Surface energy-induced anti-wetting and anti-fouling enhancement of Janus membrane for membrane distillation.

Membrane distillation (MD) presents a promising alternative to conventional desalination systems, particularly for the treatment of hypersaline wastewater. However, the large-scale application of MD is hindered by challenges such as membrane wetting, membrane fouling, and low permeate flux. Herein, we proposed an air/liquid interface deposition method to fabricate a Janus membrane, termed the PVDF-PDA/PEI-Si membrane. The membrane featured a nanosieving, superhydrophilic polydopamine/polyethylenimine (PDA/PEI) layer decorated with silica nanoparticles, coupled with a microporous, hydrophobic polyvinylidene fluoride (PVDF) layer. The introduction of a dense PDA/PEI-Si layer featuring high surface energy significantly enhanced the wetting and fouling resistance of the membrane, with a minor effect on the permeate flux. The performance enhancement was particularly evident when hypersaline water containing sodium dodecyl sulfate (SDS) and oily contaminants was used as the feed. The interactions between the membrane and contaminants were calculated using the XDLVO theory and molecular dynamics simulations to elucidate the mechanisms underlying the enhanced anti-wetting and anti-fouling properties, respectively. According to the XDLVO theory, a large energy barrier must be overcome for the SDS to attach onto the PDA/PEI-Si surface. Meanwhile, molecular dynamics simulations confirmed the weak interaction energy between the oily foulants and the PVDF-PDA/PEI-Si membrane due to its high surface energy. This study presents a promising approach for the fabrication of high-performance MD membranes and provides new insights into the mechanisms underlying the enhanced anti-wetting and anti-fouling properties.

Ultra-antiwetting Membrane for Hypersaline Water Crystallization in Membrane Distillation.

Membrane distillation (MD) has great potential in the management of hypersaline water for zero liquid discharge (ZLD) due to its high salinity tolerance. However, the membrane wetting issue significantly restricts its practical application. In this study, a composite membrane tailored for extreme concentrations and even crystallization of hypersaline water is synthesized by coating a commercial hydrophobic porous membrane with a composite film containing a dense polyamide layer, a cation exchange layer (CEL), and an anion exchange layer (AEL). When used in direct contact MD for treating a 100 g L-1 NaCl hypersaline solution, the membrane achieves supersaturation of feed solution and a salt crystal yield of 38.0%, with the permeate concentration at <5 mg L-1. The composite membrane also demonstrates ultrahigh antiwetting stability in 360 h of long-term operation. Moreover, ion diffusion analysis reveals that the ultrahigh wetting resistance of the composite membrane is attributed to the bipolar AEL and CEL that eliminate ion crossover. The literature review elucidates that the composite membrane is superior to state-of-the-art membranes. This study demonstrates the great potential of the composite membrane for direct crystallization of hypersaline water, offering a promising approach to filling the gap between reverse osmosis and conventional thermal desalination processes for ZLD application.

Mathematical Modeling of NaCl Scaling Development in Long-Distance Membrane Distillation for Improved Scaling Control.

Membrane distillation is a novel membrane-based separation technology with the potential to produce pure water from high-salinity brine. It couples transport behaviors along the membrane and across the membrane. The brine in the feed is gradually concentrated due to the permeate flux across the membrane, which is a significant factor in initiating the scaling behavior on the membrane surface along the feed flow direction. It is of great interest to investigate and estimate the development of scaling on the membrane surface. This work specifically focuses on a long-distance membrane distillation process with a sodium chloride solution as the feed. A modeling approach has been developed to estimate the sodium chloride scaling development on the membrane surface along the flow direction. A set of experiments was conducted to validate the results. Based on mathematical simplification and analytical fitting, a simplified model was summarized to predict the initiating position of sodium chloride scaling on the membrane, which is meaningful for scaling control in industrial-scale applications of membrane distillation.

Improving membrane distillation performance by Fe(II) activated sodium percarbonate oxidation during the treatment of shale gas produced water.

Membrane distillation (MD) offers promise for recycling shale gas produced water (SGPW), while membrane fouling is still a major obstacle in standalone MD. Herein, sodium percarbonate (SPC) oxidation was proposed as MD pretreatment, and the performance of the single MD, SPC-MD hybrid process and Fe(II)/SPC-MD hybrid process for SGPW treatment were systematically evaluated. Results showed that compared to raw SGPW, the application of SPC and Fe(II)/SPC led to the decrease of the fluorescent organics by 28.54 % and 54.52 %, respectively. The hydrophobic fraction decreased from 52.75 % in raw SGPW to 37.70 % and 27.20 % for SPC and Fe(II)/SPC, respectively, and the MD normalized flux increased from 0.19 in treating raw SGPW to 0.65 and 0.81, respectively. The superiority of SPC oxidation in reducing the deposited membrane foulants and restoring membrane properties was further confirmed through scanning electron microscopy observation, attenuated total reflection fourier transform infrared, water contact angle and surface tension analyses of fouled membranes. Correlation analysis revealed that hydrophobic/hydrophilic matters and fluorescent organics in SGPW took a crucial role in MD fouling. The mechanism of MD fouling mitigation by Fe(II)/SPC oxidation was attributed to the decrease in concentrations and hydrophobicity of organic by synergistic oxidation, coagulation and adsorption.

Surface Modification of Polyethylene Terephthalate Track-Etched Membranes by 2,2,3,3,4,4,5,5,6,6,7,7-Dodecafluoroheptyl Acrylate for Application in Water Desalination by Direct Contact Membrane Distillation.

In this work, the surfaces of poly (ethylene terephthalate) track-etched membranes (PET TeMs) with pore sizes of 670-1310 nm were hydrophobized with 2,2,3,3,4,4,5,5,6,6,7,7-dodecafluoroheptyl acrylate (DFHA) by photoinitiated graft polymerization. Attenuated total reflection FTIR spectroscopy (ATR-FTIR), scanning electron microscopy (SEM) coupled to an energy-dispersive X-ray spectrometer (EDX), and contact angle measurements were used to identify and characterize the TeMs. The optimal parameters for graft polymerization were determined as follows: polymerization time of 60 min, monomer concentration of 30%, and distance from the UV source of 7 cm. The water contact angle of the modified membranes reached 97°, which is 51° for pristine membranes. The modified membranes were tested for water desalination using direct contact membrane distillation (DCMD) method. The effects of membrane pore size, the degree of grafting, and salt concentration on the performance of membrane distillation process were investigated. According to the results obtained, it has been concluded that large pore size hydrophobic TeMs modified by using DFHA could be used for desalinating water.

Fouling Reduction and Thermal Efficiency Enhancement in Membrane Distillation Using a Bilayer-Fluorinated Alkyl Silane-Carbon Nanotube Membrane.

In this study, we report the robust hydrophobicity, lower fouling propensity, and high thermal efficiency of the 1H,1H,2H,2H-perfluorooctyltriethoxysilane (FAS)-coated, carbon nanotube-immobilized membrane (CNIM) when applied to desalination via membrane distillation. Referred to as FAS-CNIM, the membrane was developed through a process that combined the drop-casting of nanotubes flowed by a dip coating of the FAS layer. The membranes were tested for porosity, surface morphology, thermal stability, contact angle, and flux. The static contact angle of the FAS-CNIM was 153 ± 1°, and the modified membrane showed enhancement in water flux by 18% compared to the base PTFE membrane. The flux was tested at different operating conditions and the fouling behavior was investigated under extreme conditions using a CaCO3 as well as a mixture of CaCO3 and CaSO4 solution. The FAS-CNIM showed significantly lower fouling than plain PTFE or the CNIM; the relative flux reduction was 34.4% and 37.6% lower than the control for the CaCO3 and CaCO3/CaSO4 mixed salt solution. The FAS-CNIM exhibited a notable decrease in specific energy consumption (SEC). Specifically, the SEC for the FAS-CNIM measured 311 kwh/m3 compared to 330.5 kwh/m3 for the CNIM and 354 kwh/m3 for PTFE using a mixture of CaCO3/CaSO4. This investigation underscores the significant contribution of the carbon nanotubes' (CNTs) intermediate layer in creating a durable superhydrophobic membrane, highlighting the potential of utilizing carbon nanotubes for tailored interface engineering to tackle fouling for salt mixtures. The innovative design of a superhydrophobic membrane has the potential to alleviate wetting issues resulting from low surface energy contaminants present in the feed of membrane distillation processes.

Carbon-Based Nanocomposite Membranes for Membrane Distillation: Progress, Problems and Future Prospects.

The development of an ideal membrane for membrane distillation (MD) is of the utmost importance. Enhancing the efficiency of MD by adding nanoparticles to or onto a membrane's surface has drawn considerable attention from the scientific community. It is crucial to thoroughly examine state-of-the-art nanomaterials-enabled MD membranes with desirable properties, as they greatly enhance the efficiency and reliability of the MD process. This, in turn, opens up opportunities for achieving a sustainable water-energy-environment nexus. By introducing carbon-based nanomaterials into the membrane's structure, the membrane gains excellent separation abilities, resistance to various feed waters, and a longer lifespan. Additionally, the use of carbon-based nanomaterials in MD has led to improved membrane performance characteristics such as increased permeability and a reduced fouling propensity. These nanomaterials have also enabled novel membrane capabilities like in situ foulant degradation and localized heat generation. Therefore, this review offers an overview of how the utilization of different carbon-based nanomaterials in membrane synthesis impacts the membrane characteristics, particularly the liquid entry pressure (LEP), hydrophobicity, porosity, and membrane permeability, as well as reduced fouling, thereby advancing the MD technology for water treatment processes. Furthermore, this review also discusses the development, challenges, and research opportunities that arise from these findings.

An in-depth analysis of membrane distillation research (1990-2023): Exploring trends and future directions through bibliometric approach.

This bibliometric analysis offers a comprehensive investigation into membrane distillation (MD) research from 1990 to 2023. Covering 4389 publications, the analysis sheds light on the evolution, trends, and future directions of the field. It delves into authorship patterns, publication trends, prominent journals, and global contributions to reveal collaborative networks, research hotspots, and emerging themes within MD research. The findings demonstrate extensive global participation, with esteemed journals such as Desalination and the Journal of Membrane Science serving as key platforms for disseminating cutting-edge research. The analysis further identifies crucial themes and concepts driving MD research, ranging from membrane properties to strategies for mitigating membrane fouling. Co-occurrence analysis further highlights the interconnectedness of research themes, showcasing advancements in materials, sustainable heating strategies, contaminant treatment, and resource management. Overlay co-occurrence analysis provides temporal perspective on emerging research trends, delineating six key topics that will likely shape the future of MD. These include innovations in materials and surface engineering, sustainable heating strategies, emerging contaminants treatment, sustainable water management, data-driven approaches, and sustainability assessments. Finally, the study serves as a roadmap for researchers and engineers navigating the dynamic landscape of MD research, offering insights into current trends and future trajectories, ultimately aiming to propel MD technology towards enhanced performance, sustainability, and global relevance.

Membrane fouling analysis of air-gap membrane distillation (AGMD) for recovery of water and removal of antibiotics from a model wastewater containing antibiotics and humic acid.

The study investigates the efficiency of air-gap membrane distillation (AGMD) in water recovery and antibiotics removal from wastewater, focusing on high-concentration scenarios. Experimental findings reveal enhanced membrane performance with increasing the feed temperature, resulting in vapor permeate fluxes of up to 5 kg/m2.h at higher temperatures. Despite experiencing flux reduction caused by fouling from humic acid (HA) in the feed antibiotics solution, the antibiotics consistently maintain near-complete rejection rates (>99%) over 48 h. The foulant on the membrane surface was illustrated by SEM imaging. To know the temperature polarization and the fouling resistance, mathematical modeling was used, and it validates experimental results, elucidating temperature polarization effects and mass transfer coefficients. An increase in feed flow rates reduced thermal boundary layers, enhancing heat flux. Higher temperatures reduced HA fouling resistance. Therefore, AGMD proves effective in water recovery and antibiotics removal, with mathematical models aiding fouling understanding for future research and detailed computational fluid dynamics (CFD) models.

Maximizing the wetting resistance of fluorine-free omniphobic membranes for hypersaline wastewater desalination.

Membrane distillation (MD) equipped with omniphobic (non-wetting) membranes has found a niche in water reclamation from hypersaline industrial wastewater. Here, we examined the efficacy of non-fluorinated materials as surface coating agents for omniphobic MD membrane fabrication, and identified necessary mechanisms to attain a maximized wetting resistance using fluorine-free materials. We first prepared MD membranes with different surface chemistries using a series of linear alkylsilanes and polydimethylsiloxane (PDMS) as representative fluorine-free, low surface energy materials. Membranes modified with a longer chain alkylsilane exhibited a lower surface energy and demonstrated a greater wetting resistance in direct contact MD experiments using feedwaters of various surface tensions. Despite the nearly identical surface energy measured for the longest alkylsilane and PDMS, PDMS-modified membrane exhibited an extended antiwetting performance as compared to the membrane treated with the longest alkylsilane. To elucidate the source of the distinctive wetting resistance, we examined the nucleation and condensation kinetics on the surfaces with the different surface chemistries via environmental scanning electron microscopy. Our analysis suggests that the membranes treated with long chain alkylsilanes contain surface defects (i.e., hydrophilic regions) whereas the high mobility of the PDMS effectively minimizes the defect exposure, slowing down the condensation and subsequent surface wetting.

Influence of photothermal nanomaterials localization within the electrospun membrane structure on purification of saline oily wastewater based on photothermal vacuum membrane distillation.

Today, synergistic combination of special nanomaterials (NMs) and electrospinning technique has emerged as a promising strategy to address both water scarcity and energy concerns through the development of photothermal membranes for wastewater purification and desalination. This work was organized to provide a new perspective on membrane design for photothermal vacuum membrane distillation (PVMD) through optimizing membrane performance by varying the localization of photothermal NMs. Poly(vinylidene fluoride) omniphobic photothermal membranes were prepared by localizing graphene oxide nanosheets (GO NSh) (1) on the surface (0.2 wt%), (2) within the nanofibers structure (10 wt%) or (3) in both positions. Considering the case 1, after 7 min exposure to the 1 sun intensity light, the highest temperature (∼93.5 °C) was recorded, which is assigned to the accessibility of GO NSh upon light exposure. The case 3 yielded to a small reduction in surface temperature (∼90.4 °C) compared to the case 1, indicating no need to localize NMs within the nanofibers structure when they are localized on the surface. The other extreme belonged to the case 2 with the lowest temperature of ∼71.3 °C, which is consistent with the less accessibility of GO NSh during irradiation. It was demonstrated that the accessibility of photothermal NMs plays more pronounced role in the membrane surface temperature compared to the light trapping. However, benefiting from higher surface temperature during PVMD due to enhanced accessibility of photothermal NMs is balanced out by decrease in the permeate flux (case 1: 1.51 kg/m2 h and case 2: 1.83 kg/m2 h) due to blocking some membrane surface pores by the binder. A trend similar to that for flux was also followed by the efficiency. Additionally, no change in rejection was observed for different GO NSh localizations.

Recent developments in solar-powered membrane distillation for sustainable desalination.

The freshwater shortage continues to be one of the greatest challenges affecting our planet. Although traditional membrane distillation (MD) can produce clean water regardless of climatic conditions, the process wastes a lot of energy. The technique of solar-powered membrane distillation (SPMD) has received a lot of interest in the past decade, thanks to the development of photothermal materials. SPMD is a promising replacement for the traditional MD based on fossil fuels, as it can prevent the harmful effects of emissions on the environment. Integrating green solar energy with MD can reduce the cost of the water purification process and secure freshwater production in remote areas. At this point, it is important to consider the most current progress of the SPMD system and highlight the challenges and prospects of this technology. Based on this, the background, recent advances, and principles of MD and SPMD, their configurations and mechanisms, fabrication methods, advantages, and current limitations are discussed. Detailed comparisons between SPMD and traditional MD, assessments of various standards for incorporating photothermal materials with desirable properties, discussions of desalination and other applications of SPMD and MD, and energy consumption rates are also covered. The final section addresses the potential of SPMD to outperform traditional desalination technology while improving water production without requiring a significant amount of electrical or high-grade thermal energy.

Bead-Containing Superhydrophobic Nanofiber Membrane for Membrane Distillation.

This study introduces an innovative approach to enhancing membrane distillation (MD) performance by developing bead-containing superhydrophobic sulfonated polyethersulfone (SPES) nanofibers with S-MWCNTs. By leveraging SPES's inherent hydrophobicity and thermal stability, combined with a nanostructured fibrous configuration, we engineered beads designed to optimize the MD process for water purification applications. Here, oxidized hydrophobic S-MWCNTs were dispersed in a SPES solution at concentrations of 0.5% and 1.0% by weight. These bead membranes are fabricated using a novel electrospinning technique, followed by a post-treatment with the hydrophobic polyfluorinated grafting agent to augment nanofiber membrane surface properties, thereby achieving superhydrophobicity with a water contact angle (WCA) of 145 ± 2° and a higher surface roughness of 512 nm. The enhanced membrane demonstrated a water flux of 87.3 Lm-2 h-1 and achieved nearly 99% salt rejection efficiency at room temperature, using a 3 wt% sodium chloride (NaCl) solution as the feed. The results highlight the potential of superhydrophobic SPES nanofiber beads in revolutionizing MD technology, offering a scalable, efficient, and robust membrane for salt rejection.

Performances of PTFE and PVDF membranes in achieving the discharge limit of mixed anodic oxidation coating wastewaters treated by membrane distillation.

The mixed wastewater generated by anodic oxidation coating facilities contains high levels of various contaminants, including iron, aluminum, conductivity, chemical oxygen demand (COD), and sulfate. In this study, the effectiveness of the membrane distillation (MD) process using polytetrafluoroethylene (PTFE) and polyvinylidene fluoride (PVDF) membranes was investigated to treat mixed wastewater from an anodized coating factory. The results indicate that both hydrophobic membranes effectively removed targeted contaminants. However, the PTFE membrane achieved higher removal efficiencies, with over 99% removal of sulfate, conductivity, iron, and aluminum, 85.7% of COD, and 86% of total organic carbon (TOC). In contrast, the PVDF membrane exhibited a significant decline in removal efficiency as the temperature increased and performed well only at lower feed temperatures. The PTFE membranes outperformed the PVDF membranes in treating chemically intensive anodic oxidation wastewaters. This superiority can be attributed to the PTFE membrane's morphology and structure, which are less influenced by feed water temperature and chemicals. Additionally, its slippery surface imparts anti-adhesion properties, effectively preventing membrane fouling, and maintaining the treated water quality and flux for longer operation time.

Insights into the silica scaling behaviors in membrane distillation and anti-scaling mechanism of functional polymers.

Silica scaling imposes a significant limitation on the efficacy of membrane distillation (MD) in the treatment of hypersaline wastewater. The complex dynamic behaviors of silica at the membrane-water-air interface and the poor understanding of molecular-level anti-scaling mechanism hampers the development of effective antiscalants for mitigating silica scaling in MD. Despite using functional polymers to prevent silica polymerization, the inhibition mechanisms are unclear. Here, the kinetic process of silica scaling during MD and the potential anti-scaling mechanism of poly-ethylenimine (PEI) were investigated at the molecular level via molecular dynamics simulations. The investigation reveals that silica scales were more likely to adhere to the water-PTFE interface with a free energy potential well of -40.0 kJ mol-1 than that of the water-air interface with a -11.4 kJ mol-1 potential well. Silica scales falling at the water-air interface also migrated on the water-air interface until captured by the PTFE membrane. In this work, a representative functional amino-rich polymer PEI was constructed as silica inhibitors and its scale inhibition mechanism was elucidated. Notably, the inclusion of PEI increased the free-energy barriers for the silica polymerization reaction from 72.0 kJ mol-1 to 86.1 kJ mol-1, compared to scenarios without the antiscalants. Moreover, quantitative structure-activity relationships (QSAR) model of ΔGwater-silica was developed to predict the anti-scaling efficiencies of typical antiscalants based on machine learning method. These findings provide valuable insights into enhancing the efficiency of silica scaling mitigation strategies.

Towards the Optimization of a Photovoltaic/Membrane Distillation System for the Production of Pure Water.

The production of pure water plays a pivotal role in enabling sustainable green hydrogen production through electrolysis. The current industrial approach for generating pure water relies on energy-intensive techniques such as reverse osmosis. This study unveils a straightforward method to produce pure water, employing real-world units derived from previously simulated and developed laboratory devices. This demonstrated system is cost-effective and boasts low energy consumption, utilizing membrane distillation (MD) driven by the waste heat harnessed from photovoltaic (PV) panels. In a previous study, modeling simulations were conducted to optimize the multi-layered MD system, serving as a blueprint for the construction of prototype devices with a suitable selection of materials, enabling the construction of field-testable units. The most efficient PV-MD device, featuring evaporation and condensation zones constructed from steel sheets and polytetrafluoroethylene (PTFE) membranes, is capable of yielding high-purity water with conductivity levels below 145 µS with high flux rates.

Green and Sustainable Forward Osmosis Process for the Concentration of Apple Juice Using Sodium Lactate as Draw Solution.

China is the world's largest producer and exporter of concentrated apple juice (CAJ). However, traditional concentration methods such as vacuum evaporation (VE) and freeze concentration cause the loss of essential nutrients and heat-sensitive components with high energy consumption. A green and effective technique is thus desired for juice concentration to improve product quality and sustainability. In this study, a hybrid forward osmosis-membrane distillation (FO-MD) process was explored for the concentration of apple juice using sodium lactate (L-NaLa) as a renewable draw solute. As a result, commercial apple juice could be concentrated up to 65 °Brix by the FO process with an average flux of 2.5 L·m-2·h-1. Most of the nutritional and volatile compounds were well retained in this process, while a significant deterioration in product quality was observed in products obtained by VE concentration. It was also found that membrane fouling in the FO concentration process was reversible, and a periodical UP water flush could remove most of the contaminants on the membrane surface to achieve a flux restoration of more than 95%. In addition, the L-NaLa draw solution could be regenerated by a vacuum membrane distillation (VMD) process with an average flux of around 7.87 L∙m-2∙h-1 for multiple reuse, which further enhanced the long-term sustainability of the hybrid process.

In Situ-Grown Al2O3 Nanoflowers and Hydrophobic Modification Enable Superhydrophobic SiC Ceramic Membranes for Membrane Distillation.

Membrane distillation (MD) is considered a promising technology for desalination. In the MD process, membrane pores are easily contaminated and wetted, which will degrade the permeate flux and salt rejection of the membrane. In this work, SiC ceramic membranes were used as the supports, and an Al2O3 micro-nano structure was constructed on its surface. The surface energy of Al2O3@SiC micro-nano composite membranes was reduced by organosilane grafting modification. The effective deposition of Al2O3 nanoflowers on the membrane surface increased membrane roughness and enhanced the anti-fouling and anti-wetting properties of the membranes. Simultaneously, the presence of nanoflowers also regulated the pore structures and thus decreased the membrane pore size. In addition, the effects of Al2(SO4)3 concentration and sintering temperature on the surface morphology and performance of the membranes were investigated in detail. It was demonstrated that the water contact angle of the resulting membrane was 152.4°, which was higher than that of the pristine membrane (138.8°). In the treatment of saline water containing 35 g/L of NaCl, the permeate flux was about 11.1 kg⋅m-2⋅h-1 and the salt rejection was above 99.9%. Note that the pristine ceramic membrane cannot be employed for MD due to its larger membrane pore size. This work provides a new method for preparing superhydrophobic ceramic membranes for MD.

Contrasting mixed scaling patterns and mechanisms of nanofiltration and membrane distillation.

Oriented towards the pressing needs for hypersaline wastewater desalination and zero liquid discharge (ZLD), the contrasting mixed scaling of thermal-driven vacuum membrane distillation (VMD) and pressure-driven nanofiltration (NF) were investigated in this work. Bulk crystallization was the main mechanism in VMD due to the high salinity and temperature, but the time-independent resistance by the adsorption of silicate and organic matter dominated the initial scaling process. Surface crystallization and the consequent pore-blocking were the main scaling mechanisms in NF, with the high permeate drag force, hydraulic pressure, and cross-flow rate resulting in the dense scaling layer mainly composed of magnesium-silica hydrate (MSH). Silicate enhanced NF scaling with a 75% higher initial flux decline rate attributed to the MSH formation and compression, but delayed bulk crystallization in VMD. Organic matter presented an anti-scaling effect by delaying bulk crystallization in both VMD and NF, but specifically promoted CaCO3 scaling in NF. Furthermore, the incipient scaling was intensified as silicate and organic matter coexisted. The scaling mechanism shifted from surface to bulk crystallization due to the membrane concentration in both VMD and NF. This work fills the research gaps on mixed scaling mechanisms in different membrane processes, which offers insights for scaling mitigation and thereby supports the application of ZLD.

Progress in membrane distillation processes for dye wastewater treatment: A review.

Textile and cosmetic industries generate large amounts of dye effluents requiring treatment before discharge. This wastewater contains high levels of reactive dyes, low to none-biodegradable materials and chemical residues. Technically, dye wastewater is characterised by high chemical and biological oxygen demand. Biological, physical and pressure-driven membrane processes have been extensively used in textile wastewater treatment plants. However, these technologies are characterised by process complexity and are often costly. Also, process efficiency is not achieved in cost-effective biochemical and physical treatment processes. Membrane distillation (MD) emerged as a promising technology harnessing challenges faced by pressure-driven membrane processes. To ensure high cost-effectiveness, the MD can be operated by solar energy or low-grade waste heat. Herein, the MD purification of dye wastewater is comprehensively and yet concisely discussed. This involved research advancement in MD processes towards removal of dyes from industrial effluents. Also, challenges faced by this process with a specific focus on fouling are reviewed. Current literature mainly tested MD setups in the laboratory scale suggesting a deep need of further optimization of membrane and module designs in near future, especially for textile wastewater treatment. There is a need to deliver customized high-porosity hydrophobic membrane design with the appropriate thickness and module configuration to reduce concentration and temperature polarization (CP and TP). Also, energy loss should be minimized while increasing dye rejection and permeate flux. Although laboratory experiments remain pivotal in optimizing the MD process for treating dye wastewater, the nature of their time intensity poses a challenge. Given the multitude of parameters involved in MD process optimization, artificial intelligence (AI) methodologies present a promising avenue for assistance. Thus, AI-driven algorithms have the potential to enhance overall process efficiency, cutting down on time, fine-tuning parameters, and driving cost reductions. However, achieving an optimal balance between efficiency enhancements and financial outlays is a complex process. Finally, this paper suggests a research direction for the development of effective synthetic and natural dye removal from industrially discharged wastewater.