savings exceed 4.66 million kWh.
Q2: Will brine and raw water mixing affect water quality?A2: No. The volume mixing rate is ≤3%, which is within the acceptable range for RO systems and does not impact pure water quality or membrane lifespan.
6.2 Installation and Compatibility
Q1: Can the ERD be integrated with existing RO plants?A1: Yes. The device is designed with standard interfaces (1000PSI high-pressure flange, DN200 low-pressure pipe) and can be seamlessly connected to most RO systems without major modifications.
Q2: What preparations are required for installation?A2: Prepare a flat foundation for the ERD (supporting 1,750 kg per unit), ensure compatible pipeline sizes, and connect the control system to the RO plant’s PLC for coordinated operation.
6.3 Maintenance and Durability
Q1: What is the service life of the IPX-85 ERD?A1: Design service life is ≥10 years. Key components (SS2507 parts) are corrosion-resistant, and routine maintenance (lubrication, filter replacement) extends lifespan.
Q2: What maintenance is required regularly?A2: Monthly checks of lubrication fluid levels, quarterly inspection of seals and pressure sensors, and annual calibration of flow/pressure meters. For replacement parts, visit [accessory supporting equipment].
6.4 Warranty and Support
Q1: What is covered under the 1-year warranty?A1: Manufacturing defects in ERD bodies, valves, and control cabinets. Wear parts (seals, filters) and human-induced damages are excluded.
Q2: Is technical support available for overseas projects?A2: Yes. 24/7 online technical support is provided via WhatsApp and email; on-site support is available for complex issues (customer bears travel and labor costs).
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