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Direct contact heat exchangers can be smaller, cheaper, and have simpler construction than the surface, shell, or tube heat exchangers of the same capacity and can operate in evaporation or condensation modes. For these reasons, they have many practical applications, such as water desalination, heat exchangers in power plants, or chemical engineering devices. This paper presents a comprehensive review of experimental and numerical activities focused on the research about direct condensation processes and testing direct contact condensers on the laboratory scale. Computational Fluid Dynamics (CFD) methods and CFD solvers are the most popular tools in the numerical analysis of direct contact condensers because of the phenomenon’s complexity as multiphase turbulent flow with heat transfer and phase change. The presented and developed numerical models must be carefully calibrated and physically validated by experimental results. Results of the experimental campaign in the laboratory scale with the test rig and properly designed measuring apparatus can give detailed qualitative and quantitative results about direct contact condensation processes. In this case, the combination of these two approaches, numerical and experimental investigation, is the comprehensive method to deeply understand the direct contact condensation process.

The removal of five selected pesticide compounds in a brackish model groundwater solution was examined using a bench scale direct contact membrane distillation (DCMD) system. It was found that the rejection rate of the pesticides in DCMD is mainly influenced by its properties. Compounds with low hydrophobic characteristics and low vapour pressure showed a high rejection rate (70–99%), whereas compounds with a high vapour pressure or high hydrophobicity (LogD) showed a reduced rejection (30–50%) at a water recovery of 75%. The influence of groundwater feed solution contents such as the presence of organics (humic acid) and inorganic ions (Na + , Ca 2+ , Mg 2+ , Cl − and SO 4 2− ) as well as feed temperature (40, 55 and 70 °C) on the rejection of the pesticides in DCMD operation was also evaluated. The results showed that the presence of inorganic ions and organics in the feed solution influences the pesticides rejection in DCMD operation to a minor degree. In contrast, reduced rejection of pesticides with high vapour pressure was observed. A rapid small-scale column test (RSSCT) was carried out to study the removal of any remaining substances in the permeate by adsorption onto granular activated carbon (GAC). RSSCT showed promising performance of GAC as a post-treatment option.

Direct contact membrane distillation (DCMD) process using polyvinylidene fluoride (PVDF) membrane was used for fluoride removal from aqueous solution. This study has been carried out on heat and mass transfer analyses in DCMD. The dusty-gas model was used to analyze the mass transfer mechanism and to calculate the permeate flux. The heat transfer is analyzed based on energy balance, and the different layers are considered as a series of thermal resistances. Mass transfer analysis showed that the transition Knudsen-molecular diffusion is the dominant mechanism to describe the transport of water vapor through the pores of the PVDF membrane. The most significant operating parameter is the feed temperature. The permeate increases sensitively with feed temperature and velocity, and it shows insignificant change with feed salts concentration. Heat transfer analysis showed the conduction through the matrix of the membrane presents the major part of available energy. The increasing feed temperature leads to increase thermal efficiency (TE) and decrease temperature polarization coefficient (TPC). The experimental results are in good agreement with theoretical values. Therefore, it is suggested to work at high feed temperature, which will benefit both the thermal efficiency and permeate flux. The experimental results proved that DCMD process is able to produce almost fluoride-free water suitable for many beneficial uses.

The bioassay based on the bioluminescence inhibition of the marine bacterium Vibrio fischeri has been the most widely used test for the assessment of airborne particulate matter ecotoxicity. Most studies available use an extract of the solid sample, either made with water or organic solvents. As an alternative, a whole-aerosol test is also available where test bacteria are in actual contact with contaminated particles. In our study, different extraction procedures were compared to this direct contact test based on the V. fischeri assay and analytical measurements. The lowest PAH content and the highest EC50 were determined in water extract, while the highest PAH amount and lowest EC50 were measured in dichloromethane, hexane, and dimethyl-sulphoxide extracts. EC50 of the direct contact test was comparable to that of the methanol extract. Our results suggest that the sensitivity of the direct contact test equals to that of extraction procedures using organic solvents, moreover, it is mimicking an environmentally realistic exposure route.

It was a challenge to deal with the concentrated leachate (CL) produced by membrane treatment technique in the waste incineration. In this study, the characteristics of the condensate and solid precipitation produced from treatment of CL by lab-scale direct contact evaporation system were investigated, and a process for the treatment of CL with no waste produced was put forward. The air was heated by exhaust steam and high temperature flue gas in the waste incineration to 500℃ and used for evaporating CL. The results showed that the concentrations of COD, NH3-N, and Cl− in the condensate were 17.6 mg/L, 3.1 mg/L, and 40 mg/L at the condition of the volume of hot air = 600 L/h, pH = 7.2, and concentration factor (CF) = 10, which were lower than the limited values in the water quality standard for industry uses (GB/T 19923–2005) in China, and the condensate can be used in circulating cooling water system for supplying water. Solid precipitation consisted of K2Ca(SO4)2·H2O, NaCl, KNO3, and NaNO3. CF was not over 10 because a larger amount of CaSO4 precipitated on the wall of pipe for passing through hot air, which hindered the continuous operation of the evaporation equipment, when CF > 10. Based on thermogravimetric analysis of solid phase precipitation, the most of organic matter in CL were oxidized and decomposed, while inorganic salts were not volatilized when the heating temperature reached about 760℃. The process for the treatment of CL with no waste produced can produce char and inorganic salts such as KCl and NaCl for waste recycling.

In the present study, a suitable composition of parameters has been obtained to provide an efficient process of cooling flue gas with complete condensation of water vapour from air-water vapour mixture on a water film in co-current upward flow in the tube of the direct contact heat and mass exchanger. The results showed that the value of the irrigation density depends on the velocity of the air-water vapour mixture and the initial vapour content and should be calculated from an empirical equation. The active pipe height depends on the velocity of the air-water vapour mixture and the initial vapour content and should also be calculated from an empirical equation. For example, if the initial vapour content of the air-water vapour mixture is 11%, the velocity of the mixture is 20.8 m/s the height of the channel should not exceed 0.460 m. The value of the water heating limit temperature increases from 46◦C to 62◦C with a change in the initial vapour content from 11% to 30%. The present experimental results could be helpful in the design of direct contact heat and mass exchangers for waste heat recovery.

Membrane distillation is getting increasing attention thanks to its advantages in terms of energy consumption and final permeate quality in addition to its resistance against highly corrosive media which forms an appealing solution for industrial wastewater treatment. Despite its advantages, one of the most challenging issues in direct contact membrane distillation (DCMD) is membrane fouling and wetting. In the present research work, saline dairy effluent discharged from hard cheese industry was pretreated by macrofiltration (MAF) and ultrafiltration (UF) and processed by DCMD to investigate the extent of the aforementioned issues. Effluents pretreated by UF have led the best process performance with stable flux values at different operating conditions. Fouling has occurred in all the experiments, though their effect on the flux behavior and membrane wetting was different from one feed to the other. Changing the flow rate and the temperature difference have affected slightly the membrane wettability for all feed qualities. In all experiments, the permeate has maintained a good quality with low electrical conductivity that did not exceed 70 μS/cm and low total organic carbon < 2 mg/L.

This study applied direct-contact ultrasound-assisted Vacuum Far-Infrared (VFIR) to dry Cistanche slices, investigating the influence of radiation temperature (45 °C, 55 °C, 65 °C), ultrasonic frequency (20 kHz, 40 kHz, 60 kHz) and ultrasonic power (72 W, 96 W, 120 W) on the physicochemical properties, drying characteristics, and microstructure of Cistanche slices. The results showed that the application of ultrasound had a significant enhancement effect on the drying process, with drying time decreasing as radiation temperature, ultrasonic power, and ultrasonic frequency increased. The drying rate curves under three experimental factors exhibited a brief acceleration stage followed by a deceleration stage. Under different drying conditions, the contents of Iridoid and phenylethanoid glycosides in dried products were higher than those under natural drying (ND). Specifically, the content of catalpol at 55 °C, 96 W, 40 kHz (0.56 mg/g) and the content of Leonuride at 55 °C, 96 W, 60 kHz (0.67 mg/g) increased by 1.81 and 1.9 times, compared to ND. The rest of the nutrient content and antioxidant activity increased with the increase in ultrasonic frequency. Compared to ND, ultrasonic-assisted VFIR drying improved the color and rehydration capacity of dried products. Observation of the microstructure revealed that the application of ultrasound made the interior of Cistanche slices loose and porous. In summary, ultrasonic-assisted VFIR drying not only enhances the drying rate but also improves the quality of dried products.

Freshwater scarcity poses a critical challenge to human survival, necessitating innovative desalination solutions to meet the growing global demand for potable water. Among these, membrane distillation (MD) has emerged as a promising technology due to its high salt rejection efficiency, lower energy consumption compared to conventional thermal desalination methods such as multi-stage flash (MSF) and multi-effect distillation (MED), and its adaptability to diverse water sources, including seawater, brackish water, and wastewater. Within MD, direct contact membrane distillation (DCMD) has gained significant attention for its simplicity, high desalination flux, and potential cost-effectiveness. Unlike other MD variants, DCMD operates without requiring expensive external condensers, making it economically attractive for large-scale deployment. However, despite these advantages, DCMD faces challenges such as membrane fouling, thermal polarization, and limited long-term stability, all of which can degrade performance and increase operational costs. This review provides a comprehensive overview of DCMD technology, focusing on membrane module design, material selection, and fabrication techniques. It also addresses key operational challenges and explores innovative strategies to enhance system efficiency. Additionally, it presents an up-to-date analysis of the economic and environmental implications of DCMD and its feasibility for large-scale implementation. By offering a thorough understanding of this technology, the review aims to facilitate its optimization and unlock its full potential as a sustainable solution to global freshwater scarcity.

The problem of emulsification between Phase Change Material (PCM) and Heat Transfer Fluid (HTF) in direct contact latent heat storage systems has been reported in various studies. This issue causes the PCM to flow out of the storage tank and crystallize at unwanted locations and thus presents a major limitation for the proper operation of such systems. These anomalies become more pronounced when high HTF flow rates are employed with the aim to achieve fast heat transfer rates. The goal of this paper is to find a method which will enable the fast separation of the formed emulsion and thus the uninterrupted operation of the storage unit. In this study, three separation methods were examined and the use of superhydrophobic filters was chosen as the best candidate for the demulsification of the PCM and HTF mixtures. The filter was produced by processing of a melamine sponge with different superhydrophobic adhesives and was tested with emulsions closely resembling the ones formed in a real direct contact setup. The superhydrophobic filter obtained, was able to separate the emulsions effectively while presenting a very high permeability (up to 1,194,980 kg h−1 m−2 bar−1). This is the first time the use of a superhydrophobic sponge has been investigated in the context of demulsification in direct contact latent heat storage.