The concept of recirculation of diluate/concentrate stream is implemented in multi-stage ion concentration polarization (ICP) desalination to deal with the issue of uncontrolled concentrate streams and deteriorated overall recovery rate to treat highly concentrated oil produce water from refineries. An improved empirical optimization model was established to calculate total energy consumption for operating cost and required membrane area for capital cost for a given set of operating parameters, feed salinity, salt removal ratio, and flow velocity. Using the empirical optimization model, a techno-economic analysis is performed to evaluate the feasibility of two-stage ICP system with recirculation loops. Brine of 160 g/kg is set as the system feed stream, whereas other operating conditions such as dilaute and concentrate streams are being controlled/fixed with 20 g/kg and ~250 g/kg respectively. Also, the system can be flexibly controlled to produce a specific concentration of product water and a recovery ratio with a corresponding water cost. With careful choices of recirculation rates, one can significantly increase the recovery ratio of two-stage ICP brine treatment process (from 25% to 39%) with only minor increase in overall cost (from $16.4-25.9/m to $20.6-22.54/m), which is favourable for brine waste treatment application.
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