Design of a multistage hybrid desalination process for brine management and maximum water recovery

Hypersaline brine production from desalination plants causes huge environmental stress due to the untenable conventional discharge strategies. Particularly, brine production is expected to drastically increase in the coming few decades due to the increasing desalination capacity in attempts of forestalling water scarcity. Thereby, zero liquid discharge (ZLD) is a worth-considering solution for strategic brine management. ZLD or minimal liquid discharge (MLD) systems provide maximum water recovery with least or zero liquid waste generation and valuable salt production. In this work, a theoretical design of ZLD/MLD system is proposed for reverse osmosis (RO) brine management. Different scenarios are investigated utilizing multistage freeze desalination (FD) and its hybridization with multistage direct contact membrane distillation (DCMD), and eutectic freeze crystallization (EFC) technologies. The design is based on the experimental assessment of the indirect FD process at different feed salinities, i.e., 2 g/L to 155 g/L. FD experiments showed that ice quality is reduced at greater crystallinity levels and initial concentration. Moreover, a computational fluid dynamics (CFD) model is utilized to assess the performance of DCMD. A single DCMD module could produce 53 kg/(m2.h) of pure water operating with 69% thermal efficiency. Eventually, water recovery, water quality, as well as specific energy consumption (SEC) are evaluated for the whole system. Based on different configurations of the hybrid ZLD system, the proposed design can achieve water recovery between 40 and 93% with SEC range of 28-114 kWh/m3. Results also showed that the produced water quality exceeds drinkable water standards ( ≪ 500 mg/L). This work has provided great evidence in the practicality of ZLD/MLD systems for sustainable brine management.

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.

Innovations in textile wastewater management: a review of zero liquid discharge technology

Zero liquid discharge (ZLD) technology emerges as a transformative solution for sustainable wastewater management in the textile industry, emphasizing water recycling and discharge minimization. This review comprehensively explores ZLD's pivotal role in reshaping wastewater management practices within the textile sector. With a primary focus on water recycling and minimized discharge, the review thoroughly examines the economic and environmental dimensions of ZLD. Additionally, it includes a comparative cost analysis against conventional wastewater treatment methods and offers a comprehensive outlook on the global ZLD market. Presently valued at US $0.71 billion, the market is anticipated to reach US $1.76 billion by 2026, reflecting a robust annual growth rate of 12.6%. Despite ZLD's efficiency in wastewater recovery, environmental challenges, such as heightened greenhouse gas emissions, increased carbon footprint, elevated energy consumption, and chemical usage, are discussed. Methodologies employed in this review involve an extensive analysis of existing literature, empirical data, and case studies on ZLD implementation in the textile industry worldwide. While acknowledging existing adoption barriers, the review underscores ZLD's potential to guide the textile industry toward a more sustainable and environmentally responsible future.

Mapping the research on desulfurization wastewater: Insights from a bibliometric review (1991-2021)

Desulfurization wastewater in coal-fired power plants (CFPPs) is a great environmental challenge. This study aimed at the current status and future research trends of desulfurization wastewater by bibliometric analysis. The desulfurization wastewater featured with high sulfate (8000 mg/L), chlorite (8505 mg/L), magnesium (2882 mg/L) and calcium (969 mg/L) but low sodium (801.82 mg/L), and the concentrations of the main contaminants were critically summarized. There was an increasing trend in the annual publications of desulfurization wastewater in the period from 1991 to 2021, with an average growth rate of 15%. Water Science and Technology, Desalination and Water Treatment, Energy & Fuels, Chemosphere, and Journal of Hazardous Materials are the top 5 journals in this field. China was the most productive country (58.3% of global output) and the core country in the international cooperation network. Wordcloud analysis and keyword topic trend demonstrated that removal/treatment of pollutants dominated the global research in the field of desulfurization wastewater. The primary technologies for desulfurization wastewater treatment were systematically evaluated. The physicochemical treatment technologies occupied half of the total treatment methods, while membrane-based integrated processes showed potential applications for beneficial reuse. The challenges and outlook on desulfurization wastewater treatment for achieving zero liquid discharge are summarized.

Ionic resource recovery for carbon neutral papermaking wastewater reclamation by a chemical self-sufficiency zero liquid discharge system

Papermaking industry discharges large quantities of wastewater and waste gas, whose treatment is limited by extra chemicals requirements, insufficient resource recovery and high energy consumption. Herein, a chemical self-sufficiency zero liquid discharge (ZLD) system, which integrates nanofiltration, bipolar membrane electrodialysis and membrane contactor (NF-BMED-MC), is designed for the resource recovery from wastewater and waste gas. The key features of this system include: 1) recovery of NaCl from pretreated papermaking wastewater by NF, 2) HCl/NaOH generation and fresh water recovery by BMED, and 3) CO₂ capture and NaOH/Na₂CO₃ generation by MC. This integrated system shows great synergy. By precipitating hardness ions in papermaking wastewater and NF concentrate with NaOH/Na₂CO₃, the inorganic scaling on NF membrane is mitigated. Moreover, the NF-BMED-MC system with high stability can simultaneously achieve efficient CO₂ removal and sustainable recovery of fresh water and high-purity resources (NaCl, Na₂SO₄, NaOH and HCl) from wastewater and waste gas without introducing any extra chemicals. The environmental evaluation indicates the carbon-neutral papermaking wastewater reclamation can be achieved through the application of NF-BMED-MC system. This study establishes the promising of NF-BMED-MC as a sustainable alternative to current membrane methods for ZLD of papermaking industry discharges treatment.

Treatment of textile industry wastewater based on coagulation-flocculation aided sedimentation followed by adsorption: Process studies in an industrial ecology concept

This study examines the feasibility of treatment of textile industry wastewater using a two-step process that includes coagulation-flocculation aided sedimentation and adsorption. It also aims at finding reuse potential of the generated sludge while making the treated water recyclable for the same industry in an industrial ecology concept. The wastewater was collected from a small-scale textile plant with a discharge of 400 L/week, where more than 70 similar textile plants are located in and around the area. FeCl₃ was selected as the coagulant for the initial step in the treatment process, and a bimetallic oxide Graphene Oxide (GO) hybrid was selected as the adsorbent for the latter step of the treatment process. The experimental conditions for the coagulation process included the optimization of dose, stirring speed, stirring time, and settling time. For the adsorption process it included the optimization of stirring time, dose, and rate. The parameters like Chemical Oxygen Demand (COD) and color were checked during the treatment process and near complete removal of COD and color were achieved using the suggested materials and process. The treated water was found fit for recycling - towards making zero liquid discharge plant. Later, the sludge generated from both the steps in the processes was sundried and mixed with cement and tested for 7 days and 28 days of compressive strength. A total of 26 kg of cement was replaced, by using sludge generated from treating 100 L of textile wastewater, in the sludge-cement mix. In addition to solving the sludge problem, the process can help in reducing the requirement of cement in concrete. Finally, a detailed economic assessment for the entire study was also performed and is reported.

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.

3D-printed solar evaporator with seashell ornamentation-inspired structure for zero liquid discharge desalination

Solar-driven interfacial evaporation has enormous promise for fresh water recovery and salt harvesting, but salt accumulation-related challenges stand in its way. Herein, we report a spined groove-ridge pairs inspired by the shell ornamentation of the Vasticardium vertebratum, which addresses salt accumulation by artfully integrating salt reflux into localized salt crystallization. The seashell-mimetic radial V-groove array enables the 3D evaporator to transport water rapidly and directionally, resulting in high-performance water evaporation (∼95% efficiency) and localized crystallization. The periodic spines enlightened by the spine-bearing ridge on the seashell provide considerable micro-unit salt reflux. The 2-in-1 integration design endows the three-dimensional evaporator with superior solar-driven zero liquid discharge and excellent long-term salt resistance even when dealing with high-salinity brine (20 wt% NaCl) and a series of heavy metallic salt solutions. Our design offers a new alternative solution to avoiding salt scaling and could advance locally crystallized solar evaporators towards practical applications.

Membrane fouling behaviors in a full-scale zero liquid discharge system for cold-rolling wastewater brine treatment: A comprehensive analysis on multiple membrane processes

The challenge of water scarcity drives zero liquid discharge (ZLD) treatment to maximize reuse of industrial wastewater. Deciphering the characteristics and mechanisms of membrane fouling in the membrane-based ZLD system is crucial for the development of effective fouling control strategies. However, current studies only focused on the membrane fouling of single step, lacking in-depth understanding on the ZLD systems using multiple membrane processes. Herein, membrane fouling characteristics and mechanisms in a full-scale ZLD system for cold-rolling wastewater brine treatment were investigated via a comprehensive analysis on multiple nanofiltration (NF) and reverse osmosis (RO) membrane processes. The membrane fouling behaviors showed distinct characteristics along the wastewater flow direction in the ZLD system. Increasing amounts of foulants were deposited on the membrane surfaces with the sequence of the 1st pass RO, 1st stage NF, and 2nd stage NF processes. The organic fouling and silica scaling were more intensive in the 1st stage NF and 2nd stage NF for treating the brine of the 1st pass RO, as the foulants were rejected and concentrated by previous membrane processes. Severe inorganic fouling, containing amorphous SiO₂, Al₂O₃, and Al₂SiO₅, occurred on the membrane surface of the 2nd pass RO membrane, due to the recirculated high-concentration silica, high water recovery, and concentration polarization. For the 3rd pass RO process, both the amounts of organic and inorganic foulants decreased dramatically, due to the low foulant concentration in its influent. This work provides a comprehensive understanding of membrane fouling in a membrane-based ZLD system, facilitating the development of membrane fouling control strategies for multiple membrane processes.

Fouling mechanism in airblast atomizers and its suppression for water desalination

A detailed experimental study is presented on fouling behavior of the anti-clogging perforated plate atomizer designed for high salinity applications, and compared with a conventional (plain-jet) airblast atomizer. Low-pressure regions around fast moving air in the outer layer of spray (as in conventional atomizers: plain-jet and prefilming) due to Venturi suction were identified as the root cause of atomizer clogging, as they facilitate salt accumulation on the atomizer surface from spray. Accordingly, severe atomizer fouling, and fluctuations in spray cone angle were observed in the conventional airblast atomizer over 2 h at 100°C air and 50°C saline (44° to 76° at 35,000 ppm, and 44° to 91° at 100,000 ppm). In this regard, the perforated plate atomizer provides a novel liquid-film airblast atomization by maintaining a liquid-annulus film (around the air outlet) as the outer layer of spray. Doing so we achieved nearly complete suppression of fouling, and spray cone angle fluctuations (28° ± 1° at 35,000 ppm, and 30° ± 1° at 100,000 ppm). Later, novel liquid-film atomization was adopted in the conventional airblast atomizer. While, the conventional airblast atomization needed atomizer cleaning/maintenance after 35 min for 175°C air and 65°C saline at 100,000 ppm, the liquid-film atomization showed no sign of fouling over 14 h. Hence, current work establishes a benchmark liquid-film airblast atomization mechanism in the anti-clogging perforated plate atomizer for complete suppression of fouling in airblast atomization. This extends the application of airblast atomizers from high evaporation jet engines to ZLD-HDH desalination systems, spraying, powder metallurgy, pharmaceuticals and hospitals, and spray drying and cooling.

Developing a reclamation strategy for softening nanofiltration brine: A scaling-free conversion approach via continuous two-stage electrodialysis metathesis

A significant amount of concentrated, scaling-prone brine can be generated during the conversion of unconventional water resources to freshwater, thus necessitating the zero discharge of concentrated brine to meet environmental and resource requirements. In this study, a two-stage feed-and-bleed electrodialysis metathesis (FB-EDM) process was implemented to reclaim softening nanofiltration (SNF) brine. To determine the optimized process parameters, experiments were conducted with various initial diluate to concentrate volume ratios (V_D:V_C), applied voltages, replenishment flow rates (Q_rp), and initial diluate compartment concentration ratios (C_D1:C_D2). The results indicated that these parameters (except for the initial volume ratio) significantly influenced the FB-EDM process. The optimized conditions included a V_D:V_C of 2:1, voltage of 1.5 V per repeating unit, Q_rp of 4 L/h, and C_D1:C_D2 of 1.5:1. The two-stage FB-EDM process operating under the optimized conditions achieved an energy consumption of <0.9 kWh/kg salt, and the total dissolved solids (TDS) in terms of Cl-type and Na-type salts reached 199.1 and 224.4 g/L, respectively; the corresponding overflow rates were 1.17 and 1.14 L/h, respectively. The developed system thus demonstrated approximately 85% TDS removal and ionic conversion of the brine; additionally, the self-crystallization of CaSO₄·2H₂O was realized by blending the Cl-type and Na-type salts. This process therefore represents a suitable method for converting SNF brine into highly-concentrated liquid salts, and provides a reclamation strategy for miscellaneous salts.

Evaluation of percrystallization coupled with electrodialysis for zero liquid discharge in the pulping industry

We evaluated percrystallization at laboratory scale to determine its suitability as core technology for achieving Zero Liquid Discharge (ZLD) in a Kraft effluent desalination process. Compared with conventional evaporation/crystallization techniques, percrystallization allows to operate at room temperature and with barely pressurized fluids, using relatively unexpensive membranes and vacuum to allow evaporation of aqueous brine solutions. For further comprehension of the technology before experimentation, a computational fluid dynamics model was developed, showing how temperature affects the performance of percrystallization in terms of transmembrane flux. Additionally, we performed experiments with single and double salt solutions (NaCl and NaCl/Na₂SO₄) and concentrated industrial effluent from a Kraft pulp mill (brine from the effluent desalination with electrodialysis). Percrystallization of the concentrated industrial effluent was successfully achieved at laboratory scale, showing no signs of fouling on the membrane surface. However, high energy consumptions (above 3000 kWh/ton of evaporated water) were measured. Theoretical power consumptions of an optimized industrial percrystallization system were therefore computed. Percrystallization showed a more efficient performance compared with similar membrane systems, such as vacuum membrane distillation, but higher energy consumptions than conventional ZLD technologies (mechanical vapor compression), having an estimated energy consumption of around 110-150 kWh/ton of removed water, depending on the feed fluid temperature. Nevertheless, percrystallization could be suitable for ZLD applications where low-cost heating (e.g., solar) is available, since the vacuum energy demand is only 32-140 kWh/ton. Alternatively, it could be applied to low scale processes where the temperature of the solution must remain low (e.g., less than 40 °C).

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.

Energy efficient vortex-enhanced water evaporation technology for concentrated brine management: Theory and process simulation evaluation

Desalination drinking water systems and industrial processes generating high salinity streams require practical brine management options for disposal and/or treatment. Treatment most often involves large capacity brine concentrating processes, on the order of 2000 m3/day, that rely on water evaporation, vapor compression, and condensation. A new technology adds an aerosol-generating device to the evaporation step with the goal of energy efficient operation even at smaller scales. The principles behind the tornadic flowfield that breaks up and aerosolizes water as air and water flow over the machined surface in the device are introduced. Design of a 6.8 m3/day demonstration system, based on this new technology, producing a NaCl slurry (55 wt% solids) from a 22 wt% NaCl influent is described. Simulations of the system with three influent brine concentrations and three forms of final NaCl concentrate are presented and predicted energy usage is compared to estimates for conventional systems. By varying simulation process parameters, the heat transfer performance of the evaporator/condenser is identified as having a large impact on overall efficiency. The new system is anticipated to be most competitive, on an energy usage basis, with conventional concentrator/crystallizer systems when processing higher salinity brines and producing final concentrates containing precipitated NaCl.

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.

Recovering chemical sludge from the zero liquid discharge system of flue gas desulfurization wastewater as flame retardants by a stepwise precipitation process

In this study, a five-stage stepwise precipitation process, including pre-sedimentation, magnesium removal, gypsum precipitation, ettringite precipitation and calcium removal, was proposed as a softening pretreatment for zero liquid discharge system for flue gas desulfurization wastewater. Batch tests and long-term bench-scale experiment showed that magnesium, sulfate and calcium were efficiently removed with efficiencies all above 98.0%, leaving a clean effluent majorly containing NaCl and NaOH. The precipitated CaSO₄, CaCO₃, Mg(OH)₂ and ettringite were completely separated by stepwise precipitation, and the purity of Mg(OH)₂ and ettringite were further enhanced by washing and soaking treatment. CaSO₄ and CaCO₃ can be directly recycled as gypsum product and desulfurizing agent within the power plant, while Mg(OH)₂ and ettringite presented proper particle size and excellent thermal properties as a synergistic flame retardant. The flame retardancy of ethylene vinyl acetate copolymer were greatly improved when blended with recovered Mg(OH)₂ and ettringite, and possessed better performance by blending them together because ettringite could act as a dispersing and compatible agent of Mg(OH)₂, and relieve the intensity of smoke releasing. Chemical sludge recovery compensates the total cost of the five-stage process by 45.0%, and makes the process technically versatile, economically beneficial and environmentally friendly without solid waste production.

An electro-oxidation reactor for treatment of nanofiltration concentrate towards zero liquid discharge

Nanofiltration (NF) concentrate generated from the secondary wastewater treatment contains high concentration of ammonium nitrogen and refractory organics, thus having great environmental risks. In this study, an electro-oxidation (EO) reactor built up with a boron-doped diamond (BDD) anode is utilized to treat the NF concentrate. To reach "zero liquid discharge", a mixture of the electrolytic effluent and the raw secondary wastewater was collected and transported back to the NF module. Results show that under the current density of 30 mA·cm^-2, most of ammonia nitrogen was decomposed into N-gases within 30 min due to the active chlorine radicals generated in the electrochemical process. Moreover, the EO reactor completely eliminated antibiotics, humic acids and bacteria in the NF concentrate under long electrolysis time of 60 min. In particular, the organic pollutants removal rate was kept at a stable value in the EO reactor for a long-term operation of up to 120 h. In addition, the NF membrane remained a constant permeate flux without being affected by the membrane biofouling caused by organic components in wastewater. Our study highlights the potential of the NF-EO process as a "zero liquid discharge" approach for treatment of the secondary wastewater.

Mass transport release of heavy metal oxyanions from solidified/stabilized co-disposed flue gas desulfurization brine and coal fly ash monoliths

The coal-fired power industry faces pressing needs to improve disposal practices for the generated flue gas desulfurization (FGD) wastewater and coal fly ash (CFA). Zero-liquid-discharge (ZLD) strategies are gaining significant interest and can be achieved by co-disposing the concentrated FGD wastewater brine with CFA and Portland cement in a solidification/stabilization (S/S) process-a novel strategy that manages two wastes simultaneously. In this study, the stability of such S/S solids produced by utilizing bituminous CFA was evaluated for the mass transport release of major components (Ca²⁺, Cl^-, Mg²⁺, Na⁺, and SO₄^2-) and heavy metal oxyanions (As, Cr, and Se) in long-term leaching tests. Particularly, the impact of FeSO₄ (FS) addition to the S/S mixture for the purpose of enhancing heavy metal immobilization was assessed. Results showed that FS addition to the S/S process decreased the solid's cumulative release and flux at shorter leaching times for the major components Ca²⁺, Cl^-, Mg²⁺, Na⁺, and SO₄^2-, but this effect was diminished over time. However, FS addition significantly decreased release of oxyanions As, Cr, and Se throughout the prolonged leaching time, indicating that FS addition could increase the likelihood of successful long-term disposal of S/S solids of concentrated FGD brines containing these heavy metal oxyanions. Results of this study can help the power industry to further assess and optimize the co-disposal ZLD strategy to minimize environmental risks.

Characterization and recycling of textile sludge for energy-efficient brick production in Ethiopia

In recent years, an enormous amount of sludge is generated every day from zero liquid discharge treatment plant due to rapid expansion of industrial parks in Ethiopia. About 30,000 tons of partially dried sludge discharged to the environmental without proper waste management from all industrial parks. Thus, posing serious environmental problems. One of the most plausible means to recycle the excess sludge resource is converting it into energy-efficient brick by combining with clay. Bricks were prepared by incorporating textile sludge at different proportions (10-40%) and temperature (600, 900 and 1200 °C). Clay and sludge samples were collected from the Addis Ababa brick factory PLC and Hawassa Industrial Park. Results revealed that 10 and 20% sludge bricks satisfied criteria of class "A" bricks as per Ethiopia standards, with the compressive strength of 30.43 and 29.10 Mpa, respectively, at 1200 °C. About 26 and 50% of energy were saved during firing of 10 and 20% sludge-containing bricks, respectively, compared with pristine clay bricks. Moreover, too low concentrations of selected heavy metals found in the brick leachate, showing the sludge, were effectively stabilized in the burnt clay bricks. Thus, based on the results, we suggest the rapid utilization of huge amount of partially dried sludge resources for low-cost and efficient large-scale brick production. This will mutually benefit both the industrial parks and brick production industries. In addition, this will create thousands of jobs to the local people. Above all, the solid waste will be managed properly at textile industrial parks.

Treatment of industrial brine using capacitive deionization (CDI) towards zero liquid discharge - challenges and optimization

Thermal-based Zero Liquid Discharge (ZLD) process has been used for managing industrial brine. However, conventional thermal ZLD process is very energy intensive. In view of this, pre-concentration techniques have been applied prior to thermal process to reduce energy consumption of ZLD systems. Capacitive Deionization (CDI) is an emerging desalination technique and has yet to be extensively explored for the treatment of industrial brine especially for ZLD applications. High concentration of total dissolved solids (TDS) and high fouling potential of industrial brine are two major challenges in CDI process. This paper reviews the possible factors for optimizing CDI process in industrial brine treatment, namely, cell architectures, strategies in operation and fouling control. Cell architectures of membrane CDI (MCDI) and flow-electrode CDI (CDI) are preferred options for treating industrial brine compared with classic CDI in terms of energy consumption and fouling propensity. There are other operational strategies that could enhance the feasibility of using CDI process for ZLD application. These include reversed voltage desorption, multi-stage operation, brine recirculation and fouling control. Fouling control methods comprise pretreatment, antifouling modification, antiscalant and chemical cleaning. These methods could be integrated to optimize fouling mitigation. In addition to providing insights on feasibility of using CDI to concentrate industrial brines, this review also proposed guidelines for optimizing CDI process applied to treat industrial brines for ZLD applications.

Minimal and zero liquid discharge with reverse osmosis using low-salt-rejection membranes

Minimal and zero liquid discharge (MLD/ZLD) are wastewater management strategies that are attracting heightened attention worldwide. While conventional reverse osmosis (RO) has been proposed as a promising technology in desalination and MLD/ZLD processes, its application is limited by the maximum hydraulic pressures that current RO membranes and modules can withstand. In this study, we develop low-salt-rejection RO (LSRRO), a novel staged RO process, that employs low-salt-rejection membranes to desalinate or concentrate highly saline feed streams, requiring only moderate hydraulic pressures. Based on process modeling, we demonstrate that LSRRO can overcome the hydraulic pressure limitations of conventional RO, achieving hypersaline brine salinities (>4.0 M NaCl or 234 g L^-1 NaCl) that are required for MLD/ZLD applications, without using excessively high hydraulic pressures (≤70 bar). In addition, we show that the energy efficiency of LSSRO is substantially higher than traditional thermally-driven phase-change-based technologies, such as mechanical vapor compressor (MVC). For example, to concentrate a saline feed stream from 0.1 to 1.0 M NaCl, the specific energy consumption (SEC) of 4-stage LSRRO ranges from 2.4 to 8.0 kWh of electrical energy per m³ of feedwater treated, around four times less than that of MVC, which requires 20-25 kWh_e m^-3. Furthermore, compared to osmotically mediated RO technologies that require bilateral countercurrent stages to treat hypersaline brines, LSRRO is eminently more practical as it can be readily implemented by using 'loose' RO or nanofiltration membranes in conventional RO. Our study highlights LSRRO's potential for energy efficient brine concentration using moderate hydraulic pressures, which would drastically improve the energetic and economic performance of MLD/ZLD processes.

Solidification/stabilization of flue gas desulfurization brine and coal fly ash for heavy metals and chloride immobilization: Effects of S/S conditions and zero-valent-iron pretreatment

Effective management of flue-gas-desulfurization (FGD) wastewater and coal-combustion-residues (CCRs) are major challenges in the coal-fired power industry. The zero-liquid-discharge (ZLD) method of combining FGD brines and CCRs in solidification/stabilization (S/S) is promising due to its potential of treating both wastes in the same process. This study evaluated the performance of such a ZLD method for immobilizing heavy metals (Se, As, Cd and Cr) and chloride in FGD wastewater and/or CCRs. Effects of different coal fly ash (bituminous (BCFA) and sub-bituminous (SCFA)), activating agent (Portland cement (PC) and lime) and pretreatment of brines by zero valent iron (ZVI) on the S/S process were evaluated. Short-term and long-term leaching tests were conducted to evaluate performance of the S/S solids in pollutant retainment. The pre-treatment of FGD brine by ZVI enhanced the retainment of heavy metals when BCFA was used, but not when SCFA was used since it already performed quite well without ZVI pretreatment. Quantitative X-ray diffraction and scanning electron microscopy analyses strongly indicated the formation of Friedel's salt, Ca₂Al(OH)₆(Cl,OH)·2H₂O, is critical in the retainment of heavy metals and chloride. SCFA contained higher lime and reactive aluminate contents than BCFA; thus, S/S solids made with SCFA contained higher amounts of Friedel's salt.

Membrane-based technologies for zero liquid discharge and fluoride removal from industrial wastewater

Several defluoridation techniques for reducing high initial fluoride concentration (IFC) in wastewater have been tested, but only a few of them have achieved the permissible standards. This study examined the hybrid crystallization-reverse osmosis technique (HRO) in light of flux, fluoride removal efficiency, fouling tendency, mineral recovery, complying zero liquid discharge (ZLD), and effluent discharge standard (EDS). Simulated wastewater with an IFC of 6600 mg/L was utilized and the final HRO performance was compared with those of the low-pressure (30 bar) standalone reverse osmosis (SRO), nanofiltration (SNF), and membrane distillation (SMD) processes. Accordingly, the study on SRO and SNF revealed that pressure, feed pH, membrane type, and IFC were the major factors affecting performance, and SRO was unable to sufficiently defluoridate wastewater with IFC >614 mg/L, needing pretreatment. Subsequently, the HRO process was selected and it was seen that the optimum calcium dose and respective final effluent pH for attaining EDS and ZLD were 16.5 g/L & 7.1 and 19.8 g/L & 5.7 respectively. The best operating pH for all conditions in HRO was approximately 9. Additionally, HRO showed good mineral recovery tendency and less organic fouling. The overall comparisons of flux and residual fluoride for HRO, SRO, SNF, and SMD were 49.3 LMH & 1.21 mg/L; 34.9 LMH & 62 mg/L, 44.05 LMH & 301 mg/L, and 38 LMH & 0.9 mg/L respectively. Therefore, low-pressure HRO can be applied to treat wastewater with high IFC; good tendency of mineral recovery, as good as that of SMD.

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.

Concentrate minimization and water recovery enhancement using pellet precipitator in a reverse osmosis process treating textile wastewater

Industrial wastewater reuse together with zero or near zero liquid discharges have been a growing trend due to the requirement of sustainable water management mandated by water scarcity and tightening discharge regulations. Studies have been conducted on the reclamation of textile industry wastewater using RO processes. However a lot of scientific attention has been drawn upon limiting the amount of concentrate generated from RO processes, which depends on the concentrations of scale forming ions in the concentrate stream. Hence, this study aims at investigating the applicability of an ultra-filtration (UF) membrane integrated pellet reactor to remove scale forming ions, i.e. Ca²⁺, Mg²⁺ and Si from the concentrate of a pilot-scale textile industry RO process, for the first time in the literature. The resulting effluent was further tested in a secondary RO process to decrease concentrate volume and increase total water recovery. The pellet reactor operated at an extremely low hydraulic retention time of 0.1 h removed scale forming ions, i.e. Ca²⁺, Mg²⁺, with 90-95% efficiency, which improved the secondary RO process performance up to 92-94% overall water recovery, i.e. near zero liquid discharge was reached. Ozonation of the concentrate partially removed COD and color, which further improved the secondary RO filtration performance.

Osmosis process for leachate treatment in industrial platform: Economic and performances evaluations to zero liquid discharge

The industrial processes require large quantities of water. The presence of discharges results not only in significant environmental impact but implies wastage of water resources. This problem could be solved treating and reusing the produced wastewaters and applying the new zero liquid discharge approach. This paper discusses the design and the performances of reverse osmosis membranes for the upgrading of full scale platform for industrial liquid wastes. The final effluent from the ultrafiltration unit of the full scale plant was monitored to design the reverse osmosis unit. Previous modelling phase was used to evaluate the specific ordinary and maintenance costs and the final effluent quality (2.7 €/m³). The system was designed in triple stages at different operative pressures. The economic feasibility and the payback period of the technology at different percentages of produced permeate were determined. The recovery of 90% was identified as profitable for the reverse osmosis application. One experimental pilot plant applying the reverse osmosis was used to test the final effluent. Moreover, the same flow was treated with second pilot system based on the forward osmosis process. The final efficiencies were compared. Removals higher than 95% using the reverse system were obtained for the main macropollutants and ions. No sustainable applicability of the forward osmosis was determined.

Hydrodynamic and kinetic study of a hybrid detoxification process with zero liquid discharge system in an industrial wastewater treatment

This work focused on the degradation of toxic organic compounds such as methyl violet dye (MV) in water, using a combined photocatalysis/low pressure reverse osmosis (LPRO) system. The performance of the hybrid system was investigated in terms of the degradation efficiency of MV, COD and membrane separation of TiO2. The aim of the present study was to design a novel solar reactor and analyze its performance for removal of MV from water with titanium dioxide as the photocatalyst. Various operating parameters were studied to investigate the behavior of the designed reactor like initial dye concentration (C = 10-50 mg/L), loading of catalyst (CTiO2 = 200-800 mg/L), suspension flow rate (QL = 0.3-1.5 L/min), pH of suspension (5-10), and H2O2 concentration (CH2O2 = 200-1000 mg/L). The operating parameters were optimized to give higher efficiency to the reactor performance. Optimum parameters of the photocatalysis process were loading of catalyst (400 mg/L), suspension flow rate (0.5 L/min), H2O2 concentration (400 mg/L), and pH = 5. The designed reactor when operating at optimum conditions offered a degradation of MV up to 0.9527 within one hours of operation time, while a conversion of 0.9995 was obtained in three hours. The effluent from the photocatalytic reactor was fed to a LPRO separation system which produced permeate of turbidity value of 0.09 NTU which is closed to that of drinking water (i.e., 0.08 NTU). The product water was analyzed using UV-spectrophotometer and FTIR. The analysis results confirmed that the water from the Hybrid-System could be safely recycled and reuse. It was found that the kinetics of dye degradation was first order with respect to dye concentration and could be well described by Langmuir-Hinshelwood model. A power-law based empirical correlation was developed for the photocatalysis system, related the dye degradation (R) with studied operating conditions.