Application of Membrane Crystallization for Minerals' Recovery from Produced Water

Challenges and advancements in membrane distillation crystallization for industrial applications

Membrane distillation crystallization (MDC) is an emerging hybrid thermal membrane technology that synergizes membrane distillation (MD) and crystallization, which can achieve both freshwater and minerals recovery from high concentrated solutions. Due to the outstanding hydrophobic nature of the membranes, MDC has been widely used in numerous fields such as seawater desalination, valuable minerals recovery, industrial wastewater treatment and pharmaceutical applications, where the separation of dissolved solids is required. Despite the fact that MDC has shown great promise in producing both high-purity crystals and freshwater, most studies on MDC remain limited to laboratory scale, and industrializing MDC processes is currently impractical. This paper summarizes the current state of MDC research, focusing on the mechanisms of MDC, the controls for membrane distillation (MD), and the controls for crystallization. Additionally, this paper categorizes the obstacles hindering the industrialization of MDC into various aspects, including energy consumption, membrane wetting, flux reduction, crystal yield and purity, and crystallizer design. Furthermore, this study also indicates the direction for future development of the industrialization of MDC.

Membrane distillation crystallization for water and mineral recovery: The occurrence of fouling and its control during wastewater treatment

Membrane distillation crystallization (MDC) is an emerging technology envisaged to manage challenges affecting the desalination industry. This technology can sustainably treat concentrated solutions of produced water and industrially discharged saline wastewater. Simultaneous recovery of clean water and minerals is achieved through the integration of crystallization to membrane distillation (MD). MDC has received vast research interest because of its potential to treat hypersaline solutions. However, MDC still faces challenges in harnessing its industrial applications. Technically, MDC is affected by fouling/scaling and wetting thereby hindering practical application at the industrial level. This study reviews the occurrence of membrane fouling and wetting experienced with MDC. Additionally, existing developments carried out to address these challenges are critically reviewed. Finally, prospects suggesting the sustainability of this technology are highlighted.

Membrane Emulsification-A Novel Solution for Treatment and Reuse of Produced Water from Oil Field

Produced water (PW) is, by volume, the largest waste product of the oil- and gas-exploration industry and contains pollutants such as hydrocarbons and heavy metals. To meet the stringent environmental regulations, PW must be treated before discharging into the environment. The current study proposes a novel treatment method where PW is used to prepare oil-in-water emulsion with potential applications within the oil-exploration industry. The emulsions are prepared by applying hollow fiber membrane emulsification (ME) on PW, which inherently contains oil, as to-be-dispersed phase. The results demonstrate that the average droplet size of the emulsions is a function of pressure applied on to-be-dispersed phase and could be customized from 0.24 to 0.65 µm by varying the pressure from 0.25 to 1 bar, respectively. Stability of the emulsions was verified under high pressure and a temperature and storage period of more than 24 h. The calculations showed that an ME unit with <100 kg weight and <1 m3 volume is appropriate to transform the daily average volume of PW from the Danish part of the North Sea into the emulsions. The study provides a novel route, which also complies well with the requirements (low-weight and small spatial footprints) of the offshore oil rigs, to treat and reuse PW within the oil production process and, therefore, eliminates its environmental footprint.

Biofouling control of membrane distillation for seawater desalination: Effect of air-backwash and chemical cleaning on biofouling formation

This study explored the applicability of chemical cleaning and air-backwash to alleviate biofouling on seawater membrane distillation (SWMD). Membrane performance and wettability properties maintained at optimum duration and frequency of the treatments, as indicated by low permeate conductivity throughout the tests. The cleaning of the membrane using 2% NaOH by immersing the membrane for 30 min after 240 min operation removed the biofouling layer, indicated by low permeate conductivity of 370 µScm^-1 after cleaning. However, more frequent membrane cleaning led to membrane damage, more severe wetting, and membrane hydrophobicity reduction. Ten-second air-backwash after 240 min of operation was also effective in controlling the biofouling, particularly when conducted at air pressure of 1 bar. More frequent air-backwash resulted in more aggravated inorganic fouling and accelerated biofouling formation due to the recurring introduction of air, leading to rapid membrane wetting.

Functionalized Nanomembranes and Plasma Technologies for Produced Water Treatment: A Review

The treatment of produced water, associated with oil & gas production, is envisioned to gain more significant attention in the coming years due to increasing energy demand and growing interests to promote sustainable developments. This review presents innovative practical solutions for oil/water separation, desalination, and purification of polluted water sources using a combination of porous membranes and plasma treatment technologies. Both these technologies can be used to treat produced water separately, but their combination results in a significant synergistic impact. The membranes functionalized by plasma show a remarkable increase in their efficiency characterized by enhanced oil rejection capability and reusability, while plasma treatment of water combined with membranes and/or adsorbents could be used to soften water and achieve high purity.

Photocatalytic membrane reactors for produced water treatment and reuse: Fundamentals, affecting factors, rational design, and evaluation metrics

Treatment and reuse of produced water (PW), the largest wastewater stream generated during oil and gas production, provides a promising option to address the increasing clean water demands. High-performance treatment technologies are needed to efficiently remove the organic and inorganic contaminants in PW for fit-for-purpose applications. Photocatalytic membrane reactor (PMR) is an emerging green technology for removal of organic pollutants, photoreduction of heavy metals, photo-inactivation of bacteria, and resource recovery. This study critically reviewed the mechanisms of photocatalysis and membrane processes in PMR, factors affecting PMR performance, rational design, and evaluation metrics for PW treatment. Specifically, PW characteristics, photocatalysts properties, membranes applied, and operating conditions are of utmost importance for rational design and reliable operation of PMR. PW pretreatment to remove oil and grease, colloidal and suspended solids is necessary to reduce membrane fouling and ensure optimal PMR performance. The metrics to evaluate PMR performance were developed including light utilization, exergetic efficiency, water recovery, product water improvement, lifetime of the photocatalyst, and costs. This review also presented the research gaps and outlook for future research.

Membrane distillation crystallization technology for zero liquid discharge and resource recovery: Opportunities, challenges and futuristic perspectives

Water resources are getting limited, which emphasises the need for the reuse of wastewater. The conventional waste(water) treatment methods such as reverse osmosis (RO) and multi-effect distillation (MED) are rendered limited due to certain limitations. Moreover, the imposition of stringent environmental regulations in terms of zero liquid discharge (ZLD) of wastewater containing very high dissolved solids has assisted in developing technologies for the recovery of water and useful solids. Membrane distillation crystallization (MDCr) is an emerging hybrid technology synergising membrane distillation (MD) and crystallization, thus achieving ZLD. MDCr technology can be applied to desalinate seawater, treat nano-filtration, and RO reject brine and industrial wastewater to increase water recovery and yield useful solids. This manuscript focuses on recent advances in MDCr, emphasizing models that account for application in (waste)water treatment. MDCr has dual benefits, first the environmental conservation due to non-disposal of wastewater and second, resources recovery proving the proverb that waste is a misplaced resource. Limitations of standalone MD and crystallization are discussed to underline the evolution of MDCr. In this review, MDCr's ability and feasibility in the treatment of industrial wastewater are highlighted. This manuscript also examines the operational issues, including crystal deposition (scaling) on the membrane surface, pore wetting phenomenon and economic consequences (energy use and operating costs). Finally, opportunities and future prospects of the MDCr technology are discussed. MDCr technology can amplify natural resources availability by recovering freshwater and useful minerals from the waste stream, thus compensating for the relatively high cost of the technology.

Fouling, performance and cost analysis of membrane-based water desalination technologies: A critical review

While water is a key resource required to sustain life, freshwater sources and aquifers are being depleted at an alarming rate. As a mitigation strategy, saline water desalination is commonly used to supplement the available water resources beyond direct water supply. This is achieved through effective advanced water purification processes enabled to handle complex matrix of saline wastewater. Membrane technology has been extensively evaluated for water desalination. This includes the use of reverse osmosis (RO) (the most mature membrane technology for desalination), pervaporation (PV), electrodialysis (ED), membrane distillation (MD), and membrane crystallization (MCr). Though nanofiltration (NF) is not mainly applied for desalination purposes, it is included in the reviewed processes because of its ability to reach 90% salt rejection efficiency for water softening. However, its comparison with other technologies is not provided since NF cannot be used for removal of NaCl during desalination. Remarkably, membrane processes remain critically affected by several challenges including membrane fouling. Moreover, capital expenditure (CAPEX) and operating expenditure (OPEX) are the key factors influencing the establishment of water desalination processes. Therefore, this paper provides a concise and yet comprehensive review of the membrane processes used to desalt saline water. Furthermore, the successes and failures of each process are critically reviewed. Finally, the CAPEX and OPEX of these water desalination processes are reviewed and compared. Based on the findings of this review, MD is relatively comparable to RO in terms of process performance achieving 99% salt rejections. Also, high salt rejections are reported on ED and PV. The operation and maintenance (O&M) costs remain lower in ED. Notably, the small-scale MD OPEX falls below that of RO. However, the large-scale O&M in MD is rarely reported due to its slow industrial growth, thus making RO the most preferred in the current water desalination markets.

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

In the framework of minimum liquid discharge (MLD) or zero liquid discharge (ZLD), sustainable brine management can be achieved via appropriate hybrid treatment technologies that provide water reuse, resource recovery, energy recovery and even freshwater production. This paper reviews the state of the art brine treatment technologies targeting MLD/ZLD and resource recovery and highlights their advantages and limitations. The right combination of treatment processes can add a high value to the brine management and shift the focus from removal to recovery and reuse point and help to adopt a more circular economy approach. ZLD technologies targets 100% water recovery using both membrane- and thermal-based technologies, while they are often hindered by high cost and intensive energy requirement. Meanwhile, the recovery of salts and other resources can partially compensate the operation cost of ZLD processes. MLD is a promising option that achieves up to 95% water recovery by using mainly membrane-based technologies. At this point, feasibility assessment is important to assess the environmental and economic sound of technologies. In the second part, we provide a techno-economic assessment of the most common technologies to provide possible benefits on a desalination plant. In the latter sections, innovative brine treatment schemes are discussed aiming MLD/ZLD, while resource recovery from brine and possible valorization routes of the recovered materials are highlighted to help to reduce the overall costs of the plants and to reach the targets of circular economy.

Advances in seawater membrane distillation (SWMD) towards stand-alone zero liquid discharge (ZLD) desalination

Seawater membrane distillation (SWMD) is a promising separation technology due to its ability to operate as a stand-alone desalination unit operation. This paper reviews approaches to improve laboratory-to-pilot-scale MD performance, which comprise operational strategies, module design, and specifically tailored membranes. A detailed comparison of SWMD and sea water reverse osmosis is presented to further analyze the critical shortcomings of SWMD. The unique features of SWMD, namely the ability to operate with extremely high salt rejection and at extreme feed concentration, highlight the SWMD potential to be operated under zero liquid discharge (ZLD) conditions, which results in the production of high-purity water and simultaneous salt recovery, as well as the elimination of the brine disposal cost. However, technical challenges, such as thermal energy requirements, inefficient heat transfer and integration, low water recovery factors, and lack of studies on real-case valuable-salt recovery, are impeding the commercialization of ZLD SWMD. This review highlights the possibility of applying selected strategies to push forward ZLD SWMD commercialization. Suggestions are projected to include intermittent removal of valuable salts, in-depth study on the robustness of novel membranes, module and configuration, utilization of a low-cost heat exchanger, and capital cost reduction in a renewable-energy-integrated SWMD plant.

Water-energy nexus: desalination technologies and renewable energy sources

Rapid population growth and industrialization have contributed to a dramatic decline in the supply of freshwater. As a result, desalination is an important choice to solve the global problem of water scarcity. Nevertheless, the hyper-saline by-product, the high capital costs, and the high energy demands currently met by fossil fuels are key obstacles to the widespread adoption of desalination systems. Furthermore, desalination plants powered by fossil fuels have negative environmental impacts due to greenhouse gases (GHGs) emissions. In contrast to fossil fuels, renewable energy is abundant and clean and is therefore a promising alternative for powering desalination plants. This is why the water-energy nexus is a crucial step towards a sustainable future. Therefore, the integration of renewable energy sources (RES) into desalination is very important. The main objective of this review to analyze and evaluate desalination technologies (thermal-based and membrane-based) and RES (solar, wind, hydropower, geothermal, and biomass) that could be combined as an integrated process. Social-economic factors, environmental concerns, current challenges, and future research areas for both desalination and RES are discussed.

Lithium recovery from salt-lake brine: Impact of competing cations, pretreatment and preconcentration

The global demand of lithium is rising steadily, and many industrially advanced countries may find it hard to secure an uninterrupted supply of lithium for meeting their manufacturing demands. Thus, innovative processes for lithium recovery from a wide range of natural reserves should be explored for meeting the future demands. In this study, a novel integrated approach was investigated by combining nanofiltration (NF), membrane distillation (MD) and precipitation processes for lithium recovery from salt-lake brines. Initially, the brine was filtered with an NF membrane for the separation of lithium ions (Li⁺) from competing ions such as Na⁺, K⁺, Ca²⁺ and Mg²⁺. The extent of permeation of metal ions by the NF membrane was governed by their hydrated ionic radii. Rejection by NF membrane was 42% for Li, 48% for Na and 61% for K, while both the divalent cations were effectively rejected (above 90%). Importantly, in the NF-permeate, Mg²⁺/Li⁺ mass ratio reduced to less than 6 (suggested for lithium recovery). The result showed that MD can enrich lithium with a concentration of 2.5 for raw brine and 5 for NF-treated brine. Following the enrichment of NF-permeate by the MD membrane, a two-stage precipitation method was used for the recovery of lithium. X-ray diffraction confirmed the precipitation of lithium as well as the formation of lithium carbonate crystals.

Environmental impacts of desalination and brine treatment - Challenges and mitigation measures

Desalination is perceived as an effective and reliable process for obtaining freshwater from aqueous saline solutions such as brackish water, seawater and brine. This can be clarified by the fact that >300 million people worldwide rely on desalinated water for their daily needs. Although the desalination process offers many advantages, there are rising concerns about possible adverse environmental impacts. Generally, environmental impacts can be generated both in the construction and operation of desalination plants. A major issue of desalination is the co-produced waste called 'brine' or 'reject' which has a high salinity along with chemical residuals and is discharged into the marine environment. In addition to brine, other main issues are the high energy consumption of the desalination and brine treatment technologies as well as the air pollution due to emissions of greenhouse gasses (GHGs) and air pollutants. Other issues include entrainment and entrapment of marine species, and heavy use of chemicals. The purpose of this review is to analyze the potential impacts of desalination and brine treatment on the environment and suggest mitigation measures.

Extraction of strategically important elements from brines: Constraints and opportunities

Strategically important elements are those that are vital to advanced manufacturing, low carbon technologies and other growing industries. Ongoing depletion and supply risks to these elements are a critical concern, and thus, recovery of these elements from low-grade ores and brines has generated significant interest worldwide. Among the strategically important elements, this paper focuses on rare earth elements (REEs), the platinum-group metals and lithium due to their wide application in the advanced industrial economics. We critically review the current methods such as precipitation, ion exchange and solvent extraction for extracting these elements from low-grade ores and brines and provide insight into the technical challenges to the practical realisation of metal extraction from these low-grade sources. The challenges include the low concentration of the target elements in brines and inadequate selectivity of the existing methods. This review also critically analyzes the potential applicability of an integrated clean water production and metal extraction process based on conventional pressure-driven membrane and emerging membrane technologies (e.g., membrane distillation). Such a process can first enrich the strategically important elements in solution for their subsequent recovery along with clean water production.

Desalination brine disposal methods and treatment technologies - A review

Brine, also known as concentrate, is the by-product of the desalination process that has an adverse impact on the environment due to its high salinity. Hence, viable and cost-effective brine management systems are needed to reduce environmental pollution. Currently, various disposal methods have been practiced, including surface water discharge, sewer discharge, deep-well injection, evaporation ponds and land application. However, these brine disposal methods are unsustainable and restricted by high capital costs and non-universal application. Nowadays, brine treatment is considered one of the most promising alternatives to brine disposal, since treatment results in the reduction of environmental pollution, minimization of waste volume and production of freshwater with high recovery. This review article evaluates current practices in brine management, including disposal methods and treatment technologies. Based upon the side-by-side comparison of technologies, a brine treatment technology framework is introduced to outline the Zero Liquid Discharge (ZLD) approach through high freshwater recovery and wastewater volume minimization. Furthermore, an overview of brine characteristics and its sources, as well as its negative impact on the environment is discussed. Finally, the paper highlights future research areas for brine treatment technologies aiming to enhance the effectiveness and viability of desalination.

Seawater-driven forward osmosis for pre-concentrating nutrients in digested sludge centrate

Seawater-driven forward osmosis to enrich nutrients from sludge centrate and reduce membrane fouling is demonstrated. Due to enrichment and pH increase in the feed solution, without appropriate control measure, nutrient precipitation can occur directly on the membrane surface causing severe membrane fouling and reducing nutrient enrichment efficiency. Indeed without agitating the feed, there was less precipitation on the membrane surface, compared to with agitation. In addition, increase in the membrane area over permeate volume ratio significantly reduced the filtration time and nutrient precipitation. A novel technique to maintain the draw solution (DS) at an acidic condition was developed to improve nutrient enrichment and reduce membrane fouling. By using this technique and a high membrane surface to permeate volume ratio, nutrient enrichment similar to the theoretical efficiency was successfully demonstrated. Our technique reduced the filtration time to achieve 70% water recovery by over 90% (compared to unbuffered seawater as the DS, small membrane area, and feed agitation), as a result of significantly less membrane fouling. The amount of phosphorus precipitate on the membrane surface decreased by more than 10 times. The enrichment of ammonia and phosphorus as a function of water recovery was similar to the theoretical calculation, indicating negligible nutrient loss due to precipitation.

Treatment of Wastewater Solutions from Anodizing Industry by Membrane Distillation and Membrane Crystallization

The treatment of wastewater containing various metal ions is a challenging issue in the anodizing industry. The current study investigates the application of membrane distillation/crystallization (MD/MCr) for the simultaneous recovery of freshwater and sodium sulfate from wastewater originating from a Danish anodizing industry. MD/MCr experiments were performed on supernatant from wastewater obtained after centrifugation. The effect of various feed temperatures and cross-flow velocities on flux and crystal characteristics was investigated. The crystal growth in the feed tank was monitored through the use of an online PaticleView microscope. The crystals’ morphology and form were determined by using scanning electron microscope (SEM) and X-ray powder diffraction (XRD), respectively, while inductively coupled plasma (ICP) was applied to determine the purity of the obtained crystals. The weight and dimensions of the MD/MCr unit that were required to treat the specific amount of wastewater were evaluated as a function of the feed inlet temperature. It was demonstrated that the application of MCr allows extracting high-purity sodium sulfate crystals and more than 80% freshwater from the wastewater.

Recovery of water and minerals from shale gas produced water by membrane distillation crystallization

Shale gas produced water (SGPW) treatment imposes greater technical challenges because of its high concentration of various contaminants. Membrane distillation crystallization (MDC) has a great potential to manage SGPW since it is capable of recovering both water and minerals at high rates, up to near a zero liquid discharge (ZLD) condition. To evaluate the feasibility of MDC for SGPW treatment, MDC performance indicators, such as water recovery rate, solid production rate (SPR) and specific energy consumption (SEC), were systematically investigated, to our knowledge for the first time, by using actual SGPW from Eagle Ford Shale (USA). The main operating parameters including feed cross-flow velocity (CFV) and crystallization temperature (T_Cr) were optimized by performing a series of MDC experiments. The results reported that water and minerals were effectively recovered with 84% of recovery rate and 2.72 kg/m²day of SPR under respective optimal operating conditions. Furthermore, the scale mechanism was firstly identified as limiting factor for MDC performance degradation. Lastly, SEC of MDC was estimated to be as low as 28.2 kWh/m³ under ideal optimal operating conditions. Our experimental observations demonstrated that MDC could sustainably and effectively recover water and mineral with low energy consumption from SGPW by optimizing operating condition.