Seawater Reverse Osmosis Plant Research Articles

Removal and reincorporation of microplastics at several stages of two seawater reverse osmosis plants that provide drinking water to Barcelona metropolitan area

Seawater desalination has emerged as a crucial solution for addressing global freshwater scarcity. However, it generates significant volumes of concentrated brine waste. This brine is rich in dissolved salts and minerals, primarily, chloride (55%), sodium (30%), sulfate (8%), magnesium (4%), calcium (1%), potassium (1%), bicarbonate (0.4%), and bromide (0.2%), which are often discharged into marine environments, posing ecological challenges. This study presents a comprehensive global review of innovative technologies for recovering these constituents as valuable products, thereby enhancing the sustainability and economic viability of desalination. The paper evaluates a range of proven and emerging recovery methods, including membrane separation, nanofiltration, electrodialysis, thermal crystallization, solar evaporation, chemical precipitation, and electrochemical extraction. Each technique is analyzed for its effectiveness in isolating salts (NaCl, KCl, and CaSO4) and minerals (Mg(OH)2 and Br2), with a discussion of process-specific constraints, recovery efficiencies, and product purities. Furthermore, the study incorporates a detailed techno-economic assessment, highlighting revenue potential, capital and operational expenditures, and breakeven timelines. Simulated case studies of a 100,000 m3/day seawater reverse osmosis (SWRO) facility demonstrates that a sequential brine recovery process and associated energy balances, supported by pilot-scale data from ongoing global initiatives, can achieve over 90% total salt recovery while producing marketable products such as NaCl, Mg(OH)2, and Br2. The estimated revenue from recovered materials ranges between USD 4.5 and 6.8 million per year, offsetting 65–90% of annual desalination operating costs. The analysis indicates a payback period of 3–5 years, depending on recovery efficiency and product pricing, underscoring the economic viability of large-scale brine valorization alongside its environmental benefits. By transforming waste brine into a source of commercial commodities, desalination facilities can move toward circular economy models and achieve greater sustainability. A practical integration framework is proposed for both new and existing SWRO plants, with a focus on aligning with the principles of a circular economy. By transforming waste brine into a resource stream for commercial products, desalination facilities can reduce environmental discharge and generate additional revenue. The study concludes with actionable recommendations and insights to guide policymakers, engineers, and investors in advancing brine mining toward full-scale implementation.

Seawater reverse osmosis (SWRO) desalination generates a concentrated brine byproduct rich in dissolved salts and minerals. This study presents an extensive economic and technical analysis of recovering all major ions from SWRO brine, which includes Na, Cl, Mg, Ca, SO4, K, Br, B, Li, Rb, and Sr in comparison to conventional mining and chemical production of these commodities. Data from recent literature and case studies are compiled to quantify the composition of a typical SWRO brine and the potential yield of valuable products. A life-cycle cost framework is applied, incorporating capital expenditure (CAPEX), operational expenditure (OPEX), and total water cost (TWC) impacts. A representative simulation for a large 100,000 m3/day SWRO plant shows that integrated “brine mining” systems could recover on the order of 3.8 million tons of salts per year. At optimistic recovery efficiencies, the gross annual revenue from products (NaCl, Mg(OH)2/MgO, CaCO3, KCl, Br2, Li2CO3, etc.) can reach a few hundred million USD. This revenue is comparable to or exceeds the added costs of recovery processes under favorable conditions, potentially offsetting desalination costs by USD 0.5/m3 or more. We compare these projections with the economics of obtaining the same materials through conventional mining and chemical processes worldwide. Major findings indicate that recovery of abundant low-value salts (especially NaCl) can supply bulk revenue to cover processing costs, while extraction of scarce high-value elements (Li, Rb, Sr, etc.) can provide significant additional profit if efficient separation is achieved. The energy requirements and unit costs for brine recovery are analyzed against those of terrestrial or conventional mining; in many cases, brine-derived production is competitive due to avoided raw material extraction and potential use of waste or renewable energy. CAPEX for adding mineral recovery to a desalination plant is significant but can be justified by revenue and by strategic benefits such as reduced brine disposal. Our analysis, drawing on global data and case studies (e.g., projects in Europe and the Middle East), suggests that metals and salts recovery from SWRO brine is technically feasible and, at sufficient scale, economically viable in many regions. We provide detailed comparisons of cost, yield, and market value for each target element, along with empirical models and formulas for profitability. The results offer a roadmap for integrating brine mining into desalination operations and highlight key factors such as commodity prices, scale economies, energy integration, and policy incentives that influence the competitiveness of brine recovery against traditional mining.

Seawater Reverse Osmosis (SWRO) desalination is a critical technology for addressing global water scarcity, yet its performance can be hindered by complex process dynamics and operational inefficiencies. This study investigates the revolutionary potential of Physics-Informed Neural Networks (PINNs) for modeling SWRO desalination processes. PINNs are subsets of machine learning algorithms that incorporate physical information to help provide physically meaningful neural network models. The proposed approach is here demonstrated using operating data collected over several months in a Seawater RO plant. PINN-based models are presented to estimate the effects of operating conditions on the permeate TDS and pressure drop. The focus is on the feed water temperature variations and progressive membrane deterioration caused by fouling. Predictive models generated using PINNs showed high performances with a determination coefficient of 0.96 for the permeate TDS model and 0.97 for the pressure drop model. Results show that the use of PINNs significantly enhances the ability to predict membrane fouling and produced water quality, thereby supporting informed decision-making for RO process control.

Fouling reduces the performance of seawater reverse osmosis (SWRO) membranes by causing blockage, which leads to increased differential pressure across the membrane vessels. Over time, this can reduce efficiency and the quality of permeate. The lifespan of an RO membrane depends on the quality of the feed water, the flux the membranes are subjected to (which is influenced by the percentage recovery), and the extent of scaling/fouling the membranes accumulate. Cleaning-in-place (CIP) is a commonly carried-out practice on RO plants to counteract fouling within the membranes. This study evaluates the financial impact of membrane fouling by comparing the effect of membrane replacement and CIP on the specific energy consumption (SEC) of a SWRO plant operated in the Maldives by using operational data collected between January 2018 and January 2024. The water production and energy consumption of the plant were used to calculate the SEC. A life cycle cost analysis was carried out to determine the optimum membrane replacement period. The breakeven point for replacing every 4 years as compared to replacing them in every 5 years is 5 years. The breakeven of 4-year-period membrane replacement against a scenario where only CIP is done is 6.08 years. It was found that the SEC improves by 0.07 kWh/m³ on average after CIP. Replacing the membrane every 4 years results in the lowest energy consumption and consequently the lowest cumulative cost over a 12-year period.

In Chile, there is an increasing demand for freshwater supply for human consumption, agriculture, and industrial activities. In this sense, the country is highly threatened by climate change, which is drastically affecting the availability of water resources in the north-central region due to desertification processes. Therefore, seawater reverse osmosis (SWRO) desalination is becoming one of the most feasible alternatives to address current and future challenges regarding water scarcity in the country. This investigation aims to evaluate potential locations for a sustainable and cost-effective installation of desalination projects; the latter, under a multi-criteria and geographic information system (GIS)-model. The model was tested in the highly water scarcity-threatened Valparaiso Region, Chile, as a case study. The model was developed integrating economic and socio-environmental criteria involved in the development and/or construction of desalination projects. The results of the multi-criteria analysis show that the Valparaıso Region presents optimal areas for developing SWRO projects. Both the northern and central areas of the Region show appropriate locations for installing SWRO plants and their freshwater distribution lines, ensuring short- and long-term water supply, especially for agriculture and population consumption. The results obtained in this study could be extrapolated as a tool to assess the desalination projects development in other world regions to make future desalination projects more viable and sustainable for addressing global water demands.

Flow-electrode capacitive deionization (FCDI) is a promising technology for sustainable water treatment. However, studies on the process have thus far been limited to lab-scale conditions and select fields of application. Such limitation is induced by several shortcomings, one of which is the absence of a comprehensive process model that accurately predicts the operational performance and the energy consumption of FCDI. In this study, a simulation model is newly proposed with initial validation based on experimental data and is then utilized to elucidate the performance and the specific energy consumption (SEC) of FCDI under multiple source water conditions ranging from near-groundwater to high salinity brine. Further, simulated pilot-scale FCDI system was compared with actual brackish water reverse osmosis (BWRO) and seawater reverse osmosis (SWRO) plant data with regard to SEC to determine the feasibility of FCDI as an alternative to the conventional membrane processes. Analysis showed that FCDI is competent for operation against brackish water solutions under all possible operational conditions with respect to the BWRO. Moreover, its distinction can be extended to the SWRO for seawater conditions through optimization of its total effective membrane area via scale-up. Accordingly, future directions for the advancement of FCDI was suggested to ultimately prompt the commercialization of the FCDI process.

Optimize and analyze a large-scale grid-tied solar PV-powered SWRO system for sustainable water-energy nexus

Seawater Reverse Osmosis (SWRO) is a common technology to treat seawater to comply high freshwater demand. Currently, the main issue of seawater/brackish water as the potential sources for drinking water is vulnerable to organic pollutants. An effective pre-treatment is crucial to maintain the efficiency of SWRO for sustainable operation. Optimization of the process could be performed by a hybrid membrane combination using commercial Activated Carbon (AC) with based material coconut shell/coal and Ultrafiltration membrane (UF). For hybrid process, the activated carbon was continuously dosed into the pilot scale filtration employing PES Hollow Fiber membrane with active area of 4 m² and average pore size of 10 nm that represents a real operation filtration process (i.e., filtration flux, filtration time, backwashing, and cleaning in place), and was performed until 8 filtration cycle sequence. This study investigated membrane performance with combination technique PAC/UF and GAC/UF in Pilot scale experiments within resistance membrane and retention membrane. Combination of Activated Carbon/Ultrafiltration showed synergistic effects in the removal of organic content for COD 40%-96%, UV-VIS 43%-92% and Turbidity 73%-99%. High removal of organics pollutants (COD, UV-VIS and Turbidity) was attributed to small average pore distribution of Activated Carbon (<10 µm) that increase adsorption process. Moreover, hybrid Activated Carbon/UF adsorption kinetics can reduce filtration times to achieved optimal retention. Related to membrane performance, hybrid AC/UF resulted in less permeability declines almost double in first two filtration cycle and slightly less permeability decline until fifth cycle in comparison with single UF process. Better membrane performance can furtherly be explained from less irreversible fouling in case of AC/UF. Combination AC/UF enhanced the control of Irreversible fouling and resulted in better filtration performance as well as higher organic substance removal. Therefore, hybrid AC/UF could be seen as an effective system as pretreatment for SWRO.

A theoretical analysis on upgrading desalination plants with low-salt-rejection reverse osmosis

Review on an integrated pre-treatment system to reduce membrane accelerated biofouling during red tide occurrences in Oman

Effectiveness of ceramic ultrafiltration as pretreatment for seawater reverse osmosis

Intelligent framework for coagulant dosing optimization in an industrial-scale seawater reverse osmosis desalination plant

Desalination is emerging as one of the most promising solutions to extraction and increasing global demand for drinking water. A water purification process called reverse osmosis (RO), in which dissolved solids are separated from solutions by partially permeable membranes. Advances in membrane technology have resulted in the removal of up to 99% of salts in seawater. However, the process and system of seawater treatment RO are associated with many problems, such as scaling and fouling of the membranes, corrosion of the pumps, valves and piping system due to the highly concentrated salt solution and high chemical consumption. Nowadays, these problems have become very critical as they severely affect the desalination process and also massively deteriorate the performance and lifetime of the system components and materials. To ensure that the desalination process is always the best option for a low-maintenance, highly efficient and cost-effective system and process, a comprehensive study of these problems is essential. Therefore, this article addresses the characteristics of metallic materials and corrosion problems in the reverse osmosis process of seawater desalination, as well as the best solutions to focus on and evaluate for an optimal seawater desalination process, and the selection of the category of duplex stainless steels suitable for seawater desalination plants to reduce maintenance, avoid plant shutdown and ensure plant safety.

Seawater and brackish desalination using reverse osmosis (RO) has been a pragmatic approach to mitigating fresh water shortage in many water-stressed areas worldwide. Compared with other desalination technologies, RO has several attributes including high energy efficiency and system modularization. To achieve these notable attributes, for large-scale seawater RO plants, it is critical to accurately design and evaluate the RO process before plant installation and operation. In this study, the IMSDesign software is applied to design a seawater RO plant with a capacity of 100 m3 of fresh water per hour. The software allows to customize the design parameters and operating conditions of the RO plant to meet the design requirements. After inputting design parameters and operating conditions, the RO plant operation can be simulated to obtain its performance indexes for plant design evaluation. The evaluation results reveal that the RO plant with membrane trains arranged in 2-passes configuration can obtain high quality permeate that meets the required standards for drinking water at energy consumption and water cost of 10.66 kWh/m3 and 2.48 USD/m3, respectively.

The most recent years of research have shifted the perception of desalination brine from being waste to a high-value resource, in consonance with a circular economy perspective. The Canary Islands, containing the largest number of desalination plants per square kilometre in the world, are a perfect location to study its characteristics and evaluate its potential. A total of 10 heterogeneous seawater reverse osmosis plants were selected to determine the brine’s physicochemical characterisation, comprising 37 parameters, and its correlation to the technical and operational aspects of the desalination plants. The results show a stable narrow range of the percentage of major ions concentration in relation to the total dissolved solids (55% Cl−, 29.5% Na+, 8% SO42−, 4% Mg2+, 1.5% Ca2+, 1.2% K+, 0.5% HCO3−, and 0.2% Br−) irrespective of specific differences between plants. The results obtained in this study are highly beneficial to industrial suppliers and future users of desalination brine valorisation (DBV) technologies, allowing an estimation of the chemical composition of a brine through knowledge only of its conductivity. Such information is crucial before investing in and optimizing DBV technologies. Nonetheless, from an environmental, economic, operational, energy-based, and R&D point of view, several improvements are required to promote their large-scale feasibility and viability.

In agreement with the Water Framework Directive, Circular Economy and European Union (EU) Green Deal packages, the EU-funded WATER-MINING project aims to validate next-generation water resource solutions at the pre-commercial demonstration scale in order to provide water management and recovery of valuable materials from alternative sources. In the framework of the WATER-MINING project, desalination brines from the Lampedusa (Italy) seawater reverse osmosis (SWRO) plant will be used to produce freshwater and recover valuable salts by integrating different technologies. In particular, electrodialysis with bipolar membranes (EDBM) will be used to produce chemicals (NaOH and HCl). A novel EDBM pilot plant (6.4 m2, FuMa-Tech) has been installed and operated. The performance of EDBM for single pass under different flowrates (2-8 L·min-1) for acid, base and saline channels, and two current densities (200 and 400 A·m-2), has been analyzed in terms of specific energy consumption (SEC) and current efficiency (CE). Results showed that by increasing the flowrates, generation of HCl and NaOH slightly increased. For example, ΔOH- shifted from 0.76 to 0.79 mol·min-1 when the flowrate increased from 2 to 7.5 L·min-1 at 200 A·m-2. Moreover, SEC decreased (1.18-1.05 kWh·kg-1) while CE increased (87.0-93.4%), achieving minimum (1.02 kWh·kg-1) and maximum (99.4%) values, respectively, at 6 L·min-1.

A seawater reverse osmosis (RO) plant layout based on multistage RO with stages located at different elevations above sea level is described. The plant uses the weight of a seawater column from pumped storage as head pressure for RO (gravity-driven multistage RO) or to supplement high-pressure pumps used in RO (gravity-assisted multistage RO). The use of gravitational force reduces the specific energy for RO compared to using high-pressure pumps. By locating the RO stages at different elevations based on demand sites, the total specific energy consumption for RO and permeate transport to different elevations above sea level is reduced from that for locating the RO process entirely at sea level followed by lifting the desalinated water. A final RO stage at sea level uses seawater pressurized by energy recovery from the residual energy of the brine generated from the preceding RO stage. Examples of the plant layout that do not include pump inefficiency and head losses in pipes are described for South Sinai, Egypt, which is a mountainous region that suffers from water scarcity. A gravity-driven multistage RO with a storage tank at 660 m above sea level is considered. For five RO stages located 316–57 m above sea level with 10% recovery at each stage, the specific energy is ~ 32% lower than that for a plant located at sea level operating at the minimum specific energy followed by lifting the same quantity of desalinated water to the elevations of the distributed RO stages. For two stages located at 222 and 57 m above sea level with 30 and 20% recovery, respectively, the reduction in specific energy is ~ 27%. For gravity-assisted five-stage RO with the first stage at 260 m above sea level, while the last stage is at sea level with 10% recovery at each stage the reduction in specific energy is ~ 32%. The proposed RO plant layouts can be adapted to other regions with comparable topography.

A scalable method to fabricate high-performance biomimetic membranes for seawater desalination: Incorporating pillar[5]arene water nanochannels into the polyamide selective layer

Performance model for reverse osmosis