Adaptive Expert Generalized Predictive Multivariable Control of Seawater RO Desalination Plant for a Mineral Processing Facility

Our aim was to analyze, monitor, and predict the outcomes of processes in a full-scale seawater reverse osmosis (SWRO) desalination plant using multivariate statistical techniques. Multivariate analysis of variance (MANOVA) was used to investigate the performance and efficiencies of two SWRO processes, namely, pore controllable fiber filter-reverse osmosis (PCF-SWRO) and sand filtration-ultra filtration-reverse osmosis (SF-UF-SWRO). Principal component analysis (PCA) was applied to monitor the two SWRO processes. PCA monitoring revealed that the SF-UF-SWRO process could be analyzed reliably with a low number of outliers and disturbances. Partial least squares (PLS) analysis was then conducted to predict which of the seven input parameters of feed flow rate, PCF/SF-UF filtrate flow rate, temperature of feed water, turbidity feed, pH, reverse osmosis (RO)flow rate, and pressure had a significant effect on the outcome variables of permeate flow rate and concentration. Root mean squared errors (RMSEs) of the PLS models for permeate flow rates were 31.5 and 28.6 for the PCF-SWRO process and SF-UF-SWRO process, respectively, while RMSEs of permeate concentrations were 350.44 and 289.4, respectively. These results indicate that the SF-UF-SWRO process can be modeled more accurately than the PCF-SWRO process, because the RMSE values of permeate flowrate and concentration obtained using a PLS regression model of the SF-UF-SWRO process were lower than those obtained for the PCF-SWRO process.

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