Brine treatment technologies towards minimum/zero liquid discharge and resource recovery: State of the art and techno-economic assessment

Contrasting mixed scaling patterns and mechanisms of nanofiltration and membrane distillation

Oriented towards the pressing needs for hypersaline wastewater desalination and zero liquid discharge (ZLD), the contrasting mixed scaling of thermal-driven vacuum membrane distillation (VMD) and pressure-driven nanofiltration (NF) were investigated in this work. Bulk crystallization was the main mechanism in VMD due to the high salinity and temperature, but the time-independent resistance by the adsorption of silicate and organic matter dominated the initial scaling process. Surface crystallization and the consequent pore-blocking were the main scaling mechanisms in NF, with the high permeate drag force, hydraulic pressure, and cross-flow rate resulting in the dense scaling layer mainly composed of magnesium-silica hydrate (MSH). Silicate enhanced NF scaling with a 75% higher initial flux decline rate attributed to the MSH formation and compression, but delayed bulk crystallization in VMD. Organic matter presented an anti-scaling effect by delaying bulk crystallization in both VMD and NF, but specifically promoted CaCO3 scaling in NF. Furthermore, the incipient scaling was intensified as silicate and organic matter coexisted. The scaling mechanism shifted from surface to bulk crystallization due to the membrane concentration in both VMD and NF. This work fills the research gaps on mixed scaling mechanisms in different membrane processes, which offers insights for scaling mitigation and thereby supports the application of ZLD.

Data-Monitoring Solution for Desalination Processes: Cooling Tower and Mechanical Vapor Compression Hybrid System

The advancement of novel water treatment technologies requires the implementation of both accurate data measurement and recording processes. These procedures are essential for acquiring results and conducting thorough analyses to enhance operational efficiency. In addition, accurate sensor data facilitate precise control over chemical treatment dosages, ensuring optimal water quality and corrosion inhibition while minimizing chemical usage and associated costs. Under this framework, this paper describes the sensoring and monitoring solution for a hybrid system based on a cooling tower (CT) connected to mechanical vapor compression (MVC) equipment for desalination and brine concentration purposes. Sensors connected to the data commercial logger solution, Almemo 2890-9, are also discussed in detail such as temperature, relative humidity, pressure, flow rate, etc. The monitoring system allows remote control of the MVC based on a server, GateManager, and TightVNC. In this way, the proposed solution provides remote access to the hybrid system, being able to visualize gathered data in real time. A case study located in Cartagena (Spain) is used to assess the proposed solution. Collected data from temperature transmitters, pneumatic valves, level sensors, and power demand are included and discussed in the paper. These variables allow a subsequent forecasting process to estimate brine concentration values. Different sample times are included in this paper to minimize the collected data from the hybrid system within suitable operation conditions. This solution is suitable to be applied to other desalination processes and locations.

Mixed scaling patterns and mechanisms of high-pressure nanofiltration in hypersaline wastewater desalination

Nanofiltration (NF) will play a crucial role in salt fractionation and recovery, but the complicated and severe mixed scaling is not yet fully understood. In this work, the mixed scaling patterns and mechanisms of high-pressure NF in zero-liquid discharge (ZLD) scenarios were investigated by disclosing the role of key foulants. The bulk crystallization of CaSO4 and Mg-Si complexes and the resultant pore blocking and cake formation under high pressure were the main scaling mechanisms in hypersaline desalination. The incipient scalants were Mg-Si hydrates, CaF2, CaCO3, and CaMg(CO3)2. Si deposited by adsorption and polymerization prior to and impeded Ca scaling when Mg was not added, thus pore blocking was the main mechanism. The amorphous Mg-Si hydrates contribute to dense cake formation under high hydraulic pressure and permeate drag force, causing rapid flux decline as Mg was added. Humic acid has a high affinity to Ca2+by complexation, which enhances incipient scaling by adsorption or lowers the energy barrier of nucleation but improves the interconnectivity of the foulants layer and inhibits bulk crystallization due to the chelation and directional adsorption. Bovine serum albumin promotes cake formation due to the low electrostatic repulsion and acts as a cement to particles by adsorption and bridging in bulk. This work fills the research gaps in mixed scaling of NF, which is believed to support the application of ZLD and shed light on scaling in hypersaline/ultra-hypersaline wastewater desalination applications.

The Future of Municipal Wastewater Reuse Concentrate Management: Drivers, Challenges, and Opportunities

Water reuse is rapidly becoming an integral feature of resilient water systems, where municipal wastewater undergoes advanced treatment, typically involving a sequence of ultrafiltration (UF), reverse osmosis (RO), and an advanced oxidation process (AOP). When RO is used, a concentrated waste stream is produced that is elevated in not only total dissolved solids but also metals, nutrients, and micropollutants that have passed through conventional wastewater treatment. Management of this RO concentrate─dubbed municipal wastewater reuse concentrate (MWRC)─will be critical to address, especially as water reuse practices become more widespread. Building on existing brine management practices, this review explores MWRC management options by identifying infrastructural needs and opportunities for multi-beneficial disposal. To safeguard environmental systems from the potential hazards of MWRC, disposal, monitoring, and regulatory techniques are discussed to promote the safety and affordability of implementing MWRC management. Furthermore, opportunities for resource recovery and valorization are differentiated, while economic techniques to revamp cost-benefit analysis for MWRC management are examined. The goal of this critical review is to create a common foundation for researchers, practitioners, and regulators by providing an interdisciplinary set of tools and frameworks to address the impending challenges and emerging opportunities of MWRC management.

Theoretical and Experimental Analysis of Osmotically Assisted Reverse Osmosis for Minimum Liquid Discharge

Osmotically assisted reverse osmosis (OARO) is an innovative process that shows promising potential in the treatment of brine produced by conventional reverse osmosis (RO) systems. This study presents a theoretical and experimental analysis of the OARO process, focusing on its application to achieve minimum liquid discharge (MLD). This theoretical analysis includes the development of a mathematical model to describe the transport phenomena occurring during OARO. By considering mass balance equations coupled with transport equations, the theoretical model allows for the simulation of a full-scale system consisting of a single-stage RO and a four-stage OARO. Experimental investigations are also conducted to validate the theoretical model and to evaluate the performance of the OARO process. A laboratory-scale OARO system is designed and operated using a synthetic RO brine. Various operating conditions, including applied pressure, feed concentration, and draw concentration, are varied to investigate their effects on process performance. The experimental results demonstrate the feasibility of OARO as an MLD solution and also validate the predictions of the theoretical model, confirming its reliability for process optimization and design. The results of the theoretical analysis show that OARO has the potential to significantly improve water recovery compared to conventional RO. Based on the simulation, the optimal operating conditions are explored, leading to a significant reduction (up to 89%) in the volume of brine discharge.

Desalination, Water Re-use, and Halophyte Cultivation in Salinized Regions: A Highly Productive Groundwater Treatment System

Groundwater salinization is a problem affecting access to water in many world regions. Though desalination by conventional reverse osmosis (RO) can upgrade groundwater quality for drinking, its disadvantages include unmanaged brine discharge and accelerated groundwater depletion. Here, we propose a new approach combining RO, forward osmosis (FO), and halophyte cultivation, in which FO optimally adjusts the concentration of the RO reject brine for irrigation of Salicornia or Sarcocornia. The FO also re-uses wastewater, thus, reducing groundwater extraction and the wastewater effluent volume. To suit different groundwater salinities in the range 1-8 g/L, three practical designs are proposed and analyzed. Results include specific groundwater consumption (SGC), specific energy consumption (SEC), wastewater volume reduction, peak RO pressure, permeate water quality, efficiency of water resource utilization, and halophyte yield. Compared to conventional brackish water RO, the results show superior performance in almost all aspects. For example, SGC is reduced from 1.25 to 0.9 m3 per m3 of drinking water output and SEC is reduced from 0.79 to 0.70 kW h/m3 by a FO-RO-FO system treating groundwater of salinity 8 g/L. This system can produce 1.1 m3 of high-quality drinking water and up to 4.9 kg of edible halophyte per m3 of groundwater withdrawn.

Effect of thermal characteristics on the chemical quality of real-brine treatment through hydrophilic fiber-based low-grade heat-powered humidification-dehumidification process

Considering the increasing demand for desalination plants and their byproduct brine, this study investigated a humidification-dehumidification (HDH) system for treating membrane distillation-generated real high-salinity brine using low-grade heat (45-70 ℃) to explore its feasibility for sustainable energy-efficient minimal liquid discharge. A novel super-hydrophilic fabric was adopted for accelerated humidification, and its impact on brine droplet miscarriage characteristics was evaluated. The influence of the operating fluid thermal properties (cycle 1: air preheating; cycle 2: air and brine dual-fluid preheating; and cycle 3: air post-heating after humidification) on the brine treatment efficiency, energy consumption, and chemical quality of freshwater produced was analyzed in detail to establish their characteristic nexus. It was identified that, during humidification, increasing the brine temperature (up to 55 ℃) influenced its ionic mobility, thereby promoting efficient separation of the salts/minerals and contributing to achieving better freshwater quality. Furthermore, although cycle 3 exhibited improved system thermal efficiency (gained output ratio equal to 1.77), its non-preheated air contributed to a negative effect of the reduced humidity ratio (∼17 g/kg), leading to a lower freshwater productivity of 67% than that of cycle 2 (29 g/kg and 70%). The present study also illustrates a novel effect of evaporative deposition occurring due to air-water interaction on the fabric humidifier surface, with an exploration of its effect on reducing freshwater chemical quality. The freshwater generated from optimum thermal cycle 2 exhibited reduced pH (by ∼63%), sodium (99.9%), chloride (99.9%), toxic boron (99.7%), and other chemical contaminants, thereby satisfying the major international water reuse standards.

Distributed desalination using solar energy: A technoeconomic framework to decarbonize nontraditional water treatment

Desalination using renewable energy offers a route to transform our incumbent linear consumption model to a circular one. This transition will also shift desalination from large-scale centralized coastal facilities toward modular distributed inland plants. This new scale of desalination can be satisfied using solar energy to decarbonize water production, but additional considerations, such as storage and inland brine management, become important. Here, we evaluate the levelized cost of water for 16 solar desalination system configurations at 2 different salinities. For fossil fuel-driven plants, we find that zero-liquid discharge is economically favorable to inland brine disposal. For renewable desalination, we discover that solar-thermal energy is superior to photovoltaics due to low thermal storage cost and that energy storage, despite being expensive, outperforms water storage as the latter has a low utilization factor. The analysis also yields a promising outlook for solar desalination by 2030 as solar generation and storage costs decrease.

Multistage Surface-Heated Vacuum Membrane Distillation Process Enables High Water Recovery and Excellent Heat Utilization: A Modeling Study

Surface-heated membrane distillation (MD) enhances the energy efficiency of desalination by mitigating temperature polarization (TP). However, systematic investigations of larger scale, multistage, surface-heated MD system with high water recovery and heat recycling are limited. Here, we explore the design and performance of a multistage surface-heated vacuum MD (SHVMD) with heat recovery through a comprehensive finite difference model. In this process, the latent heat of condensation is recovered through an internal heat exchanger (HX) using the retentate from one stage as the condensing fluid for the next stage and an external HX using the feed as the condensing fluid. Model results show that surface heating enhances the performance compared to conventional vacuum MD (VMD). Specifically, in a six-stage SHVMD process, 54.44% water recovery and a gained output ratio (GOR) of 3.28 are achieved with a surface heat density of 2000 W m^-2, whereas a similar six-stage VMD process only reaches 18.19% water recovery and a GOR of 2.15. Mass and energy balances suggest that by mitigating TP, surface heating increases the latent heat trapped in vapor. The internal and external HXs capture and reuse the additional heat, which enhances the GOR values. We show for SHVMD that the hybrid internal/external heat recovery design can have GOR value 1.44 times higher than that of systems with only internal or external heat recovery. Furthermore, by only increasing six stages to eight stages, a GOR value as high as 4.35 is achieved. The results further show that surface heating can reduce the energy consumption of MD for brine concentration. The multistage SHVMD technology exhibits a promising potential for the management of brine from industrial plants.

Decarbonized and circular brine management/valorization for water & valuable resource recovery via minimal/zero liquid discharge (MLD/ZLD) strategies

Brine (saline wastewater/water) from desalination, salt lakes, and industrial activities (e.g., pharmaceutical industries, oil & gas industries) has received a lot of attention around the world due to its adverse impact on the environment. Currently, several disposal methods have been applied; however, these methods are nowadays unsustainable. To tackle this problem, brine treatment and valorization is considered a promising strategy to eliminate brine discharge and recover valuable resources such as water, minerals, salts, metals, and energy. Brine valorization and resource recovery can be achieved via minimal and zero liquid discharge (MLD & ZLD) desalination systems. Commercially successful technologies such as reverse osmosis (RO) and distillation cannot be adopted as standalone technologies due to restrictions (e.g., osmotic pressure, high-energy/corrosion). Nonetheless, novel technologies such as forward osmosis (FO), membrane distillation (MD) can treat brine of high salinity and present high recovery rates. The extraction of several ions from brines is technically feasible. The minerals/salts composed of major ions (i.e., Na⁺, Cl^-, Mg²⁺, Ca²⁺) can be useful in a variety of sectors, and their sale prices are reasonable. On the other hand, the extraction of scarce metals such as lithium, rubidium, and cesium can be extremely profitable as their sale prices are extremely higher compared to the sale prices of common salts. Nonetheless, the extraction of such precious metals is currently restricted to a laboratory scale. The MLD/ZLD systems have high energy consumption and thus are associated with high GHGs emissions as fossil fuels are commonly burned to produce the required energy. To make the MLD/ZLD systems more eco-friendly and carbon-neutral, the authors suggest integrating renewable energy sources such as solar energy, wind energy, geothermal energy, etc. Besides water, minerals, salts, metals, and energy can be harvested from brine. In particular, salinity gradient power can be generated. Salinity gradient power technologies have shown great potential in several bench-scale and pilot-scale implementations. Nonetheless, several improvements are required to promote their large-scale feasibility and viability. To establish a CO₂-free and circular global economy, intensive research and development efforts should continue to be directed toward brine valorization and resource recovery using MLD/ZLD systems.

Techno-Economic Analysis of Brine Treatment by Multi-Crystallization Separation Process for Zero Liquid Discharge

This study analyses the concept of a novel multi-crystallization system to achieve zero liquid discharge (ZLD) for desalination plants using an innovative heat recovery system consisting of a heat transfer fluid and a compressor to reduce energy consumption. The main focus is to recover water and separately extract salts from seawater brines with high purity, including calcite, anhydrite, sodium chloride, and epsomite, which can be sold to the cement industry. The system is compared with a conventional brine treatment system. The energy demand and economic feasibility of both systems are assessed to evaluate profitability at a scale of 1000 kg/h. The results estimate that the utilization of a heat recovery fluid reduces energy consumption from 690 kWhth/ton of feed brine to 125.90 kWhth/ton equaling a total electric consumption of 60.72 kWhe/ton. The system can recover 99.2% of water and reduce brine discharge mass by 98.9%. The system can recover 53.8% of calcite at near 100% purity, 96.4% of anhydrite at 97.7% purity, 91.6% of NaCl at near 100% purity, and 71.1% of epsomite at 40.7% purity. Resource recovery accounts for additional revenues, with halite and water accounting respectively for 69.85% and 29.52% of the income. The contribution of calcite and anhydrite to revenue is very low due to their low production. The levelized cost of water (LCOW) of the multi-crystallization system is 13.79 USD/m3 as opposed to 7.85 USD/m3 for the conventional ZLD system. The economic analyses estimate that the conventional ZLD system can achieve payback after 7.69 years. The high electricity cost, which accounts for 68.7% of the annual expenses, can be produced from renewable sources.

Societal values, tensions and uncertainties in resource recovery from wastewaters

The recovery of resources, including water reuse, has been presented as a solution to overcome scarcity, and improve the economic and environmental performance of water provision and treatment. However, its implementation faces non-technical challenges, including the need to collaborate with new stakeholders and face societal acceptance issues. Looking at the prominence of the circular economy in current policy developments and the challenges to resource recovery, exploring these issues is urgently needed. In this work, we reviewed a broad range of literature to identify societal values relevant to the recovery of water and other resources from wastewaters, particularly urban and industrial wastewater and desalination brines. We discuss tensions and uncertainties around these values, such as the tension between socio-economic expectations of resource recovery and potential long-term sustainability impacts, as well as uncertainties regarding safety and regulations. For addressing these tensions and uncertainties, we suggest aligning common methods in engineering and the natural sciences with Responsible Innovation approaches, such as Value Sensitive Design and Safe-by-Design. To complement Responsible Innovation, social learning with a Sustainability Transitions or Adaptive Governance perspective is suggested.

Technical and Environmental Feasibilities of the Commercial Production of NaOH from Brine by Means of an Integrated EDBM and Evaporation Process

Electrodialysis with bipolar membranes (EDBMs) is a technology that offers a great potential for the introduction of the principles of a circular economy in the desalination industry, by providing a strategy for the recovery of HCl and NaOH from brine via the process of seawater reverse osmosis (SWRO). Both chemicals are widely employed in desalination facilities, however NaOH presents a special interest due to its higher requirements and cost. Nevertheless, the standard commercial concentrations that are commonly employed in the facilities cannot be obtained using the state of the art EDBM technology itself. Therefore, the aim and main purpose of this work is to prove the technical and environmental feasibilities of a new approach to produce commercial NaOH (50%wt.) from SWRO brine by means of an integrated process of EDBMs followed by a triple effect evaporation. The global process has been technically evaluated in terms of the specific energy consumption (SEC) (kWh·kg^-1 NaOH) and the environmental sustainability performance has been analyzed by its carbon footprint (CF) (kg CO₂-eq.·kg^-1 NaOH). The influence of the current density, and the power source in the EDBM stage have been evaluated on a laboratory scale while the influence of the feed stream concentration in the evaporation stage has been obtained through simulations using Aspen Plus. The lowest SEC of the integrated process (SEC_OV), 31.1 kWh·kg^-1 NaOH, is obtained when an average current density of 500 A·m^-2, provided by a power supply (grid mix), is applied in the EDBM stage. The environmental burdens of the integrated process have been quantified by achieving reductions in the CF by up to 54.7% when solar photovoltaic energy is employed as the power source for EDBMs, with a value of 5.38 kg CO₂-eq.·kg^-1 NaOH. This study presents a great potential for the introduction of the principles of a circular economy in the water industry through the recovery of NaOH from the high salinity waste stream generated in SWRO facilities and opens the possibility of the reuse of NaOH by its self-supply in the desalination plant.

Modelling and Parametric Analysis of a Brine Treatment Unit Using a High-Temperature Heat Pump and a Vacuum Evaporator

The brine produced from desalination systems is a highly concentrated mixture, including cleansing chemicals from the water treatment processes that can possibly degrade ecosystems in discharge areas. Evaporation is a widely used method for the treatment of high salinity mixtures; however, it requires careful monitoring of the temperature and pressure in order to protect the equipment from the highly corrosive environment of the brine discharge. The proposed brine treatment system is based on the principle of vacuum evaporation with the use of a high-temperature heat pump, which is classified as “green technology”. In this study, a thermodynamic analysis of a vacuum evaporation system with a nominal freshwater production capacity of 160 L/h has been carried out, employing a numerical tool to model the flash evaporator and the heat pump. The analysis focuses on the parameters that present the most significant impact on the system’s efficiency and water production, such as the recirculation ratio, the set-point temperature of the heat pump and the pressure difference provided by the vacuum pump. The results show that, for the constant vacuum pressure difference, the water production increases with the increase in the set-point temperature and the recirculation ratio, but leads to the reduced COP of the heat pump and to an elevated specific energy consumption. Moreover, it is shown that an increased vacuum pressure difference leads to increased water production, but reduces the COP. Finally, the minimum specific energy consumption of 150 kWh/m3 of produced freshwater can be achieved for a set-point at 75 °C and vacuum of 0.21 bar, leading to a levelized cost of water about 11 €/m3.