ENERGY RECOVERY TURBINES

Meeting the challenge of a thirsty world

Our References speak for themselves

Calder AG is a privately owned Swiss based organisation established in 1981, with associate companies in the UK and Spain. We are world leaders in the manufacture and supply of the most efficient Energy Recovery Turbines for the Reverse Osmosis process. In keeping with the finest traditions of Swiss engineering, Calder prides itself in delivering robust, high quality energy recovery turbines, engineered with the latest corrosion resistant materials, designed to give reliable continuous operation under arduous conditions. The principle benefits you will experience when working with Calder as your project partner are: 20 years experience in the manufacture and supply of Energy Recovery Turbines, Pump Units and Pump Systems to the RO Industry. 20 years RO process experience. We have a good knowledge of the RO process and can advise on the incorporation of energy recovery equipment, and the implications on the process. High quality products designed exclusively for the RO market. Over 1,000 units in operation. Reference plants that have been in operation for over 15 years at the same energy efficiency, saving the same power today as when first installed. Proven low operating costs due to high reliability and practical design for maintenance. Working with an enthusiastic team of engineers who enjoy the RO industry.
CALDER AG, Egliswil, Switzerland Manufacturers of the worlds leading Energy Recovery Turbine

Our current range of Energy Recovery Turbines and high pressure pumps incorporate the latest design improvements and knowledge gained in conjunction with our customers on hundreds of RO plants around the world. This experience allows us to give our customers the best possible support when specifying, selecting and installing a pump and energy recovery turbine into an RO plant. Our well-trained team of service engineers ensure comprehensive support during start-up and after sales service, either on a call out or contract basis. The engineering and process knowledge of our service engineers ensures the best possible support.

ISO

900

We handle our projects on a partnership bases.

CALDER Energy Recovery Turbine

Calder Energy Recovery Turbines are designed and manufactured specifically for the Reverse Osmosis industry by a company who understand the need for energy efficiency and product reliability. With an installation list of over 1,000 Calder turbines operating on Reverse Osmosis plants world-wide, and a total installed capacity in excess of 2,000,000 m3/day (528 MGD). Our client portfolio is our best reference. RO Plant designers and operators around the world select the Calder Energy Recovery Turbine for its high efficiency, excellent reliability, proven durability and low maintenance cost. Our standard 3-year warranty demonstrates our confidence in the Calder ERT. In keeping with the Calder tradition of leadership in energy recovery technology, the new series of turbines have been designed to maximise efficiency and reduce cost without compromising quality. Building on over 20 years of experience supplying energy recovery turbines to the RO industry, we have achieved a number of radical improvements: Maximising hydraulics giving higher efficiencies. High efficiency resulting in potable water production below 2.6 kW/m3. Horizontal split case design for easy access. Heavy-duty bearings for long & reliable operation. Super Duplex stainless steel construction for extra long life. FRP housing on small units for low weight. Flat efficiency curve to maximise energy recovery over a wide range of operating pressures.

Seawater RO plant in Spain with 7 trains and a production of 110,000 m3/d (29 MGD)

When you consider all of the features built into the Calder ERT, youll find that no other energy recovery device can match the innovation, energy efficiency and dependability that you will get with a Calder energy recovery turbine.
Seawater RO plant in the Balearic Islands with 9 trains and a production of 90,000 m3/d (24 MGD)

The Principle
The System
The Calder Energy Recovery Turbine (ERT) takes advantage of the high-pressure energy, which remains in the concentrate (brine) from the reverse osmosis process. The high-pressure concentrate enters the Calder ERT through the inlet nozzle. The high pressure water stream drives the ERT rotor which then produces rotating power used to assist the main electric motor in driving the high-pressure pump. The Calder ERT rotor and nozzle is optimised to convert the kinetic energy of the jet into rotating mechanical energy, enabling the turbine to operate at maximum efficiency with the liquid brine being discharged at atmospheric pressure. This concept allows a smaller, less costly motor to be utilised and saves a very considerable proportion of the power and cost necessary to drive the high pressure feed pump.

Control
The system is very easy to operate with only one control, comprising the adjustable inlet nozzle, which is required to set and maintain the system pressure. The plant is started up with the inlet nozzle fully open. The hand wheel or actuator operating the nozzle, is then adjusted until the system pressure is reached. The nozzle directs the jet of high-pressure concentrate onto the Calder ERT rotor buckets, rotating the wheel and shaft assembly.

Product Range
Calder Energy Recovery Turbines are designed to operate with either centrifugal pumps or plunger pumps. A range of standard turbines are available with a power recovery potential up to 1.5 MW. Larger units are available as engineered product built to suit seawater and brackis water applications. The Calder ERT can be direct coupled to motors or pumps at speeds up to 3,600 rev/min.

HP Pump Skid M

~
Pump Throttle Valve

Permeat

From Cartridge Filters

HP Pump
Turbine Nozzle Valve

Membrane

Turbine

Reject Line

Drain
Turbine Model RO-290-40-20 RO-290-40-30 RO-290-65 RO-310-65 RO-350-65 RO-310-70 RO-350-70 RO-310-75 RO-350-75 RO-310-80 RO-350-80 RO-310-100 RO-350-100 RO-310-80-2 RO-350-80-2 RO-310-100-2 RO-350-100-2 RO-310-100-4 RO-350-100-4 Max. Flow
m3/h (USGPM)

Max. Power
kW HP

Frequency
Hz

Seawater RO plant in Spain with 14 trains and a production of 140,000 m3/d (37 MGD)

15 25 40 55 80 110 110 150 150 200 200 250 250 330 330 550 650 900 1200

66 110 176 242 352 484 484 661 661 881 881 1101 1101 1453 1453 2422 2860 3963 5284

28 45 75 100 150 210 210 290 290 390 390 500 500 640 340 960 1100 1500 1500

38 61 101 135 203 284 284 392 392 527 527 675 675 864 459 1296 1460 2025 2025

5060 5060 5060 5060 5060 60 50 60 50 60 50 60 50 60 50 60 50 60 50

Advantages of the CALDER ERT

Efficiency
The high quality construction with precision-engineered components provides high energy efficiency, typically up to 90 percent. This means as much as 90 percent of the hydraulic energy remaining in the concentrate can be recovered and converted into rotary power, saving power and running costs. Calder energy recovery turbines run in air on start-up and begin to generate power as soon as the concentrate stream enters the ERT (typically 40% of system pressure). It is possible to size the electric motor for as little as 60% of the total power required to drive the high-pressure pump.

Convenience of Operation
The inlet nozzle of the turbine replaces the brine control valve fitted to conventional plants. An adjustable nozzle assembly is incorporated to enable the required operating conditions to be set easily after start-up and also allow original operating conditions to be re-established quickly if conditions change. Adjustment of the nozzle can be done either manually or by motor drive (actuator) as an option. It is important to note that the Calder ERT recovers all of the energy available in the concentrate stream. There is no bleed, bypass or mixing as exists in other systems.

Construction
Each turbine is a horizontal shaft, single rotor which is a precision casting machined to accurate tolerances and dynamically balance. The rotor is carried on a shaft of Duplex material running in heavy duty self-aligning roller bearings with grease lubrication system. The turbine casing of our smaller units are manufactured of non-metallic FRP material. All mechanical forces acting on the turbine are contained within an epoxy coated steel frame. Turbines RO-350-80 and larger have Duplex steel casings. The turbines are of the horizontal split case design with external bearings. All components are easily accessible for inspection without disturbing piping or alignment. The adjustable nozzle assembly has a 3 Victaulic inlet connection. The nozzle can be mounted in any one of four 90 degree orientated positions to suite a wide variety of inlet pipe configurations. Substantial research and development has gone into the hydraulic design of our turbine rotors resulting in exceptionally high efficiencies over a wide operating range. In the case of our larger turbines efficiencies in excess of 90% are now possible.

Return on Investment
The moderate capital cost of the CALDER ERT and the high operational efficiency ensure an excellent return of investment compared to other recovery devices. Power consumption of a typical sea water high-pressure pump train fitted with a Calder ERT will be 2.6 to 2.8 kWh/m3 product. This combined with minimal maintenance results in very short payback periods.

Convenience of Installation
The turbine discharge is a standard ANSI or DIN flange for easy connection to the discharge pipe. The inlet flange is normally a Victaulic connection, but ANSI or DIN flanges are also available.

Working Reliability
The simplicity of the Calder Energy Recovery Turbine, with only one rotating element, results in inherent reliability under continuous operating conditions. Many years of operational experience has influenced our radical engineering and design, when combined with careful material selection, results in long term reliability and efficiency of the Calder ERTs.

The Calder ERT offers several opportunities and advantages to the end user.

Seawater RO plant in Trinidad with 5 trains and a production of 110,000 m3/d (29 MGD)

Seawater RO plant in Caribean Area with 2 trains and a production of 10,000 m3/d (2.6 MGD)

Design Features
Cross Section RO-290-65 / 310-65 / 350-65 RO-350-70 / 350-75 1. 2. 3. 4. 5. 6. 7. Totally Sealed, non-metallic Casing Horizontal Split Case Design External Taper Roller Bearing Integrated Double Labyrinth Seals Integrated Discharge Flange, ANSI and DIN Precision cast Duplex Stainless Steel Rotor New + High Efficiency + Calder Hydraulic Design Cross Section RO-350-80 / 350-100

1. 2. 3. 4. 5. 6. 7.

Horizontal Split Case Design Super Duplex Stainless Steel Casing External Taper Roller Bearing Integrated Double Labyrinth Seals Integrated Discharge Flange, ANSI and DIN Precision cast Duplex Stainless Steel Rotor New + High Efficiency + Calder Hydraulic Design

1 2 3

1 2 3

4 6,7 5

4 6,7 5

CALDER Turbine with GRP Casing Design

CALDER Turbine with Super Duplex Casing Design

Energy Consumption
Typical Plant Example
Train Capacity: Product Flow: Conversion: Membrane configuration: Req. Membrane pressure: 10,000 m3/ day (2.64 MGD) 417 m /h (1,836 USGPM)
3

Electric Motor
Speed: Power: Motor Efficiency: 2,985 rev/min (for 50 Hz application) 1,300 kW (1,730 HP) 96.5 %

50% Single Stage 68 bar (986 PSI)

Calculation of Energy Consumption

Required Pump Power = 834 m3/ h x (68-2) bar / 0.87/ 36 = 1,757.5 kW (2,356 HP) Turbine Recovered Energy = 417 m3/h x 67 bar x 0.90 / 36 = 698.5 kW (936 HP) Power absorbed by Motor = 1,757.5 kW - 695.5 kW = 1,059 kW (1,420 HP)

HP-Pump
Type: Flow: Suction Pressure: Discharge Pressure: Pump Efficiency: Centrifugal 834 m3/h (3,672 USGPM) 2 bar (29 PSI) 68 bar (986 PSI) 87%

Energy Recovery Turbine

Type: Flow: Brine Pressure: ERT Efficiency: RO-350-100-2 417 m3/h (1,836 USGPM) 67 bar (972 PSI) 90 %

Specific Energy Consumption = 1,059 kW / 0.965 / 417 m3 / h = 2.63 kWh / m3 Product

Product: 417 m3/h From ERT 852 kW

Brine: 509 m3 / h / 67 bar

From Motor 1,110 kW

=
HP-Pump 1,963 kW To Membrane: 926 m3 / h / 68 bar Feed: 926 m3/ h / 2 bar

ENERGY RECOVERY TURBINES

CALDER AG Industrie Nord I CH-5704 Egliswil Phone +041 62 769 60 60 I Fax +041 62 769 60 70 calder-ag@calder.ch I www.calder.ch CALDER LIMITED Gregorys Bank I Worcester WR3 8AB I England Phone +044 1905 723 255 I Fax +044 1905 723 904 pumps@calder.co.uk I www.calder.co.uk/pumps CALDER IBERIA Madrid I Spain Phone +034 91634 02 57 I Fax +034 91638 54 95 calder-ag@calder.ch