Water and mineral recovery, zero waste, process and production facility

Abstract

A zero-waste brine, treatment process, method and treatment facility for separating desired materials from recovered subsurface fluids into different groupings for categorization, collection, purification and monetization, generally. Specifically, the present invention is utilized to optimize the purification of non-potable, brine water and to the separation and purification of said water whereby specific mineral byproducts are extracted and resultant water undergoes a chlor-alkali process producing NaOH and HCI wherein, the NaOH may he further mixed with CO2 to produce Na2CO3, effectuating carbon capture, which may then be sequestered via utilization. This process may be applied to transported brine to a facility, the access point of a single operational or non-operational well and / or across a group of wells and or facilities, in the aggregate.

Description

[0001] In the United States Patent Office

[0002] TITLE

[0003] Water and M ineral Recovery, Zero Waste, Process and Production Facility

[0004] INVENTORS

[0005] Jorge Manrique

[0006] Joseph Manrique

[0007] CROSS-REFERENCE TO RELATED APPLICATIONS

[0008] LLS. Provisional Patent Application No. tS3 / 7O4,241 filed October 7, 2024

[0009] FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0010] Non-Applicable

[0011] SPECIFICATION

[0012] Field of the Invention

[0013] The present invention relates generally to zero-waste raw water (Le., brine, brackishwater} treatment processes, methods and treatment facilities for separating desired products (e.g., water, minerals) into disparate groupings for categorization and monetization, generally. Specifically, the present invention is utilized to optimize the purification ofnon- potable (well) water, or hydrogeological resources that, without purification treatment, will remain unusable for consumption, .and to the separation and purification of said water whereby specific minerals (e.g,, lithium) is extracted and resultant water undergoes a chlor-alkali process producing NaOl 1 and HC1, wherein the NaOH may be further mixed with CO2 to produce NasCGv to be used as feedstock, effectuating carbon capture for producing value added chemical products, by making the CO2 a part of the molecular structure of the product. This process may be applied to raw water volumes coming from a single well and / or across a group of wells and facilities or to hydrogeological resources that without purification treatment will remain unusable for consumption, in the aggregate.

[0014] Description of the Related Art

[0015] The current state of the art lacks significant advantages- when compared to inventor’s holistic approach to water purification, mineral collection and carbon capture in the proposed solutions. Prior art and existing technology focus solely on water purification, mineral separation (and concentration) and / or carbon capture as separate events and processes wherein the efficiencies of a holistic approach to brine purification and carbon capture lose several efficiencies by segregated activities where products and by-products are capable of further utility and value in subsequent processes when integrated into a system or series of systems. Moreover, the current process and method is designed and implemented to both maximize production (i.e., producing as large a quantity of each desired product as possible), at the highest efficiency, lowest cost and highest remuneration rate, all while moving as close to zero emissions as practicable, for both extracted water and mineral components but also through the carbon capture component in post- pmductiom

[0016] Where current industry is relegated to implementing singularized, individual technologies, inventors focus on quantification of lithium reserves, for example, and utilization of large-scale development and execution that is not directed to a single technology. By combining technologies existing as an alternative to any singular approach, multiple technologies are integrated incorporating exploration, production, processing and field operations developed to transform lithium recovery from small scale operation to an industrial base business 1 ) securing a continuous supply of lithium, 2) which is scalable, 3) integratable into existing systems and technologies by 4) leveraging efficient and effective use of Capital, while 4) maintaining ESG sustainability of the operation without waste.

[0017] For example, inventors focus on all aspects of a large-scale development from land, legal, water right Issues, geoscience, well drilling and completion, production facilities, processing technologies for lithium recovery, and critical minerals and materials (CM.M) and battery materials recovery from saturated brine including, but not limited to, well infrastructure, pre-, post-, and processing of saturated brines, lithium, and CM.M mineral recovery (coneentration, selective CM'M), processing water polishing, disposal, reinjection, CMM commercialization and mineral use (J,e., batten-' manufacturing).

[0018] The present invention typifies the discussed “integrated approach'* which requires less vol ume of water compared to current methods without the need for environmentally and ecologically untoward acids ar chemicals resulting in a byproduct -- potable water - processed to consumption levels.

[0019] To wit, prior art in the field focuses exclusively on extracting a single mineral, or selected minerals, and does not contemplate production of multiple mineral / chemicalspecies, water, or carbon capture. What is more, no other technology has the capability to utilize resultant process byproducts to produce zero waste, or even a wholly negligible waste, or processes of accomplishing same.

[0020] The present invention therefore encompasses a holistic approach to maximizing recovery from brine resources with potable water byproducts all whi le exhibiting a minimal carbon footprint.

[0021] Some examples of particularized components of an integrated system include:

[0022] Exploration

[0023] • Integration of data sources: geology, seismic. Resistivity Mapping, Magneto- Telluric MT surveys, soil testing, seismic, magnetic surveys, mineral composition, surface soil testing, logging, and / or petrophysics;

[0024] • G&G and Engineering;

[0025] • screening and valuation of target locations and performance criteria;

[0026] • international development; and ♦ environmental assessment and permitting.

[0027] Land Work and Permits

[0028] • land & legal counsel and screening pf land locations; cost of entry, acreage, royalties, and water issues;

[0029] • screening of land location* and potential targets;

[0030] * accessibility to develop and for product to market;

[0031] • de-risk acreage availability, permits / claims (lode, mining, exploration); and » legal & land situation and water rights.

[0032] Data Testing Wells

[0033] * Types: data slim wells, slim core holes, surface pads, wells include drilling, logging and completion, production testing and lifting;

[0034] * coring, production testing, fluid sampling & brine geo-chemical testing; and * resource description - reservoir description of strata-bound lithium saturated brine.

[0035] Reservoir

[0036] • Geology and petrophysical parameters;

[0037] * screening and valuation of potential targets;

[0038] * reservoir delineation: resource assessment; * volumes and reserves valuation;

[0039] • subsurface modeling, numerical reservoir simulation;

[0040] * simulation of scenarios, brine flow in porous media;

[0041] ♦ saturation, temperature, mineral concentration (geochemical);

[0042] ♦ reinjection options; and • forecasting performance scenarios for key input to financial performance.

[0043] Well Architecture & Operations Well drilling and completion designs;

[0044] ♦ maximizing contact: drilling, logging, completion & testing, core holes, slim holes, test & production wells, horizontak / grass roots;

[0045] • well completions: ssmds / fmes production, gravel pack, screens; * fluid sampling & geo-chemical testing; brine mineral composition;

[0046] * production deliverability: production lifting methods & monitoring;

[0047] • maintaining rates for lithium (and CMM) & water processing;

[0048] • production maintenance strategy; and

[0049] ♦ CAPEX <& Field Operating Costs, Process'mg, Processing. Post Processing

[0050] * .Parameters for lithium concentration and recovery;

[0051] * implementation and integration of technologies;

[0052] * flowsheets & processes) multiple lithium recovery technologies;

[0053] • develop flowsheet to process low lithium saturated brines (50 ppm to 150 ppm); * pre- and pro-: Filtration options (RO & Direct, ceramic filters);

[0054] » processing: DEE modeling kinetics and performance for sepamion / extaction: m ineral concentration & temperature : CAPEX requirements;

[0055] ♦ KPI’s for financial outlook & production deliverability of lithium -(and CMM) & water (costs for production and injection);

[0056] ♦ Rates Sustainability: Production Maintenance;

[0057] ♦ by product tor waste) is processed water conditioned for fanning, livestock, potable;

[0058] ♦ processing operating costs;

[0059] ♦ KPI's for lithium concentration and recovery; and

[0060] ♦ monitoring: artificial intelligence & machine learning.

[0061] In terms of brine concentration and location, comprehensive reservoir description of strata-bound lithium saturated brine may be determined through Integration of .geology, petrophysics, coring, logging, well testing; Magneto-Telluric (MT) surveys, resistivity mapping via several techniques developed throughout the oil and gas industry which have direct applicability to lithium and CMM processing and recovery including sophisticated workflows and software to use 3D static models and geo-cellular models with static and dynamic properties that utilize sophisticated workflows and software to use 3D static models and geo-cellular models with static and dynamic properties - all models which perform resource assessment to calculate ranges of in-place volumes, predict fluid flow and pressure drawdown, forecast and predict production as well as optimize field development. Yet, in terms of the new and novel advancements in the field of ‘Zero Waste’ fresh water and improved efficiencies in recovery of rare earth minerals (le., purified water and REE lithium) from saturated brines, these brines may be subdivided into geothermal brines, oilfield brines and salar brines wherein sal ar brines are the focus of the present invention in terms of lithium recovery. And while saturated salar brines typically have the highest concentration of lithium, this is not to be observed to the exclusion of other dissolved solids .(e.g., Ca-caicium, Mg-magnesium, K-Potassium, Na-Sodium and CL- chlorine), as provided below, which, dependent upon the particular dissolved solids, different resource produc tion streams may be developed to extract certain chemicals based on well composition profiles as in Table I (where TDS is the sum of all dissolved ions).

[0062] Table I

[0063] As well as averages, as provided in Table 2.

[0064] [ _ Ipeiith lft) li ippm) jca ippm))Mg (ppm)|K fepsyl-Ma (pprnHci (ppm; |T&S j U82 ~tui | 228 j 1,267 | itjn | '"B^Q | 40,000 j fable 2

[0065] Generally, and as a means of providing an exemplary representation of separation, lithium, calcium, magnesium and potassium may be removed from concentrated brines during an initial mineral processing (via, primarily, either two main methods of separation: ion exchange and membrane separation) and sodium and chloride may be separated and procured for commercialization through a chlor-alkali step for subsequent commercia fixation , This chlor-alkali step, while utilized within the industry to produce NaOH, HCL, and Bleach (NaCIO), is generally recognized for producing the aforementioned products, this process is accomplished inefficiently in terms of integration into an overall procurement and purification system.

[0066] Namely, removal of mineral products NaOH, HCL, and Bleach (NaCIO) results in a concentrated NaCl solution through membrane and electrolysis technology as a means to generate NasCOs as an internally utilized reagent at costs averaging 30 percent less thansourcing from the open market. Moreover, carbon capture credits can be claimed for the CO?, used in the NasCOs generation where current pricing, regulatory structure and legislated reimbursement rates of $25 to $65 per ion as a means of further reducing overall costs. What is more, use of membrane technologies RO / FO (Similar to seawater desalination facilities) can separate freshwater from the brine saturating it further and reducing the DLE / DLP facility footprint, Specific to the present disclosure, LiOH and Li2CO, Ca(OI l)2 and CaCO3, Mg(OH) 2 and MgCO3. KOH and K2CO3, NaOH, HOI and Bleach (NaCIO) may be proeessed / obtained via conversion reactions for Hydroxide (OH), as sodium hydroxide

[0067] (NaOH), as follows:

[0068] UCI + NaOH - LiOH -f- NaCL Ca(Cl)2 + 2NaOH = Ca(0H)2 + 2NaCI

[0069] Mg(CI)2 * 2NaOH - Mg(0.H)2 •+• 2NaCI

[0070] KC B- NaOH KOH + NaCl

[0071] And where additional processing technology may be utilized to produce NaOH "in house” to produce LiCL Ca(Cl)2, Mg(CI)2 and KC1 and where additional reactions for Carbonate (CO3), as Nas CO}, are as follows:

[0072] LiOH + Na2CO3 = LI2CO3 4 NaOH

[0073] Ca(QH)2 ■+ Na2CO3 - CaCO3 + 2NaOH

[0074] Mg(OH}2 r Na2CO3 « MgCO3 + 2NaOH KOH *• Na2CO3 - K2CO3 + NaOH

[0075] As a system-wide approach, brine may be concentrated through an innovative use of existing proven teehnologies and important operating improvements of a flow process using a number of membrane technologies, separation of freshwater from the brine saturates the brine further and reduces the mineral extraction process and facility footprint through arrangement of technologies in series can maximize the necessary capacity of the unit and reduce CAPEX and operating costs, as depleted below:

[0076]

[0077] Where physical limitations on existing technologies of TDS reach upper limitations at approximately 40,000 TDS with saturated brines, and improved technologies reach such limits at approximately 80,000 - 100,000 I DS with saturated brines in the technology field. Though, by concentrating the incoming brine before sending the brine to mineral extrac tion units, inventors produce a value adding product at the same time as decreasing the capital cost of the mineral extraction.

[0078] Expressly, removal of water from the brine, the present process approximately doubles the lithium concentration ofthe incoming fluid providing marked advantages over OPEX and CAPEX as the processing facility directly decreases in size as the lithium concentration resulting in increases with higher incoming concentration also increasing purity and recovery as it is easier for the active material to “pick up” Lithium, This is due to the increased concentration gradient causing improved diffusion of lithium into the molecular structure of the active material. in terms of increasing concentration, at 100,000 TDS, active methods of concentration are few, with most solutions being experimental. However, there is a proven method historically wherein further concentration of toe brine may be achieved through the use of evaporation ponds relying upon solar methods which may be additionally assisted through heat generation (e.g,, induction heathers) which increase water removal, accelerates salt and REE concentrations thereby improving ease of mineral recovery (as shown below in Table 3,

[0079] The proposed method of element concentration through evaporation provides two (2) distinct advantages: (I ) concentration of the brine using a infinity renewable resource (solar energy) and (2) settling of undesirable precipitates before entering the mineral extraction process. Moreover, by decreasing the size of evaporation ponds, in ventors may more efficiently concentrate REEs (i.e„ lithium} all while also more effectively managing un wanted precipitates ,

[0080] To wit, the above identified elements and total TDS may be more efficiently managed to exceed the current processing capacity of even the most advanced comparable systems (as in Table 3)

[0081] Table 3

[0082] In addition, by practically choosing certain completions, more concentrated zones may be selected based on concentration of desired particulates wherein, for example, CV-Ts log measurements evidence, specifically in terms of lithium, evidenced increases in lithium concentration as depth increases as i n Table 4 (below).

[0083] ■Fable 4 By selectively completing the we Improve our lithium concentration (starting at a depth of 585 feet in rows 9-26) before ever reaching any of the flirtation systems where a 40 ppm is realized by maximizing extraction efforts and providing for potential automated production based on real time measurements of lithium concentration in combination with an Artificial Intelligence (Al) engine (as seen in Table 5)

[0084] Table 5 in fact, the process itself may be subdivided into pre-processing, processing and post- processing stages wherein in pre-processing water is removed from the system to the greatest extent practical and / or technically and economically feasible for brine saturation and element concentration resulting in both (a) fresh water and (b) concentrated brine. During Processing, concentrated brine undergoes selective mineral removing processing resulting in a range of minerals through separation, concentration and purification to deliver purified concentrated aqueous mineral streams, fresh water, and concentrated NaCI brine.

[0085] Post-processing may then be utilized to achieve one to a plurality of resultant products including: (i) transfer of NaCI brine to a post processing facility, a chlor-alkali process, (ii) processing to produce NaOH and HO (as defined above), (iii) mixing of NaOH with CO2 to produce Na2C03, depending on cost effectiveness or production needs, and / or (iv) NaOH may be mixed with Na2CO3 can then be mixed with the concentrated aqueous mineral streams to produce carbonated salts, again depending on cost effectiveness, pricing, or production needs. Ultimately, though, the present system and methods may provide multiple results for i) fresh water, ii) selective production of lithium or CMMs, iii) utilization of resultant NaOH for use in COS capture and utilization - all in a single and / or multi-stage process or processes.

[0086] Based on the above description, design components results in “Zero Liquid Discharge” whereby both elements and fresh water are ultimately resultant products which may then be economically sources and commercialized including: (a) a “plug-n-play5’ modular configuration, which is technology agnostic, (b) production of desirable battery materials (ex. LI0H and LfeCOs), (c) water purification and production in areas typically classified as arid, semi-arid and desert, (d)

[0087] COS consumption during proposed produces) creation, (e) maximization of element and water recovery within a saturated brine reservoir through targeted reservoiris) selection, (f) resource assessment of quantifiable reserve composition, concentration (qualification) and quantification and (g) increases efficiencies within existing and future targeted subsurface reservoirs to maximize drilling, completion and production operations for improvements in CAPEX, Opex, Operating Costs, Processing Costs and Environmental footprints.

[0088] And where the applicability of the present disclosure is wide-ranging, certain advantages become apparent especially in terms of H2 production and CMM (Critical Mineral and Materials) recovery.

[0089] As will be appreciated and understood by those having requisite skill in the field, similar processes may be combined with CPU & COs for Ffe general ion, namely with regard to seawater. Seawater processed using proven “desal” technology / projcct developer provides improvements using RO (depending on seawater return specs) including ion removal largely dependent on specification & impurities and typically is accomplished using proven Electro-De-Ionizer (EDI) technology and / or M2 Electrolysis wherein, pre-processed and purified water goes to electrolyzers and related technology where H2 is collected, compressed and liquefied to required specifications.

[0090] Too, technologies for an '‘extraction method” may be designed for improved efficiency & scalability. Processing & extraction IP based on combination and flowsheet sequencing of proven technologies where production and manufacturing IP drives efficiency gains and cost optimization rcpresentationally depicted below:

[0091]

[0092] According to the present Invention, the present system and methods are extendable extended to cover multiple processes from water purification to CMM recovery and valuable chemical products allowing for the derivation of multiple results for fresh water, selective production of lithium or CMM, and / or utilization of NaGH for use in CO2 capture and utilization existing a single process or over multiple processes selectable based on desired outputs and products.

[0093] An exemplary flow chart details a multi-stage production fecility where several steps are demonstrable as to evidence various and variable end products including (1) concentration facilities, (2) potable water, (3) ion removal, 1'4) chlor-alkali processing, (S) consumption of CO2, (6) and carbonate salts production: More specifically:

[0094]

[0095] Further, io terms ofprocessing of concentrated Na€l brine:

[0096] Or in the case of limited CO2 hut am ample supply of renewal energy:

[0097] And wherein the is an established carbonate plant and H2 and NaCI. are th« desired products:

[0098] Or where an existing lithium operation ahd / or water reclamation is desired:

[0099] Previous inventions are cost prohibitive and have high water consumption as well as large carbon footprints. The proposed invention greatly reduces or may even eliminate these issues, by not requiring reinjection wells, by being self -sustained by producing our own water and reagents and capturing carbon dioxide.

[0100] Summary of the Invention

[0101] The present invention relates to the on-site pre-processing, processing, and postprocessing of subsurface brine from wellbores evidencing a zero-waste mineral separation and chemical production facility which enables

[0102] 1) the production of fresh water from an incoming brine stream, or adding for production and potential consumption, of hydrogeological resources that, without the present invention and combination of pre- processing, processing, and post-processing treatments, remain as unusable resources:

[0103] 2) the extraction csf minerals: and

[0104] 3) finally , the production of value-added chemicals to allow tor no waste products.

[0105] The present invention achieves this goal by combining pre-processing, processing and post-processing, as follows; i) fire-Processiaa

[0106] Taking raw (unfiltered, unadulterated) brine from subsurface sources and separating said brine into “grade” or “qualities” to await treatment whereby the brine is processed to filter and “squeeze out” as much water as is economically feasible for a designated brine composition resulting in: (a) fresh water and (b) concentrated brine; iij Processing

[0107] Concentrates.! brine then undergoes further mineral removing processing resulting in a range of minerals through separation, concentration and purification resulting in purified concentrated aqueous mineral streams. fresh water, and concentrated NaCI brine; and iii) Post-Processing

[0108] NaCt brine is then transferred to a post processing facility, which is primarily a chlor-alkali process, along with other processes, to produce

[0109] NaOH and HCI. NaOH can then either be mixed with CD2 to produce Na2CO3, depending on cost effectiveness, and Na2CO3 can then be mixed with the concentrated aqueous mineral streams to either produce a carbonate mineral salt, depending again on the cost effectiveness and current pricing.

[0110] The objective is to provide a system for production of fresh water, selective production of strategic materials (e,g., Lithium), and utilization of resultant NaOH for use in carbon capture and utilization - all .in a single process or via multiple combined processes.

[0111] SUMMARY

[0112] The present invention advances actively controlling field production and retrieval of fluids from subsurface production wells with a wide range of fluid and mineral compositions and concentrations to process different fluid concentrations of mineral containing brine. The stated ’goal is to (1 ) maximize water, mineral recovery, and separation, (2) reduce refining cost, (3) optimize financial return of separated and collected water and mineral and (4) utilizing, via a chlor-alkali process, biproducts from the above purification, isolation and collection process to combine NaOH and CO2 into Na2C03 for carbon capture and utilization. This method may be facilitated, controlled and directed through implementation of an Artificial Intelligence (Al) / machine learning (ML) software programs wherein past data analysis may be used to determine the costs and benefits of present and future, concentrations and recovery rates, based on current financial markets, to positively affect and regulate production (e.g., water and mineral concentrations and percentages) on a wcll-by-well or plant-by-plant basis or any combination thereof. Using real-time plant, information and real time pricing information, minerals and water may be recovered from brine and process byproducts may be utilized to enhance byproduct utilization for additional benefit including but not limited to carbon capture whereby the ratio of water to mineral recovery may be based on efficiency, cost and market pricing of minera ls, water and resulta nt bi -products, or any combination thereof, to determ ine the most efficient and / or economical use of scarce resources to maximize resultant products and bi-products.

[0113] The present invention, methods) and system(s) udlizes / utilize real time cost, and pricing information control systems in the processing of recovery of subsurface fluids and minerals, together weighing the real time cost and pricing information of products in relation to bi-products, to provide optimum and optimized extraction of fluids, solids

[0114] (minerals) and chemicals to accomplish an overall utilization of brine that selectively refines, on an ongoing basis, the purification and recovery process through the controlling well field and chemical plant processes.

[0115] Here, it is the case, that the present invention accomplishes following main objectives:

[0116] • creates an environmentally acceptable and viable freshwater source from an otherwise unusable (unpotable) hydrogeological resource that without purification treatment will remain unsuited for consumption; ♦ extracts, recovers -and produces minerals from brine reservoirs;

[0117] • effectively utilizes ‘'leftover"’ and depleted brine to produce additional value-added chemicals; and

[0118] • implements a system for carbon capture via a chlor-alkali process: and * creating a zero-emission process. BRIEF DESCRIPTION OF 'HiE DRAWINGS S A clear understanding of the key features of the invention summarized above may be had by reference to the appended drawings, which illustrate the current method and system of the present invention, although it will be understood that such drawings depict preferred embodiments of the invention and, therefore, are not to be considered as limi ting its scope regarding other embodiments which the in vention is capable of contemplating. 10 FIG. 1 — shows a fully integrated water and mineral reclamation model with carbon capture;

[0119] FIG. 2 - illustrates an addition to an existing mineral production facility or NaCl brine facility wanting to extract additional value from i ts operation in the form of generating its own carbonate products without additional reagents;

[0120] 15 FIG, 3 - displays a flowsheet for the process without the carbon capture aspect to produce hydroxide or chlorides where NaCl brine is not a desired product;

[0121] FIG. 4 - displays a flowsheet for ths process without the carbon capture aspect to produce hydroxide or chlorides where NaCl brine is a desired product;

[0122] FIG, 5 - upstream processing- to feed into a mineral processing facility with the sole

[0123] 20 focus being fresh water generation.

[0124] And while the present invention, integrated system and method of use are amendable to modifications and alternative configurations, embodiments thereof have been shown, by way of example only, in the drawings and ate described herein in adequate detail to teach those having skill in the art how to make and practice the same.

[0125] 25 it should, however, be understood that the above description and preferred

[0126] 23

[0127] ... — — ............ embodiments disclosed, are not intended to limit the invention to the embodiment disclosed, but on the contrary, the invention disclosure is intended to cover all modifications, alternatives and equivalents falling within the spirit and scope of the inventionas defined within the claim’s broadest reasonable interpretation that is consistent with the specification,

[0128] DETAILED DESCRIPTION

[0129] The following description and accompanying drawings are expressly illustrative and are not to be interpreted as limiting. Various key features are described to provide those understanding and having skill, in the art the requisite description to make and use to the same. However, it is to be understood that certain features that are routine in the art, which are not described in detail, would prove pedantic and rote to the skilled artisan.

[0130] It bears to include, though, that the present invention may be practiced, in various cases, in one, some or all embodiments, preferred or simply described, with or without some of all details or features without departing from the overall concept of the invention as detailed and described.

[0131] References to “an embodiment”, “preferred embodiment”, “one embodiment”, “another embodiment’ and "yet another embodiment” means that said “embodiments” are inclusi ve of all other “embodiments” and that a key feature, structure or iteration may be borne across all embodiments where their inclusion is not obviated by physical or structural inabilities to incorporate or combine said features, structures, or iterations or where their incorporation would wo / render the present invention inoperable for its intended use. To the contrary1, “embodiments” as they are described herein are inclusive of all embodiments and not mutually exclusive of other embodiments. It is also in the understanding of inventors that not all features may be included in all embodiments while several featuresmay be included in one embodiment or across embodiments.

[0132] Terms used within the present application are io be read as having their ordinary meanings in the art, as defined by the disclosure, and within the context of the surrounding defining language. Those terms, used by inventors, may, as well, be defined using specific terminology and descriptions which are provided in the disclosure enumerating such terms and may have those meanings ascribed to each term as defined by those terms’ secern pa-ny in g I anguage .

[0133] Section headings, titles and subtitles may be used strictly for organizational purposes and should not he interpreted as limiting the disclosed subject matter in any way. And while certain descriptions or embodiments may appear under a certain heading, section, title or subtitle, these descriptions and embodiments pertain to the invention and disclosure overall and should be read to apply to the entire specification.

[0134] Fig. 1 corresponds to an active well field wherein brine enters the system and water is removed to the greatest extent practicable and / or economically ideal based on current market pricing. Concentrated Brine is then processed further to remove ions / minerais including but not limited to Lithium, Calcium, Magnesium and Potassium. Further concentrated brine (NaCl Brine) is then subjected to a chlor-alkali treatment process wherein products consist of Sodium Hydroxide, Hydrochloric Acid and Sodium Hypochlorite, The derived Sodium Hydroxide is then combined with Carbon Dioxide, via a. CO2 reactor process, io produce Sodium Carbonate. Sodium Carbonate is then used as a reagent and added to the hydroxides or Chlorides produced from the ‘Ion Removal* step. resulting in "Carbonate Out" of Lithium Carbonate, Calcium Carbonate, Magnesium

[0135] Carbonate and Potassium Carbonate.

[0136] This Figure 1 provides a complete flowsheet diagram for the proposed mineral extraction facility, As presented, the proposed flowsheet diagram shows products that may be recovered at each stage of the process. The process flowsheet design provides great flexibility for selective optimization, with products that can be separated selectively at each step, either for sale or for further conversion depending on which product provides the best performance results. The desired performance is based on Key Performance Indicators (KPFs) that can be financial indicators (ROI, 1RR, NPV) based on market Indicators such as supply and demand requirements, with technical indicators defined by the plant technical limits, plant operational limits, maintenance and operating costs, net profitability requirements, and current carbon credits IRA tax incentives. As shown in Fig. 2, an alternate described process is another embodiment of a production method which may be advantageous whether it is the mineral extraction facility seeking to dispose of and / or commercialize brine, A, a consumer is seeking specific chemical products (i.e>, NaOH, HC1), B, a consumer seeking fresh (potable water), C, and / or a consumer is desirous to sequester and capture carbon dioxide from the atmosphere as a commercializable product, D. And, although outlined separately, this may be representative of individual producers and consumers or a multi-producer, multi-consumer process, or any combination thereof.

[0137] Fig. 3 delineates yet another embodiment of a retrospective addition (“add on”) to a mineral production facility wherein a carbon capture aspect is not necessary Fig. 4evinces another embodiment whereby a functional mineral production plant also requires NaCl as a desirous product (in addition "to or exclusive of) water.

[0138] Fig. 5 depicts yet another embodiment wherein a mineral production facility wishes to add water reclamation.

[0139] Water Recovery. tmd Processing

[0140] 1. Step I : During the water recovery portion of the processes, the incoming brines may be of varying qualities and concentrations. As the brine enters the processing unit, the brine is categorized, based on a particularized concentration requirement for the brine to meet the necessary technical specifications of the mineral recovery facility and the operating cost required to meet these specifications. The brine or brines are concentrated, and the “waste” (freshwater) is separable and actively separated from the subsurface (brine) water at this beginning step.

[0141] 2. Step I to 2: When selectively removing the minerals of interest these can either be removed as chlorides or hydroxides depending on the supply and demand market characteristics as well as expected pricing for each mineral, species or product extracted from the brine. The waste byproducts during this stage are a concentrated NaCl brine and removed fresh water.

[0142] 3- Steps 2 to Step 3: The depleted brine is sent to the chlor-alkali facility, to be converted into chlor-alkali products such as sodium hydroxide, hydrochloric acid, and sodium hypochlorite (bleach). These products may then be extracted for their own value or used to convert some of the previous products into other value adding chemicals (described later), used in previous processes as feed stock, .or can be ■concen (rated and sold with the waste here being the fresh water specs.

[0143] 4. Step 4: Carbon dioxide is introduced into the process, to convert the necessary amount of sodium hydroxide into sodium carbonate. This sodium carbonate may then be used either as feedstock io other processes or utilized in the next step.

[0144] 5- Step 5: The sodium carbonate may be combined either with chloride products or with hydroxide products depending on the optimization criterion, which may meet the maximum ROI at the current best pricing. Precipitated carbonate salts with either sodium chloride or sodium hydroxide are the resultant waste product. These sodium products may then be recycled or sold.

[0145] Use of Artificial Lntelligence.'fMachine Learning

[0146] Ultimately, once pre-processed fluids reach the process facility, AVML is utilized to direct these fluids to the necessary unit operation based on composition (particulate concentration) and based on best / ' optimum financial KPI’s as derived from prices derived ta currently existing financial markets (ex. oil & gas, mineral markets, and the like). This analysis and control is achieved by using analytical instruments (sensors) wherein fluid is delivered, monitored and analyzed using process control equipment at varying and variable points in production based on, but not limited to, fluid quantity, particulate concentration, particulate value (e.g., current market pricing of lithium), production costs and, importantly, market pricing. As this may be a variable and ongoing calculation, past, current and future (predictive) modeling- may be utilized singly or in combination to determine modifications to the filtering, recovery and purification process. Operating costs are monitored, analyzed and computed by AI / ML software algorithmically which is then associated with existing brine (including content and concentations). Collected data is subsequently used to allow Al / ML software to make real- time cost allocation and raw material procurement based on past, present, future and / or a combination of past, present, and future cost analysis predictive modelling as determined by analysis of actual (current, past or both) and theoretical (future) predictive models and data.

[0147] In practice, fluid (brine) is brought into the facility where software directs.said fluid to the necessary unit operation-based on operating cost and financial KPI's of the specific fluid (or mineral species). This may also be influenced by products and quantities sought and costs of procurement. This occurs in real time and allows for the AI / ML software operation to make real time adjustments based on fluid amount and content.

[0148] In addition, in the case of on-site fluid collection, determinations may be made on fluid recovery rates, fluid content and. individually and / or in combination, which producing unit (well) is most cost effective to operate and at what rate (up to and including ofl) is recommended or recommendable based on the weighted average of the key features described above. Taking advantage of fluctuating operating costs, product pricing, or a combination thereof, the operator of the current system and method of use may leverage several determinative factors, or based on past and current conditions, prioritize benefits (e.g., reduced costs, increased net revenue, desirability to maximize carbon capture) and deemphasize other factors (reliance upon non-renewable energy) as conditions and incentives dictate. Additionally, Al / ML software, with or without overarching emphasis on otic or several factors, allows for producing selective products depending on which product provides the best financial Kiffs based on particularized brine composition and content.

[0149] The product quality and pricing may then be analyzed, retrospectively, and used to allow for better future decision making as a predictive model A “mass balance" is performed at this step to ensure accounting of all inlet streams and outlet streams and to analyze unit performance. 1'his data is then fed back upstream via a feedback loop where the software continues to optimize each step to ensure maximum financial KPI’s and / or model or predict future cost, need or a combination thereof.

[0150] Ultimately, Al, 'ML software collects all generated data and analyses determining how each change in the prcduction / injection system, via a post-mortem review, as well as pricing and costs, affected the whole process, retrospectively. The data and analyses are stored in a *data historian" where the data is further analyzed by the Arti ficial Intelligence and Machine Learning algorithms to generate predictive scenarios, ran simultaneously to actively control to further optimize and enhance the steps in the process on an ongoing basis. Thereby twin modeling may be used to prospectively generate one to a plurality of potential modelling scenarios to better prognosticate future outcomes and to more efficiently seek to determine potentialities before processes are initiated.

[0151] Finally, the energy required to run the pre-processing, processing and postprocessing water treatment facilities herein described may be non-renewable, renewable or a combination thereof.

[0152] The particular embodiments disclosed above are merely illustrative, as the processes, systems, methods, or a combination thereof, may he modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of? the teachings herein.

[0153] It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description with significant advantages being described and illustrated. Although the present application is shown in a limited number of forms, it is not limited to just these farms but is amenable to various changes which are whol ly recognized and incorporated within the teachings of the present application.

Claims

CLAIMS1 , A sy stem of low to zero emissions water, mineral and chemical recovery processes comprising the steps oft water purification; said water being brines: said brines exhibiting enhanced concentration gradients resulting in increased critical minerals and materials (CMM) per volume; said enhanced concentration gradients produced through membrane^nhaneed water removal, solar evaporation, heat generation, or a combination thereof; removal of critical minerals and materials (CMM); said membrane-enhanced brine concentration resulting in water removal products potable water, particulates removal, or a combination thereof chlor-alkali processing; said chlor-alkali processing producing NaOH and 1 IC1, wherein the NaOH may be further mixed with CO2 to produce NaaCOs to be used as feedstock, effectuating carbon capture,2. The system of claim 1 applied to one to a plurality of water sources for aggregation of said purified water, critical minerals and materials, and for carbon capture, 3 , The system of claim 2 wherein said critical minerals and materials are lithium, calcium, magnesium, potassium, sodium, chlorine, or a combination thereof.

4. The system of claim 3 wherein said lithium, calcium, magnesium and potassium may be removed from concentrated brines via ion exchange and membrane separation and sodium, chloride is separated and procured for commercial ization through a ch ior-alkal i step or a combination thereof.

5. The system of claim 4 wherein removal of concentrated NaOH, HCL, and Bleach (NaClO) result tn NaaCOs production, COj is consumed, and hydroxide is utilized to produce LiQH and LI2CO, Ca(0H)2 and CaCO3, Mg(OH) 2 and MgC03, KOH and K2CO3, NaOH, HCl, NaClO, or a combination thereof.

6. The system of claim 5 wherein generated NaOH is utilized to produce LiCl, Ca(CI)2, Mg(Ci)2 and KCI , where additional reactions for Carbonate (CO3). as Naa COy produce LiCl, Ca(CI}2, Mg(CI)2 and KCl.

7. The system of claim 6 wherein Naz CCb is utilized to produce IJ2CO3, CaCO3, MgCO3, K2CO3, NaOH, or a combination thereof,8. The system of claim 1 wherein brine processing may- be divided into one or more pre-processing steps, one or more processing steps, one or more post-processing steps, -or a combination thereof, to produce concentrated brine, potable water, or berth,9. The system of claim 8 wherein concentration zones of particularized CMMs are selectively targeted to enhance said CMM recovery before extraction, grades of brine is .separated and categorized, filtering is, conducted, or a combination thereof, in a pre-processing step.

10. T he system of claim 8 wherein, during processing concentrated brine undergoes selective mineral removing processing resulting in a range of minerals through separation, concentration and purification to deliver purified concentrated aqueous mineral streams, fresh water, and concentrated NaCi brine.1 1. The system of claim 8, during pust-proe essi ng wherein a plurality of resultant products are produced (i.e., potable water. CMMs), CO2 Is consumed, and subsequent processes are conducted including transfer of NaCI brine to a post-processing facility for chlor-alkali processing, postprocessing to produce NaOH and HO, mixing of NaOH with €02 to produce Na2CO3, mixing NaOH with Na2CO3 then mixed, with concentrated aqueous mineral streams to produce carbonated salts, carbon capture and utilization, or a combination thereof.

12. The system of ciaim 11 wherein said CMMs are lithium in the form of LiOH and LitCO.?.

13. The system of claim 1 1 wherein Ctt & COJ are utilized for Th generation through Electro-Deionizer (EDI) technology, M2 E lectrolysi s, or a combination thereof for use in brine, saltwater or both.

14. The system of claim 8 wherein said one or more pre-processing steps, one or more processing steps, one dr more post-processing steps are controlled an d directed through implementation of an .Artificial Intelligence (Al) / machine learning (ML) software programs wherein past data analysis is -used to determine the costs and benefits of present and future concentrations and recovery nates, based on current financial markets, to positively affect and regulate production (e.g,, water and mineral concentrations and percentages) on a well-by-well or plant-by-pkmt basis or any combination thereof.

15. The sy stem of claim 14 wherein said Artificial Intelligence (Al) / machine learning (ATI .) software programs use real-time plant information and real time pricing information, minerals and water is recovered from brine and process byproducts are utilized to enhance byproduct utilization tor additi onal benefit including but not lim i ted to carbon c apture whereby the ratio of water to minera l recovery may be based on efficiency, cost and market pricing of minerals, water and resultant bi-products, Of any combination thereof to determine the most efficient and / or economical use of scarce resources to maximize resultant products and bi-produets.

16. The system of claim 15 where i n products are separa ted selectively at each step or steps, either for sale or for further conversion, based on Key Performance Indicators (Kl’i’s) as financial indicators(R.OI, 1RR, NPV) based on market indicators such as supply and demand requirements, with technical indicators defined by the plant technical limits, plant operational limits, maintenance and operating costs, net profitability requirements, and current carbon credits IRA tax Incentives.17, The system of claim 16 wherein said A17ML is utilized to direct brines, fluids, solids, or a combination thereofthe necessary unit operation based on composition (particulate concentration) and based on best / optinwrn financial KPI’s. as derived from prices derived from currently existing financial markets based on fluid quantity, particulate concentration, particulate value (e.g., current market pricing of lithium), production costs, market pricing, or a combination thereof.

18. The system of claim 17 wherein said Al / ML software conducts variable and ongoing calculations, past, current and future (predictive) modeling, or a combination thereof, utilized singly or in combination, to determine modifications to the filtering, recovery and purification .process to make real-time cost allocation and raw material procurement determinations and adjustments based on analysis »f actual (current, past or both) and theoretical (future) predictive models and data.19, A method of separating desired materials (e.g„ water, minerals) from recovered subsurface formation water comprising: separating brine into water and different grouping of segregated products; collecting said water, and said products; purifying said water, and said products;monetizing said water, and said products based on quantity, quality and value; subjecting resultant brine to a chlor-alkali process producing NaOH and HCf; utilizing Na0H to mix with sequestered C02 to .produce Na2CO3, effectuating carbon capture; and using said Na2CO3 as a reagent in part of the process effectively sequestering the CO2 into solid form.37

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