Search Results (27)

Extending the recovery ratio (RR) of brackish water reverse osmosis (RO) plants to zero liquid discharge (ZLD, i.e., ≥95%) is vital, particularly inland, where the cost of safe retentate disposal is substantial. Various suggestions appear in the literature; however, many of these are impractical in the real world. Often, the limiting parameter that determines the maximal recovery is the SiO₂ concentration that develops in the RO retentate and the need to further desalinate the high osmotic pressure retentates produced in the process. This work combines well-proven treatment schemes to attain RR ≥ 95% at a realistic cost. The raw brackish water undergoes first a 94% recovery nanofiltration (NF) step, whose permeate undergoes a further 88-RR RO step. To increase the overall RR, the retentate of the 1st RO step undergoes SiO₂ removal performed via iron electro-dissolution and then a 2nd, 43% recovery, RO pass. The retentate of this step is combined with the NF retentate, and the mix is treated with mechanical vapor recompression (MVR) (RR = 62.7%). The results show that >95% recovery can be attained by the suggested process at an overall cost of ~USD 0.70/m³. This is ~60% higher than the USD 0.44/m³ calculated for the baseline operation (RR = 82.7%), making the concept feasible when either the increase in the plant’s capacity is regulatorily requested, or when the available retentate discharge method is very costly. The cost assessment accuracy was approximated at >80%. Full article

With water availability being one of the world’s major challenges, this study aims to propose a Zero Liquid Discharge (ZLD) system for treating saline effluents from an urban wastewater treatment plant (UWWTP), thereby supplementing into the existing water cycle. The system, which employs membrane (nanofiltration and reverse osmosis) and thermal technologies (multi-effect distillation evaporator and vacuum crystallizer), has been installed and operated in Cyprus at Larnaca’s WWTP, for the desalination of the tertiary treated water, producing high-quality reclaimed water. The nanofiltration (NF) unit at the plant operated with an inflow concentration ranging from 2500 to 3000 ppm. The performance of the installed NF90-4040 membranes was evaluated based on permeability and flux. Among two NF operation series, the second—operating at 75–85% recovery and 2500 mg/L TDS—showed improved membrane performance, with stable permeability (7.32 × 10⁻¹⁰ to 7.77 × 10⁻¹⁰ m·s⁻¹·Pa⁻¹) and flux (6.34 × 10⁻⁴ to 6.67 × 10⁻⁴ m/s). The optimal NF operating rate was 75% recovery, which achieved high divalent ion rejection (more than 99.5%). The reverse osmosis (RO) unit operated in a two-pass configuration, achieving water recoveries of 90–94% in the first pass and 76–84% in the second. This setup resulted in high rejection rates of approximately 99.99% for all major ions (Cl⁻, Na⁺, Ca²⁺, and Mg²⁺), reducing the permeate total dissolved solids (TDS) to below 35 mg/L. The installed multi-effect distillation (MED) unit operated under vacuum and under various inflow and steady-state conditions, achieving over 60% water recovery and producing high-quality distillate water (TDS < 12 mg/L). The vacuum crystallizer (VC) further concentrated the MED concentrate stream (MEDC) and the NF concentrate stream (NFC) flows, resulting in distilled water and recovered salts. The MEDC process produced salts with a purity of up to 81% NaCl., while the NFC stream produced mixed salts containing approximately 46% calcium salts (mainly as sulfates and chlorides), 13% magnesium salts (mainly as sulfates and chlorides), and 38% sodium salts. Overall, the ZLD system consumed 12 kWh/m³, with thermal units accounting for around 86% of this usage. The RO unit proved to be the most energy-efficient component, contributing 71% of the total water recovery. Full article

Zero-liquid discharge (ZLD) of desulfurization wastewater from coal-fired power plants is a critical challenge in the thermal power industry. Flash evaporation technology provides an efficient method for wastewater concentration and the recovery of high-quality freshwater resources. In this study, numerical simulations of the high-temperature and high-pressure spray flash evaporation process within a flash tank were conducted using the Discrete Phase Model (DPM) and a self-developed heat and mass transfer model for superheated droplets under depressurization conditions. The effects of feedwater temperature, pressure, nozzle spray angle, and mass flow rate on spray flash evaporation characteristics were systematically analyzed. Key findings reveal that (1) feedwater temperature is the dominant factor, with the vaporization rate significantly increasing from 19.78% to 55.88% as temperature rises from 240 °C to 360 °C; (2) higher pressure reduces equilibrium time (flash evaporation is complete within 6 ms) but shows negligible impact on final vaporization efficiency (stabilized at 33.93%); (3) increasing the spray angle provides limited improvement to water recovery efficiency (<1%); (4) an optimal mass flow rate exists (0.2 t/h), achieving a peak vaporization rate of 42.6% due to balanced evaporation space utilization. This work provides valuable insights for industrial applications in desulfurization wastewater treatment. Full article

Water regeneration in PVC production is a key issue to consider, given the high freshwater consumption rate of the process. This research evaluates the inherent safety of poly(vinyl chloride) (PVC) production via suspension polymerization by implementing mass and energy integration strategies in combination with wastewater regeneration under a zero-liquid-discharge (ZLD) approach. The impact of these integrations on process safety was examined by considering the risks associated with the handling of hazardous materials and critical operations, as well as the reduction in waste generation. To this end, the Inherent Safety Index (ISI) methodology was employed, which quantifies hazards based on factors such as toxicity and flammability, enabling the identification of risks arising from system condition changes due to the implementation of sustainable water treatment technologies. Although the ISI methodology has been applied to various chemical processes, there are few documented cases of its specific application in PVC plants that adopt circular production strategies and water resource sustainability. Therefore, in this study, ISI was used to thoroughly evaluate each stage of the process, providing a comprehensive picture of the safety risks associated with the use of sustainable technologies. The assessment was carried out using simulation software, computer-aided process engineering (CAPE) methodologies, and information obtained from safety repositories and expert publications. Specifically, the Chemical Safety Index score was 22 points, with the highest risk associated with flammability, which scored 4 points, followed by toxicity (5 points), explosiveness (2 points), and chemical interactions, with 4 points attributed to vinyl chloride monomer (VCM). In the toxicity sub-index, both VCM and PVC received 5 points, while substances such as sodium hydroxide (NaOH) and sodium chloride (NaCl) scored 4 points. In the heat of reaction sub-index, the main reaction scored 3 points due to its high heat of reaction (−1600 kJ/kg), while the secondary reactions from PVA biodegradation scored 0 points for the anoxic reaction (−156.5 kJ/kg) and 3 points for the aerobic reaction (−2304 kJ/kg), significantly increasing the total index. The Process Safety Index scored 15 points, with the highest risk found in the inventory of hazardous substances within the inside battery limits (ISBL) of the plant, where a flow rate of 3241.75 t/h was reported (5 points). The safe equipment sub-index received 4 points due to the presence of boilers, burners, compressors, and reactors. The process structure scored 3 points, temperature 2, and pressure 1, reflecting the criticality of certain operating conditions. Despite sustainability improvements, the process still presented significant chemical and operational risks. However, the implementation of control strategies and safety measures could optimize the process, balancing sustainability and safety without compromising system viability. Full article

Zero Liquid Discharge (ZLD) is a wastewater management strategy that eliminates liquid waste while maximizing water use efficiency. This article reviews the primary ZLD technologies used for desulfurization wastewater (DWW) treatment in coal-fired power plants. These technologies include the thermal process and the membrane process. The thermal process includes “concentrated crystallization” technology and “gas evaporation and drying” technology. The paper also highlights recent advances in membrane technology for power plant wastewater treatment. The advantages and limitations of each technique are discussed. Membrane technology is considered a promising solution for wastewater recycling, while thermal technology offers easy operation and maintenance without the need for pretreatment. Finally, the paper outlines possible future directions for the treatment of DWW. Full article

As the demand for sustainable water and wastewater management continues to rise in both desalination and industrial sectors, there is been notable progress in developing Zero Liquid Discharge (ZLD) and Minimal Liquid Discharge (MLD) systems. Membrane technologies have become a key component of these systems, providing effective solutions for removing contaminants and enabling the recovery of both water and valuable resources. This article explores recent advancements in the design and operation of ZLD and MLD systems, discussing their benefits, challenges, and how they fit into larger treatment processes. Emphasis is given to membrane-based processes, such as reverse osmosis (RO), membrane distillation (MD), and forward osmosis (FO), as well as hybrid configurations, and innovative membrane materials. These advancements are designed to address critical challenges like fouling, scaling, high energy demands, and high brine production. The article also explores exciting research directions aimed at enhancing the efficiency and durability of membrane technologies in ZLD and MLD systems, paving the way for new innovations in sustainable water management across various industries. Full article

Water scarcity necessitates desalination technologies, yet their high energy demands and brine disposal challenges hinder sustainability. This research study evaluates the energy footprint and carbon emissions of thermal- and membrane-based desalination technologies, alongside Minimal/Zero Liquid Discharge (MLD/ZLD) frameworks, with a focus on renewable energy source (RES) integration. Data revealed stark contrasts: thermal-based technologies like osmotic evaporation (OE) and brine crystallizers (BCr) exhibit energy intensities of 80–100 kWh/m³ and 52–70 kWh/m³, respectively, with coal-powered carbon footprints reaching 72–100 kg CO₂/m³. Membrane-based technologies, such as reverse osmosis (RO) (2–6 kWh/m³) and forward osmosis (FO) (0.8–13 kWh/m³), demonstrate lower emissions (1.8–11.7 kg CO₂/m³ under coal). Transitioning to RES reduces emissions by 90–95%, exemplified by renewable energy-powered RO (0.1–0.3 kg CO₂/m³). However, scalability barriers persist, including high capital costs, RES intermittency, and technological immaturity in emerging systems like osmotically assisted RO (OARO) and membrane distillation (MD). This research highlights RES-driven MLD/ZLD systems as pivotal for aligning desalination with global climate targets, urging innovations in energy storage, material robustness, and circular economy models to secure water resource resilience. Full article

In the present paper, we have conducted a comprehensive analysis of vapor pressures of both saturated and unsaturated solutions, alongside a study of evaporation using synthetic and natural fabrics for industrial applications in brackish water treatment under zero liquid discharge (ZLD) philosophy. By determining the vapor pressures of saturated solutions, we obtained results consistent with those of other researchers, extending the range of tested temperatures from 1 to 50 °C and successfully fitting the parameters of an Antoine-type equation. Similarly, positive results were achieved for unsaturated solutions, where various parameters of different equations accounting for the salt concentration were estimated, simplifying the fitting procedure. Natural evaporation tests from water surfaces using saturated solutions revealed that salts with higher associated vapor pressures exhibit higher evaporation rates. On the other hand, hydrated salts retain water in their structure and are significantly affected by ambient humidity. Evaporation studies on natural and synthetic fabrics with saturated NaCl and CuSO₄·5H₂O solutions showed distinct behaviors. NaCl increased both the evaporation rate and salt deposition with each cycle. In contrast, CuSO₄·5H₂O reduced the absorption capacity by blocking the fabric’s structure, decreasing the evaporation efficiency over successive cycles. Full article

In the present study, nine fabrics have been tested for brackish water treatment with the aim of industrial application under the concept of zero liquid discharge (ZLD). Moisture content was determined, where it was observed that the lignocellulosic fabrics had a moisture content ranging from 2.5 to 8.5%. The wetting contact angle showed that the flax with polylactic acid (LPLA) was the most hydrophobic. The determination of the liquid absorption capacity showed that, of the synthetic fabrics, the one with the highest absorption, both in distilled water and in brackish water, was the polyester (PES) fabric with an absorption of 816% compared to its initial weight. In the natural fabrics, the highest absorption capacity was shown by the wet-laid without treatment (WL-WT) fabric for both distilled water and brackish water, although it required several cycles of operation to maintain this stable absorption. Exposure to brackish water improved the absorption capacity of all samples. Mechanical and thermal characterization showed that the synthetic fabrics were more resistant than the natural fabrics, although they may compete in terms of applicability. The capillarity study showed that the most hydrophilic fabrics completed the test the fastest. Finally, the composting degradation test showed that those fabrics with polylactic acid (PLA) content degraded faster in the first 14 days and thereafter the degradation of the lignocellulosic content showed a slower degradation until 112 days. The Bam fabric did not degrade during the course of the experiment. Full article

Membrane distillation (MD) is proposed as an environmentally friendly technology of emerging interest able to aid in the resolution of the worldwide water issue and brine processing by producing distilled water and treating high-saline solutions up to their saturation with a view toward reaching zero liquid discharge (ZLD) at relatively low temperature requirements and a low operating hydrostatic pressure. Topic modeling (TM), which is a Machine Learning (ML) method combined with Natural Language Processing (NLP), is a customizable approach that is ideal for researching massive datasets with unknown themes. In this study, we used BERTopic, a new cutting-edge Python library for topic modeling, to explore the global and local themes in the MD separation literature. By using the BERTopic model, the words describing the collected dataset were detected together with over- and underexplored research topics to guide MD researchers in planning their future works. The results indicated that two global themes are widely discussed and are relevant to MD scientists abroad. In brief, these topics are permeate flux, heat-energy recovery, surface modification, and polyvinylidene fluoride hydrophobic membranes. BERTopic discovered 62 local concepts. The most researched local topics were solar applications, membrane scaling, and electrospun membranes, while the least investigated were boron removal, dairy effluent applications, and nickel wastewater treatment. In addition, the topics were illustrated in a 2D plane to better understand the obtained results. Full article

Aniline is a highly toxic organic pollutant with “carcinogenic, teratogenic and mutagenesis” characteristics. In the present paper, a membrane distillation and crystallization (MDCr) process was proposed to achieve zero liquid discharge (ZLD) of aniline wastewater. Hydrophobic polyvinylidene fluoride (PVDF) membranes were used in the membrane distillation (MD) process. The effects of the feed solution temperature and flow rate on the MD performance were investigated. The results showed that the flux of the MD process was up to 20 L·m⁻²·h⁻¹ and the salt rejection was above 99% under the feeding condition of 60 °C and 500 mL/min. The effect of Fenton oxidation pretreatment on the removal rate of aniline in aniline wastewater was also investigated, and the possibility of realizing the ZLD of aniline wastewater in the MDCr process was verified. Full article

Herein, the alkaline supernatant of a struvite recovery system from municipal wastewater was successfully co-managed with acid mine drainage (AMD). Various ratios (v/v) of AMD to struvite supernatant were examined, and the quality of the passively co-treated effluent and of the generated sludge were examined using state-of-the-art analytical techniques including ICP-OES, FE-SEM/FIB/EDX, XRD, XRF, and FTIR. The optimum ratio was 1:9, where metals and sulphate were largely removed from AMD, i.e., from higher to lower score Fe (~100%) ≥ Pb (~100%) ≥ Ni (99.6%) ≥ Cu (96%) ≥ As (95%) ≥ Al (93.7%) ≥ Zn (92.7%) > Ca (90.5%) > Mn (90%) ≥ Cr (90%) > sulphate (88%) > Mg (85.7%), thus implying that opportunities for mineral recovery could be pursued. The pH of the final effluent was regulated to acceptable discharge levels, i.e., 6.5 instead of 2.2 (AMD) and 10.5 (struvite supernatant), while a notable reduction in the electrical conductivity further implied the attenuation of contaminants. Overall, results suggest the feasibility of the passive co-treatment of these wastewater matrices and that opportunities for direct scaling up exist (e.g., using waste stabilization ponds). Furthermore, apart from the initial recovery of struvite from municipal wastewater, metals could also be recovered from AMD and water could be reclaimed, therefore introducing circular economy and zero liquid discharge in wastewater treatment and management. Full article

Zero liquid discharge (ZLD) is a technique for treating high-salinity brine to obtain freshwater and/or salt using a solar interface evaporator. However, salt accumulation on the surface of the evaporator is a big challenge to maintaining stable water evaporation. In this study, a simple and easy-to-manufacture evaporator, also called a crystallizer, was designed and fabricated by 3D printing. The photothermal layer printed with polylactic acid/carbon composites had acceptable light absorption (93%) within the wavelength zone of 250 nm–2500 nm. The micron-sized voids formed during 3D printing provided abundant water transportation channels inside the crystallizer. After surface hydrophilic modification, the crystallizer had an ultra-hydrophilic channel structure and gravity-assisted salt recovery function. The results revealed that the angles between the photothermal layers affected the efficacy of solar evaporation and the yield of solid salt. The crystallizer with the angle of 90° between two photothermal layers could collect more solid salt than the three other designs with angles of 30°, 60°, and 120°, respectively. The crystallizer has high evaporation and salt crystallization efficiency in a high-salinity brine environment, which is expected to have application potentials in the zero liquid discharge of wastewater and valuable salt recovery. Full article

Mine water usually contains heavy metals and other inorganic and organic pollutants that contaminate water bodies. Reverse osmosis (RO) techniques are capable of producing purified water that meets discharge regulations. However, the problem of RO concentrate disposal and utilization is still not solved. The well-known zero liquid discharge (ZLD) process provides total concentrate utilization at the power industries but seems unreasonably expensive for the treatment of large amounts of mine water due to required chemical softening and the evaporation of concentrate. In the present article, a new approach to increase the recovery of reverse osmosis and to avoid high operational costs is demonstrated and discussed. The new technique involves radical RO concentrate flow reduction and withdrawal, together with dewatered sludge. The idea to “hide” concentrate in dewatered sludge is proposed and demonstrated during experiments. The article demonstrates results of the conducted experimental program aimed at reduction of volumes of all liquid wastes produced during mine water treatment using a new approach to concentrate it with a cascade of nanofiltration membranes and to reach a TDS value of 110–120 g per liter. The obtained concentrate is mixed with the wet sludge, which is further dewatered and withdrawn together with the dewatered sludge. Experiments are conducted that demonstrate a reduction in calcium in the concentrate due to deposition of calcium carbonate on the “seed crystals” in the circulation mode. Another distinguishing feature of the new technique is the separation of concentrate into two streams containing high concentrations of monovalent ions (sodium and ammonium chlorides) and divalent ions (calcium, magnesium and copper sulphates). Flow diagrams of the processes are presented to demonstrate the water treatment technique used to produce deionized water and two types of sludges: sludge after clarification and sludge after calcium carbonate deposition. Full article

Clothing, one of the basic needs, demands the growth of textile industries worldwide, resulting in higher consumption and pollution of water. Consequently, it requires extensive treatment of textile effluent for environmental protection as well as reuse purposes. Primary treatment, secondary treatment, and tertiary treatment are the three major phases of textile wastewater treatment. Secondary treatment under aerobic and anaerobic circumstances is carried out to decrease BOD, COD, phenol, residual oil, and color, whereas primary treatment is utilized to remove suspended particles, oil, grease, and gritty materials. However, biological treatment is not fully capable of treating water according to discharge/reuse standards. Hence, tertiary treatment is used to remove final contaminants from the wastewater. Adsorption is regarded as one of the most feasible processes for dye and metal removal in consideration of cost and variation in the adsorbent. Though membrane filtration is an efficient process, the cost of operation limits its application. It’s unfortunate that there isn’t a universally applicable treatment solution for textile effluents. Therefore, the only flexible strategy is to combine several therapy modalities. Treatment of complicated, high-strength textile wastewater depending on pollutant load will be more successful if physical, chemical, and biological approaches are used in tandem. Enforcement of stringent environmental regulation policies, increasing costs and demand for freshwater, and the rising costs and difficulties associated with wastewater disposal are accelerating efforts toward achieving ZLD. Additionally, research into methods for extracting useful materials from wastewater has blossomed in recent years. As such, the purpose of this analysis is to give a holistic overview of textile wastewater treatment systems, with a focus on zero liquid discharge (ZLD) and efficient resource recovery, both of which may hasten the transition to more sustainable water management. Full article