Real-Time Energy Optimal Control of Two-Stage Reverse Osmosis Desalination

A two-level model-based control system for energy-optimal operation of a two-stage reverse osmosis (RO) membrane desalination system was developed and field demonstrated. The control scheme was based on the specific energy consumption (SEC) framework accounting for pump efficiencies, physical system constraints, and temporal variability of feed salinity. The SEC framework consisted of a higher-level (supervisory) control system that guided a lower-level controller for real-time SEC optimization. The supervisory controller combined real-time plant data and the SEC model to determine the energy-optimal first-stage water recovery and the overall permeate water recovery (unless specified), and membrane permeability for a target permeate production. The derived operating state was then applied to control the RO plant operation through the lower-level control system, consisting of three separate feedback loops regulating the RO feed flow rate, first-stage RO pressure, and the second-stage RO pressure via control of the first-stage and second-stage RO feed pumps, and the RO concentrate valve. The two-level control system was demonstrated for a mobile brackish water desalination plant capable of permeate productivity up to 98 m³/day. Field testing demonstrated robust simultaneous control of the dynamically coupled control variables and effective energy-optimal operation.