The Role of Freezing Temperature in Modulating Chitosan Gel Structure and Evaporation Performance for Seawater Desalination

Interfacial solar evaporation has emerged as a promising strategy for freshwater production, where 3D evaporators offer distinct advantages in heat management and salt rejection. Freeze–thaw cycling is a widely adopted fabrication method for 3D hydrogel evaporators, yet the impact of preparation conditions (e.g., freezing temperature) on their evaporation performance remains poorly understood, hindering rational optimization of fabrication protocols. Herein, we report the fabrication of chitosan-based hydrogel evaporators via freeze–thaw cycles at different freezing temperatures (−20 °C, −40 °C, and −80 °C), leveraging its low cost and environmental friendliness. Characterizations of crosslinking density and microstructure reveal a direct correlation between freezing temperature and network porosity, which significantly influences evaporation rate, photothermal conversion efficiency, and anti-salt performance. It is noteworthy that the chitosan hydrogel prepared at −80 °C demonstrates an excellent evaporation rate in high-salinity environments and exhibits superior salt resistance during continuous evaporation testing. Long-term cyclic experiments indicate that there was an average evaporation rate of 3.76 kg m−2h−1over 10 cycles, with only a 2.5% decrease observed in the 10th cycle. This work not only elucidates the structure–property relationship of freeze–thaw fabricated hydrogels but also provides a strategic guideline for tailoring evaporator architectures to different salinity conditions, bridging the gap between material design and practical seawater desalination.