A novel hybrid arc discharge–thermal method for sustainable brine treatment and resource recovery

The continuous increase in brine production from desalination processes poses significant environmental and sustainability challenges, particularly due to the limitations of current treatment and disposal technologies. In this study, we present a novel hybrid Arc Discharge–Thermal (AD-thermal) method that integrates an atmospheric pressure plasma with a thermal process to enhance brine evaporation and salt crystallization efficiency while substantially reducing energy consumption. Three types of electrical discharges—arc, spark, and corona—were systematically applied to real brine samples, with arc discharge exhibiting the highest performance in both evaporation rate and salt recovery. To further operational stability, we developed and implemented a voltage pulse-modulated arc discharge system. Application of the AD-thermal method resulted in a 200% increase in evaporation rate and a 60% reduction in energy consumption compared to traditional thermal approaches. Importantly, the salt recovered using the AD-thermal method exhibited significantly higher purity and improved crystal quality compared to salt obtained from conventional thermal methods. Additionally, numerical simulation of the corona discharge provided mechanistic insights into plasma–brine interface and reactive species behavior. Our findings demonstrate the strong potential of the AD-thermal method for sustainable, industrial-scale brine management and zero liquid discharge applications. This work advances the understanding of plasma-assisted evaporation and crystallization processes and paves the way for the development of sustainable, energy-efficient, and environmentally friendly solutions for brine treatment.