Recovery of Valuable Products From Reject Brine
Recovery of Valuable Products From Reject Brine
Desalination Plants
Oswald Eppers, K-UTEC AG Salt Technologies
Summary
Desalination plants do not only produce potable water, but also for every liter of
freshwater output an average of 1.5 liters of hypersaline reject brine containing
additionally potentially hazardous chemicals added in the desalination process.
Ecotoxicological studies have proven negative environmental impacts on marine
ecosystems caused by the dumping of such residues in the sea. This fact sometimes
leads to a rejection of desalination projects by the local population because of concerns
about possible negative impacts on the fishing industry and tourism. Therefore,
improved brine management strategies are required to mitigate the negative
environmental and economic impacts on waste management and drinking water
production. This paper presents a strategy that uses reject brine to produce valuable
products such as potassium, magnesium, and calcium salts, as well as additional
byproducts with a high demand by the chemical industry, agriculture or other industries
such as caustic soda, bromine, green hydrogen, ammonia or methanol. The production
of valuable products from waste streams generates additional revenue sources leading
to an overall reduction in desalination costs, while at the same time mitigating negative
environmental impacts. Depending on local settings and project characteristics, in an
ideal case, a cero liquid discharge seawater desalination can be implemented with the
use of solar evaporation ponds, if necessary, in combination with technical evaporation
systems for reject brine processing. However, the general drawback of such a cero liquid
discharge strategy is the very high energy demand for water evaporation, required for
fractional salt crystallization. This shortcoming can be at least partially compensated by
producing in areas with high evaporation and low precipitation where solar evaporation
can be ideally used, such as those found on the Pacific coast of northern Chile and Peru.
1. Introduction
According to an UN-backed paper (Edward Jones et al., 2019), about 142 million m3 of
reject brine is generated worldwide per day, most of it in Saudi Arabia, UAE, Kuwait and
Qatar, where currently 55% of the total global share in seawater desalination capacity
is installed.
The most applied technologies for desalination are multistage is reverse osmosis and
flash distillation. Particularly in areas without the accesso to very cheap fossil energy
resources, reverse osmosis, which consists of using a semi-permeable membrane that
allows water but not the dissolved salts to pass through, is becoming increasingly
important. In the case of reverse osmosis, the remaining hypersaline reject brine has a
salt concentration approximately 1.6 - 2.5 times higher than the salinity of seawater,
and additionally containing traces of potentially hazardous anti-scalants and anti-fouling
agents used in the process mainly for membrane protection. It has been found that the
discharge of reject brine into the sea, particularly without prior dilution, can cause
severe environmental damages to the marine ecosystem. To mitigate these
environmental impacts, the brine should be retained in a tank or pond where it is diluted
with fresh seawater (usually at a ratio of 1:4) before its discharge into the sea. However,
since this practice is energy intense, the most applied method is the direct discharge
through a submarine outfall, which has the function of achieving the fastest possible
brine dispersion to minimize environmental impacts. Ideally the discharge point should
consider an area of low ecological sensitivity and catch a strong current to optimize
plume dispersion and minimize the area of the impacted zone. Therefore, the brine
discharge point typically should be located as far offshore as possible and discharge flow
rate should not be too high. Typical brine discharge velocities in engineering designs are
in the range from 2 to 8 m/s (José Vargas, 2018). Other alternatives avoiding a direct
discharge to the ocean, such as discharge to surface water or sewers, deep-well injection
and brine evaporation ponds, are rather the exceptions.
Ecotoxicological studies conducted in several countries show that brine discharge causes
real damage to the marine ecosystem in the discharge area, which can negatively affect
local fish industry (Nurit Kress and Bella Galil, 2015; Jill Woodworth, 2008; Anton
Purnama, 2014). The composition of brines is more complex than it appears at first
glance due to the presence of chemicals to prevent membrane blockage with potentially
negative ecotoxicological effects, including coagulants in the pretreatment phase (iron
or aluminum salts, polymers), biocides added as algaecides (including chlorine),
antifoulants (including copper compounds) and membrane preservatives (like sodium
bisulfite), antiscalants (polyphosphates, polyphosphonates, polyacrylic acid, polymaleic
acid), etc. In addition, there are other reagents used for cleaning reverse osmosis
membranes (acid and alkaline solutions, as well as detergents) and pH and water
hardness regulators. These chemicals are added at various stages of the process in
generally low concentrations and are subsequently eliminated with the reject brine
without pretreatment. To mitigate the negative impacts, it would be necessary to
decontaminate the reject brine or waste from membrane cleaning in a water treatment
plant prior to its discharged – a process that for cost reasons is not viable. Apart from
the concentration of salts and the presence of potentially ecotoxic chemical compounds,
adverse effects on the ecosystem were also observed due to differences in the
temperature of the reject brine and seawater. Rather unexpectedly, partially irreversible
damage to polychaetes, crustaceans, plants, fish and phytoplankton was detected even
in dilutions of less than 10 to 20 times with seawater (Nurit Kress and Bella Galil, 2015).
It should be noted that the dilution zone of the reject brine with seawater can extend to
distances of more than 500 meters, depending on the concentration gradient and
current conditions (Anton Purnama, 2014). There are sensitive species such as kingfish
in Australia (Seriola Ialandi), where a 70-fold dilution of the brine with seawater is
required to avoid damage to the fish population (Jill Woodworth, 2008). These findings
lead us to question the validity of some results of numerical dispersion models applied
in programs such as CORMIX or VISUAL PLUMES (José Alonso Vargas Torres, 2018; ANA,
2017). Such type of simulation programs is frequently applied in environmental impact
studies to justify a direct discharge of reject brine by using submerged outfalls, without
counting on results of site-specific ecotoxicological studies. High costs and time
requirements are the main reason that ecotoxicological studies are the exception, rather
than standard practice. In most projects, reject brines are discharged without any
pretreatment into the sea, relying on a rapid dilution of the effluent (Nurit Kress and
Bella Galil, 2015).
In conclusion, the high concentration of salts in the reject brine is only one factor among
many in explaining the environmental impacts on the marine ecosystem. A cocktail that
includes high local salinity, the presence of potentially ecotoxic chemicals, oxygen
depletion and other stressors such as elevated temperature can have a profound impact
on benthic organisms, which can subsequently translate into observable ecological
effects throughout the food chain.
For the separation of valuable salts in high quality and with a reasonable production
yield, the reject brine must be processed appropriately. The biggest challenge in this
process is the concentration of enormous quantities of reject brine, required for the
subsequent fractional crystallization of salts. A reverse osmosis plant with a daily
freshwater production capacity of 10,000 m3 has a reject brine production of
approximately 14,000 m3 per day (assuming a typical recovery ratio of 0.42 for reverse
osmosis processes). To start crystallizing lower solubility salts and sodium chloride, it is
necessary to concentrate the reject brine by a factor of more than 7. This means that
the 14,000 m3 brine will need to be condensed to approximately 2000 m3, which under
economic considerations is only viable using solar evaporation ponds with the sun as
free energy source. However, this free energy comes with long evaporation times and
construction costs of hectar-sized evaporation ponds, which in general must be lined
with geomembranes for impermeability. At project sites where such evaporation ponds
cannot be constructed due to space or other geographic constraints, brines need to be
concentrated by replacing some or in a worst-case scenario all of the ponds by technical
evaporation technologies, preferably supplied with solar energy sources. In most cases,
however, a combination of solar and technical evaporation can be applied to find a
compromise between economics and such logistical constraints.
A way out of this dilemma is the application of the same process elements already
successfully applied at industrial scale in the potash and lithium industry. Key for the
economic and technical feasibility in most of these projects is the application of sun
energy for water evaporation and proven cost-effective technologies for fractional salt
crystallization and processing. Recently, direct extraction methods for lithium and other
cations have been introduced in the industry, but definitive breakthroughs for mass
application have not yet been achieved due to the lack of long-term experience on an
industrial scale (K-UTEC 2021, William Stringfellow and Patrick Dobson, 2021).
In the first step, solar energy is used in a series of open-air evaporation ponds to increase
the concentration of the salts until saturation is reached. Depending on the space
available for setting up evaporation ponds, direct extraction techniques and/or technical
evaporation can also be included in the process scheme as already explained before. At
the beginning, low solubility salts like calcium and magnesium carbonate and gypsum
precipitate. After reaching a critical concentration with a brine density of about 1.21,
the major ions sodium and chloride start to precipitate as table salt, NaCl.
Figure 2: Simplified block flow diagram of the K-UTEC Process for maximum recovery
of valuable products from brine resulting from seawater desalination.
In the first step, the precipitated NaCl is collected and processed to produce table salt
and other salt qualities, as well as for the possible production of other downstream
products such as sodium hydroxide solution (NaOH), hydrochloric acid (HCl) or sodium
carbonate (Na2CO3). Calcium chloride (CaCl2) can also be crystallized from this solution
as a by-product. A second evaporation step is necessary for the recovery of a salt mixture
that is widely known as kainite-type mixed salt (KTMS), containing potassium chloride
(KCl), magnesium sulfate (MgSO4) and NaCl.
This salt mixture is the feedstock to produce potassium sulfate (SOP) in the desired
quality, applying a series of chemical, mechanical and thermal processes. As an
intermediate step, after the first evaporation stage and before the production of KTMS,
NaCl is precipitated with some impurities like calcium sulfate and iron hydroxide. This
saline fraction can be dissolved and recirculated to be reused in the process to increase
recovery efficiency. Subsequently, a liquid fraction rich in magnesium, chloride and
sulfate ions is obtained from these processes and is called bittern solution (bittern). This
solution can be used for the extraction of hydrated magnesium sulfate or epsomite
(MgSO4 *7H2O) by cooling crystallization under controlled conditions. In addition,
bromine is also found in the residual fraction of bitters in sufficient concentrations for
recovery. Apart from the above, the production of magnesium compounds such as
magnesium hydroxide (Mg[OH]2) and magnesium oxide (MgO) from the remaining brine
can be achieved.
As an example of a proposed process scheme, Figure 3 shows a block flow diagram for
SOP production from harvested KTMS, which is produced from the reject brine of
seawater desalination plants (Heiner Marx et al., 2019). The KTMS from the reject brine
evaporation process is reacted under certain conditions that allow the formation of the
intermediate product Schoenite, a double hydrated salt, consisting of magnesium
sulfate, potassium sulfate and water (K2Mg(SO4)2• 6H2O). Subsequently, K2SO4 (SOP) is
separated by controlled crystallization and MgSO4 remains in solution. At the end of the
process, the separated Schoenite is decomposed into SOP, a fertilizer in great demand
on the international market. The SOP produced is then further processed to separate
adherent brine by centrifugation and to dry the product. The main aqueous streams of
hot and cold mother liquor are circulated in-process to increase the overall production
yield.
The bitter solution remaining from these processes is sent for further processing to
obtain other products such as epsomite, elemental bromine and magnesium oxide. As
an additional option to improve the cost-benefit ratio of the process, the production of
additional products such as boron as boric acid and lithium as chloride, carbonate or
hydroxide can be considered. For the selective recovery of boron, the electrodialysis
method with monovalent anion exchange membranes can be applied to improve the
concentration factors. The separation of lithium from brine is an economic challenge
due to the generally low lithium concentrations, but it is technically feasible using state-
of-the-art selective extraction techniques (K-UTEC, 2021). In this context, it is worth
mentioning that a new process allows the direct production of lithium hydroxide from
lithium chloride without the use of toxic reagents and with a minimum of additional
water expenditure (Oswald Eppers, 2020).
The recovering rubidium, iodine and strontium is technically also feasible, but in general
not considered in the process, mainly for reasons of high investment costs and low
concentrations of these elements in the brine.
Figure 3 - Potassium sulfate production (SOP) from kainite-type mixed salt (KTSM)
obtained from brine concentration.
Figure 4: General scheme of desalination process with use of reject brine for salt,
green hydrogen and derivatives production.
Apart from ammonia, a series of other “green” chemicals are available from green
hydrogen, including green methanol. Methanol is both an important industrial chemical
and a useful multipurpose fuel that could play an increasingly important role in a carbon-
neutral energy mix. Pure methanol is easily transportable, is readily flammable, and
burns without visible flame to form carbon dioxide and water. It has high knock
resistance, which allows a higher compression ratio compared to traditional gasoline or
diesel engines. Currently, most methanol is obtained by catalytic conversion of syngas,
which is usually produced by steam reforming of natural gas [J. Ott et al., 2012]. As an
alternative to syngas, green methanol can also be produced by direct hydrogenation of
pure CO2 (preferably from a sustainable CO2 capture) with H2 with high selectivity on
commercially available Cu/ZnO-based catalysts. The economic feasibility of this CO2
hydrogenation to methanol has been investigated in several studies (Harri Nieminen et
al., 2019). It was found that the total cost is generally dominated by the hydrogen
production cost, which consists of the capital cost for the electrolyzer and the electricity
cost.
5. Conclusion
In seawater desalination, a large volume of hypersaline reject brine containing low
concentrations of potentially ecological hazardous chemicals is generated, whose
discharge to the ocean can result in environmental problems in the marine ecosystem.
A way out of this problem is the conversion of this problematic waste material into a
resource to produce commercially valuable salts and other products like green hydrogen
and ammonia. The approach has not only the advantage of avoiding ecological damages,
but also can generate additional income streams which lead to an overall reduction of
freshwater production costs. As each project has its own characteristics, individual
feasibility assessments are required in order to determine the profitability of a designed
reject brine processing. The most feasible process route for valuable salt production is
the use of solar energy for brine concentration in open evaporation ponds, combined
with high energy-efficient technical evaporation technologies, a minimum chemical
reagent requirement and an overall optimization of waste management with waste
minimization and recycling strategies. Particularly in arid areas, such as the pacific coasts
of Peru and Chile, characterized for high evaporation rates and extremely low rainfall,
the use of solar energy for the concentration of reject brine is a preferred strategy where
logistically feasible.
Literature:
1. Edward Jones, Manzoor Qadir, Michelle T.H. van Vliet, Vladimir Smakhtin and
Seong-mu Kang (2019), The state of desalination and brine production: A global
outlook,Science of The Total Environment,Volume 657, 2019, Pages 1343-1356,
https://doi.org/10.1016/j.scitotenv.2018.12.076
2. José Alonso Vargas Torres (2018), Evaluación del Impacto Ambiental del
efluente submarino del proyecto PROVISUR empleando el modelo CORMIX,
Tesis para optar el Título de Ingeniero Civil, Pontifica Universidad Católica del
Perú, Facultad de Ciencias e Ingeniería, Lima, September 2018.
3. Nurit Kress and Bella Galil (2015), Impact of seawater desalination by reverse
osmosis on the marine environment, In: Efficient Desalination by Reverse
Osmosis - A guide to RO practice, Chapter 8, IWA Publishing, Volume 14, ISBN
9781780405049; and publications mentioned in the book.
4. Jill Woodworth (2008), The Provision of Reverse Osmosis Brine Toxicity Testing
on Larval Kingfish (Seriola Ialandi), Marine Toxicity Tests, Report ECX08-1809
and ECX08-1810, GeoTech.
5. Anton Purnama (2014), Environmental Quality Standards for Brine Discharge
from Desalination Plants, Chapter 18 of the book: Recent Progress in
Desalination, Environmental and Marine Outfall Systems, Springer Verlag, ISBN
978-3-319-19123-2.
6. Autoridad Naciona del Agua, ANA (2017). Guía para la determinación de la zona
de mezcla y le evaluación del impacto de un vertimiento de aguas residuales
tratadas a un cuerpo natural de agua. Lima.
(https://repositorio.ana.gob.pe/handle/20.500.12543/900)
7. a) K-UTEC AG Salt Technologies (2022), private communication, unpublished
results, b) Abdel-Mohsen O., Mohamed, Evan K., Paleologos and Fares M.
Howari (2021), Pollution Assessment for Sustainable Practices in Applied
Sciences and Engineering, Editor: Butterworth-Heinemann, ISBN 978-0-12-
809582-9
8. Youngkwon Choi, Gayathri Naidu, Long D. Nghiem, Sangho Leeb and
Saravanamuthu Vigneswaran (2019), Membrane distillation crystallization for
brine mining and zero liquid discharge: opportunities, challenges, and recent
progress, Environmental Science: Water Resource and Technology, Issue 7,
2019.
9. J. Justin Robert Paden, P.K. Tewari, P.K. Tewari, D. Venkatram and D. Barnabas
(2007), Spray flash evaporator for low-temperature saline water desalination
application, International Journal of Nuclear Desalination 2(4), 2007.
10. Nayar, Kishor G., Jenifer Fernandes, Ronan K. McGovern, Bader S. Al-Anzi, and
John H. Lienhard V, (2019), Cost and Energy Needs of RO-ED Crystallizer
Systems for Zero Brine Discharge Seawater Desalination, Desalination 457 (May
2019): 115-132, 2019 Elsevier B.V.
11. Paripurnanda Loganathan, Gayathri Naidu and Saravanamuthu Vigneswaran
(2017), Mining valuable minerals from seawater: a critical review, Environ. Sci.:
Water Res. Technol.,2017,3,37-53.
12. a) K-UTEC (2021), Lithium Mining, From Resource Exploration to Battery
Grade Lithium
(https://www.academia.edu/59055549/Lithium_Mining_From_Resource_Explo
ration_to_Battery_Grade_Lithium); b) William T. Stringfellow and Patrick F.
Dobson (2021), Technology for the Recovery of Lithium from Geothermal
Brines, Energies 2021, 14(20), 6805 (https://www.mdpi.com/1996-
1073/14/20/6805)
13. Heiner Marx, Stephan Kaps, Bernd Schultheis and Markus Pfänder (2019),
Potassium sulfate - a precious by-product for solar salt works, World Salt
Symposium Report, Bull. Soc. Sea Water Sci., Jpn., 73, 89 - 93
(shorturl.at/abnMU).
14. Markus Pfänder, Stephan Kaps and Bernd Schultheis (2018), SOP Production
from Sea Bittern, Presentation at the International Conference "Salt Asia 2018",
29-30 November 2018, Inter Continental Grand Stanford, Hong Kong.
15. Oswald Eppers (2020), New Eco-efficient Process for the Production of High
Purity Lithium Hydroxide, Researchgate (https://bit.ly/3pKyO8v).
16. Heiner Marx, CEO of K-UTEC Salt Technologies (2021), unpublished
information.
17. B. Kroposki, J. Levene, K. Harrison, P.K. Sen, F. Novachek (2006), Electrolysis:
Information and Opportunities for Electric Power Utilities, Technical Report
NREL/TP-581-40605 September 2006
(https://www.nrel.gov/docs/fy06osti/40605.pdf)
18. Ott, J.; Gronemann, V.; Pontzen, F.; Fiedler, E.; Grossmann, G.; Kersebohm,
D.B.; Weiss, G.; Witte, C. (2012), Methanol. In Ullmann’s Encyclopedia of
Industrial Chemistry; Wiley-VCH Verlag GmbH & Co. KGaA: Weinheim,
Germany, 2012; pp. 1–27.
19. Harri Nieminen, Arto Laari and Tuomas Koiranen (2019), CO2 Hydrogenation
to Methanol by a Liquid-Phase Process with Alcoholic Solvents: A Techno-
Economic Analysis, Processes 2019, 7, 405.
About the Author: Oswald Eppers is a PhD Chemist and business development
representative of K-UTEC AG Salt Technologies in South America. K-UTEC is an engineering
and consulting company specialized in salt mining and salt processing, with emphasis on
lithium and potassium salt production projects; oswald.eppers@k-utec.es; www.k-utec.de