Innovative Recovery Methods for Metals and Salts from Rejected Brine and Advanced Extraction Processes—A Pathway to Commercial Viability and Sustainability in Seawater Reverse Osmosis Desalination

Abstract

Seawater desalination has emerged as a crucial solution for addressing global freshwater scarcity. However, it generates significant volumes of concentrated brine waste. This brine is rich in dissolved salts and minerals, primarily, chloride (55%), sodium (30%), sulfate (8%), magnesium (4%), calcium (1%), potassium (1%), bicarbonate (0.4%), and bromide (0.2%), which are often discharged into marine environments, posing ecological challenges. This study presents a comprehensive global review of innovative technologies for recovering these constituents as valuable products, thereby enhancing the sustainability and economic viability of desalination. The paper evaluates a range of proven and emerging recovery methods, including membrane separation, nanofiltration, electrodialysis, thermal crystallization, solar evaporation, chemical precipitation, and electrochemical extraction. Each technique is analyzed for its effectiveness in isolating salts (NaCl, KCl, and CaSO4) and minerals (Mg(OH)2 and Br2), with a discussion of process-specific constraints, recovery efficiencies, and product purities. Furthermore, the study incorporates a detailed techno-economic assessment, highlighting revenue potential, capital and operational expenditures, and breakeven timelines. Simulated case studies of a 100,000 m3/day seawater reverse osmosis (SWRO) facility demonstrates that a sequential brine recovery process and associated energy balances, supported by pilot-scale data from ongoing global initiatives, can achieve over 90% total salt recovery while producing marketable products such as NaCl, Mg(OH)2, and Br2. The estimated revenue from recovered materials ranges between USD 4.5 and 6.8 million per year, offsetting 65–90% of annual desalination operating costs. The analysis indicates a payback period of 3–5 years, depending on recovery efficiency and product pricing, underscoring the economic viability of large-scale brine valorization alongside its environmental benefits. By transforming waste brine into a source of commercial commodities, desalination facilities can move toward circular economy models and achieve greater sustainability. A practical integration framework is proposed for both new and existing SWRO plants, with a focus on aligning with the principles of a circular economy. By transforming waste brine into a resource stream for commercial products, desalination facilities can reduce environmental discharge and generate additional revenue. The study concludes with actionable recommendations and insights to guide policymakers, engineers, and investors in advancing brine mining toward full-scale implementation.