Cost–Benefit and Market Viability Analysis of Metals and Salts Recovery from SWRO Brine Compared with Terrestrial Mining and Traditional Chemical Production Methods

Seawater reverse osmosis (SWRO) desalination generates a concentrated brine byproduct rich in dissolved salts and minerals. This study presents an extensive economic and technical analysis of recovering all major ions from SWRO brine, which includes Na, Cl, Mg, Ca, SO4, K, Br, B, Li, Rb, and Sr in comparison to conventional mining and chemical production of these commodities. Data from recent literature and case studies are compiled to quantify the composition of a typical SWRO brine and the potential yield of valuable products. A life-cycle cost framework is applied, incorporating capital expenditure (CAPEX), operational expenditure (OPEX), and total water cost (TWC) impacts. A representative simulation for a large 100,000 m3/day SWRO plant shows that integrated &ldquo:brine mining&rdquo: systems could recover on the order of 3.8 million tons of salts per year. At optimistic recovery efficiencies, the gross annual revenue from products (NaCl, Mg(OH)2/MgO, CaCO3, KCl, Br2, Li2CO3, etc.) can reach a few hundred million USD. This revenue is comparable to or exceeds the added costs of recovery processes under favorable conditions, potentially offsetting desalination costs by USD 0.5/m3 or more. We compare these projections with the economics of obtaining the same materials through conventional mining and chemical processes worldwide. Major findings indicate that recovery of abundant low-value salts (especially NaCl) can supply bulk revenue to cover processing costs, while extraction of scarce high-value elements (Li, Rb, Sr, etc.) can provide significant additional profit if efficient separation is achieved. The energy requirements and unit costs for brine recovery are analyzed against those of terrestrial or conventional mining: in many cases, brine-derived production is competitive due to avoided raw material extraction and potential use of waste or renewable energy. CAPEX for adding mineral recovery to a desalination plant is significant but can be justified by revenue and by strategic benefits such as reduced brine disposal. Our analysis, drawing on global data and case studies (e.g., projects in Europe and the Middle East), suggests that metals and salts recovery from SWRO brine is technically feasible and, at sufficient scale, economically viable in many regions. We provide detailed comparisons of cost, yield, and market value for each target element, along with empirical models and formulas for profitability. The results offer a roadmap for integrating brine mining into desalination operations and highlight key factors such as commodity prices, scale economies, energy integration, and policy incentives that influence the competitiveness of brine recovery against traditional mining.