Non-metallic materials for sustainable desalination systems: Performance, durability, and industrial validation

Innovative non-metallic materials have the potential to overcome many of the challenges associated with current desalination technologies. These include corrosion in saline conditions, scaling and fouling of equipment, mechanical failure, and high energy consumption. Current desalination systems using metallic materials provide structural integrity but also generate additional expenses and environmentally damaging consequences through the need for ongoing corrosion-related maintenance and component replacements. The use of novel non-metallic materials in high-pressure desalination system components, particularly those operating at pressures > 50 bar, is likely to be an important step in developing more sustainable desalination practices. A review has been undertaken on recent case study reports from major desalination plants, including the successful application of high-pressure resin (HPRP) at 80 bar pressure by the Saudi Water Authority (SWA), which demonstrated the feasibility of using non-metallic materials in high-stress applications. This review systematically analyses literature published between 2015 and 2025, including peer-reviewed research articles and industrial case studies from large-scale desalination plants. Particular emphasis is placed on validated engineering applications and pilot-scale demonstrations to ensure the reliability and practical relevance of the conclusions. The paper explores new technologies, including graphene-oxide-based membranes, carbon-nanotube-based composites and bio-inspirational materials, that may improve permeability and selectivity while enhancing the fouling-resistance of membranes and reducing energy usage by up to 30%. The results suggest that strategic deployment of advanced materials could significantly lower the carbon footprint of desalination operations and enhance their economic viability. Nanomaterial based membrane technology offers the prospect of improved salt rejection and increased water flux rates; smart or responsive materials may exhibit self-healing properties and adaptive behaviour. In conclusion, this review paper confirms that further pilot-scale trials will be required to demonstrate the scalability and applicability of new laboratory-based technologies, so they can be integrated into large-scale industrial systems to achieve global sustainability goals and climate targets. • First comprehensive review integrating industrial-scale validation of high-pressure resin piping systems (at 80 bar). • Component-specific materials analysis - approach provides actionable insights for engineers, designers, and plant operators. • Presenting a holistic materials roadmap for sustainable desalination infrastructure. • Integrates life-cycle assessment (LCA), circular economy principles, and carbon footprint reduction strategies. • Presents a balanced, evidence-based comparison among corrosion-resistant alloys (CRAs), stainless steels, and advanced non-metallic alternatives.