Purification of Produced Water by Ceramic Membranes: Material Screening, Process Design and Economics

Produced water, generated from underlying formations during the recovery of hydrocarbons, constitutes the largest waste stream associated with oil and gas production. Currently, over 90% of produced water is reinjected into the formation, either in support of enhanced oil recovery or for disposal. In arid areas, reclamation of produced water for beneficial uses such as irrigation or tower cooling may be an attractive alternative if the produced water can be purified to an adequate quality, specifically through the removal of dissolved components including inorganic compounds (salts, heavy metals, and radiochemicals) and organic compounds (fatty acid, aliphatic, and aromatics). Membranes technologies show advantages in both energy efficiency and high water quality. Due to the presence of dissolved organics, reverse osmosis with organic membranes is highly limited. Research efforts focus on developing new materials that are less prone to fouling and are easy to regenerate. Novel ceramic membranes are relatively new classes of material that show promising application in produced water purification due to their extreme stability in harsh environments and optional choices for regeneration. This paper details the results of investigations of produced water purification by microporous ceramic membranes, including metal oxide membranes, clay membranes, and zeolite membranes. Techniques for membrane fabrication, process design, and economic aspects are also discussed.