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.

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.

Precipitation and recovery of phosphorus from the wastewater hydrolysis tank.

Phosphorus, a limited resource, is also an environmental pollutant that should be removed from wastewater and ideally reused. A pilot-scale facility was set up and used to precipitate and recover phosphorus from wastewater. The return activated sludge in a hydrolysis tank was flocculated and separated and the solid material returned to the hydrolysis tank; the flocculation process did not harm the microorganisms. Phosphate in the reject water was precipitated with different calcium salts and the phosphorus-containing precipitate recovered. The precipitate consisted mainly of phosphate and calcium, and under 5% of the final product consisted of iron and aluminum. Around 20% of the precipitate was organic material. The pilot-scale test was supplemented with bench-scale tests using calcium salt, magnesium salt, and NaOH/KOH. Without the addition of calcium ions, phosphate could be precipitated by increasing pH to 9.5, resulting in a concentration of phosphorus in the reject water of under 2 mg/L. If calcium salt was added (Ca:P ratio of 2:1), it was possible to remove phosphate at pH 9 (<1 mg/L). In general, the concentration of dissolved phosphate was 8-10 mg/L lower after precipitation when calcium salt was used compared with all other tested salts. This difference increased if additional phosphate was added to the sludge. The bench- and pilot-scale experiments yielded comparable data. At the pilot-scale facility, it was possible to remove 90% of the phosphate by adding calcium salt and regulating the pH to 8.5.

Selective electrodialysis for simultaneous but separate phosphate and ammonium recovery.

Nutrients were extracted from digester supernatant sampled from a full-scale enhanced biological phosphorus removal (EBPR) wastewater treatment plant. A four-compartment selectrodialysis setup was used to extract ammonium and phosphate in two separate compartments. The initial phosphate recovery rate was measured to be 0.072 mmol m-2 s-1 and the initial ammonium recovery rate was measured to be 1.31 mmol m-2 s-1. The ammonium recovery rate was 18 times higher than that for phosphate, whereas the molar concentration of ammonium in the feed was 10 times higher than that of phosphate. An average recovery of 72 ± 1% and 90 ± 10% for ammonium and phosphate was observed after 3 h of operation. A monovalent anion selective (MVA) membrane was used to avoid ammonium and reduce the concentration of monovalent anions in the phosphorus stream. The pH in the phosphorus stream was kept at 10 so phosphate did not pass the MVA membrane. A membrane area of 26 m2 per m3 digester supernatant was required to recover 70% of phosphate and ammonium for the digester supernatant that contained 6 mM phosphate and 105 mM ammonium.

Desalination of Groundwater from a Well in Puglia Region (Italy) by Al2O3-Doped Silica and Polymeric Nanofiltration Membranes.

Some of the groundwater aquifers in the Puglia Region, Italy, suffer from high salinity and potential micropollutant contamination due to seawater infiltration and chemical discharge. The objective of this study is twofold: to evaluate the performance of the recently reported alumina-doped silica nanofiltration membranes for water potabilization, and to provide a possible solution to improve the groundwater quality in the Puglia Region while maintaining a low energy-footprint. Two lab-made alumina-doped silica membranes with different pore structures, namely S/O = 0.5 and S/O = 2, were tested with real groundwater samples and their performances were compared with those of a commercial polymeric membrane (Dow NF90). Moreover, groundwater samples were sparked with acetamiprid, imidacloprid, and thiacloprid to test the membrane performance in the presence of potential contamination by pesticides. At a trans-membrane pressure of 5 bar, NF90 could reduce the groundwater conductivity from 4.6 to around 1.3 mS·cm-1 and reject 56-85% of the model pesticides, with a permeate flux of 14.2 L·m-2·h-1. The two inorganic membranes S/O = 2 and S/O = 0.5 reduced the permeate conductivity to 3.8 and 2.4 mS·cm-1, respectively. The specific energy consumption for all three membranes was below 0.2 kWh·m-3 which indicates that the potabilization of this groundwater by nanofiltration is commercially feasible.

Pilot-scale study for phosphorus recovery by sludge acidification and dewatering.

Phosphorus recovery from wastewater is a focus area in Denmark; the aim is to recover at least 80% of the phosphorus. In order to extract phosphorus, surplus sludge from wastewater treatment plants was acidified (pH 2-4) to increase the dissolved phosphorus concentration, which then can be precipitated and recovered. Pilot-scale acidification and dewatering tests were done using sludge from three different wastewater treatment plants: plant (1) digested primary and secondary sludge, plant (2) digested primary sludge, and plant (3) non-digested sludge. Treatment of digested sludge gave the highest phosphorus release, but the acid consumption was high due to carbon dioxide stripping. The dry matter content of the acidified dewatered sludge was high (20-40%), but the dry matter content in the filtrate increased with decreasing pH. Approximately half of the dry matter content in the filtrate could be removed by introducing an additional separation step. The optimal pH for phosphorus extraction was 3, where up to 68% of the phosphorus was dissolved. Part of the released orthophosphate was lost with the filter cake but still, 60% of the total phosphorus content in the sludge ends up in the filtrate.

Acidification and recovery of phosphorus from digested and non-digested sludge.

Acidification was used to dissolve phosphorus from digested and non-digested sludge from five wastewater treatment plants in order to make phosphorus accessible for subsequent recovery. More phosphorus was dissolved from digested sludge (up to 80%), with respect to non-digested sludge (∼25%) and the highest release was observed at pH 2. The acid consumption for digested sludge was higher than for non-digested sludge due to the presence of the bicarbonate buffer system, thus CO2 stripping increased the acid consumption. In all the experiments, the sludge was exposed to acid for 1 h. For the five tested sludge types, 60-100 mmol o-P was released per added mol H2SO4. It was mainly iron and calcium compounds that accounts for the phosphorus release at low pH. The release of heavy metals was in general low (<30%) for all the wastewater treatment plant, as Zn, Cd and Ni showed the most critical release after acidification of non-digested sludge.

Treated Seawater as a Magnesium Source for Phosphorous Recovery from Wastewater-A Feasibility and Cost Analysis.

Conventional resources of phosphorous are at high risk of depletion in the near future due to current practices of its exploitation, thus new and improved exploration methodologies need to be developed to ensure phosphorous security. Today, some treatment plants recover phosphorous from municipal wastewater as struvite (MgNH4PO4·6H2O). Magnesium is often added to the wastewater as MgCl2·6H2O to facilitate the phosphorous recovery. However, the use of magnesium increases the costs of the process and is not aligned with sustainable development, therefore, alternative magnesium sources have to be found. The current study analyzes the feasibility of integrated membrane processes for magnesium recovery from seawater for utilization in the phosphorous recovery process. The integrated membrane systems consist of nanofiltration (NF), membrane distillation (MD), and membrane crystallization (MCr). The lowest associated cost is found for standalone NF treatment. However, the additional treatment with MD and MCr produces fresh water and salts like NaCl or potentially other valuable minerals at the expense of low-grade heat.

Application of Membrane Crystallization for Minerals' Recovery from Produced Water.

Produced water represents the largest wastewater stream from oil and gas production. Generally, its high salinity level restricts the treatment options. Membrane crystallization (MCr) is an emerging membrane process with the capability to extract simultaneously fresh water and valuable components from various streams. In the current study, the potential of MCr for produced water treatment and salt recovery was demonstrated. The experiments were carried out in lab scale and semi-pilot scale. The effect of thermal and hydrodynamic conditions on process performance and crystal characteristics were explored. Energy dispersive X-ray (EDX) and X-ray diffraction (XRD) analyses confirmed that the recovered crystals are sodium chloride with very high purity (>99.9%), also indicated by the cubic structure observed by microscopy and SEM (scanning electron microscopy) analysis. It was demonstrated experimentally that at recovery factor of 37%, 16.4 kg NaCl per cubic meter of produced water can be recovered. Anti-scaling surface morphological features of membranes were also identified. In general, the study provides a new perspective of isolation of valuable constituents from produced water that, otherwise, is considered as a nuisance.