Developing Insights into Pretreatment Optimization: Effects of Eliminating Lime and Soda Ash in Groundwater RO Desalination

In arid and water-stressed regions, groundwater desalination plants are critical for ensuring reliable potable water supplies, making improvements in their operational efficiency and cost effectiveness a priority for utilities. In many such facilities, lime and soda ash softening remain common pretreatment practices, which increase chemical consumption and sludge generation, prompting the need for alternative low-chemical strategies. This study evaluates the technical, operational, and economic implications of transitioning a full-scale brackish groundwater desalination plant, from lime–soda ash softening (old plan) to a low-chemical pretreatment strategy based on antiscalant dosing (new plan) upstream of reverse osmosis (RO). Key parameters, including pH, total hardness, calcium and magnesium hardness, silica, iron, alkalinity, and total dissolved solids (TDS), were measured and compared at multiple locations within the treatment plant under both the old and new plans. Removing lime and soda ash caused higher levels of hardness, alkalinity, and silica in the water before RO treatment, increasing the risk of scaling. Operationally, the feed pressure increased from 11.43 ± 0.16 bar (old plan) to a peak of 25.50 ± 0.10 bar in the new plan, accompanied by a decline in water production. Chemical cleaning effectively restored performance, reducing feed pressure to 13.13 ± 0.05 bar, confirming that fouling and scaling were the primary, reversible causes. Despite these challenges, the plant consistently produced water that complied with Saudi Standards for Unbottled Drinking Water (e.g., pH = 7.18 ± 0.09, TDS = 978.27 ± 9.26 mg/L). Economically, the new strategy reduced operating expenditure by approximately 54% (0.295 → 0.135 $/m3), largely due to substantial reductions in chemical and sludge handling costs, although these savings were partially offset by higher energy consumption and more frequent membrane maintenance. Overall, the findings emphasize the importance of systematic performance evaluation during operational transitions, providing guidance for utilities seeking to optimize pretreatment design while maintaining compliance, long-term membrane protection, and environmental sustainability.