Energies 15 04619
Energies 15 04619
Energies 15 04619
Review
Produced Water Treatment and Valorization:
A Techno-Economical Review
Ramon Sanchez-Rosario and Zacariah L. Hildenbrand *
Department of Chemistry and Biochemistry, The University of Texas at El Paso, 500 W. University Ave,
El Paso, TX 79968, USA; [email protected]
* Correspondence: [email protected]
Abstract: In recent years, environmental concerns have urged companies in the energy sector to
modify their industrial activities to facilitate greater environmental stewardship. For example, the
practice of unconventional oil and gas extraction has drawn the ire of regulators and various environ-
mental groups due to its reliance on millions of barrels of fresh water—which is generally drawn from
natural sources and public water supplies—for hydraulic fracturing well stimulation. Additionally,
this process generates two substantial waste streams, which are collectively characterized as flowback
and produced water. Whereas flowback water is comprised of various chemical additives that are
used during hydraulic fracturing; produced water is a complex mixture of microbiota, inorganic and
organic constituents derived from the petroliferous strata. This review will discuss the obstacles of
managing and treating flowback and produced waters, concentrating on the hardest constituents to
remove by current technologies and their effect on the environment if left untreated. Additionally,
this work will address the opportunities associated with repurposing produced water for various
applications as an alternative to subsurface injection, which has a number of environmental concerns.
This review also uses lithium to evaluate the feasibility of extracting valuable metals from produced
water using commercially available technologies.
plasma mass spectrometry (ICP-MS) facilitate the analysis of metal and nonmetal ions [5].
In particular, ion chromatography (IC) is the “go-to” method for pertinent anions (i.e., chlo-
ride, sulfate, sulfide, nitrate, bromide). Methods for the characterization and quantitation
of microbial constituents include aerobic and anaerobic plate count (i.e., selective, and non-
selective media), Gram staining, microscopy, and molecular methods (i.e., immunological-
and nucleic-acid-based techniques). Common molecular methods include polymerase
chain reaction (PCR) and DNA sequencing [35]. Analysis of protein profiles by matrix-
assisted laser desorption ionization–time-of-flight-mass spectrometry (MALDI-TOF-MS)
is a relatively recent innovation that facilitates the rapid identification of microorganisms
compared to traditional methods [32]. Lastly, bulk water quality parameters, such as total
dissolved solids, total suspended solids, turbidity, organic and inorganic carbon content,
pH and oxidation reduction potential (ORP), are predominantly quantified through the use
of sensors, titration and gravimetric methods [20,36]. The use of these analytical techniques
in concert provides considerable insight into the complex composition of FP, which is
essential in developing and designing an effective treatment regimen.
Traditionally, large FP volumes are managed via disposal into the subsurface through
saltwater disposal wells (SWDs). This consists of transporting the waste fluid (i.e., trucking
or pipelines) to a designed site, where the fluid is pumped and sequestered into deep geo-
logic formations [37]. However, this practice comes with a series of environmental concerns.
For example, spills during the transport of FP to disposal sites can lead to groundwater and
surface water contamination. In 2017, a study modelled different spillage scenarios with
varying soil types, spill intensities and depth of ground water, concluding that benzene
and toluene—toxicity-inducing compounds—are the primary contaminants of concern [38].
Another study from 2019 reported an increase in bromide, radium, strontium, lithium and
boron downstream from a spill site in comparison to upstream, which translated into a
reduction in the growth of fish and the survival of mussels [39]. Additionally, spill events
can vary the concentration of ions and increase the total dissolved solids (TDS) in nearby
areas and natural water streams, respectively [40]. Overall, these are just a few examples of
the various threats to environment associated with the disposal of FP. Another key aspect
to consider is water management.
During the period from 2009 to 2017, a total of 11.43 billion barrels of water were used
for HF in the US, with the Permian Basin increasing its water intake by 1.26 billion barrels
since 2009. According to Scanlon et al., this represents 0.1% of the US water withdrawal in
2015 [41]. In 2017, Permian Basin reported an annual PW volume (106 ) of 1,663.21 barrels
(bbl) as well as a water demand for HF of (106 ) 1,322.26 bbl. By 2017, the Permian Basin had
an increment in PW volume approximately 20 times higher compared to 2011 [41,42]. In
view of this, the Permian region is a prime candidate to substantially benefit from recycling
PW, as it will reduce the demand of high volumes of fresh water, favoring the main urban
centers Lubbock and Midland-Odessa, with a total population of 466,200 individuals
(2010) [43]. In fact, far more FP is being produced than the required for HF, this could
be a major opportunity for the agricultural sector. For instance, from 2000–2014, 91% of
total water used in this area was destined for irrigation, followed by 6% for municipal
use and 2% for industry and livestock [43]. Another significant concern for residents in
shale regions is the increasing seismic events. Induced seismicity is a risk when injection is
performed into deep bedrock formations, as it may lubricate pre-existing geological faults
and provoke fault slips [44]. In 2020, Benson et al. concluded that extracting and injecting
fluids affects the natural seismicity of a given area. Furthermore, subsurface injection
has a particular association with earthquakes because it drives critically stressed faults to
failure by increasing pore pressure [45]. In recent years, seismicity rates have increased
12-fold since 2008 in West Texas [46]. Moreover, documented cases of induced earthquakes
have been observed in Canada, the United Kingdom, and China as well, with events of
up to 5.7 on the Richter scale [47]. For these reasons, the state of New Mexico no longer
grants permits for disposals as a preventative action that aims to decrease the occurrence
of seismicity in the area. Nevertheless, seismologists have difficulties in determining
Energies 2022, 15, 4619 4 of 18
exactly whether the earthquakes are naturally occurring, if they are caused by the hydraulic
fracturing processes or if they result from post-injection of wastewater.
Taken as a whole, the potential treatment and reuse of FP for HF would significantly
reduce the reliance on freshwater resource in shale energy regions, particularly in the
Bakken and Permian Basins, thus alleviating water stress in nearby communities and
retaining large volumes of water in the water cycle. Assuming that FP is treated to an
appropriate standard, a growing number of applications are available, such as agricultural
and surface water discharge, domestic usage and aquifer recharge. Ultimately, the fre-
quency of injection-well-induced earthquakes could be greatly attenuated by the utilization
of treated FP.
Current technologies applied in FP treatment include membrane and media filtration,
chemical oxidation and thermal and ion exchange methods. Typical setbacks for these
methods are membrane clogging, corrosion, high cost of chemicals, need of pre-treatment
and post-treatment, and solid separation [4]. Utilizing novel technologies in the treatment of
FP could reduce the negative impacts associated with SWDs, while making UOG operations
more sustainable and offering potential ancillary economic opportunities. For example, one
option for the industrial sector is the extraction of precious and semiprecious metals that are
in high demand, such as cobalt, nickel and particularly lithium. The mining and extraction
of precious metals found in FP represents a relatively unexplored opportunity for the energy
sector. This article reviews the current state of produced water characterization techniques
and treatment technologies. First, we discuss the efficacies of various treatment modalities
commonly used to remediate FP, including established and emerging technologies, and
how they are utilized to remove various classes of biogeochemical constituents found in FP.
Secondarily, we cover the costs of treatment and the options for extracting metals from FP
using Li extraction technologies and their associated costs as an example.
this technology involve the addition of nanoparticles to enhance the removal of major
organics from fracking wastewater [51].
Table 1. Inorganic constituents and other parameters of fracturing waste waters from Bakken Shale
and Permian Basin, the regulated concentration ranges for reuse in well stimulation [15] and in
agricultural and consumption use [52,53]. * represents the reported average of three measurements
in the study.
Figure 1. Schematics for multistage flash distillation (MSF). Extracted from Panagopoulos et al.,
Figure 1. Schematics for multistage flash distillation (MSF). Extracted from Panagopoulos et al.
2019 [62]. [62].
Many ongoing efforts for the treatment of FP incorporate separation and desalina-
Many ongoing efforts for the treatment of FP incorporate separation and desalin
tion [72]. Similarly, a common practice is the utilization of powdered activated carbon
[72]. Similarly, a common practice is the utilization of powdered activated carbon (P
(PAC) for the depletion of dissolved organic carbon (DOC), turbidity and organic compo-
for the depletion of dissolved organic carbon (DOC), turbidity and organic compon
nents. Other operations include softening hardness ions by the addition of caustic soda [54],
Other operations include softening hardness ions by the addition of caustic soda [54
demineralization through membrane distillation [73] and removal of organic components
mineralization through membrane distillation [73] and removal of organic compon
by coagulation followed by ultrafiltration [74]. Furthermore, biologically active membranes
by coagulation followed by ultrafiltration [74]. Furthermore, biologically active m
help remove organics and salinity [13]. The use of these techniques in tandem is generally
branes help remove organics and salinity [13]. The use of these techniques in tande
required to remediate FP to a reusable and/or recyclable standard.
generally required to remediate FP to a reusable and/or recyclable standard.
The commercial methods implemented in desalination of seawater, typically membrane-
The commercial
based and thermal-based [62], fail tomethods
meet the implemented
requirements for in desalination of seawater,
processing wastewater fromtypically m
brane-based and thermal-based [62], fail to meet the requirements
UOG. However, the elevated values of TDS (>50,000) in FP can lead to difficult scenarios for proce
when treating the approximately 250 million barrels produced globally each day [75]. ForFP can le
wastewater from UOG. However, the elevated values of TDS (>50,000) in
example, the difficult scenarios
FP in the Permianwhen treating
Basin has TDSthevalues
approximately
three to 250
five million barrelswhen
times higher produced glo
each day [75]. For example, the FP in the Permian Basin has TDS
compared to those of seawater (see Table 1) [76]. Common challenges include corrosion, values three to five t
higher when compared to those of seawater (see Table
fouling and scaling of the membrane when precipitation conditions are met [77].1) [76]. Common challenges inc
corrosion, fouling and scaling of the membrane when precipitation
Forward osmosis allows the separation of water from dissolved solids by employing conditions are
a semipermeable[77]. membrane and the difference in osmotic pressure as driving force. In
contrast to RO, it is believed to be more appropriate for high-TDS matrices, such as FP [78].
Additionally, FO is a cost-competitive and reliable alternative for wastewater treatment [79]
that exhibits great potential in removing heavy metal ions, including Cr2 O7 2− , HAsO4 2− ,
Pb2+ , Cd2+ , Cu2+ and Hg2+ [80].
A previous study suggested that reusing PW in the energy sector is a better option
than surface discharge due to safety concerns. Alternatively, its authors suggested thermal
distillation (TD) as the appropriate treatment modality [42]. Regardless of being one of
the most utilized operations for saline water recycling, TD’s energy consumption must be
addressed when treating PW since scaling may lead to a to insulation of heat exchangers
and, consequently, inefficient heat transfer. Again, the elevated price of anticorrosion
materials to build this facility should be considered, since high costs affect the feasibility at
an industrial scale. Similarly, osmotic properties constrain the application of membrane
technologies in highly saline brines [62].
Recent advances in membrane technology, as well as integration of existing procedures,
show promising results in processing high-TDS watersIn 2018, Sardari et al. demonstrated
that electrocoagulation (EC) pre-treatment followed by direct contact membrane (DCMD)
was effective in recovering up to 57% from a sample with a TDS of 135 g/L. However,
they suggested a reduction in the sedimentation time for practical applications [81]. Fur-
thermore, pretreatment with antiscalants such as 1-hydroxyethylidene-1,1-diphosphonic
acid (HEDP) increased the performance of carbon-nanotube-immobilized membranes in
membrane distillation (MD) [82]. Additionally, Ahmad et al. (2020) proposed a hybrid
technology that incorporates assisted reverse osmosis (ARO), microfiltration and reverse
osmosis—introduced as MF-ARO-RO—for which individual operations enhanced the abil-
tions [81]. Furthermore, pretreatment with antiscalants such as 1-hydroxyethylidene-1,1-
diphosphonic acid (HEDP) increased the performance of carbon-nanotube-immobilized
membranes in membrane distillation (MD) [82]. Additionally, Ahmad et al. (2020) pro-
posed a hybrid technology that incorporates assisted reverse osmosis (ARO), microfiltra-
Energies 2022, 15, 4619 8 of 18
tion and reverse osmosis—introduced as MF-ARO-RO—for which individual operations
enhanced the ability to withstand different salinity effects and profiles. Although the ad-
dition of ARO to the MF-RO system represented an increase in the total cost, it was pre-
ity to withstand different salinity effects and profiles. Although the addition of ARO to the
sented as the cheapest alternative for high-salinity FP [83].
MF-RO system represented an increase in the total cost, it was presented as the cheapest
Recent studies developed a combined membrane system consisting of an electrodi-
alternative for high-salinity FP [83].
alysisRecent
chamber followed
studies developedby ananofiltration and membrane
combined membrane distillation
system consisting of an(ED-NF-MD),
electrodial- rep-
resented in Figure
ysis chamber followed2. The system facilitated
by nanofiltration zero liquid
and membrane discharge
distillation and allowed
(ED-NF-MD), rep-a water
recovery
resented inofFigure
up to 99.8%
2. The with
systemnofacilitated
need for chemical
zero liquidantiscalants
discharge and[84].allowed
Regardless
a waterof being a
laboratory-scale experiment,
recovery of up to 99.8% with nothe novel
need method antiscalants
for chemical has underlying
[84]. potential
Regardlessinofhigh-TDS
being wa-
a laboratory-scale
ters experiment,
treatment at industrial the novel method has underlying potential in high-TDS
scale.
waters treatment at industrial scale.
Figure 2. Diagram of the integrated ED-NF-MD system. CM: cation exchange membrane; AM: anion
exchange membrane; ED: electrodialysis; NF: nanofiltration; VMD: vacuum membrane distillation.
Reproduced with permission from Zhao et al., 2020 [84].
costs range from USD $3.00 to $30.00/bbl, including storage and transport [88]. Recently,
MD modalities were studied for reuse waste waters of HF operations, resulting in costs
ranging from USD $0.11 to $0.90/bbl of treated fluid [89]. Operational costs of RO and FO
typically stand at USD ~$1.00/bbl. Providing an initial cost for the acquisition of these
membranes is challenging due to their performance dependency on influent TDS levels
and throughput requirements. In Table 2, the annual cost for FP disposal in Permian and
Bakken is compared to treatment costs, assuming treatment take place in situ based on
mobile treatment modalities.
Table 2. Annual cost for disposal and treatment of FP in Permian Basin and Bakken Shale, assuming
both are performed on-site. * Based on USD $0.03/bbl/mile trucking cost and an average distance of
20 miles from the source to the nearest disposal site.
Table 3. Quantities and values of extractable metals from Permian Basin and Bakken.
Value of Value of
Total Extractable Total Extractable
Industry/Terminal Price (USD/kg) Extractable Metals Extractable Metals
Element Mass in FP, kg Mass in FP, kg
Uses [93] in Millions, M in Millions, M
(Bakken) * (Permian) *
(Bakken) (Permian)
Sodium salts
Na $2.57–3.43 7.59 ×109 $22,776.39 1.35 × 1010 $40,453.20
production
Li Batteries $81.40–85.60 3.39 × 106 $283.12 4.97 × 106 $415.06
K Fertilizer/saltproduction $12.10–13.60 3.56 × 108 $4574.50 2.21 × 108 $2836.95
Sr Firework $6.50–6.70 8.62 × 107 $569.01 2.05 × 108 $1352.41
Cement
Ca fabrication/reducing $2.21–2.35 1.48 × 109 $3379.85 3.31 × 109 $7535.40
agent
Mg Alloying agent $2.30 1.45 × 108 $334.04 4.73 × 108 $1088.53
Mn Steel making $1.80 6.12 × 105 $1.10 8.46 × 106 $15.23
Co Batteries $32.8 6.28 × 103 $0.21 0 $0.00
Ni Batteries $13.90 1.04 × 105 $1.44 5.29 × 103 $0.07
B Glass and ceramics $3.68 7.78 × 106 $28.63 0 $0.00
* Calculations based on amount of FP generated per annum (54.6 × 109 L for Bakken and 264.4 × 109 L for
Permian) multiplied by the average ion concentration, as illustrated in Table 1.
The feasibility of mining precious metals relies on: (1) the location of the play;
(2) the cost of the treatment modality; (3) the market price of the element. In particu-
lar, the Permian Basin has levels of K of 1100 mg/L (see Table 1), and the combined osmosis
system has a cost of USD $2.32/bbl. The recovery of 1 kg of K would require the treatment
of approximately 5.72 bbl of FP (USD $13.34); as shown in Table 3, the market price for
K is USD ~$12.10/kg, which shows that it is not economically viable to extract K from
the Permian region. Similarly, the expenditures for the acquisition of Li and Sr are USD
$776.27 and $17.80, respectively. Meanwhile, the cost of K extraction in Bakken utilizing the
previous analogy is USD $1.53 for 1 kg of K, which could be further sold for USD $12.10,
producing a significant profit margin. The cost of recovery of Sr in Bakken is approximately
USD $5.96, which also makes it viable. Additional costs involving possible purification
steps should be considered. According to the USGS National Mineral Information Center,
the domestic production of salt satisfies 85.11% of the reported salt consumption in the
US (excluding Puerto Rico) [94]. The estimated extractable value for sodium chloride in
the Permian Basin alone represents approximately 73% of the salt demand in 2021. Other
outlets for these byproducts are to be explored.
The challenges associated with treating FP, along with the variety of modalities avail-
able for this purpose, steer the efforts into a combined technologies approach as shown
in Figure 3. This FP valorization process integrates: (1) an oxidation step; (2) chemical
coagulation/precipitation; (3) filtration; (4) a membrane system; (5) electrocoagulation.
The first three steps achieve the removal of microorganisms and part of the organic matter
found in FP. The membrane system target the ions, and the EC polishes the metal for its
recovery. The utilization of embedded membranes aids in the removal of persistent ions
such as B. The resulting treated water could be used for crop irrigation or to replenish
natural sources, or it could be recycled in UOG operations depending on the attained
parameters and the requirements set by FAO, EPA or the oil and gas industry.
Figure 3. Schematic of the valorization process for FP. Step-by-step methodologies are applied to
Figure 3. Schematic of the valorization process for FP. Step-by-step methodologies are applied to
extractprecious
extract preciousmetals
metals from
from FP,
FP, adding
adding an
an aggregated
aggregated value
value to
to this
this waste.
waste.
As previously mentioned, the interest in finding alternative sources of lithium has
3.2. Feasibility of Extracting Precious Metals in Certain Shale Energy Basins
triggered a race in the study of various technologies for Li extraction from brines. As shown
The U.S.
in Figure Geological
4, these Survey
techniques (USGS)
range fromistypical
a national
solventagency that collects
extractions data chemically
to novel of natural
resource
modifiedconditions.
surfaces forThe USGS provides a database with information about the abun-
adsorption.
danceTheof certain elements
conventional typically
solar present
evaporation in FP,
method is their
a veryorigin and other
cost-effective bulk parameters
procedure; however,
[95]. According to the database, metals like Na, K, Mg, Ca and Sr are common
the extensive land area required hinders its application, as does the limited selectivity in most
for a
shales at elevated concentrations. However, there is limited information about
particular ion of interest. Whilst solvent extraction and phosphate precipitation facilitate ions with
more industrial
the recovery of relevance,
lithium, the such as Co, Ni and
environmental Li. Morecosts
concerns, studies
andare needed in thesteer
coprecipitation charac-
the
terization
industrialofefforts
FP to toward
establish a better
less foundation
polluting options.when Some dabbling
adsorptiveinto materials
this field. containing
The feasi-
bility of metal
aluminum andextraction
titanium relies on a minimum
each offered promisingthreshold
results offorion
Li concentration. In Tablethe
extraction. However, 4,
these values on
dependence arepHshown
mustfor
be certain elements
overcome, as mustalong with viable
the challenges in locations for their
the desorption extrac-
mechanism
tion.
of LiThe
fromthreshold calculations
the Al surface and theare based on the
competition concentrations
of cations reported for
on titanium-based Permian [96].
adsorbents Ba-
sin
As (refer to Table 1)
for manganese and amaterials,
based treatmentthecost of USD $2.32
conversion fromper bbl of FP.to industrial-scale and
laboratory-
the limited understanding of the adsorption/desorption process represent a challenge [97].
Nanofiltration and ion exchange technologies have been utilized in industrial scenarios for
the removal of ions with great results. Nevertheless, metal extraction requires a combination
of resins at different stages if not targeted to a particular metal. Additionally, matrices such
as FP require further separation processes, compromising the feasibility on an industrial
scale. Recently, encouraging results proposed a highly selective polymer for the efficient
extraction of lithium in presence of other ions, such as Na and K. More importantly, Li can
be easily released by increasing temperature; this is particularly interesting for possible
industrial applications [98].
The “E3 Metals Corp” agency operates within the Leduc Formation in Alberta, Canada.
They are able to recover >90% of Li from oilfield brines with Li concentrations of 74.6 mg/L
in the form of hydrated lithium hydroxide (LiOH·H2 O), with an annual production capacity
of 20,000 mt. The reported capital expenditure (CapEx) for this infrastructure is USD
$602,000 MM, and the operation expenditure (OpEx) is USD $73,200 MM [100]. The
magnitude of the initial investment for the construction of a similar structure in the United
States frustrates the acquisition of these treatment sites in the shales. As a possible solution,
a centralized facility should be considered to which the FP from the regional shales could be
transported and treated via pipelines or trucks, resulting in a minimized economic impact
that this strenuous investment may cause to the UOG industry.
Energies 2022, 15, 4619 12 of 18
Table 4. Metal thresholds and abundance. Minimum concentration of metals required for feasible
extractions and their abundance. Calculations are based on treatment costs of USD 2.32/bbl, further
isolation processes not included.
Duperow
Li 179.29
Unknown Permian New Mexico
Oriskany Ss Appalachian New York
Madison Williston
Duperow Williston
Grenora Charles Williston North Dakota
Figure 4. Available technologies for extracting Li from brines. Description of the mechanism of
extraction for Li of the several commercial technologies and their developers [99].
4. Conclusions
The reuse of treated FP will relieve the water stress caused by HF in arid regions such as
the Permian Basin. Due to more FP being produced than is required for injection, recycling
in agriculture is an attractive option for this excess, as most of the water consumption in the
Permian region is dedicated to irrigation. Remaining challenges in FP sanitation include the
complete characterization of FP, the high cost of the materials used to build facilities and the
lack of methods for removing difficult ions such as boron. Whilst a variety of technologies
are available for the treatment of highly saline brines, the appropriate strategy should be a
combination of sequential steps. Although promising a sustainable solution, the high CapEx
associated with the development of a facility with these requirements is not economically
Energies 2022, 15, 4619 14 of 18
favorable. The intensive capital cost of such investment demands joint efforts from the
involved industries for the construction of a centralized treatment facility that facilitates
the purification of water as well as the extraction of these valuable metals (Figure 4). The
recuperation of Li is possible in Permian, Palo Duro, the Gulf Coast, Williston, Appalachia
and many other regions, as is the recovery of Sr, Ca, Mg, Na and K. In this sense, based
on the numerous studies available and the growing demand by the energy sector, lithium
should be the candidate for the development of this pilot strategy. A drawback to treating
FP down to reuse standards is the generation of extremely salty brines/sludge. Although
found in low concentrations in the Permian Basin, the accumulation of radionuclides
in these brines can generate low-level nuclear waste. Furthermore, assuming all the
produced water is treated in both Bakken and Permian Basin, the sum of extractable salt
will represent approximately 116% of the domestic consumption in 2021 with these plays
alone (USGS, 2022). Other outlets for these surplus materials have yet to be explored.
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