Practical Methodology for a Three-Dimensional-Printed Hybrid Desalination System

In response to the growing demand for potable water, this study presents a practical methodology for designing and fabricating a hybrid desalination system that integrates reverse electrodialysis and electrodialysis using 3D-printing technology. The hybrid system combines the energy generation potential of RED with the salt removal capabilities of ED, reducing energy consumption. Customized reactors were designed to enhance flow distribution and ion exchange, with computational fluid dynamics simulations validating the hydrodynamic performance. The reactors were fabricated using 3D printing, allowing rapid, cost-effective production, with functional reactors constructed in under 24 h. The system achieved a 15% reduction in salt concentration within one hour, with a specific energy consumption of 0.1388 Wh/m3 and a water recovery rate of 50%. These results demonstrate the functionality of the RED-ED hybrid system for achieving energy savings and performing water desalination. This methodology provides a scalable and replicable solution for water treatment applications, especially in regions with abundant salinity gradients and limited freshwater resources, while offering a multidisciplinary approach that integrates physicochemical and engineering principles for effective device development.