Reverse Osmosis Process Control
Reverse osmosis systems operating at industrial scale process millions of gallons daily while managing multiple critical parameters—from transmembrane pressure differentials to permeate quality. Current manual control approaches require operators to balance membrane fouling, energy consumption, and water recovery rates across varying feed conditions, often leading to sub-optimal performance and premature membrane degradation.
The core challenge lies in developing control systems that can dynamically optimize operational parameters while preventing membrane damage and maintaining consistent output quality.
This page brings together solutions from recent research—including machine learning systems for predictive maintenance, automated chemical dosing controls, and real-time fouling detection algorithms. These and other approaches aim to improve plant efficiency while extending membrane life through precise, automated control of critical operating parameters.
1. Enhancing Energy Efficiency of Industrial Brackish Water Reverse Osmosis Desalination Process using Waste Heat
alanood a alsarayreh, mudhar a alobaidi, iqbal m mujtaba - PSE Press, 2025
The Reverse Osmosis (RO) system has the potential as a vibrant technology to generate high-quality water from brackish sources. Nevertheless, progressive growth in and electricity demands necessitates development of sustainable desalination technology. This can be achieved by reducing specific energy consumption process, which would also reduce environmental footprint. study proposes concept overall multistage multi-pass RO Arab Potash Company (APC) Jordan via heating feed water. utilisation waste heat generated different units production plant APC such steam condensate supplied exchanger is feasible technique entering system. To systematically assess contribution temperature on performance metrics including use, generic model developed. Model based simulation used evaluate effect temperature. results indicate clear enhancement while using temperatures close maximum recommended manufacture. It been noticed that an increase 25 C 40 result saving more than 27%.
2. Portable Reverse Osmosis System with Recycled Concentrate and Integrated Energy Recovery Device
GOVERNMENT OF THE UNITED STATES AS REPRESENTED BY THE SECRETARY OF THE ARMY, 2025
Portable reverse osmosis water filtration system with improved efficiency and reduced filter replacement. The system recycles concentrate fluid to increase permeate yield and minimize filter replacement. It has a mixing chamber with an adaptor and regulator, a feed pump, a boost pump, an energy recovery device, and a membrane apparatus with a concentrate chamber and permeate chamber. Concentrate is recycled to the mixing chamber via the regulator, and high-pressure concentrate goes to the energy recovery device. This allows more permeate to be extracted before replacing filters.
3. Reverse Osmosis System Retrofit Incorporating Turbochargers, Isobaric Chamber, and Multistage Pump for Multi-Stage Configuration
FLUID EQUIPMENT DEVELOPMENT COMPANY LLC, 2025
Retrofitting a single-stage reverse osmosis (RO) system to a multi-stage RO system with higher recovery without replacing major components like high-pressure pumps (HPP) and energy recovery devices (ERDs). The retrofit involves adding a second RO stage and using turbochargers, an isobaric chamber, and a multistage pump to recover energy. The turbochargers replace the interstage pumps between stages. The isobaric chamber reduces feed pressure for the second stage. The multistage pump increases feed pressure for the first stage. This allows higher recovery without significant capital cost and maintenance compared to replacing the HPP and ERDs.
4. 3D-Printed Water Treatment Membrane with Tapered Interface for Enhanced Cross-Flow Velocity and Fouling Resistance
EVOVE LTD, 2025
A membrane for water treatment that reduces fouling and improves flux compared to traditional membranes. The membrane has a unique interface design with a reduction in dimensional properties toward the retentate outlet. This creates higher cross-flow velocities to disrupt concentration polarization and prevent fouling. The membrane is also manufacturable by 3D printing to enable customization and optimization. The 3D printing allows tuning of the interface geometry and pore structure for improved fouling resistance. The membrane can also be used in water treatment modules and systems for reducing divalent ion concentrations.
5. Barge-Integrated Reverse Osmosis System with Watertight Cooling Tank and Remote Operation Capabilities
LONGITUDE 123 INC, 2025
A seawater-fed reverse-osmosis desalination plant that uses a watertight tank inside the barge or monopile to house the reverse-osmosis tubes. The tank is filled with water/fluid that is circulated to cool the tubes and transfer heat to an exterior seawater radiator. This allows close tube spacing without overheating issues. The seawater intake, pumps, reverse-osmosis membranes, and brine discharge are all contained inside the barge/monopile. The freshwater output is piped to shore using buried HDPE pipes. Grid power and internet connectivity are provided via HDD-installed cables. This allows remote operation of the plant without onsite personnel.
6. Membrane Processes for Remediating Water from Sugar Production By-Product Stream
amal el gohary ahmed, christian jordan, eva maria walcher, 2025
Sugar production generates wastewater rich in dissolved solids and organic matter, improper disposal poses severe environmental risks, exacerbates water scarcity, creates regulatory challenges. Conventional treatment methods, such as evaporation chemical precipitation, are energy-intensive often ineffective at removing fine particulates impurities. This study evaluates membrane-based separation a sustainable alternative for reclamation sugar recovery from industry effluents, focusing on replacing with membrane processes, ensuring high permeate quality, mitigating fouling. Cross-flow filtration experiments were conducted lab-scale system 70 C to suppress microbial growth, comparing direct reverse osmosis (RO) of the raw effluent an integrated ultrafiltration (UF)RO process. Direct RO resulted rapid fouling, which was characterized via SEM, EDS, FTIR elucidate fouling mechanisms. A tight UF (5 kDa) pre-treatment before significantly mitigated improved performance, enabling 75 % recovery, maintaining conductivity below 0.5 mS/cm, sustaining stable flux, reducing blocking.
7. Multi-Criteria Decision Making: Sustainable Water Desalination
dongfeng li, mohamed hassan, nuno bimbo - Multidisciplinary Digital Publishing Institute, 2025
With an increasingly more urbanised global population, surface water and groundwater resources are being/have become outpaced by growing demand. The oceans could address this pertinent scarcity issue, once their high-salinity content is removed. Water desalination thus be a crucial pathway towards addressing scarcity. However, conventional known to highly energy-intensive, with limited scalability potentially significant negative environmental impacts. Multi-criteria Decision Making (MCDM) presents novel approach sustainable based on sustainability-related criteria. Fuzzy Analytical Hierarchy Process (FAHP) was implemented determine the most optimal small-scale, modularised, remote reverse osmosis (RO) plant configurations. Twelve configurations were assessed, four capacities (50, 100, 150, 200 m3/day) three diesel-to-solar photovoltaic energy (1000%, 7525%, 6040%). hybridised generally ranked higher, particularly when less reliant diesel, at small(er) capacities, in terms of criteria: sustainability, overall efficiency, standalone potential while maintaining competitive cos... Read More
8. Hollow Fiber Membrane Module with Series-Connected Elements in Pressure Vessel
TOYOBO MC CORP, 2025
Hollow fiber membrane module for improving overall treatment efficiency of reverse osmosis systems. The module has a pressure vessel containing a series of hollow fiber membrane elements. The elements are connected together using a connector. By connecting the elements in series instead of feeding the concentrated feed to later stages, all elements receive the unconcentrated feed, maximizing water production. This improves overall treatment efficiency compared to feeding concentrated feed to later stages.
9. Evaluation of the Genericity of an Adaptive Optimal Control Approach to Optimize Membrane Filtration Systems
aymen chaaben, fatma ellouze, nihel ben amar - Multidisciplinary Digital Publishing Institute, 2025
This study explores the application and robustness of an adaptive optimal control (AOC) strategy to optimize operation membrane filtration systems. The proposed is based on a constant flux model where fouling primarily due cake layer formation. algorithm dynamically finds ratio between (F) backwash (BW) time in response system disturbances, thereby adapting operational state order its performance terms energy consumption. was successfully applied both microfiltration (MF) ultrafiltration (UF) systems quantitatively demonstrated effectiveness reducing consumption controlling fouling. It proved robust against uncertainties real-time adaptability even under varying realistic disturbance conditions. implementation this facilitated adaptation filtration/backwash (F/BW) dynamic disturbances. result underlines that behavior predominantly driven by fluctuations mixed liquor suspended solids (MLSSs). Compared conventional fixed-time modes, AOC led significant savings, ranging from 7% 30%, lifespan extension, mainly through more efficient permeate pump usage.
10. Reverse Osmosis System with Sequential High-Flux and Low-Flux Membrane Filtration
ORGANO CORP, 2025
Reverse osmosis water treatment system and method that uses a two-stage filtration process to improve water quality. In the first stage, a high-flux reverse osmosis membrane removes impurities from the feed water. In the second stage, a lower-flux reverse osmosis membrane further filters the permeate from the first stage. The key difference is that the second-stage membrane has a lower flux per pressure unit than the first-stage membrane. This allows lowering the water quality degradation that can occur when using a membrane with lower rejection. By using a second-stage membrane with lower flux, the water quality can be improved compared to using a single high-flux membrane.
11. Mild Tuning of the Microbial Habitat via Titanium-Based Pre-coagulation Mitigates Reverse Osmosis Membrane Fouling
ruonan gao, haojie ding, mengyao gu - American Chemical Society, 2025
Membrane fouling remains a persistent challenge in reverse osmosis (RO) systems. Devising effective strategies to mitigate membrane has become crucial for sustainable water treatment. Here, we propose titanium-based pre-coagulation strategy RO mitigation through regulation of the microbial habitat feed. The performance Ti(SO4)2 desulfurization wastewater and subsequent mechanism were systematically investigated. Our findings revealed that Ti induced an acidized environment, maintained balance between organic inorganic depositions, fostered beneficial community resisted rapid fouling. 20 day operations different scenarios (Ti, Al, Ctrl) showed group membranes highest normalized flux at 57.15%, outperforming Ctrl Al groups by 7.92% 15.16%, respectively. Microbial analyses, including taxonomic profiling metagenomic analysis, demonstrated Ti-based reduced dominance extracellular polymeric substance (EPS)-secreting genera, such as Sphingopyxis, while promoting Terrimonas Paenarthrobacter, with acid-tolerance traits EPS production. This shift mitigated biofouling enhancing limiting biofilm... Read More
12. Energy savings in SWRO desalination via PRO hybridization: a parametric study
ahmed s alghamdi, amr mohamed mahmoud, sultan ahmed - Frontiers Media, 2025
This study investigates the potential for energy reduction in a full-scale Seawater Reverse Osmosis (SWRO) desalination plant through hybrid integration with Pressure Retarded (PRO). A pilot test using 60 m 2 PRO membrane kit helped determine key operating parameters, including draw solution (DS) pressure and resulting dilution fluxes. Subsequently, analysis was conducted 650 of area. The demonstrated up to 12.56% specific consumption under optimized conditions. Energy savings were found correlate positively lower feed pressures, higher brine availability, optimal rates, while being negatively impacted by losses high DS-to-FS flow ratios. confirms viability PRO-SWRO hybridization as method enhancing efficiency, highlights areas further optimization design hydraulic configuration.
13. Modular Fluid Purification System with Sequential Multi-Stage Treatment and Energy Recapture
KATZ WATER TECH LLC, 2025
A system for efficiently and cost effectively removing impurities from fluids like water, oilfield wastewater, and produced water. The system uses a series of stages with devices like filtration, coagulation, reverse osmosis, thermal distillation, and recapture. The stages are arranged in a coordinated manner to progressively purify the fluid, remove specific components, and recapture energy. This allows efficient, customizable purification and recycling of wastewater while minimizing freshwater use. The stages can be containerized for portable, modular systems.
14. Concentration of High-Salinity Brine Using Single-Stage Membrane Capacitive Deionization
tie gao, yunfei he, ao gong - American Chemical Society, 2025
Concentrating saline water is essential for zero liquid discharge (ZLD) of wastewater. However, prevailing membrane-based technologies, such as reverse osmosis (RO) and electrodialysis (ED), can hardly handle high concentration differences (C) in a single stage, where multi-stage operation needed, which increases the operational difficulties energy input. membrane capacitive deionization (MCDI) theoretically applicable to C. This study explored feasibility employing an MCDI brine concentrating proposed several regulating measures on electrode's porosity, electrical quantity charging-discharging, desorption conditions. Based determination salt fluxes, these were confirmed mitigate transfer across membrane, thereby facilitating transportation concentrating. To address mass imbalance between adsorbed desorbed, novel pre-charge strategy was designed, enabled successful continuous over 50 cycles. A difference 161 g/L NaCl achieved per highest reported result among RO, ED, studies. The rate 38.4 g/(m2h) with comparative consumption at RO ED. demonstrated that optional technology futu... Read More
15. Simulation of Biofouling Caused by Bacillus halotolerans MCC1 on FeNP-Coated RO Membranes
maria magdalena armendarizontiveros, teresa romerocortes, victor hugo perezespana - Multidisciplinary Digital Publishing Institute, 2025
Reverse osmosis (RO) desalination technology offers a promising solution for mitigating water scarcity. However, one of the major challenges faced by RO membranes is biofouling, which significantly increases costs. Traditional simulation models often overlook environmental variability and do not incorporate effects membrane-surface modifications. This paper develops bacterial growth model prediction seawater performance, applicable to commercial membranes, can be either uncoated or coated with iron nanoparticles (FeNPs nZVI). FeNPs were selected due their known antimicrobial properties potential mitigate biofilm formation. The native bacterium Bacillus halotolerans MCC1 was used as biofouling bacterium. Growth kinetics determined at different temperatures (from 26 50 C) pH values 4 10) obtain parameters. Microbial on modeled using Monod equation. performance evaluated in terms hydraulic resistance permeate flux under clean biofouled conditions. validated data obtained laboratory scale. Bacteria grew faster 42 C 10. had more significant effect than temperature rate. FeNP-coated ex... Read More
16. Membrane Filtration System with Sequential Nanofiltration and Reverse Osmosis Stages for Ion Separation and Brine Concentration
NANYANG TECHNOLOGICAL UNIVERSITY, 2025
Integrated membrane filtration system for brine management in desalination plants to mitigate environmental impacts of high salinity discharge. The system uses a sequence of nanofiltration (NF) stages followed by reverse osmosis (RO) stages. The NF stages perform diafiltration to dilute and separate ions. The NF permeate feeds the RO stages. This allows optimizing ion fractionation and brine concentration while avoiding high salinity discharge.
17. Reverse Osmosis System with Machine Learning-Based Membrane Fouling Prediction and Flow Rate Optimization
SYNAUTA INC, 2025
Optimizing reverse osmosis water desalination systems using machine learning to reduce operating costs and improve performance by predicting when to clean the membranes. The system measures parameters like feed pressure, flow, salinity, temperature, etc. and uses a trained ML model to determine fouling levels and optimize flow rates through the stages. This allows reducing energy use while maintaining permeate production. By predicting when fouling will inflect and decline, cleaning can be timed to minimize energy vs waiting for a 10% flux drop. The ML model also balances flow across stages for energy savings.
18. Closing the loop: model-predictive control for a closed-circuit reverse osmosis system
dhrubajit chowdhury, aurora kuras, derek weix - IWA Publishing, 2025
ABSTRACT This article presents a model-predictive controller (MPC) for the maximization of energy efficiency closed-circuit desalination reverse osmosis (CCRO) system. CCRO is process producing drinking water that based on cyclic operation with following two phases: (a) filtration and (b) drain. In this article, we test model predictive control optimal process. The most important features our approach are as follows: selection structure enables reliable forecasts phase (up to 3 h), an on-line calibration strategy ensures forecast reliability, (c) satisfaction equipment safety operational constraints selected setpoints. We challenge through deliberate introduction changes in unmeasured feed concentration applied constraints. Our results indicate frequent parameter updates critical maintain reliability MPC purposes. addition, illustrate identifiability not guaranteed variation flow rates necessary even though never operates steady state. Finally, can compute rate setpoints maximize while satisfying applicable
19. Reverse Osmosis System with Sequential Membrane Units and Energy Recovery via Hydraulic Motor-Generator Configuration
DANFOSS AS, 2025
Reverse osmosis system with optimized energy consumption for water treatment applications like desalination or wastewater reclamation. The system uses a chain of membrane units connected in sequence. Each membrane unit has an inlet, outlet, and concentrate outlet. The concentrate outlet of a unit feeds into the inlet of the next unit. The final unit's concentrate outlet connects to a hydraulic motor. This motor is connected to an electric generator. The generator can drive a pump upstream of a membrane unit to boost feed pressure. This recycles concentrate energy to drive the system. It eliminates wasteful high-pressure feed pumps. The motor can be variable frequency to adapt to changing conditions. Sensors on the axial piston machines monitor flow and pressure.
20. Apparatus and Method for Intermittent Biocide Dosing with Controlled Oxidation Potential in Reverse Osmosis Systems
ORGANO CORP, 2025
Water treatment method and apparatus to prevent biofouling of reverse osmosis (RO) membranes without harming the membranes. The method involves intermittently adding biocides to the water feed to the RO membrane. The biocide dose and frequency are adjusted based on membrane fouling levels. This prevents excessive biocide concentrations that can harm the membrane. The biocide addition is tuned to keep oxidation potential below a threshold without exceeding it. This prevents biocide-induced membrane fouling while still providing adequate biocide dosing to prevent organic growth.
Reverse osmosis control systems with automation are enhancing desalination and water purification techniques to guarantee dependably pure drinking water. In addition, algorithms and sensors are used to reinforce the reverse osmosis system for best performance.
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