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The low flux and high energy consumption problems of the conventional three-stage air-gap membrane distillation (AG-AG-AG)MD system caused by the low temperature difference between hot and cold feed at both sides of the membrane and high boundary layer thickness were solved successfully by replacing one of the three stages of air gaps by a water gap. The novel three-stage air-gap–water-gap membrane distillation (AG-AG-WG)MD system reduced energy consumption and increased flux due to efficient internal heat recycling by virtue of a water-gap module. Heat and mass transfer in novel and conventional three-stage systems were analyzed theoretically. Under a feed temperature of 45 °C, flow rate of 20 l/h, cooling temperature of 20 °C, and concentration of 340 ppm, the (AG-AG-WG)MD promoted flux by 17.59% and 211.69%, and gained output ratio (GOR) by 60.57% and 204.33% compared with two-stage (AG-WG)MD and one-stage AGMD, respectively. This work demonstrated the important role of a water gap in changing the heat and mass transfer where convection heat transfer across the water gap is faster by 24.17 times than conduction heat transfer through the air gap. The increase in flux and GOR economized the heating energy and decreased waste heat input into the system. Additionally, the number of MD stages could increase the achieving of a high flux with operation stability.

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A novel internal heat recycling concept for reducing energy consumption and increasing flux through three-stage air-gap–water-gap membrane distillation system