Oilfield-produced water treatment with SiC-coated alumina membranes☆

During the extraction of fossil fuels, a complex waste stream is produced simultaneously, also known as produced water (PW). Membrane filtration is a promising technology that can successfully enable the treatment and reuse of PW. Silicon carbide (SiC) membranes are preferred for PW treatment, due to their low (ir)reversible fouling compared to other ceramic membranes. However, full SiC membrane is expensive and thus economically less feasible. Therefore, we established a method for coating SiC on alumina (Al2O3) ultrafiltration membranes, based on low-pressure chemical vapor deposition at 860 degrees C. In the presented study the fouling resistance and behavior of these novel membranes, with various pore sizes and under different operating conditions, including flux and crossflow velocity, were evaluated. We also used Al2O3 membranes and SiC-coated Al2O3 membranes in constant flux mode to treat real oilfield PW with high salinity (142 mS/cm) and COD (22670 mg/L). Additionally, the fouling mechanisms in the SiC-coated and Al2O3 membranes were analyzed with the help of Focused Ion BeamScanning Electron Microscopy imaging. The major findings were that pore blockage served as the initial (irreversible) fouling mechanism and that the (reversible) cake layer, a mixture of organic and inorganic components, dominated the rest of the filtration cycle, where the SiC coated membrane performed better than the original alumina membrane. In addition, it was found that the application of the SiC coating, and the selection of the appropriate pore size (62 nm) and crossflow velocity (0.8 m/s) increased the fouling mitigation, potentially advancing the utilization of ultrafiltration in treating saline PW for reuse purposes.