Membrane distillation (MD) has shown promise for concentrating a wide variety of brines, but the knowledge is limited on how different brines impact salt scaling, flux decline, and subsequent wetting. Furthermore, past studies have lacked critical details and analysis to enable a physical understanding, including the length of experiments, the inclusion of salt kinetics, impact of antiscalants, and variability between feed-water types. To address this gap, we examined the system performance, water recovery, scale formation, and saturation index of a lab-scale vacuum membrane distillation (VMD) in long-running test runs approaching 200 h. The tests provided a comparison of a variety of relevant feed solutions, including a synthetic seawater reverse osmosis brine with a salinity of 8.0 g/L, tap water, and NaCl, and included an antiscalant. Saturation modeling indicated that calcite and aragonite were the main foulants contributing to permeate flux reduction. The longer operation times than typical studies revealed several insights. First, scaling could reduce permeate flux dramatically, seen here as 49% for the synthetic brine, when reaching a high recovery ratio of 91%. Second, salt crystallization on the membrane surface could have a long-delayed but subsequently significant impact, as the permeate flux experienced a precipitous decline only after 72 h of continuous operation. Several scaling-resistant impacts were observed as well. Although use of an antiscalant did not reduce the decrease in flux, it extended membrane operational time before surface foulants caused membrane wetting. Additionally, numerous calcium, magnesium, and carbonate salts, as well as silica, reached very high saturation indices (>1). Despite this, scaling without wetting was often observed, and scaling was consistently reversible and easily washed. Under heavy scaling conditions, many areas lacked deposits, which enabled continued operation; existing MD performance models lack this effect by assuming uniform layers. This work implies that longer times are needed for MD fouling experiments, and provides further scaling-resistant evidence for MD.

Membrane distillation crystallization (MDCr) is an approach for treating hypersaline wastewaters and enabling zero-liquid-discharge (ZLD) systems. However, its performance is often inhibited by concentration polarization, scaling, and membrane wetting. Heterogeneous seeding has been proposed to shift crystallization into the bulk phase, yet its quantitative influence on flux stability, wetting resistance, and crystal growth remains poorly understood. This study investigates air-gap MDCr (AGMDCr) of 300 g L⁻¹ NaCl using polypropylene (PP) and polytetrafluoroethylene (PTFE) membranes under seeded and unseeded conditions. Introducing 0.1 g L⁻¹ SiO₂ seeds (30–60 µm) enhanced steady-state permeate flux by 41% and maintained salt rejection ≥ 99.99%, indicating effective suppression of wetting. Seeding shifted the crystal size distribution from fine (mean 50.6 µm, unseeded) to coarse (230–340 µm), consistent with reduced primary nucleation and preferential growth on seed surfaces. At 0.6 g L⁻¹, the flux decreased relative to 0.1–0.3 g L⁻¹, consistent with near-wall solids holdup and hindered transport at high seeding concentration. The PTFE membrane exhibited a 47% higher flux than PP, primarily due to its reduced thermal resistance and optimized module geometry at the same flow rate. These results demonstrate that appropriately sized and dosed SiO₂ seeding effectively stabilizes flux and suppresses wetting in MDCr.