Adding spiral-wound vs flat-sheet config options to RO and OARO (wate…

…rtap-org#1272) * Half width for membrane fold * changed width halving implementation * added config options for flat_plate vs spiral_wound modules * added ModuleType congif to RO and OARO tests * ran black * adding config error test: not working yet * ran black * updated error logic and test values * Option B: Removed FrictionFactor config option * ran pylint * updated OARO * Corrected Flux Eqn for RO1D * fixed flux and mass transfer eqn units * adjusted RO1D test * ran black * Added a line to the cod to differentiate the two area calcs * ran black * updated RO0D and RO1D tests * updated and ran black * updated module_type config option descriptions * fixed diff area on OARO1D * added 1D sprial wound P_loss test * ran black * renamed test * added spiral-wound support to docs * added to OARO docs * debugging * debug * dirty fix * revert fix * test * fixed for flux eqn * added friction_factor by module_type * ran black * removed custom friction factor * removed friction_factor custom option * Update watertap/core/membrane_channel_base.py Co-authored-by: Adam Atia <[email protected]> * returned FrictionFactor to init * updated FrictionFactor class description * removed custom option * fixing eq_area check * fixing OARO merge conflicts * ran black --------- Co-authored-by: Adam Atia <[email protected]>
agarciadiego · Apr 26, 2024 · b30c16a · b30c16a
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diff --git a/docs/technical_reference/unit_models/osmotically_assisted_reverse_osmosis_0D.rst b/docs/technical_reference/unit_models/osmotically_assisted_reverse_osmosis_0D.rst
@@ -4,6 +4,7 @@ This osmotically assisted reverse osmosis (OARO) unit model
    * is 0-dimensional
    * supports a single liquid phase only
    * supports steady-state only
+   * supports flat-sheet and spiral-wound module designs
    * is based on the solution-diffusion model and film theory
    * assumes isothermal conditions
    * assumes the feed-side flows in the forward direction
@@ -177,7 +178,8 @@ Equations
    "Reynolds number",":math:`Re = \frac{\rho v_f d_h}{\mu}`"
    "Hydraulic diameter",":math:`d_h = \frac{4\epsilon_{sp}}{2/h_{ch} + (1-\epsilon_{sp})8/h_{ch}}`"
    "Cross-sectional area",":math:`A_c = h_{ch}W\epsilon_{sp}`"
-   "Membrane area",":math:`A_m = LW`"
+   "Membrane area (flat-plate)",":math:`A_m = LW`"
+   "Membrane area (spiral-wound)",":math:`A_m = 2LW`"
    "Pressure drop",":math:`ΔP = (\frac{ΔP}{Δx})_{avg}L`"
    "Feed-channel velocity",":math:`v_f = Q_f/A_c`"
    "Friction factor",":math:`f = 0.42+\frac{189.3}{Re}`"

diff --git a/docs/technical_reference/unit_models/osmotically_assisted_reverse_osmosis_1D.rst b/docs/technical_reference/unit_models/osmotically_assisted_reverse_osmosis_1D.rst
@@ -4,6 +4,7 @@ This osmotically assisted reverse osmosis (OARO) unit model
    * is 1-dimensional
    * supports a single liquid phase only
    * supports steady-state only
+   * supports flat-sheet and spiral-wound module designs
    * is based on the solution-diffusion model and film theory
    * assumes isothermal conditions
    * assumes the feed-side flows in the forward direction

diff --git a/docs/technical_reference/unit_models/reverse_osmosis_0D.rst b/docs/technical_reference/unit_models/reverse_osmosis_0D.rst
@@ -4,6 +4,7 @@ This reverse osmosis (RO) unit model
    * is 0-dimensional
    * supports a single liquid phase only
    * supports steady-state only
+   * supports flat-sheet and spiral-wound module designs
    * is based on the solution-diffusion model and film theory
    * assumes isothermal conditions
 
@@ -159,7 +160,8 @@ Equations
    "Reynolds number",":math:`Re = \frac{\rho v_f d_h}{\mu}`"
    "Hydraulic diameter",":math:`d_h = \frac{4\epsilon_{sp}}{2/h_{ch} + (1-\epsilon_{sp})8/h_{ch}}`"
    "Cross-sectional area",":math:`A_c = h_{ch}W\epsilon_{sp}`"
-   "Membrane area",":math:`A_m = LW`"
+   "Membrane area (flat-plate)",":math:`A_m = LW`"
+   "Membrane area (spiral-wound)",":math:`A_m = 2LW`"
    "Pressure drop",":math:`ΔP = (\frac{ΔP}{Δx})_{avg}L`"
    "Feed-channel velocity",":math:`v_f = Q_f/A_c`"
    "Friction factor",":math:`f = 0.42+\frac{189.3}{Re}`"

diff --git a/docs/technical_reference/unit_models/reverse_osmosis_1D.rst b/docs/technical_reference/unit_models/reverse_osmosis_1D.rst
@@ -4,6 +4,7 @@ This reverse osmosis (RO) unit model
    * is 1-dimensional
    * supports a single liquid phase only
    * supports steady-state only
+   * supports flat-sheet and spiral-wound module designs
    * is based on the solution-diffusion model and film theory
    * assumes isothermal conditions
 

diff --git a/watertap/core/membrane_channel_base.py b/watertap/core/membrane_channel_base.py
@@ -71,6 +71,16 @@ class TransportModel(Enum):
     SKK = auto()
 
 
+class ModuleType(Enum):
+    """
+    flat_sheet: flat-sheet module configuration
+    spiral_wound: spiral-wound module configuration
+    """
+
+    flat_sheet = auto()
+    spiral_wound = auto()
+
+
 class PressureChangeType(Enum):
     """
     fixed_per_stage: pressure drop across membrane channel is a user-specified value
@@ -85,12 +95,11 @@ class PressureChangeType(Enum):
 
 class FrictionFactor(Enum):
     """
-    flat_sheet: Darcy's friction factor correlation by Guillen & Hoek
-    spiral_wound: Darcy's friction factor correlation by Schock & Miquel, 1987
+    default_by_module_type: Will revert FrictionFactor to either the Darcy's friction factor correlation
+    by Guillen & Hoek (flat-plate) or by Schock & Miquel (spiral-wound)
     """
 
-    flat_sheet = auto()
-    spiral_wound = auto()
+    default_by_module_type = auto()
 
 
 CONFIG_Template = ConfigDict()
@@ -261,6 +270,24 @@ class FrictionFactor(Enum):
     ),
 )
 
+CONFIG_Template.declare(
+    "module_type",
+    ConfigValue(
+        default=ModuleType.flat_sheet,
+        domain=In(ModuleType),
+        description="Membrane geometry for flat-sheet or spiral-wound",
+        doc="""
+        Options to account for geometry differences between flat sheet and spiral wound membranes.
+
+        **default** - ``ModuleType.flat_sheet``
+
+        "``ModuleType.flat_sheet``", "Module type option for flat-sheet membrane modules"
+        "``ModuleType.spiral_wound``", "Module type option for spiral-wound membrane modules, this option accounts for how membranes in spiral-wound modules are folded which reduces the channel width by half"
+
+        """,
+    ),
+)
+
 CONFIG_Template.declare(
     "has_pressure_change",
     ConfigValue(
@@ -303,19 +330,18 @@ class FrictionFactor(Enum):
 CONFIG_Template.declare(
     "friction_factor",
     ConfigValue(
-        default=FrictionFactor.flat_sheet,
+        default=FrictionFactor.default_by_module_type,
         domain=In(FrictionFactor),
         description="Darcy friction factor correlation",
         doc="""
         Options to account for friction factor correlations.
 
-        **default** - ``FrictionFactor.flat_sheet`` 
+        **default** - ``FrictionFactor.default_by_module_type`` 
 
     .. csv-table::
         :header: "Configuration Options", "Description"
 
-        "``FrictionFactor.flat_sheet``", "Friction factor correlation for flat-sheet membrane modules"
-        "``FrictionFactor.spiral_wound``", "Friction factor correlation for spiral-wound membranes"
+        "``FrictionFactor.default_by_module_type``", "Friction factor correlation that is specific to the supported membrane modules type"
     """,
     ),
 )
@@ -358,7 +384,8 @@ def add_total_pressure_balances(
         has_pressure_change=True,
         pressure_change_type=PressureChangeType.calculated,
         custom_term=None,
-        friction_factor=FrictionFactor.flat_sheet,
+        module_type=ModuleType.flat_sheet,
+        friction_factor=FrictionFactor.default_by_module_type,
     ):
         super().add_total_pressure_balances(
             has_pressure_change=has_pressure_change, custom_term=custom_term
@@ -378,7 +405,9 @@ def eq_equal_pressure_interface(b, t, x):
             self._add_pressure_change(pressure_change_type=pressure_change_type)
 
         if pressure_change_type == PressureChangeType.calculated:
-            self._add_calculated_pressure_change(friction_factor=friction_factor)
+            self._add_calculated_pressure_change(
+                module_type=module_type, friction_factor=friction_factor
+            )
 
     def add_interface_isothermal_conditions(self):
 
@@ -710,7 +739,9 @@ def _add_interface_stateblock(self, has_phase_equilibrium=None):
         )
 
     def _add_calculated_pressure_change(
-        self, friction_factor=FrictionFactor.flat_sheet
+        self,
+        module_type=ModuleType.flat_sheet,
+        friction_factor=FrictionFactor.default_by_module_type,
     ):
         self._add_calculated_pressure_change_mass_transfer_components()
 
@@ -749,32 +780,35 @@ def eq_velocity(b, t, x):
             return b.velocity[t, x] * b.area == b.properties[t, x].flow_vol_phase["Liq"]
 
         ## ==========================================================================
-        # Darcy friction factor based on eq. S27 in SI for Cost Optimization of Osmotically Assisted Reverse Osmosis
-        if friction_factor == FrictionFactor.flat_sheet:
-
-            @self.Constraint(
-                self.flowsheet().config.time,
-                self.length_domain,
-                doc="Darcy friction factor constraint for flat sheet membranes",
-            )
-            def eq_friction_factor(b, t, x):
-                return (b.friction_factor_darcy[t, x] - 0.42) * b.N_Re[t, x] == 189.3
-
-        # Darcy friction factor based on eq. 24 in Mass transfer and pressure loss in spiral wound modules (Schock & Miquel, 1987)
-        elif friction_factor == FrictionFactor.spiral_wound:
-
-            @self.Constraint(
-                self.flowsheet().config.time,
-                self.length_domain,
-                doc="Darcy friction factor constraint for spiral-wound membranes",
-            )
-            def eq_friction_factor(b, t, x):
-                return b.friction_factor_darcy[t, x] == 6.23 * b.N_Re[t, x] ** -0.3
+        if friction_factor == FrictionFactor.default_by_module_type:
+            # Darcy friction factor based on eq. S27 in SI for Cost Optimization of Osmotically Assisted Reverse Osmosis
+            if module_type == ModuleType.flat_sheet:
+
+                @self.Constraint(
+                    self.flowsheet().config.time,
+                    self.length_domain,
+                    doc="Darcy friction factor constraint for flat sheet membranes",
+                )
+                def eq_friction_factor(b, t, x):
+                    return (b.friction_factor_darcy[t, x] - 0.42) * b.N_Re[
+                        t, x
+                    ] == 189.3
+
+            # Darcy friction factor based on eq. 24 in Mass transfer and pressure loss in spiral wound modules (Schock & Miquel, 1987)
+            elif module_type == ModuleType.spiral_wound:
+
+                @self.Constraint(
+                    self.flowsheet().config.time,
+                    self.length_domain,
+                    doc="Darcy friction factor constraint for spiral-wound membranes",
+                )
+                def eq_friction_factor(b, t, x):
+                    return b.friction_factor_darcy[t, x] == 6.23 * b.N_Re[t, x] ** -0.3
 
+            else:
+                raise ConfigurationError(f"Unrecognized module_type type {module_type}")
         else:
-            raise ConfigurationError(
-                f"Unrecognized friction_factor type {friction_factor}"
-            )
+            pass
 
         ## ==========================================================================
         # Pressure change per unit length due to friction
@@ -1021,11 +1055,3 @@ def validate_membrane_config_args(unit):
                 unit.config.concentration_polarization_type,
             )
         )
-
-    if (
-        unit.config.pressure_change_type != PressureChangeType.calculated
-        and unit.config.friction_factor != unit.config.get("friction_factor")._default
-    ):
-        raise ConfigurationError(
-            "\nChanging the 'friction_factor' will have no effect if the 'pressure_change_type' is not `PressureChangeType.calculated`"
-        )
diff --git a/watertap/unit_models/osmotically_assisted_reverse_osmosis_1D.py b/watertap/unit_models/osmotically_assisted_reverse_osmosis_1D.py
@@ -208,8 +208,8 @@ def eq_connect_mass_transfer(b, t, x, p, j):
         )
         def eq_permeate_production(b, t, x, p, j):
             return (
-                -b.feed_side.mass_transfer_term[t, x, p, j]
-                == b.width * b.flux_mass_phase_comp[t, x, p, j]
+                -b.feed_side.mass_transfer_term[t, x, p, j] * b.length
+                == b.flux_mass_phase_comp[t, x, p, j] * b.area
             )
 
     def calculate_scaling_factors(self):

diff --git a/watertap/unit_models/osmotically_assisted_reverse_osmosis_base.py b/watertap/unit_models/osmotically_assisted_reverse_osmosis_base.py
@@ -36,6 +36,7 @@
     validate_membrane_config_args,
     ConcentrationPolarizationType,
     TransportModel,
+    ModuleType,
 )
 
 from watertap.core import InitializationMixin
@@ -116,6 +117,7 @@ def build(self):
             balance_type=self.config.momentum_balance_type,
             pressure_change_type=self.config.pressure_change_type,
             has_pressure_change=self.config.has_pressure_change,
+            module_type=self.config.module_type,
             friction_factor=self.config.friction_factor,
         )
 
@@ -153,6 +155,7 @@ def build(self):
             balance_type=self.config.momentum_balance_type,
             pressure_change_type=self.config.pressure_change_type,
             has_pressure_change=self.config.has_pressure_change,
+            module_type=self.config.module_type,
             friction_factor=self.config.friction_factor,
         )
 
@@ -341,15 +344,24 @@ def _add_area(self, include_constraint=True):
 
         if include_constraint:
             if not hasattr(self, "eq_area"):
-                # Membrane area equation
-                @self.Constraint(doc="Total Membrane area")
-                def eq_area(b):
-                    return b.area == b.length * b.width
-
-            else:
-                raise ValueError(
-                    "include_constraint was set to True inside of _add_area(), but area constraint already exists."
-                )
+                if self.config.module_type == ModuleType.flat_sheet:
+                    # Membrane area equation for flat plate membranes
+                    @self.Constraint(doc="Total Membrane area")
+                    def eq_area(b):
+                        return b.area == b.length * b.width
+
+                elif self.config.module_type == ModuleType.spiral_wound:
+                    # Membrane area equation
+                    @self.Constraint(doc="Total Membrane area")
+                    def eq_area(b):
+                        return b.area == b.length * 2 * b.width
+
+                else:
+                    raise ConfigurationError(
+                        "Unsupported membrane module type: {}".format(
+                            self.config.module_type
+                        )
+                    )
 
     def _add_flux_balance(self):
 

diff --git a/watertap/unit_models/reverse_osmosis_1D.py b/watertap/unit_models/reverse_osmosis_1D.py
@@ -188,8 +188,8 @@ def eq_connect_mass_transfer(b, t, x, p, j):
         )
         def eq_mass_flux_equal_mass_transfer(b, t, x, p, j):
             return (
-                b.flux_mass_phase_comp[t, x, p, j] * b.width
-                == -b.feed_side.mass_transfer_term[t, x, p, j]
+                b.flux_mass_phase_comp[t, x, p, j] * b.area
+                == -b.feed_side.mass_transfer_term[t, x, p, j] * b.length
             )
 
         # ==========================================================================

diff --git a/watertap/unit_models/reverse_osmosis_base.py b/watertap/unit_models/reverse_osmosis_base.py
@@ -36,6 +36,7 @@
     validate_membrane_config_args,
     ConcentrationPolarizationType,
     TransportModel,
+    ModuleType,
 )
 from watertap.costing.unit_models.reverse_osmosis import cost_reverse_osmosis
 
@@ -100,7 +101,6 @@ def build(self):
             balance_type=self.config.momentum_balance_type,
             pressure_change_type=self.config.pressure_change_type,
             has_pressure_change=self.config.has_pressure_change,
-            friction_factor=self.config.friction_factor,
         )
 
         self.feed_side.add_control_volume_isothermal_conditions()
@@ -287,10 +287,24 @@ def _add_area(self, include_constraint=True):
         )
 
         if include_constraint:
-            # Membrane area equation
-            @self.Constraint(doc="Total Membrane area")
-            def eq_area(b):
-                return b.area == b.length * b.width
+            if self.config.module_type == ModuleType.flat_sheet:
+                # Membrane area equation for flat plate membranes
+                @self.Constraint(doc="Total Membrane area")
+                def eq_area(b):
+                    return b.area == b.length * b.width
+
+            elif self.config.module_type == ModuleType.spiral_wound:
+                # Membrane area equation
+                @self.Constraint(doc="Total Membrane area")
+                def eq_area(b):
+                    return b.area == b.length * 2 * b.width
+
+            else:
+                raise ConfigurationError(
+                    "Unsupported membrane module type: {}".format(
+                        self.config.module_type
+                    )
+                )
 
     def _add_flux_balance(self):