Design of a multistage hybrid desalination process for brine management and maximum water recovery

Hypersaline brine production from desalination plants causes huge environmental stress due to the untenable conventional discharge strategies. Particularly, brine production is expected to drastically increase in the coming few decades due to the increasing desalination capacity in attempts of forestalling water scarcity. Thereby, zero liquid discharge (ZLD) is a worth-considering solution for strategic brine management. ZLD or minimal liquid discharge (MLD) systems provide maximum water recovery with least or zero liquid waste generation and valuable salt production. In this work, a theoretical design of ZLD/MLD system is proposed for reverse osmosis (RO) brine management. Different scenarios are investigated utilizing multistage freeze desalination (FD) and its hybridization with multistage direct contact membrane distillation (DCMD), and eutectic freeze crystallization (EFC) technologies. The design is based on the experimental assessment of the indirect FD process at different feed salinities, i.e., 2 g/L to 155 g/L. FD experiments showed that ice quality is reduced at greater crystallinity levels and initial concentration. Moreover, a computational fluid dynamics (CFD) model is utilized to assess the performance of DCMD. A single DCMD module could produce 53 kg/(m².h) of pure water operating with 69% thermal efficiency. Eventually, water recovery, water quality, as well as specific energy consumption (SEC) are evaluated for the whole system. Based on different configurations of the hybrid ZLD system, the proposed design can achieve water recovery between 40 and 93% with SEC range of 28–114 kWh/m³. Results also showed that the produced water quality exceeds drinkable water standards (≪ 500 mg/L). This work has provided great evidence in the practicality of ZLD/MLD systems for sustainable brine management.