America’s Authority in Membrane Treatment
Ceramic Membranes
Membrane Filtration support is made by extrusion, and then fiber. Flat sheet ceramic membranes
multiple layers of the ceramic are submerged in the fluid and clean
Membrane filtration is becoming the
membrane material are applied. Flat water is drawn through the membrane.
technology of choice in liquid
sheet membrane elements typically
separations around the world for Ceramic elements come in different
have the membrane coating on the
applications including desalination dimensions that can be beneficial for
outside and tubular membrane
pretreatment, removal of suspended different applications. Some tubular
elements typically have several flow
solids from water and wastewater, types may be as long as 1,500 mm (5
channels in the structure with the
membrane bioreactors (MBR), as well feet) long. Diameters vary also and
membrane coatings on the inside.
as food and beverage processing. Most typically range from 20 to 200 mm.
Nitrides and carbides of similar metals
of the membranes produced today have Filter channels can range from one
may also be used as the barrier layer.
a polymeric barrier layer but ceramic very wide channel in an element to
The combined support structure and
membranes are now available for many 100s of very narrow channels with
membrane layer is often referred to as a
applications. inside diameters ranging from 1.0 - 25
“membrane element” or ceramic
mm (0.6 – 1.0 inches). Flat
Ceramic Membranes element.
membranes can have up to 6 ft2 of
Ceramic membranes bring the porosity Pore Sizes, Channel Diameters and surface area per sheet.
expected for microfiltration/ Active Area The diameter of the feed channels, its
ultrafiltration (MF/UF) separation shape, the channel length and the
The porous membrane layer will have
along with the added features of a number of channels per element will
distinct pores ranging from open
durable material with high chemical, impact the membrane surface area of a
microfiltration (1,4µm) to tight UF
temperature and pressure tolerance. ceramic element. Ceramic membrane
(1kD) and even nanofiltration (250D).
Ceramic membranes offer proven elements of various shapes, diameters
Ceramic monolithic elements have
lifecycles up to 20 years or more and and lengths can have surface areas
multiple passageways or channels for
are used in potable water treatment, typically ranging from several ft 2 to
the feed fluid to flow through the
food and dairy industry, chemical nearly 300 ft 2. There can be one or up
element or pass through the hollow
industry and waste water treatment
applications. In addition, there are a
number of liquid separations that have
very demanding conditions, and within
those realms, ceramic membranes are
being used extensively.
Membrane Material
Ceramic membranes utilize a porous
support such as alpha alumina or
silicon carbide covered with a porous
inorganic membrane layer of aluminum
oxide, titanium oxide, zirconium oxide
or silicon carbide rather than a
polymeric barrier layer. The tubular,
flat sheet, monolithic or hollow fiber
to several thousand ceramic membrane even clean-in place efforts with acids, Equipment and Skids
elements in a membrane module. alkalis and bleach restore the Additional equipment for a ceramic
membrane filter for repeated reuse. membrane process might include an air
Membrane & Process Variations There are other ceramic systems that compressor to assist air scours (for
Ceramic membranes are available in do not use backwash and have been in submerged ceramic flat sheets) and
flat sheet, monolithic, hollow fiber and operation for over twenty years, backwashing, as well as chemical
multichannel tubular elements. Flat employing alternatives like back pulse, make-up tanks. Air scour for ceramic
sheet ceramic membranes are typically air sparging and dynamic shock. flat plates is not required in all cases
outside-in flow; monolithic, hollow and there are municipal systems in
Flux rates of tens to thousands of gfd
fiber and multichannel elements are operation without air scour. Some
are being realized in operating systems.
typically inside-out in dead end or ceramic membrane manufacturers have
One manufacturer reports Marker
cross flow configuration. The filtrate is developed process designs so that they
based Direct Integrity Test (DIT)
collected as it exits the exterior surface can operate like most other pressurized
challenge tests for ceramic membranes
of the porous material (element). polymeric membranes and can fit into
used for surface water to potable and
There are some models of ceramic the open platform design concepts
have run challenge tests at 2,000 gfd.
membranes elements with slots built utilized by several equipment OEM’s.
Another has NSF419 approval for DIT
into the monolith that collect filtrate There are now cases of a ceramic
Challenge similar to polymeric
and direct it to the outside of the membrane module retrofitting into an
membranes. Ceramics are very
element. The channel diameter chosen existing polymeric membrane system
hydrophilic and therefore have high
is adapted to the viscosity or TSS of and for the most part, utilizing the
water permeability.
the liquid to be treated. A pressurized existing infrastructure of piping,
feed stream can run from the inlet end Pretreatment controls, and backwash pumps.
to an outlet face in a cross-flow
Some ceramic membrane systems may The ability to position more membrane
arrangement. Ceramic membranes
need some degree of pretreatment to elements in a module and more
used for drinking water applications are
reduce the load on the membrane plant modules in a system can reduce the
both flat sheet, outside in, as well as
or remove excess oil from the feed CAPEX required for a given system.
multichannel inside-out running in
stream. High concentrations of small There are modularized, skidded
either dead end and cross flow modes
particulates, fibers and other items can systems for ceramic membranes which
of operation. Flat sheet ceramic
block the feed channels and were found provide a significant reduction in
membranes have also been used for
to erode the matrix when the wrong installed costs. Some of the
drinking water, MBR and sludge
type or configuration of ceramic manufacturers of ceramic membrane
dewatering applications.
element was used. Some synthetic oils systems sell or rent pilot equipment.
Flow Patterns and grease may be difficult to remove
from the matrix. Pretreatment methods
In some dead end flow configurations,
might include centrifugation or
the membrane is run in an inside-out
coagulation/flocculation
mode with the feed flowing inside the
settlement to remove large
passageway and filtrate recovered on
particles or skim off free oil.
the outside of the membrane. As the
Submerged flat-sheet ceramic
solids accumulate at the membrane
membranes and tubular
surface, the flow rate will drop off at
membranes tend to be usable
constant pressure, or the transmembrane
with higher solids and oil con-
pressure will increase at constant flow,
centrations. Similar to
until a backwash with water or
polymeric membranes, ceramic
compressed air is required. A backwash
flat-sheet membranes used for
drives the filter cake off the membrane
MBR applications typically
surface and produces a concentrated
require a 2mm pre-screen.
stream of solids for disposal or
recycling to the front of the process.
Chemically enhanced backwash and
Ceramic Membranes, Advantages, tolerances, with working conditions A feature mentioned for ceramic
Disadvantages and Applications mostly limited by the sealing materials membranes is the possibility of reusing
and vessel/module structures. the membrane material itself. Due to
Advantages
the materials of construction, in some
Like other ultrafiltration and Ceramic membranes can have a high
cases, used ceramic membranes could
microfiltration membrane products, packing density like a hollow fiber
be recycled as raw ceramic material to
ceramic membranes offer reliable module.
make other products. This could
operation with a positive barrier against As with microfiltration and ultrafiltration reduce disposal costs and eliminate
water quality upsets. They are operations, ceramic membranes will landfill issues
mechanically strong and can be used in remove disinfection by-product (DBP)
applications where there is increased Energy requirements of ceramic
precursors from surface water supply
oil and suspended solids in the feed. membranes may be less than other
sources with proper coagulation, and
They are also abrasion resistant. membrane separations. Lifecycle costs
with or without flocculation. They can
Ceramic and capital costs can be competitive, or
membranes are better than,
durable with a polymeric
resistance to membranes.
degradation by a Advances in
wide range of ceramic membrane
chemicals and technology and
chemical processes offer
concentrations, greater energy
which allows more efficiency,
aggressive chemical reduction in
cleaning procedures cleaning
to be used over a requirements,
pH range of 0-14. minimization of
Ceramic chemical usage
membranes have a and elimination of
high resistance to filtrate losses,
ozone and chlorine, which contributes
which allows for to lifecycle costs
their use for in favor of ceramic
disinfecting raw membranes.
water prior to membranes These also remove suspended solids at a ≥ There have been reports of ceramic
membranes are thermally stable and 98% filtrate water recovery rate. membranes with 18 years of operation,
can withstand temperatures up to several Ceramic membranes provide an with little loss in
hundred ºF. Some of the limitations for absolute barrier against upsets or permeability. In some cases,
ceramic membranes apply only to the surges in fluctuating raw water quality, manufacturers may offer a 20-year
gaskets and other module materials, which is characterized by a rapid warranty.
and not necessarily to the ceramics. In increase of suspended solids and oils. In rare cases, if chemical cleaning does
all cases consideration should be given Reduction or elimination of filtrate not work effectively, the ceramic
to the type of ceramic material used. losses is made possible by minimizing elements can be heated in an external
or eliminating some of the separation oven by the membrane manufacturer to
High flux rates can be achieved with steps needed in conventional processes.
ceramic membranes since they can burn off the contaminants.
Ceramic membranes do not need to
tolerate higher cross flow, which stay wet like polymeric membranes; Disadvantages
allows for extended process runs, they can be drained, removed from use
resulting in a lower TMP for a given Ceramic membranes have many useful
and then restarted after being out of properties, but the economics due to
flux. Ceramic membranes have very service.
high thermal stability and pressure historically higher capital costs for the
membranes and their system type must Applications Additional applications of ceramic
be considered and compared against membranes in food industry is in for
Potable Water Applications
recent advancements in cost reduction. beverage applications, such as juice
There are a limited number of The use of ceramic membranes to clarification, s and beer production that
full-scale installations for potable water produce potable water in the United require daily cleanings and, in many
treatment and municipal MBR. States is limited to a half dozen cases, thermal and chemical
Ceramic systems that can operate at installations as of 2017. In Japan, there sanitization. Other applications include
half the CAPEX and OPEX of are over 130 potable water facilities cell separation in amino acid
polymeric membrane processes are using ceramic membranes dating back production, lactic acid production,
being promoted in the industry and to 1998, where the facility is still using fermentation broth treatment, oil/water
deserve attention. the original membranes. A drinking separations and sugar syrup production.
water plant in Japan rated at 46 MGD,
Claims of extended life cycles are treating surface water was Chemical Industry Applications
inviting, but there are some possible
commissioned in April 2014. Several 1 Ceramic membranes are used in
methods for ceramic membrane
MGD drinking water plants have been industrial applications that include oil/
degradation, including the possibility
installed in Delaware, Texas and water separations, catalyst recovery,
of chemical attack (very limited and
Mississippi and have been in operation textile needs, waste water and even
mainly by fluoric acid), and thermal
in the USA since 2014. A 10 MGD alkaline cleaning solution recovery.
shock of the matrix. An advantage of plant treating reclaimed secondary Applications to treat produced water
ceramic membranes is the ability to
effluent and surface water from a that might be high in oil and grease,
heat the matrix to restore flow.
reservoir for indirect potable reuse which are problematic for polymeric
However, too rapid a change in stated up in January 2015 in Parker, membranes are using ceramic
temperature, such as the introduction of
Colorado membranes. Facilities in Colorado,
a cold liquid, can result in thermal
Texas and Alberta have been installed
shattering of some of the ceramic
to treat oil laden waters. Additionally,
materials and destruction of the
there are gas phase separations that use
element. Limits of no more than a
ceramic membranes, including
30ºC temperature differential and
separation of hydrogen from the waste
controlled heating or cooling rates are
steam of refinery and gasification
to be followed as recommended by
plants, as well as separation of carbon
certain manufacturers. Careful
dioxide from natural gas to a
operating controls can minimize this Food and Dairy Industry
concentration of less than 2% for
risk. Generally, ceramic membranes The food and dairy industry has pipelines of natural gas.
are not to be frozen, although there are embraced ceramic membranes for their
some exceptions with some specific unique properties. There are a number Sanitary Waste Water Treatment
designs.
of installations around the world using Ceramic MBRs are now being
Certain ceramic membranes can be these products for their sanitization considered in the United State but may
subject to erosion from particulates in properties and durability. The majority find market share in industrial MBR
the feed stream, colliding with the of ceramic membrane applications in and smaller municipal MBR
membrane surface due to their the dairy industry are for Extended applications. Ceramic membranes can
materials of construction and Shelf Life (ESL) milk where polymeric be an effective integrity barrier for
manufacturing method. Fortunately, membranes simply will not work. In pathogens and this will be a key
more durable ceramic membranes with addition, there are systems operating consideration for log removal credits in
abrasion resistance exist as seen in that are used to defat whey, curd potable reuse applications including
other applications, where ceramics are cheese and other dairy products. their use in MBRs
specifically used for their abrasion Another application that has been using
resistance quality in applications like ceramic membranes is the fractionation
powdered activated carbon and ceramic of whey proteins in the cheese making
bearings. process.
Other Applications and Considerations Conclusion
Ceramic membrane’s durability, wide range of thermal and Ceramic membranes have many desirable properties and are
chemical stability and long lifecycles make them ideal being used extensively in water purification, food and dairy
candidates for difficult applications that would otherwise foul applications as well as for industrial needs. These market
polymeric membranes and limit their useful life. Although uses of ceramics will continue to increase. As ceramic
ceramic membranes have traditionally been more costly than membrane production volume grows and product innovations
polymeric membranes, recent innovations such as; increasing reduce the capital cost, use of ceramic membranes will
surface area, reducing cleaning complexity and reducing increase. They will be more prominent as they are better
manufacturing costs have made them more competitive. As understood for use in potable water, waste water recycling,
their volume grows, especially where lifecycle costs and reuse, and even produced water in the oil field.
value are considered, ceramics will find increased use in water
treatment and other applications due to these advantages.
Ceramic membranes do not remove dissolved components
like reverse osmosis membrane, but do a very effective job of
removing very fine solids and larger molecules and
coagulated dissolved organic carbon (DOC) from solution.
However, some ceramic membranes entering the market are
in the nanofiltration range and may exhibit some salt
rejection. Ceramic membrane systems have also been used as
a pretreatment prior to ion exchange and reverse osmosis
systems.
This material has been prepared as an
educational tool by the American
Membrane Technology Association
(AMTA). It is designed for dissemination
to the public to further the understanding
of the contribution that membrane water
treatment technologies can make toward
improving the quality of water supplies in
the US and throughout the world.
For more information, please contact:
American Membrane Technology
Association (AMTA)
2409 SE Dixie Highway
Stuart, Florida 34996
Phone: (772) 463-0820
Fax: (772) 463-0860
Email: admin@[Link]
or visit our website at:
[Link]
(FS-21) Jan. 2018
