Multi-stage humidification-dehumidification system integrated with a crystallizer for zero liquid discharge of desalination brine

Desalination plants discharge a massive volume of brine every day, which negatively affects the ecosystem, particularly the subsurface ecology and marine life. To mitigate the brines' detrimental effects on the environment and facilitate the recovery of salt crystals and freshwater, the Zero Liquid Discharge (ZLD) approach was proposed. This study proposes four different configurations of multistage humidification dehumidification systems integrated with a crystallizer, exploring their energy and economic implications. Key findings from the study include the higher Gained Output Ratio (GOR) in series configurations due to lower temperature differences, resulting in lower heater energy consumption. The crystallizer significantly enhances water productivity, but it is a major consumer of both electricity (85%) and thermal energy (50.45-57.7%) in the system. Increasing the heat source temperature reduces the Specific Electrical Energy Consumption (SEEC) and the specific area while slightly increasing the Specific Thermal Energy Consumption (STEC). Elevated cooling water temperature raises SEEC and specific area but has negligible effects on STEC. Higher feed water flow rates increase SEEC but lower both STEC and specific area. Feed salinity elevation decreases productivity, SEEC, STEC, and specific area. The crystallizer constitutes 15.43-26.44% of the total capital cost, with series configurations incurring higher costs. Unit freshwater production costs, considering salt selling, range from 1.733 to 4.821 $.m-3. In a waste heat scenario, parallel configurations become profitable, where freshwater can be distributed at zero cost, while the produced salt crystals can be sold at an even lower price of $58.09 per tonne and $57.04 per tonne, respectively.