Already today wind power offers low and long-term stable costs of energy and therefore is able to compete with large scale conventional power generation. Using wind power directly for energy intensive industrial processes requires an optimized hybrid configuration as well as a balanced load and/or energy management. The technical and economical specifics for wind powered seawater desalination (RO) as a completely integrated solution are presented and emphasize its capability and potential to be implemented in medium and large scale within the next few years. The technology to desalinate seawater by wind power focuses on the continuous adaptation of the membrane process to the current wind power generation (load management) what results in variable operation parameters. The wind energy share directly usable for the process (wind penetration) in a wind-desalination subgrid constellation will be influenced by many aspects: • Installed capacities (desalination, wind turbine, potable water storage) • Integrated management systems (load, energy & storage) • Resource scenarios (wind) • Demand scenarios (water) Dependent on the installed wind power capacity three classes can be defined: • Desalination with wind power support (low penetration) • Wind powered desalination (medium/ high penetration) • Wind power project with coupled desalination (high penetration) The economic viability/application areas will be presented by the Levelized Water Cost (LWC) for typical plant configurations and relevant parameter variations. Since conventional grid power is intended to be replaced by wind power the grid tariff is the significant criteria for the economic viability/application areas of wind powered vs. conventional processing. High grid tariffs (together with low feed-in compensation) may economically rectify the installation of extended desalination capacities. Joachim Käufler (speaker), civil engineer with main focus on steel and plant constructions. He has substantial work experience of product development, planning/consulting, project development and turn-key implementations within the fields of steel and plant constructions of conventional power plants and renewable energy systems. Robert Pohl, mechanical engineer/mechatronics. He has research and development experience of product development of wind powered reverse osmosis and prepares a related PhD-thesis. Hadi Sader, mechanical engineer and MSc. in renewable energies. He has research and work experience of product and project development and training in renewable energies and wind power applications.

1. Wind Powered Industrial Processes
applications for
electrothermal processes and
seawater desalination
Webinar, Leonardo ENERGY
September 27, 2011
Dipl.-Ing. Joachim Käufler, 1
SYNLIFT Systems GmbH, Berlin

2. Content
 Company presentation
 Wind powered Industrial Processes (WIP) – Basics
 Application for electro thermal processing
 Application for seawater desalination
Dipl.-Ing. Joachim Käufler, 2
SYNLIFT Systems GmbH, Berlin

3. SYNLIFT Systems: Who We Are
 project developer for turnkey
wind power plants - worldwide
 full range of services -
from early stage investigation
to final operation management
 design and launch of innovative
wind power applications -
e.g. wind powered seawater
desalination
®
consulting services for other
wind power applications -
e.g. wind powered
electrothermal processing
© SYNLIFT Systems GmbH
Dipl.-Ing. Joachim Käufler, 3
SYNLIFT Systems GmbH, Berlin

4. Renewable Energy Integration
The measures can be classified as follows :
Generation transition to more flexible power generation
capacities;
Storage development of energy storage technologies at utility and
consumer level;
Distribution new and reinforced connections between
control zones;
new and reinforced transmission lines;
offshore grid installation;
energy exchange between control zones and subgrids;
Consumption demand side management and load management;
Dipl.-Ing. Joachim Käufler, 4
SYNLIFT Systems GmbH, Berlin

5. Load Management
For load balancing by load management two complementary approaches
exist:
Interregional approach:
 suitable trading and pricing or business models necessary;
 complex system with many power market players involved (loose connections);
 flexible, strong (and therefore costly) transmission system essential;
 smart grid philosophy;
Local approach:
 complementary optimised generation/consumer entities coupled within local sub-grids
on different levels;
 major energy amount transferred between generation/consumer entities directly;
 minor energy amount exchanged temporarily with the next grid level upwards in both
directions;
 typical sub-grid applications are:
a) large scale power plants to supply large-scale consumer directly
(e.g. commercial or industrial Combined Heat and Power plant);
b) PV-generators for private or communal self-consumption (micro- or mini-grids).
Dipl.-Ing. Joachim Käufler, 5
SYNLIFT Systems GmbH, Berlin

6. Local Approach
~ conventional power ~
grid
subgrid
energy costs = energy costs =
power generation power generation
+ grid use + grid use
+ fees & taxes (+ fees & taxes)
Potential for local value creation with low and longterm stable
costs...e.g. for energy intensive industrial processes...
Dipl.-Ing. Joachim Käufler, 6
SYNLIFT Systems GmbH, Berlin

7. Energy Intensive Industrial Processes
Type 1 Type 2
Energy Consumption / unit produced (EC): low high
Total amount of units produced / period (TA): high low
Type 1: membrane processes - e.g. seawater desalination (RO)
EC = 3,5 - 5,5 kWh / t
TA = 500 - 300.000 t / d
energy share of product costs: 30 - 60%
Type 2: electrothermal processes - e.g. aluminium melting
EC = 410 - 690 kWh / t
TA = 1 - 100 t / d
energy share of product costs: 5 - 20% [0]
Processes with a high level of energy demand and/or energy share of product
costs ideal to be developed as… Wind Powered Industrial Process (WIP)…
Dipl.-Ing. Joachim Käufler, 7
SYNLIFT Systems GmbH, Berlin

8. WIP Basics (I): Why Wind Power?
Power Generation Price Increase Volatility
Costs in EURcent/kWh in % p.a.
Fossil fueled PG (> 5 MW) 3-10 3-5 medium to strong
Wind PG (> 1 MW) 3-10 <1 low
PV PG (10 … > 1,000 kW) 12-32 <1 low
Solar thermal PG (> 50 MW) 19-24 <1 low
Economic prognosis for a power plant installed in 2010 (Fraunhofer ISE partly)
Wind power at many (coastal) sites is competitive with large-scale fossil
fueled power generation ... already today … tendency increasing.
Wind power is mainly independent of price trends and volatility.
Dipl.-Ing. Joachim Käufler, 8
SYNLIFT Systems GmbH, Berlin

9. WIP Basics (II): Relevance of tariffs
The optimal system layout is mainly affected by the level of tariffs:
grid tariff
low: conventional process
medium: wind powered process – without LM
high: wind powered process – with LM
feed in tariff
low: process with wind power supply
medium: wind powered process
high: wind project with coupled process
Dipl.-Ing. Joachim Käufler, 9
SYNLIFT Systems GmbH, Berlin

10. WIP Basics (III): Wind Power Capacity
power
1
power
Process with wind power time
(feed-in tariff level: low) 2
time
power
Wind Powered Process 3
1 2 3 (feed-in tariff level: medium)
surplus energy – wind
process energy – wind
process energy - grid
time
Wind Power with process
(feed-in tariff level: high)
Dipl.-Ing. Joachim Käufler, 10
SYNLIFT Systems GmbH, Berlin

11. WIP Basics (IV): Wind Penetration
wind energy used directly for the process
Wind Penetration (WP) = _________________________________
overall energy demand of the process
Most influential WP parameters are:
 Wind power capacity (related to process capacity);
 Storage capacity (on energy and/or product side);
 Process load management and/or capacity;
Dipl.-Ing. Joachim Käufler, 11
SYNLIFT Systems GmbH, Berlin

12. WIP Basics (V): Wind Power Capacity
power
1
power
Process with wind power time
(feed-in tariff level: low) 2
time
power
Wind Powered Process 3
1 2 3 (feed-in tariff level: medium)
surplus energy – wind
process energy – wind
process energy - grid
time
Wind Power with process
(feed-in tariff level: high)
Dipl.-Ing. Joachim Käufler, 12
SYNLIFT Systems GmbH, Berlin

13. WIP Basics (VI): Storage Capacity & Technology
Project integrated storage facilities increase the wind energy share directly used for the
process (wind penetration) and decrease the energy exchange with the main grid
respectively.
3 options of large-scale/multi-hour storage integration:
Option 1: energy storage (nominal process capacity)
battery
Option 2.1: product storage (additional process capacity)
tank
Option 2.2: product storage (flexible process capacity)
tank
Dipl.-Ing. Joachim Käufler, 13
SYNLIFT Systems GmbH, Berlin

14. WIP Basics (VII): Process Load Management
Dipl.-Ing. Joachim Käufler, 14
SYNLIFT Systems GmbH, Berlin

15. Wind powered electrothermal process (I)
Dipl.-Ing. Joachim Käufler, 15
SYNLIFT Systems GmbH, Berlin

16. Wind powered electrothermal process (II)
Principle of load management in casting house industry
Type A: Variable melting & heat holding
- buffering on energy side –
+ no new media & technology
+ casting process unmodified
+ known procedure (peak loads)
- heat holding/storage ability vs.
temperature / insulating
Type B: Variable melting & casting
- buffering on product side -
+ no new media & technology
- casting process variable!
Prior solution: Type A
Dipl.-Ing. Joachim Käufler, 16
SYNLIFT Systems GmbH, Berlin

17. Principles of Desalination
Distillation Membrane Process
Membrane
Vapour
Cooling
Seawater Condensate Seawater Permeate
Heat
Dipl.-Ing. Joachim Käufler, 17
SYNLIFT Systems GmbH, Berlin

18. Desalination Technologies
Seawater Desalination Processes
Phase-change Single-phase
Thermal Processes Membrane Processes
Multistage Flash Evaporation Reverse Osmosis
(MSF) (RO)
Multi Effect Distillation
(MED)
Vapor Compression (VC)
Mechanical (MVC) &
Thermal (TVC)
Dipl.-Ing. Joachim Käufler, 18
SYNLIFT Systems GmbH, Berlin

19. Thermal vs. Membrane Process
Thermal Process (MSF) Membrane Process (RO)
approx. 13 kWhel/m³
Energy Consumption 3.5 – 5.5 kWhel/m³
(70 kWhth + 3 to 4 kWhel)
Recovery 10% to 20% (brine recycling) 30 - 50 %
700 - 1,500
Investment [$/(m³/day)] 1,000 - 1,500
(10 % thereof for membranes)
approx. 0.06 to 0.1
Chemicals [$/m³] approx. 0.03 to 0.05
(downwards, UF pretreatment)
every 5 years
Membrane Replacement n.a.
(2% of investment / year)
Brine, Quantity Distillate x 4 to 9 Permeate X 1 to 4
Brine, Quality Chemicals, Heat Chemicals
Washing of Filters (fortnightly)
O&M Scaling disposal
and Membranes (bimonthly)
Less High, Fouling Sensitivity,
Robustness High
Feed water Monitoring !!!
Improvement Potential Low Medium
Dipl.-Ing. Joachim Käufler, 19
SYNLIFT Systems GmbH, Berlin

20. Economics of Desalination
Constraints: Plant Capacity 30,000 m³/day
Interest Rate 7%
Project Life 20 years
Price Electricity 0.065 US$/kWh
MSF MED VC RO
(therm.) (therm.) (therm.) (membr.)
Specific
Investment Cost 1,200 – 1,500 900 – 1,000 950 – 1,000 700 - 900
[$/m³/day]
Total Cost Product
[$/m³] 1.10 – 1.25 0.75 – 0.85 0.87 – 0.95 0.68 – 0.82
Source: Seawater and Brackish Water Desalination in the Middle East, North Africa and Central Asia, World Bank 2004
Dipl.-Ing. Joachim Käufler, 20
SYNLIFT Systems GmbH, Berlin

21. Installed Desalination Technologies
Distribution of installed plant capacity according to
desalination process
16,3
36,5
47,2
MSF RO MED, VC and Others
1) Fig.: Source: 2004 IDA Worldwide Desalting Plants Inventory Report No 18; published by Wangnick Consulting
Dipl.-Ing. Joachim Käufler, 21
SYNLIFT Systems GmbH, Berlin

22. RO (I): Main Components
.
High-pressure pump Reverse osmosis Permeate flow
membrane module
Feed flow
q Flow
p Pressure
Retentate flow
F Feed
P Permeate
R Retentate
0 Ambient
Energy recovery device
Dipl.-Ing. Joachim Käufler, 22
SYNLIFT Systems GmbH, Berlin

23. RO (II): Variable Operation
Preconditions for variable / wind powered operation
• broad load range to avoid excessive modularity and frequent activation/deactivation
sequences;
• low and uniform energy consumption per unit of product within the total load range;
• high process dynamic to adjust the process to the fluctuating wind power quickly;
Challenges
• common operation is uninterrupted at nominal capacity with constant parameters;
• no long-term experiences of membrane behaviour under strong variable operation;
Tests
• long-term tests with variable and constant operated membranes;
• real time computer simulations based on real wind speed series;
Results
• deterioration of the variable operated membrane could not be observed.
Dipl.-Ing. Joachim Käufler, 23
SYNLIFT Systems GmbH, Berlin

24. RO (III): Variabel Operation (Tests)
SWRO-Membranes SW30-2540 at variable and constant feed pressure. Feed concentration of 36,4 g/l total salinity at 25°C.
Dipl.-Ing. Joachim Käufler, 24
SYNLIFT Systems GmbH, Berlin

25. SYNWATER® The System (I)
SYNWATER® components: high process flexibility for low and strong wind
periods;
SYNWATER® LM: load management system with:
basic functionality: wind-dependent processing
extended functionality: flexible tariff and demand scenarios for energy
and water considerable (smart grid)
SYNWATER® a modular system: wind turbine and plant capacities individually
adaptable to project specifics;
Dipl.-Ing. Joachim Käufler, 25
SYNLIFT Systems GmbH, Berlin

26. SYNWATER® The System (II)
1 Kernel modules (container option)
2 UF membranes
4 5
3 RO membranes
4 5
4 Control room
5 Consumables, spare parts
8
8 8
6 Media trench 1
1
7 Feed water intake / beach well 1
Pre-processing facilities
8 Potable water storage tanks/
Post-processing facilities
9 Wind turbine
10 Roof structure (textile option)
6
2
9
3 10
7
Dipl.-Ing. Joachim Käufler, 26
SYNLIFT Systems GmbH, Berlin

27. Economic Aspects: Basic Assumptions (I)
seawater desalination as WIP… what is meant:
 desalination capacity of at least 500 m3 per day (no upper limit)
 grid-connected systems (on-grid)
 fully automated
 only commercially available standard components used
seawater desalination as WIP … what is not meant:
 small scale applications
 off-grid systems
 special solutions (e.g. mechanical coupling wind / RO)
Dipl.-Ing. Joachim Käufler, 27
SYNLIFT Systems GmbH, Berlin

28. Economic Aspects: Basic Assumptions (II)
Project Wind Turbine SWRO
(WT)
project time [years] investment [€/kW inst. cap.] investment [€/m3 daily cap.]
20 1.250 - 1.450 800 - 1.100
interest rate [%] O&M cost [€/kWh] O&M cost [€/m³]
5-8 0,010 - 0,014 0,25 – 0,35
annuity factor [-] feed-in tariff [€/kWh] energy consumption [kWh/m³]
0,0802 - 0,1019 0,04 - 0,07 3,5 – 5,5
capacity factor [%]
25 - 35
Considering the local wind conditions (capacity factor) and the energy
consumption the WT capacity is designed to meet the annual energy
demand of the plant (category: Wind Powered Process).
CDM effects are not considered.
Dipl.-Ing. Joachim Käufler, 28
SYNLIFT Systems GmbH, Berlin

29. Economic Aspects: Fields of Application
Extended SYNWATER® capacities
Standard SYNWATER® capacities
Conventional desalination
Dipl.-Ing. Joachim Käufler, 29
SYNLIFT Systems GmbH, Berlin

30. SYNWATER® Our Services
For SYNWATER® projects we are offering the
following services...separately or as full-
service package:
• Fact Finding Mission
• Feasibility Study / Proposal
• Investment Consulting / Financing
• Technical Design
• Turn-key Implementation
• Operation & Maintenance
• Training
Beside Delivery Transactions also BOT/BOO
business models are negotiable.
profitable & sustainable
already today!
© SYNLIFT Systems GmbH
Dipl.-Ing. Joachim Käufler, 30
SYNLIFT Systems GmbH, Berlin

31. Wind Powered
Industrial Processes
profitable & sustainable
already today!
Thank you for your attention
www.synliftsystems.de
info@synliftsystems.de
Dipl.-Ing. Joachim Käufler, 31
SYNLIFT Systems GmbH, Berlin