Reuse of shale gas flowback and produced water: Effects of coagulation and adsorption on ultrafiltration, reverse osmosis combined process

Industrial circular water use practices through the application of a conceptual water efficiency framework in the process industry

Increased industrial water demand and resource depletion require the incorporation of sustainable and efficient water and wastewater management solutions in the industrial sector. Conventional and advanced treatment technologies, closed-water loops at different levels from an industrial process to collaborative networks among industries within the same or another sector and digital tools and services facilitate the materialization of circular water use practices. To this end, the scope of this paper is the application of the Conceptual Water Efficiency Framework (CWEF), which has been developed within the AquaSPICE project aspiring to enhance water circularity within industries in a holistic way. Four water-intensive process industries (two chemical industries, one oil refinery plant and one meat production plant) are examined, revealing its adaptability, versatility and flexibility according to the requirements of each use case. It is evident that the synergy of process, circular and digital innovations can promote sustainability, contribute to water conservation in the industry, elaborating a compact approach to be replicated from other industries.

A cost-effective and high efficient Janus membrane for the treatment of oily brine using membrane distillation

Membrane distillation technology could utilize low-grade heat to desalinate brine, but the membrane material often suffers from disadvantages of low permeation flux and weak robustness to contaminants. To address these issues, the commercial polytetrafluoroethylene (PTFE) membrane was modified by cost-effective chemicals of tannic acid and (3-Aminopropyl)-triethoxysilane (APTES) to construct hydrophilic/underwater superoleophobic nano-rough structures on the surface to enhance its flux and oil-fouling resistance in direct contact membrane distillation. The results show that a high underwater oil contact angle of 180° is observed to the membrane surface due to the rough nanostructures functionalized by abundant hydroxyl groups. Despite the additional mass transfer resistance provided by the rough nanostructures, the flux was increased noticeably. This is mainly attributed to the strong interactions between the abundant hydroxyl groups of hydrophilic layer surface and water molecules, leading to a part of free water staying at intermediate transition state (IW). The mass transfer resistance of the hydrophilic layer itself is reduced as a consequence of decreased evaporation enthalpy of water, thereby increasing the flux. Moreover, while the flux of the pristine membrane is reduced by 84.18%, the flux of Janus membrane remains the same when treating mineral oil brine emulsions with oil concentration up to 1500 ppm in comparison with the result for 35 g l-1brine solution, indicating that the Janus membrane is safe from the oil contamination. Our work provides a fine guidance for membrane distillation to treat high oily brine.

The water footprint of hydraulic fracturing for shale gas extraction in China

The rapid expansion of shale gas extraction worldwide has raised significant concerns about its impact on water resources. China is expected to undergo a shale revolution following the U.S. Most of the information on water footprint of shale gas exploration and hydraulic fracturing has been focused on the U.S. Here, we addressed this knowledge gap by establishing a comprehensive database of shale gas extraction in China, utilizing operational data from over 90 % of shale gas wells across the country. We present systematic analysis of water usage and flowback and produced water (FP water) production from all the major shale gas fields in China. Between 2012 and 2022, a total of 2740 shale gas wells were hydraulically fractured in China, primarily located in Sichuan and Chongqing Province. About 113 million m3 water was used for hydraulic fracturing, resulting in a cumulative shale gas production of 116 billion m3. As of 2022, the annual water use for hydraulic fracturing exceeded 20 million m3, and the annual FP water production reached 8.56 million m3. Notably, 80 % ~ 90 % of the FP water has been reused for hydraulic fracturing since 2020, accounting for 29 % to 35 % of the annual water usage for hydraulic fracturing. Water use per well in China varies primarily between 21,730 m3 to 61,070 m3 per well, and water use per horizontal length ranges primarily between 20 m3/m and 35 m3/m. The average ultimate FP water production per well in China was estimated to be 22,460 m3. The water use intensity (WUI) for shale gas extraction in China mainly ranges from 7 to 25.4 L/GJ, which is significantly higher than that of the U.S. This disparity is largely due to the lower Estimated Ultimate Recovery (EUR) of shale gas wells in China. Despite the considerable water consumption during the hydraulic fracturing process, shale gas has a relatively low water footprint compared to other conventional energy resources in China. The Produced water intensity (PWI) for shale gas extraction in China ranges from 3.9 to 7.3 L/GJ, which is consistent with the previously reported PWI values for shale gas extraction in the U.S. This study predicts water usage and FP production spanning the period 2023 to 2050 under two scenarios to assess the potential impact of shale gas extraction on water resources in the Longmaxi shale region in Sichuan Basin. The first scenario assumed a constant drilling rate, while the second assumed a yearly 10 % increase in drilling rate. With an assumed FP water reuse rate of 85 % for hydraulic fracturing, the estimated annual freshwater consumption for the two scenarios is 10.4 million m3 and 163 million m3, respectively. This accounts for only 0.28‱ and 4.4‱ of the total annual surface water resources in Sichuan and Chongqing Province. Our findings suggest that freshwater usage for hydraulic fracturing in humid Southern China is small relative to available surface water resources. However, prospective large-scale shale gas extraction in other arid and semi-arid regions may enhance the regional water scarcity. It is necessary to develop new hydraulic fracturing technologies that can use saline groundwater or other types of marginal water, and explore alternative management and treatment strategies for FP water.

From waste to resource: Membrane technology for effective treatment and recovery of valuable elements from oilfield produced water

Oilfield produced water, a toxic and saline byproduct of the oil and gas industry, has become a global concern due to its adverse environmental and human health impacts. With large volumes of oilfiled produced water generated annually and predictions of even higher volumes in the near future, effective treatment and resource recovery are imperative. This review paper explores the potential of membrane technology, particularly integrated membrane systems, in treating and recovering valuable elements from oilfield produced water. The increasing attention to this topic is evident, but research on resource recovery still needs to be expanded. Membrane technology offers a promising solution due to its efficiency and minimal need for chemical additives or thermal inputs. However, challenges such as fouling, resistance to oil and organics, and economic viability must be addressed. By discussing oilfield produced water characteristics, treatment methods, practical applications, challenges, and prospects, this review underscores the transformative role of membrane technology in turning oilfield produced water into a valuable resource. Additionally, it emphasizes the importance of research in developing anti-fouling membranes, sustainable waste management techniques, and efficient cleaning protocols while considering economic implications and market dynamics for resource recovery.

Removal of organic pollutants in shale gas fracturing flowback and produced water: A review

Shale gas has been developed as an alternative to conventional energy worldwide, resulting in a large amount of shale gas fracturing flowback and produced water (FPW). Previous studies focus on total dissolved solids reduction using membrane desalination. However, there is a lack of efficient and stable techniques to remove organic pollutants, resulting in severe membrane fouling in downstream processes. This review focuses on the concentration and chemical composition of organic matter in shale gas FPW in China, as well as the hazards of organic pollutants. Organic removal techniques, including advanced oxidation processes, coagulation, sorption, microbial degradation, and membrane treatment are systematically reviewed. In particular, the influences of high salt on each technique are highlighted. Finally, different treatment techniques are evaluated in terms of energy consumption, cost, and organic removal efficiency. It is concluded that integrated coagulation-sorption-Fenton-membrane filtration represents a promising treatment process for FPW. This review provides valuable information for the feasible design, practical operation, and optimization of FPW treatment.

Preparation of PVDF-PVP Composite Membranes for Oily Wastewater Treatment

The oil and gas industry and related applications generate large quantities of oily wastewater, which can adversely affect the environment and human health if not properly handled. This study aims to prepare polyvinylidene fluoride (PVDF) membranes incorporated with polyvinylpyrrolidone (PVP) additives and utilize them to treat oily wastewater through the ultrafiltration (UF) process. Flat sheet membranes were prepared using PVDF dissolved in N,N-dimethylacetamide, followed by the addition of PVP ranging from 0.5 to 35 g. Characterization by scanning electron microscopy (SEM), water contact angle, Fourier transform infrared spectroscopy (FTIR), and mechanical strength tests were performed on the flat PVDF/PVP membranes to understand and compare the changes in the physical and chemical properties of the membranes. Prior to the UF process, oily wastewater was treated by a coagulation-flocculation process through a jar tester using polyaluminum chloride (PAC) as a coagulant. Based on the characterization of the membrane, the addition of PVP improves the physical and chemical properties of the membrane. The membrane's pore size becomes larger, which can increase its permeability and flux. In general, the addition of PVP to the PVDF membrane can increase the porosity and decrease the water contact angle, thereby increasing the membrane's hydrophilicity. With respect to filtration performance, the wastewater flux of the resultant membrane increases with increasing PVP content, but the rejections for TSS, turbidity, TDS, and COD are reduced.

A review of the development in shale oil and gas wastewater desalination

The development of the shale oil and gas extraction industry has heightened concerns about shale oil and gas wastewater (SOGW). This review comprehensively summarizes, analyzes, and evaluates multiple issues in SOGW desalination. The detailed analysis of SOGW water quality and various disposal strategies with different water quality standards reveals the water quality characteristics and disposal status of SOGW, clarifying the necessity of desalination for the rational management of SOGW. Subsequently, potential and implemented technologies for SOGW desalination are reviewed, mainly including membrane-based, thermal-based, and adsorption-based desalination technologies, as well as bioelectrochemical desalination systems, and the research progress of these technologies in desalinating SOGW are highlighted. In addition, various pretreatment methods for SOGW desalination are comprehensively reviewed, and the synergistic effects on SOGW desalination that can be achieved by combining different desalination technologies are summarized. Renewable energy sources and waste heat are also discussed, which can be used to replace traditional fossil energy to drive SOGW desalination and reduce the negative impact of shale oil and gas exploitation on the environment. Moreover, real project cases for SOGW desalination are presented, and the full-scale or pilot-scale on-site treatment devices for SOGW desalination are summarized. In order to compare different desalination processes clearly, operational parameters and performance data of varying desalination processes, including feed salinity, water flux, salt removal rate, water recovery, energy consumption, and cost, are collected and analyzed, and the applicability of different desalination technologies in desalinating SOGW is qualitatively evaluated. Finally, the recovery of valuable inorganic resources in SOGW is discussed, which is a meaningful research direction for SOGW desalination. At present, the development of SOGW desalination has not reached a satisfactory level, and investing enough energy in SOGW desalination in the future is still necessary to achieve the optimal management of SOGW.

Granular activated carbon (GAC) fixed bed adsorption combined with ultrafiltration for shale gas wastewater internal reuse

Membrane processes are widely applied in shale gas flowback and produced water (SGFPW) reuse. However, particulate matters and organic matters aggravate membrane fouling, which is one of the major restrictions on SGFPW reuse. The present study proposed fixed bed adsorption using granular activated carbon (GAC) combined with ultrafiltration (UF) for the first time to investigate the treatment performance and membrane fouling mechanism. The adsorption of GAC for SGFPW was best described by the Temkin isotherm model and the pseudo-second-order kinetic model. GAC fixed bed pretreatment with different empty bed contact times (EBCT) (30, 60 and 90 min) showed the significant removal rate for dissolved organic carbon (DOC) and turbidity, which was 34.7%-42.4% and 98.1%-98.9%, respectively. According to characterization of UF membrane fouling layer, particulate matters and organic matters caused major part of membrane fouling. After being treated by GAC fixed bed, total fouling index (TFI) and hydraulic irreversible fouling index (HIFI) respectively decreased by more than 32.5% and 18.3% respectively, showing the mitigation effect of GAC fixed bed on membrane fouling. According to the XDLVO theory, GAC fixed bed also mitigated membrane fouling by reducing the hydrophobic interactions between the foulants and the UF membrane. The integrated GAC fixed bed-UF process produced high-quality effluents that met the water quality standards of SGFPW internal reuse, which was an effective technology of the SGFPW reuse.

Review of oilfield produced water treatment technologies

Produced water is the wastewater formed when water is brought from subsurface reservoirs during oil or gas extraction. Currently, produced water is mainly treated using conventional trains that contain adsorbates, membrane filters, phase separators and cyclones. This paper reviewed the detailed characteristics of oilfield-produced water and the assessment of multiple technologies at primary, secondary, and tertiary treatments stages. The effectiveness of the treatment technology from the production of waste, energy requirements, usage of chemicals and the treatment effect of contaminants has been discussed. Then a qualitative assessment was presented in terms of energy requirements, robustness, flexibility, waste generation, modularity, and mobility, which has become critical to the development and application prospects of any technology.

Produced Water Treatment and Valorization: A Techno-Economical Review

In recent years, environmental concerns have urged companies in the energy sector to modify their industrial activities to facilitate greater environmental stewardship. For example, the practice of unconventional oil and gas extraction has drawn the ire of regulators and various environmental groups due to its reliance on millions of barrels of fresh water—which is generally drawn from natural sources and public water supplies—for hydraulic fracturing well stimulation. Additionally, this process generates two substantial waste streams, which are collectively characterized as flowback and produced water. Whereas flowback water is comprised of various chemical additives that are used during hydraulic fracturing; produced water is a complex mixture of microbiota, inorganic and organic constituents derived from the petroliferous strata. This review will discuss the obstacles of managing and treating flowback and produced waters, concentrating on the hardest constituents to remove by current technologies and their effect on the environment if left untreated. Additionally, this work will address the opportunities associated with repurposing produced water for various applications as an alternative to subsurface injection, which has a number of environmental concerns. This review also uses lithium to evaluate the feasibility of extracting valuable metals from produced water using commercially available technologies.

Treatment of shale gas produced water by magnetic CuFe2O4/TNTs hybrid heterogeneous catalyzed ozone: Efficiency and mechanisms

Magnetic spinel ferrite (CuFe₂O₄) has been applied to catalyze ozone for treating the practical shale gas produced water (PW) in our previous study. In this work, CuFe₂O₄/titanium nanotubes (TNTs) catalyst was successfully prepared by an impregnation-calcination method. Characterization results revealed that the crystal form of CuFe₂O₄ was bound to the surface of TNTs, the particle size is much smaller than the pure CuFe₂O₄ crystal particle, which could weaken the influence of the internal diffusion process on its catalytic efficiency. The experimental results showed that the removal ratio of COD_Cr in the CuFe₂O₄/TNTs/O₃ system was approximately 14% higher than that of the CuFe₂O₄/O₃ system. The dissolution of metal elements decreased to one-third that of the CuFe₂O₄/O₃ system. The inhibition ratio of PW on the growth of E. coli K12 decreased 68% after the CuFe₂O₄/TNTs catalytic oxidation process. Experimental results of complete capture experiments illustrated that the yield of HO• of the CuFe₂O₄/TNTs/O₃ system was 10-19% higher than that of the CuFe₂O₄/O₃ system. The elemental valence analysis revealed that the transition of Cu(II)-Cu(III) and Fe(II)-Fe(III) coexisted in the catalytic system. Besides, the surface hydroxyl groups promoted the electron transfer process and enhanced the ozone adsorption affinity. The proposed catalytic mechanisms of the CuFe₂O₄/TNTs/O₃ system were proposed via the above analysis.

The mineralization ability of a chloride-resistant γ-Cu2(OH)3Cl Fenton catalyst: effects of the cation type, salt concentration and organic pollutants

A chloride-resistant heterogeneous Fenton catalyst γ-Cu2(OH)3Cl is used to mineralize aromatic organics (phenol, bisphenol A, salicylic acid and aniline) in saline solutions with different salts (MgCl2, CaCl2, NaCl and KCl) and concentrations.

Evaluation of Fenton and modified Fenton oxidation coupled with membrane distillation for produced water treatment: Benefits, challenges, and effluent toxicity

Membrane distillation is a promising technology to desalinate hypersaline produced waters. However, the organic content can foul and wet the membrane, while some fractions may pass into the distillate and impair its quality. In this study, the applicability of the traditional Fenton process was investigated and preliminarily optimized as a pre-treatment of a synthetic hypersaline produced water for the following step of membrane distillation. The Fenton process was also compared to a modified Fenton system, whereby safe iron ligands, i.e., ethylenediamine-N,N'-disuccinate and citrate, were used to overcome practical limitations of the traditional reaction. The oxidation pre-treatments achieved up to 55% removal of the dissolved organic carbon and almost complete degradation of the low molecular weight toxic organic contaminants. The pre-treatment steps did not improve the productivity of the membrane distillation process, but they allowed for obtaining a final effluent with significantly higher quality in terms of organic content and reduced Vibrio fischeri inhibition, with half maximal effective concentration (EC₅₀) values up to 25 times those measured for the raw produced water. The addition of iron ligands during the oxidation step simplified the process, but resulted in an effluent of slightly lower quality in terms of toxicity compared to the use of traditional Fenton.

Organics removal from shale gas wastewater by pre-oxidation combined with biologically active filtration

Biological treatment technology is increasingly explored in shale gas wastewater (SGW) treatment owing to its cost effectiveness and requires efforts to improve its efficacy. In this work, ozone and ferrate(VI) oxidation pre-treatment were evaluated to enhance the performance of the subsequent biologically active filtration (BAF) in the removal of organic contaminants. The oxidation improved the SGW biodegradability and organic composition under relative high salinity (~20 g/L). Due to the degradation activity of microorganisms, the organics removal efficiency in the BAF system was observed to gradually improve and then reaching stability in long-term continuous-mode operation. The removal rate of dissolved organic carbon (DOC) of the ozone-BAF (O₃-BAF) and the ferrate(VI)-BAF (Fe(VI)-BAF) systems was 83.2% and 82.8% , respectively, higher than that of BAF alone (80.9%). This increase was attributed to higher activity and content of microorganisms in O₃-BAF and Fe(VI)-BAF systems. Two uncultured bacterial species with high abundance of 7.2-21.0% and 2.24-22.31% in genus Rehaibacterium and genus Methyloversatilis were significantly correlated with DOC removal and fluorescent organics removal, respectively. More research is needed to understand whether the species were new and their specific function. This study provides valuable suggestions for extracting safe water from SGW with an efficient treatment train.

Efficient integrated module of gravity driven membrane filtration, solar aeration and GAC adsorption for pretreatment of shale gas wastewater

Low-cost and efficient treatment processes are urgently needed to manage highly decentralized shale gas wastewater, which seriously threatens the environment if not properly treated. We propose a simple integrated pretreatment process for on-site treatment, whereby gravity driven membrane filtration is combined with granular activated carbon (GAC) adsorption and solar aeration. The rationale of exploitment of sustainable solar energy is that most shale gas production areas are decentralized and located in desert/rural areas characterized by relatively scarce transportation and power facilities but also by abundant sunshine. In this study, GAC and aeration significantly increased the stable flux (170%) and improved effluent quality. Specifically, the dissolved organic carbon removal rate of the integrated system was 44.9%. The high stable flux was attributed to a reduction of extracellular polymeric substances accumulated on the membrane, as well as to the more porous and heterogeneous biofilm formed by eukaryotes with stronger active predation behavior. The prevailing strains, Gammaproteobacteria (35.5%) and Alphaproteobacteria (56.5%), played an important active role in organic carbon removal. The integrated system has great potential as pretreatment for shale gas wastewater due to its low energy consumption, low operational costs, high productivity, and effluent quality.

Biomineralization of hypersaline produced water using microbially induced calcite precipitation

Reusing produced water (PW) as the subsequent hydraulic fracturing fluid is currently the most economical and dominant practice in the shale oil and gas industry. However, high Ca²⁺ present in PW needs to be removed prior to reuse to minimize the potential for well clogging and formation damage. In this study, the microbially induced calcite precipitation (MICP), as an emerging biomineralization technique mediated by ureolytic bacteria, was employed to remove Ca²⁺ and toxic contaminants from hypersaline PW for the first time. Batch and continuous studies demonstrated the feasibility of MICP for Ca²⁺ removal from hypersaline PW under low urea and nutrient conditions. Throughout the continuous biofiltration operation with biochar as the media, high removal efficiencies of Ca²⁺ (~96%), organic contaminants (~100%), and heavy metals (~100% for As, Cd, Mn and Ni, 92.2% for Ba, 94.2% for Sr) were achieved when PW co-treated with synthetic domestic wastewater (SDW) under the condition of PW:SDW = 1:1 & urea 4 g/L. Metagenomic sequencing analysis showed that a stable ureolytic bacterial consortium (containing Sporosarcina and Arthrobacter at the genus level) was constructed in the continuous biofiltration system under hypersaline conditions, which may play a crucial role during the biomineralization process. Moreover, the combination of the MICP and ammonium recovery could significantly reduce the acute toxicity of PW towards Vibrio fischeri by 72%. This research provides a novel insight into the biomineralization of Ca²⁺ and heavy metals from hypersaline PW through the MICP technique. Considering the low cost and excellent treatment performance, the proposed process has the potential to be used for both hydraulic fracturing reuse and desalination pretreatment on a large scale.

Polysulfone-Polyvinyl Pyrrolidone Blend Polymer Composite Membranes for Batik Industrial Wastewater Treatment

Batik wastewater, in general, is colored and has high concentrations of BOD (biological oxygen demand), COD (chemical oxygen demand), and dissolved and suspended solids. Polysulfone (PSf)-based membranes with the addition of polyvinyl pyrrolidone (PVP) were prepared to treat batik industrial wastewater. PSf/PVP membranes were prepared using the phase inversion method with N-methyl-2 pyrrolidone (NMP) as the solvent. Based on the membrane characterization through FESEM, water contact angle, porosity, and mechanical tests showed a phenomenon where the addition of PVP provided thermodynamic and kinetic effects on membrane formation, thereby affecting porosity, thickness, and hydrophilicity of the membranes. The study aims to observe the effect of adding PVP on polysulfone membrane permeability and antifouling performance on a laboratory scale through the ultrafiltration (UF) process. With the addition of PVP, the operational pressure of the polysulfone membrane was reduced compared to that without PVP. Based on the membrane filtration results, the highest removal efficiencies of COD, TDS (total dissolved solid), and conductivity achieved in the study were 80.4, 84.6, and 83.6%, respectively, on the PSf/PVP 0.35 membrane operated at 4 bar. Moreover, the highest color removal efficiency was 85.73% on the PSf/PVP 0.25 operated at 5 bar. The antifouling performance was identified by calculating the value of total, reversible, and irreversible membrane fouling, wherein in this study, the membrane with the best antifouling performance was PSf/PVP 0.25.

Desalination of Produced Water by Membrane Distillation: Effect of the Feed Components and of a Pre-treatment by Fenton Oxidation

The treatment of produced waters (by-products of oil and gas extraction) with the innovative process of membrane distillation is challenging, because these highly saline streams contain high concentrations of organic compounds and hydrocarbons that cause membrane wetting and impairment of performance. To design the most compact treatment scheme and with the aim of obtaining an easier management of produced water for reuse purposes, Fenton oxidation is here investigated as a feed pre-treatment that may produce an effluent easily handled by membrane distillation. In high-recovery membrane distillation tests, we systematically investigate the detrimental effects of individual contaminants in a synthetic produced water mimicking the composition of a real sample. The recovery rate depends strongly on the initial salinity, which eventually causes scaling and pore blocking. Surfactants are found to be mainly responsible for membrane wetting, but volatile and hydrophobic organics also spoil the quality of the product water. A Fenton oxidation pre-treatment is thus performed to degrade the target organics, with the aim of enhancing the effectiveness of the following membrane distillation and to improve the quality of the final product. The combined oxidation-membrane distillation scheme has both advantages and limitations, which need to be carefully evaluated and further investigated.