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Membrane distillation (MD) has shown strong promise for treating hypersaline produced water (PW) streams. Scaling and fouling on the membrane surface, however, have been identified as major challenges for commercialization and widespread application. The focus of this study was to first identify the nature of foulants and scalants on the membrane surface and then investigate the pretreatment strategies that mitigate the extent of fouling and scaling on the membrane surface. Vacuum MD (VMD) was selected for this study because of its higher flux at more moderate feed temperatures that eventually leads better assessment of fouling and scaling on the membrane surface. VMD flux tests were carried out with three different real PW samples at total dissolved solids concentrations in the range of 120–160 g/L. It was found that an efficient pretreatment prior to MD is required to mitigate the fouling potential of the organic matter, mostly suspended constituents, in PW samples. Suspended organics fouled and quickly wetted the MD membrane. Major conventional treatments, including filtration, oxidation, coagulation, air floatation, and aeration were investigated to pretreat the PW before VMD tests. A comprehensive comparative analysis is presented showing that the ultrafiltration and coagulation pretreatments displayed the best performance in mitigating the fouling and scaling, while oxidative pretreatment was found to be effective in reducing the iron concentration to less than 5 ppm. The surface of scaled membranes was carefully characterized to further evaluate the performance of each pretreatment. The components that had the highest tendency to precipitate on the membrane surface were identified as strontium sulfate, calcium carbonate, sodium chloride, iron oxide, and silica. These findings are supported by thermodynamic estimation of the saturation index. • Membrane distillation proposed for desalinating hypersaline produced water • Suspended organic matter fouls the membrane, leading to immediate membrane wetting. • Pretreatment of produced water required for long-term performance • Fouling and scaling characterized; sulfate and carbonates found as major scalants • Produced water concentrated to 290 g/L and +50% water recovery achieved [ABSTRACT FROM AUTHOR]

[Display omitted] • A parametrized thermodynamic model proposed to predict phase equilibria. • Performance of the MD simulated in a subroutine custom model. • Scaling of salts are predicted during MD operation. • Scaling prediction is validated via experimental results. • Complex interaction among molecular and ionic species are highlighted. Membrane distillation (MD) for water treatment is significantly impaired by the scaling of dissolved minerals. The type and content of minerals generally measured as total dissolved solids (TDS) in hypersaline brines not only reduce the MD flux but also control the scaling behavior on the membrane surface. The scaling-induced pore blockage further reduces water flux and eventually leads to membrane wetting. The scaling problem is even more pronounced in the treatment of produced water (PW) as it contains 3–7 times higher TDS concentrations, compared to seawater. Theoretically, the necessary conditions for a salt to precipitate can be traced from its solubility product constant and activity of the constituents within the solution. Therefore, a comprehensive thermodynamic model is necessary to represent the electrolyte behavior and to predict the precipitation of different salts in a complex solution like PW. We pursued electrolyte Nonrandom Two Liquid Theory (eNRTL), a state-of-the-art electrolyte model, to address the PW fluid phase equilibria. With a fully parameterized eNRTL model, we predicted salt precipitations in two different PW samples and compared the results against the experimental findings. Furthermore, we forecast the precipitation of salts in response to the change in PW concentration and temperature in the MD operation. [ABSTRACT FROM AUTHOR]