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<p>The increasing production of brine from reverse osmosis systems requires innovative methods for their effective management and resource recovery. In this study, a spray-cyclone direct evaporation system was designed that uses a low-temperature hot air flow to continuously evaporate micron-sized brine droplets. The geometric design of the cyclone and optimized spray nozzle was performed using 3D modeling using computational fluid dynamics (CFD) and the Euler-Lagrange multiphase approach with Extended Two-Phase CFD Modeling, in which the advanced temperature and concentration behavior of the droplets, including thermal distribution, salt concentration gradient, and gradual evaporation, were simultaneously modeled. Under the best-performing condition within the investigated CFD–experimental operating range, corresponding to an inlet air temperature of 70&#xa0;°C and an air mass flow rate of 0.03&#xa0;kg/s, the evaporation efficiency reached 96.5%. A system-level energy assessment estimated the specific evaporation energy to be 2.5–3.8 kWh/m³, while heat recovery through a shell-and-tube heat exchanger reduced the net energy requirement by approximately 28%. The findings indicate that the proposed system with its compact design, high efficiency, and energy recovery approach is an effective option for achieving zero liquid discharge (ZLD) in the management of brines in reverse osmosis systems.</p>

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A low-temperature spray-cyclone system for zero-liquid discharge treatment of RO brine using extended two-phase CFD modeling and experimental validation

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年8月5日

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  • Hamed Noori,
  • Sohrabali Ghorbanian,
  • Hooman Fatoorehchi,
  • Hossein Sakhaeinia

摘要

The increasing production of brine from reverse osmosis systems requires innovative methods for their effective management and resource recovery. In this study, a spray-cyclone direct evaporation system was designed that uses a low-temperature hot air flow to continuously evaporate micron-sized brine droplets. The geometric design of the cyclone and optimized spray nozzle was performed using 3D modeling using computational fluid dynamics (CFD) and the Euler-Lagrange multiphase approach with Extended Two-Phase CFD Modeling, in which the advanced temperature and concentration behavior of the droplets, including thermal distribution, salt concentration gradient, and gradual evaporation, were simultaneously modeled. Under the best-performing condition within the investigated CFD–experimental operating range, corresponding to an inlet air temperature of 70 °C and an air mass flow rate of 0.03 kg/s, the evaporation efficiency reached 96.5%. A system-level energy assessment estimated the specific evaporation energy to be 2.5–3.8 kWh/m³, while heat recovery through a shell-and-tube heat exchanger reduced the net energy requirement by approximately 28%. The findings indicate that the proposed system with its compact design, high efficiency, and energy recovery approach is an effective option for achieving zero liquid discharge (ZLD) in the management of brines in reverse osmosis systems.