The economic impact of fouling in spiral wound membranes is not yet well explored. There has been an established assumption that the cost of fouling in membrane processes is significant, but this hypothesis has not been thoroughly evaluated. We conducted an economic analysis on seven full-scale installations, four nanofiltration (NF) and three reverse osmosis (RO), to estimate the cost of fouling in industrial plants. The cost of fouling was calculated in detail, including costs of increase in feed channel pressure drop, water permeability reduction, early membrane replacement, and extensive cleaning-in-place (CIP). The estimated cost of fouling was expressed as a fraction of operational expenses (OPEX) for each plant and the major cost factors in fouling and CIP costs were identified. The selected NF plants were fed with anoxic ground water, while the feed water to RO plants was either surface water or municipal wastewater effluent. All the NF plants produce drinking water, while the RO plants produce demineralized water for industrial applications. We found that the cost of fouling in the RO plants was around 24% of OPEX, while the fouling related costs in NF cases was only around 11% due to the low biofouling potential of the anoxic ground water. The major factor in the cost of fouling is the early membrane replacement cost, followed by additional energy and with only a minor contribution from the cleaning costs. The down-time cost (caused by the interruption of water production during a CIP event) can be the major CIP cost factor for the plants with frequent cleaning events, while the cost of chemicals dominates in the plants with non-frequent CIP. In case of manual cleaning-in-place, the cost of fouling is increased by around 2% for the RO plants with frequent CIP. The manual execution of CIP cleaning is an attention point to reconsider, as the reviewed plants hold an automated CIP cleaning, providing membrane productivity advantages.

Long-term human Space missions will rely on regenerative life support as resupply of water, oxygen and food comes with constraints. The International Space Station (ISS) relies on an evaporation/condensation system to recover 74–85% of the water in urine, yet suffers from repetitive scaling and biofouling while employing hazardous chemicals. In this study, an alternative non-sanitary five-stage treatment train for one “astronaut” was integrated through a sophisticated monitoring and control system. This so-called Water Treatment Unit Breadboard (WTUB) successfully treated urine (1.2-L-d⁻¹) with crystallisation, COD-removal, ammonification, nitrification and electrodialysis, before it was mixed with shower water (3.4-L-d⁻¹). Subsequently, ceramic nanofiltration and single-pass flat-sheet RO were used. A four-months proof-of-concept period yielded: (i) chemical water quality meeting the hygienic standards of the European Space Agency, (ii) a 87-±-5% permeate recovery with an estimated theoretical primary energy requirement of 0.2-kWh_p-L⁻¹, (iii) reduced scaling potential without anti-scalant addition and (iv) and a significant biological reduction in biofouling potential resulted in stable but biofouling-limited RO permeability of 0.5 L-m⁻²-h⁻¹-bar⁻¹. Estimated mass breakeven dates and a comparison with the ISS Water Recovery System for a hypothetical Mars transit mission show that WTUB is a promising biological membrane-based alternative to heat-based systems for manned Space missions.

Human urine is a valuable resource for nutrient recovery, given its high levels of nitrogen, phosphorus and potassium, but the compositional complexity of urine presents a challenge for an energy-efficient concentration and refinery of nutrients. In this study, a pilot installation combining precipitation, nitrification and electrodialysis (ED), designed for one person equivalent (1.2 L_urine d⁻¹), was continuously operated for ∼7 months. First, NaOH addition yielded calcium and magnesium precipitation, preventing scaling in ED. Second, a moving bed biofilm reactor oxidized organics, preventing downstream biofouling, and yielded complete nitrification on diluted urine (20–40%, i.e. dilution factors 5 and 2.5) at an average loading rate of 215 mg N L⁻¹ d⁻¹. Batch tests demonstrated the halotolerance of the nitrifying community, with nitrification rates not affected up to an electrical conductivity of 40 mS cm⁻¹ and gradually decreasing, yet ongoing, activity up to 96 mS cm⁻¹ at 18% of the maximum rate. Next-generation 16S rRNA gene amplicon sequencing revealed that switching from a synthetic influent to real urine induced a profound shift in microbial community and that the AOB community was dominated by halophilic species closely related to Nitrosomonas aestuarii and Nitrosomonas marina. Third, nitrate, phosphate and potassium in the filtered (0.1 μm) bioreactor effluent were concentrated by factors 4.3, 2.6 and 4.6, respectively, with ED. Doubling the urine concentration from 20% to 40% further increased the ED recovery efficiency by ∼10%. Batch experiments at pH 6, 7 and 8 indicated a more efficient phosphate transport to the concentrate at pH 7. The newly proposed three-stage strategy opens up opportunities for energy- and chemical-efficient nutrient recovery from urine. Precipitation and nitrification enabled the long-term continuous operation of ED on fresh urine requiring minimal maintenance, which has, to the best of our knowledge, never been achieved before.