Surface-heated membrane distillation (MD) enhances the
energy efficiency
of desalination by mitigating temperature polarization (TP). However,
systematic investigations of larger scale, multistage, surface-heated
MD system with high water recovery and heat recycling are limited.
Here, we explore the design and performance of a multistage surface-heated
vacuum MD (SHVMD) with heat recovery through a comprehensive finite
difference model. In this process, the latent heat of condensation
is recovered through an internal heat exchanger (HX) using the retentate
from one stage as the condensing fluid for the next stage and an external
HX using the feed as the condensing fluid. Model results show that
surface heating enhances the performance compared to conventional
vacuum MD (VMD). Specifically, in a six-stage SHVMD process, 54.44%
water recovery and a gained output ratio (GOR) of 3.28 are achieved
with a surface heat density of 2000 W m–2, whereas
a similar six-stage VMD process only reaches 18.19% water recovery
and a GOR of 2.15. Mass and energy balances suggest that by mitigating
TP, surface heating increases the latent heat trapped in vapor. The
internal and external HXs capture and reuse the additional heat, which
enhances the GOR values. We show for SHVMD that the hybrid internal/external
heat recovery design can have GOR value 1.44 times higher than that
of systems with only internal or external heat recovery. Furthermore,
by only increasing six stages to eight stages, a GOR value as high
as 4.35 is achieved. The results further show that surface heating
can reduce the energy consumption of MD for brine concentration. The
multistage SHVMD technology exhibits a promising potential for the
management of brine from industrial plants.