Theoretical and Experimental Studies of Permeate Fluxes in Double-Flow Direct-Contact Membrane Distillation (DCMD) Modules with Internal Recycle

A new DCMD module design that introduces an insulation barrier of negligible thickness to divide the open duct of the hot-saline feed into two subchannels for dual-flow operation was investigated. This configuration enables one subchannel to operate in a cocurrent-flow mode and the other in a countercurrent-flow recycling mode, thereby significantly enhancing the permeate flux. Theoretical and experimental investigations were conducted to develop modeling equations capable of predicting the permeate flux in DCMD modules. These studies demonstrated the technical feasibility of minimizing temperature polarization effects while improving flow characteristics to boost permeate flux. Results indicated that increasing both convective heat-transfer coefficients and residence time generally improved device performance. The dual-flow operation increased fluid velocity and extended residence time, leading to reduced heat-transfer resistance and enhanced heat-transfer efficiency. Theoretical predictions and experimental results consistently showed that the absorption flux improved by up to 40.77% under the double-flow operation with internal recycling configuration compared to a single-pass device of identical dimensions. The effects of inserting the insulation barrier on permeate flux enhancement, power consumption, and overall economic feasibility were also discussed.