The Middle East and North Africa region faces critical water scarcity and food security challenges that threaten economic development. Fertilizer use supports food self-sufficiency, but its production is highly water intensive. Supplying desalinated water to a decarbonized fertilizer plant offers an environmentally sustainable pathway.
This study investigates co-locating a decarbonized fertilizer plant with a seawater desalination facility, optionally implementing minimum liquid discharge (MLD) to generate additional revenue through recovery of magnesium hydroxide and sodium chloride (NaCl). Three configurations were modeled: a conventional seawater reverse osmosis (SWRO)-based plant; and two MLD configurations using high-pressure RO (HPRO), osmotically-assisted RO (OARO), and crystallizers. Financial performance was assessed using a novel discounted and allocated levelized cost (DALC) method, internal rate of return (IRR), and net present value (NPV).
In a Moroccan case study, the conventional configuration achieved the lowest DALC and energy consumption (0.70 USD/m3water and 3.8 KWhel/m3), with an IRR of 23.9 %. The first MLD configuration had higher costs (0.94 USD/m3water, 12.0 KWhel/m3) and a lower IRR (14.5 %), with water recovery limited to 71.4 % due to nonuse of magnesium crystallizer effluent (60.4 % in the conventional setup). Reusing this effluent in the second MLD configuration increased water recovery to 96.7 %, yet higher impurities at the NaCl crystallizer feed reduced the IRR to 9.7 %, which could be improved through financing strategies such as lowering capital costs to endorse the MLD-maximizing option.
The findings emphasize advancing impurity removal methods and exploring innovative project financing strategies to enable financially and environmentally sustainable seawater desalination for decarbonized fertilizer production.
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