Product Overview

Designed for high-salinity industrial process water and targeted wastewater reuse, this high-recovery skid-mounted Reverse Osmosis (RO) system achieves overall permeate recovery rates between 80% and 95% while operating at pressures up to 80 bar (1,160 psi). By combining high-rejection polyamide thin-film composite (TFC) spiral-wound membranes with multi-stage interstage pressure boosting, the system counters rising concentrate osmotic pressure, significantly minimizing waste concentrate volume while delivering continuous permeate with conductivity below 10 µS/cm.

Key Specifications

Parameter	Technical Specification / Value
Permeate Capacity	5 m³/h – 150 m³/h (22 – 660 GPM) per skid
Recovery Rate	80% – 95% (feed profile dependent)
Operating Pressure	15 bar – 80 bar (217 psi – 1,160 psi)
Feed Water TDS Limit	1,000 mg/L – 25,000 mg/L
Salt Rejection	≥ 99.5% nominal (99.2% minimum)
Power Consumption	1.8 – 3.2 kWh/m³ permeate produced
Operating Temperature	5°C – 45°C
Footprint (Base Unit)	3.5 m x 1.5 m x 2.2 m (5 m³/h unit base size)

Performance Features

Interstage Pressure Boosting: Intermediate booster pumps re-pressurize concentrate between stages, overcoming osmotic pressure to maintain uniform cross-flow velocity and prevent rapid tail-element scaling.

Automated Clean-In-Place (CIP): Programmable PLC initiates automated low-pressure permeate flushes during shutdowns and triggers localized chemical cleaning based on differential pressure telemetry.

Inline Telemetry & Monitoring: Sensors continuously record feed/permeate conductivity, pH, ORP, temperature, line pressures, and stage flow rates.

Hydraulic Energy Recovery: Optional energy recovery devices harvest residual hydraulic pressure from concentrated brine streams, lowering motor power draw by up to 35%.

Typical Applications

Boiler Feedwater Pretreatment: Desalinates high-TDS intake water to reduce chemical consumption and regeneration frequency in downstream demineralizer beds.

Cooling Tower Blowdown Recovery: Reclaims cooling tower blowdown for recirculation, lowering raw water intake volumes and municipal sewer discharge fees.

Industrial Wastewater Reuse: Treats industrial process effluent from chemical, textile, and metal finishing operations for non-potable plant utilities.

Zero Liquid Discharge (ZLD) Pre-Concentration: Pre-concentrates thermal evaporator feed streams, reducing crystallizer footprint, energy consumption, and capital expenditure.

Major Mechanical Components

High-Pressure Pumps: Duplex SS316L or Super Duplex SS2205 multi-stage centrifugal pumps with variable frequency drives (VFD).

Membrane Elements: High-rejection, anti-fouling 8040 spiral-wound polyamide composite membranes.

Pressure Vessels: Multi-port side-entry FRP pressure housings rated from 300 psi to 1,200 psi.

Control Enclosure: NEMA 4X / IP65 electrical enclosure featuring PLC hardware, touchscreen HMI, and industrial Ethernet communication modules.

Piping & Frame Architecture: High-pressure piping in SS316L or Super Duplex steel; low-pressure lines in Schedule 80 PVC or CPVC, mounted on epoxy-coated steel skids.

Feed Water Quality Limits

Parameter	Maximum Permissible Limit
Silt Density Index (SDI15)	< 3.0
Turbidity	< 1.0 NTU
Free Chlorine / Oxidants	< 0.1 mg/L
Total Iron & Manganese	< 0.05 mg/L
Oil & Grease	< 0.1 mg/L
Chemical Oxygen Demand (COD)	< 50 mg/L

Configuration & Sizing Matrix

Permeate Output	Feed TDS Profile	Array Staging	Expected Recovery	System Model
5 – 15 m³/h	< 3,000 mg/L	2-Stage (2:1 Ratio)	80% – 85%	HR-RO-10K
20 – 50 m³/h	3,000 – 10,000 mg/L	3-Stage with Interstage Boost	85% – 90%	HR-RO-50K
60 – 150 m³/h	10,000 – 25,000 mg/L	3-Stage High-Pressure Array	90% – 95%	HR-RO-150K

Customization Options

Structural Materials: Epoxy-coated carbon steel, SS304, or SS316L structural frames engineered for local wind and seismic load requirements.

Process Metallurgy: High-pressure manifolding configurable in SS316L, Super Duplex SS2205, or Titanium Grade 2 for corrosive feed streams.

Automation Platform: Allen-Bradley ControlLogix, Siemens S7-1500, or Schneider Electric PLCs integrated with Ethernet/IP, Modbus TCP, or Profinet protocols.

Chemical Dosing Modules: Integrated dosing assemblies for antiscalant, sodium bisulfite, acid, and caustic feed with dual diaphragm pumps and calibration cylinders.

Containerized Systems: Insulated 20-foot or 40-foot high-cube shipping containers fitted with HVAC climate control, interior lighting, and secondary containment floors.

Manufacturing & Quality Assurance

Precision Welding: Orbital TIG welding on stainless steel pipe runs using inert Argon gas backing purge, supported by dye penetrant and radiographic non-destructive testing (NDT).

Hydrostatic Pressure Testing: High-pressure manifolds undergo hydrostatic pressure testing at 1.5 times maximum design pressure for a minimum 4-hour hold duration.

Factory Acceptance Testing (FAT): Fully assembled skids undergo hydraulic and electrical wet-testing prior to dispatch to verify flow rates, salt rejection, VFD response, and safety interlocks.

Quality Standards: Fabricated in compliance with ISO 9001 quality frameworks, ASME Section VIII pressure vessel codes, and CE machinery Directives.

Packaging & Export Logistics

Export Crating: IPPC ISPM-15 heat-treated timber crates reinforced with internal steel structural framing and anti-vibration rubber isolation pads.

Corrosion Protection: Equipment sealed in heavy-duty vapor corrosion inhibitor (VCI) vacuum shrink wrap with desiccants placed inside all electrical junction boxes.

Transport Dimensions: Skid dimensions suit standard 20ft/40ft open-top or high-cube ocean containers, complete with designated pre-slung lifting lugs for crane handling.

Frequently Asked Questions

Q: What determines the maximum recovery rate for my feed water profile?

A: The achievable recovery rate is primarily governed by scaling species such as silica, calcium sulfate, and barium sulfate. Proper pretreatment and precise chemical antiscalant dosing allow recovery rates up to 90%–95% without precipitation.

Q: How does interstage boosting prevent membrane scaling?

A: By increasing pressure between membrane stages, flux distribution remains uniform across all pressure vessels. This avoids low-flow dead zones in final elements, keeping cross-flow velocity high and minimizing foulant deposition.

Q: What documentation is supplied with the equipment for regulatory compliance?

A: Each system ships with material test reports (MTRs) for pressure-retaining components, hydrostatic test certificates, weld inspection logs, sensor calibration sheets, and official compliance certificates.

Q: What is the lead time for custom-engineered RO units?

A: Standard units ship within 6 to 8 weeks following drawing approval. Customized units involving specialized metallurgy, specific PLC platforms, or containerized housings require 10 to 14 weeks for fabrication and factory testing.

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High-Recovery Industrial RO System