Achieving Zero Waste and CO2 Reduction in Saline Water Treatment—Sustainable Salt and Ice Recovery Using Pipe Freeze Crystallization

This study investigates the application of pipe freeze crystallization (PFC) as a sustainable, zero-waste technology for treating high-salinity industrial wastewater, enabling the simultaneous recovery of salts and clean water. PFC addresses the limitations of traditional brine treatment methods such as evaporation ponds and distillation, which are energy-intensive, produce concentrated brine requiring disposal, and emit significant CO2. A pilot demonstration plant in Olifantsfontein, South Africa, served as the basis for this research. The plant operates at an energy consumption rate of 330 kJ/kg, significantly lower than distillation’s 2200 kJ/kg. It efficiently recovers high-purity Na2SO4 and clean ice, which can be reused as water, with plans underway to incorporate NaCl recovery. Comparative analyses highlight PFC’s energy efficiency and reduced CO2 emissions, achieving an 82% reduction in greenhouse gas emissions compared to evaporation-based methods. This study evaluates the operational parameters and scalability of PFC for broader industrial applications. X-ray Diffraction analysis confirmed that the Na2SO4 recovered from the pilot plant achieved a purity level of 84.9%, demonstrating the process’s capability to produce valuable, market-ready by-products. These findings reinforce PFC’s potential as a cost-effective and environmentally sustainable alternative to conventional methods. PFC offers a transformative solution for managing saline effluents, aligning with zero-waste objectives and contributing to reduced environmental impact. This technology provides industries with an economically viable solution for resource recovery while supporting compliance with stringent environmental regulations.