Water shortage is becoming a critical worldwide issue, particularly in dry and coastal regions with limited or unstable freshwater supplies. This challenge highlights the need for sustainable desalination methods, like solar stills, to supply clean water in areas with limited resources. Nonetheless, typical solar stills struggle with low natural convection caused by unsuitable glass-cover designs and ineffective flow organization inside the unit. Addressing these limitations requires new design strategies integrating geometry optimization with internal flow-control elements. This study presents a comprehensive numerical analysis to boost the freshwater yield of a single-basin solar still through optimization of glass cover geometries and internal flow dynamics. Four distinct glass covers including conical (Case 1), hemispherical (Case 2), trapezoidal with peripheral condensate collection (Case 3), and trapezoidal with central collection (Case 4) were evaluated to assess their influence on natural convection, heat transfer rates, and distillate output. Next, the integration of internal baffle was investigated, followed by sensitivity analysis of baffle radius within the best-performing configuration. Results show that conical and hemispherical shapes significantly outperform trapezoidal designs, with the conical cover achieving the highest freshwater productivity, 8.44% higher than the trapezoidal peripheral design (Case 3). For baffle radius, a non-linear trend emerges: increasing radius initially reduces output, reaching a minimum at 0.6, then improving productivity by 21.1% when increased to 0.8. Upgrading from the poorest trapezoidal design (Case 3) to the optimized conical design with a 0.8 baffle yields a 30.6% rise in freshwater output and a 37.8% increase in the Nusselt number. The economic assessment further shows that the optimized configuration shortens the payback period from 4.7 to 3.6 years and raises long-term cumulative profit by nearly 40%.
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