ThermOcean

A desalination platform powered entirely by the ocean's own temperature gradient — no grid, no fuel. Treated as an energy problem, the cost fell out of it.

Role Team Lead
Team 20 researchers
Year 2025–26
51% reduction in levelized water cost vs. the Gizo, Solomon Islands baseline
28,600 liters of freshwater per day (modeled) — enough for 1,430 people
$21,000 staged competition funding secured

The problem

Gizo, in the Solomon Islands, is the kind of place desalination was supposed to help: surrounded by seawater, short on fresh water, and at the end of a fuel supply chain that makes every liter expensive. Conventional desalination needs either grid electricity or active heating — and the cost of water there is, mostly, the cost of that energy.

The DOE Marine Energy Collegiate Competition asks teams to put marine energy to work on real coastal problems. We chose to make water.

The reframe

The cost problem was really an energy problem — so the thermocline did the work twice.

The ocean already maintains a temperature gradient — warm at the surface, cold below the thermocline. That gradient is low-grade energy, unusable for most machines but exactly the kind of heat a membrane-distillation process wants. Instead of generating electricity to power a desalination plant, the platform harvests low-grade ocean-thermocline heat directly: warm surface water drives evaporation across the membrane, cold deep water pulls condensation. No grid connection. No fuel deliveries. The energy bill — the thing that actually sets the price of water in Gizo — falls out of the design.

Modeled output: 28,600 liters per day, fresh water for 1,430 people, with the projected levelized cost of water 51% below the Gizo baseline.

Design

The heart of the platform is a conductive-gap membrane-distillation module. My design contribution was its finned channel: a modular geometry that supports interchangeable fin configurations, so the team could test heat-transfer trade-offs in hardware instead of arguing about them in simulation.

Interchangeable fins turned a design argument into a test matrix. When the geometry is swappable, you don’t have to be right the first time — you have to be measurable.

Build & test

We built the lab-scale prototype and I led its testing. That end of the project — machining, sealing, instrumenting, running — is where the design either holds up or doesn’t.

It held up. The team won Best Build & Test honors against 27 teams at the DOE Marine Energy Collegiate Competition, a judgment specifically of prototype design and testing rigor.

Leading the team

Twenty undergraduate and graduate researchers, two DOE competitions running in parallel. I set MECC’s technical direction, drove the industry-mentor strategy, and aligned the Hydropower Collegiate Competition planning with its incoming lead. The budget — $21,000 in staged competition funding tied to proposal deliverables — I built and managed first, then deliberately delegated.

The work also traveled: we co-authored and presented “Utilizing Ocean Thermoclines for Water Desalination” at NCUR 2026, and ran three K-12 outreach events that put hands-on builds in front of 226 students.

Lessons

The project’s central lesson is the reframe itself: the most expensive part of a system is often an energy flow wearing a cost costume. Finding the gradient that’s already there — and using it twice — beat every version of the design that tried to fight thermodynamics head-on.

Connected to
Technologies
SOLIDWORKS · ANSYS
Capabilities
Mechanical Design · Manufacturing · Systems Integration · Rapid Prototyping · Leadership
Organizations
Warsinger Water Lab · Purdue University · U.S. Department of Energy
Research areas
Marine Energy · Desalination · Thermal Systems
Inspect the evidence
Simplified system diagram: cold deep water and warm surface water feed an energy cycle that drives a desalination unit producing fresh water, with a solar collector at the surface.
diagram System concept — thermocline-driven desalination The one-slide version of the system: the ocean’s own temperature gradient drives both the energy cycle and the desalination.
Schematic of Ocean Thermal Energy Conversion: warm shallow seawater feeds an evaporator and cold deep seawater a condenser, driving a turbine for electricity generation.
diagram Concept — OTEC cycle schematic Baseline OTEC cycle considered during concept generation.
Diagram of a point absorber: a floating buoy drives a translator along a reactor shaft below the surface, converting wave motion to power.
diagram Concept — point-absorber wave energy Wave-energy point absorber evaluated as an auxiliary power source.
3D concept of a barge carrying the membrane distillation system, water storage tanks, OTEC unit, pumping station, battery, and engine room, with point absorbers inside the barge frame.
diagram Concept — offshore barge platform Offshore barge variant: everything on one hull, point absorbers built into the frame.
3D concept of a fixed offshore platform with a mirror-focused water-heating truss column, deck-mounted OTEC and storage tanks, a submerged membrane distillation unit, and fresh water pumped to the mainland.
diagram Concept — fixed offshore platform Fixed-platform variant: solar-heated truss column, submerged MD unit, water piped ashore.
3D concept of an onshore desalination plant: shore-based membrane distillation and storage tanks fed by offshore point-absorber buoys, an OTEC unit, and a mirror-array solar water heater.
diagram Concept — onshore plant Onshore variant: seawater is pumped ashore, keeping all equipment on land.
Sketch of a boat retrieving fresh water from a floating offshore storage tank.
diagram Concept — boat water retrieval Water logistics option: boats collect from an offshore storage tank.
Sketch of a pipe pumping fresh water from an offshore storage tank to buildings on shore.
diagram Concept — piped delivery to shore Water logistics option: a fixed pipe delivers water to shore.
Sketch of a membrane distillation system feeding a storage tank floating at the ocean surface.
diagram Concept — surface storage tank Storage option: freshwater tank floating at the surface.
Sketch of a membrane distillation system feeding a storage tank anchored below the ocean surface.
diagram Concept — submerged storage tank Storage option: submerged tank, clear of surface traffic.
Sketch of a seawater intake protected by a mesh trash rack ahead of the pipe to the membrane distillation system.
diagram Concept — trash-rack intake Intake protection: a mesh trash rack keeps debris out of the MD feed.
Sketch of silicone sealant applied between two bolted plates of an assembly.
diagram Concept — silicone sealing Sealing approach carried into the prototype: silicone between bolted assemblies.
Overhead photo of a cardboard system mockup with labeled turbine, generator, condenser, evaporator, pumps, water tank, and membrane distillation system connected by hoses.
photo Prototype — annotated piping mockup Full-system cardboard mockup used to fix the order of piping connections before committing to hardware.
Slide titled Membrane Distillation and Organic Rankine Cycle System: a photo of the cardboard mockup beside bullets recording the decision to model but not build the ORC.
photo Prototype — MD and ORC system decisions The mockup’s output: piping order fixed, and the ORC judged too complex and expensive to build — modeled instead.
Cross-section of the full-scale platform on oil-rig legs: solar collector on top, membrane distillation deck and organic Rankine cycle deck below, with a cold-water pipe reaching 1,000 m and a 30°C surface intake.
diagram Design — full-scale platform cross-section Full-scale architecture: MD deck above, power cycle below, drawing 5°C water from 1,000 m depth.
Cutaway of the membrane distillation deck: a finned hot feed side and a cold side across a membrane with a permeate channel, shown as one module of a five-vessel array.
diagram Design — MD module section The MD module in section — the finned feed channel is the design contribution the prototype tested.
Piping diagram of five membrane distillation vessels manifolded in parallel between hot and cold lines, with a storage tank and pump.
diagram Design — five-module MD array Five MD modules manifolded in parallel on the full-scale deck.
Diagram of the organic Rankine cycle deck: pump, evaporator, condenser, and turbine in a closed loop between hot and cold seawater lines.
diagram Design — organic Rankine cycle section The power deck: a closed Rankine loop spanning the same thermal gradient.
Diagram of a serpentine solar collector heating seawater across successive passes from a cool inlet to a hot outlet.
diagram Design — solar collector Solar boost: a serpentine collector raises feed temperature before the MD deck.
Exploded CAD render of the conductive-gap membrane distillation module: acrylic housings, gaskets, and the finned heat-transfer plate.
cad Build — finned CGMD module, exploded CAD The as-built lab module: an interchangeable finned plate between gasketed acrylic housings.
Handwritten stress analysis of the acrylic MD housing: bolt loads and plate bending at 500 kPa, giving factors of safety of 217 for the bolts and 3,579 for the acrylic channel.
report Build — housing stress analysis Hand calcs behind the housing: bolt and plate stresses at 500 kPa, factors of safety before machining.
Timeline from year-one lab bench testing (~$10,000) through module stress testing and 1/20th- and 1/4-scale trials in Cairns, Australia, to full-scale deployment in Gizo, Solomon Islands (~$30 million).
diagram Business — ten-year scaling plan The scaling case: lab bench to Gizo in ten years, $10k to $30M.