This paper presents the development of a rigorous theoretical model to predict the transmembrane flux of a flat sheet hydrophobic composite membrane, comprising both an active layer of polytetrafluoroethylene and a scrim-backing support layer of polypropylene, in the direct contact membrane distillation (DCMD) process. An integrated model includes the mass, momentum, species and energy balances for both retentate and permeate flows, coupled with the mass transfer of water vapor through the composite membrane and the heat transfer across the membrane and through the boundary layers adjacent to the membrane surfaces. Experimental results and model predictions for permeate flux and performance ratio are compared and shown to be in good agreement. The permeate flux through the composite layer can be ignored in the consideration of mass transfer pathways at the composite membrane. The effect of the surface porosity and the thickness of active and support layers on the process performance of composite membrane has also been studied. Among these parameters, surface porosity is identified to be the main factor significantly influencing the permeate flux and performance ratio, while the relative influence of the surface porosity on the performance ratio is less than that on flux.

An economic desalination system with a small scale and footprint for remote areas, which have a limited and inadequate water supply, insufficient water treatment and low infrastructure, is strongly demanded in the desalination markets. Here, a direct contact membrane distillation (DCMD) process has the simplest configuration and potentially the highest permeate flux among all of the possible MD processes. This process can also be easily instituted in a multi-stage manner for enhanced compactness, productivity, versatility and cost-effectiveness. In this study, an innovative, multi-stage, DCMD module under countercurrent-flow configuration is first designed and then investigate both theoretically and experimentally to identify its feasibility and operability for desalination application. Model predictions and measured data for mean permeate flux are compared and shown to be in good agreement. The effect of the number of module stages on the mean permeate flux, performance ratio and daily water production of the MDCMD system has been theoretically identified at inlet feed and permeate flow rates of 1.5 l/min and inlet feed and permeate temperatures of 70 °C and 25 °C, respectively. The daily water production of a three-stage DCMD module with a membrane area of 0.01 m at each stage is found to be 21.5 kg.

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