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Techno-economic optimization of large-scale two-stage brackish water reverse osmosis systems using dimensionless
Muhammad H Elbassoussi1, Omar G Kaoud1, Syed M Zubair1
1Department of Mechanical Engineering, King Fahd University of Petroleum & Minerals (KFUPM), Dhahran, Saudi Arabia.
Water Research
|January 23, 2026
Summary
This study optimizes brackish-water reverse osmosis (RO) systems by co-designing array layout and operating conditions. Optimal designs minimize energy consumption and water cost, providing scale-independent guidance for RO plant sizing.
Area of Science:
- Water treatment technologies
- Chemical engineering
- Environmental science
Background:
- Large-scale brackish-water reverse osmosis (RO) systems require integrated design of array layout and operating parameters.
- Existing frameworks often lack comprehensive optimization under discrete sizing constraints.
Purpose of the Study:
- To extend a validated dimensionless two-stage RO framework for plant-array sizing.
- To perform multi-objective optimization minimizing specific energy consumption (SEC) and specific cost of water (SCW).
- To provide scale-independent design guidance and a lookup table for RO systems.
Main Methods:
- Utilized a dimensionless two-stage RO framework for optimization.
- Solved multi-objective optimization problems for feed pressures (20-40 bar) and salinities (3000-15,000 ppm).
- Generated Pareto fronts, selected knee points, and synthesized global maps for performance and feasibility metrics.
Main Results:
- Optimal arrays favor a large first stage with a smaller polishing stage (vessel ratio ≈0.40-0.43).
- The system adapts to osmotic loading by adjusting the second-stage pressure ratio and active-area parameter.
- Achieved SEC and SCW ranges of ~0.96-2.03 kWh/m³ and $0.67-$0.87/m³, respectively.
Conclusions:
- The study provides a robust method for co-designing RO systems, balancing energy, cost, and performance.
- Optimal configurations and operating strategies were identified for various brackish water conditions.
- The findings offer practical tools for efficient and cost-effective brackish water desalination plant design.
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