Microstructured Zirconia Ceramic Membrane Tube for Process Filtration

Solving Application Challenges with ADCERAX® Zirconia Ceramic Membrane Tube in Industrial Liquid Processing

ADCERAX® Zirconia Ceramic Membrane Tube is specifically engineered to address filtration challenges in industries requiring stable throughput, chemical durability, and consistent purity. Its micro-porous structure and strong mechanical stability enable reliable separation and purification in diverse continuous-flow systems.

• Clarification of Dairy and Beverage Streams Using Zirconia Ceramic Membrane Tube

  ✅Key Advantages

  1. High Flux Retention under CIP Cleaning
  Zirconia Ceramic Membrane Tube maintains over 95% of its initial flux after 100 alkaline and steam cleaning cycles, verified under pH 12 CIP conditions. This stability enables continuous milk and juice clarification without frequent shutdowns for membrane replacement.
  2. Cold Filtration Capability for Heat‑Sensitive Liquids
  The membrane structure supports efficient separation at below 40 °C, ensuring the preservation of natural enzymes and vitamins in dairy and beverage products. Its non‑reactive zirconia matrix avoids taste or odor alteration during processing.
  3. Long Operational Lifetime in Beverage Lines
  Laboratory validation and industrial trials confirm a service life of >5 years in continuous fruit‑juice production, with fouling resistance reducing cleaning frequency by 30 % compared to polymeric membranes.

  ✅ ️Problem Solved

  A European dairy processor reported severe flux decay of polymeric membranes after three months of daily CIP cleaning, causing batch delays and product waste. After switching to ADCERAX® Zirconia Ceramic Membrane Tube, the line operated continuously for 18 months with stable throughput and no chemical degradation. Filtration clarity improved by 25 %, and annual membrane replacement costs dropped by 40 %, proving long‑term reliability in cold beverage clarification systems.

• Solvent Recovery and Catalyst Separation in Fine Chemical Production

  ✅Key Advantages

  1. Corrosion Resistance in Strong Solvent Media
  Zirconia Ceramic Membrane Tube remains structurally stable in 10 wt % H₂SO₄ and 5 wt % NaOH environments, verified after 200 hours of immersion testing. It delivers steady filtration performance even when exposed to reactive organic solvents such as ethanol and acetone.
  2. Consistent Particle Retention for Catalyst Recovery
  In catalyst‑laden streams, the membrane achieves 98 % separation efficiency with minimal flux loss across multiple reaction cycles. The controlled pore geometry ensures effective recovery of catalyst particles sized 0.02–0.1 µm.
  3. Reduced Downtime through Chemical‑Cleaning Endurance
  After repeated solvent wash cycles, zirconia membranes maintain >90 % permeability recovery, minimizing maintenance interruptions. Plants report a 25 % reduction in total process downtime per year compared with polymeric systems.

  ✅ ️Problem Solved

  A fine‑chemical producer in Japan faced recurring shutdowns due to swelling and cracking of PTFE membranes during acidic catalyst filtration. ADCERAX® Zirconia Ceramic Membrane Tube replaced these modules, sustaining operation in a pH 1–13 solvent loop for over 14 months. Catalyst recovery efficiency increased from 89 % to 98 %, solvent purity improved to <50 ppm residuals, and annual filter‑replacement costs were cut by over 60 %.

• Treatment of High‑COD Oily Wastewater with Zirconia Ceramic Membrane Tube

  ✅Key Advantages

  1. High COD and Oil Rejection Efficiency
  In pilot wastewater tests, Zirconia Ceramic Membrane Tube achieved >90 % COD reduction and 99 % oil removal, maintaining stable flux under trans‑membrane pressure of 3 bar. Its fine pore structure effectively separates emulsified oils and suspended solids.
  2. Oxidative Cleaning Compatibility
  The zirconia membrane withstands NaClO 5000 ppm oxidative cleaning without surface corrosion or loss of integrity after 200 cycles, verified through SEM surface inspection. This enables aggressive chemical regeneration without membrane failure.
  3. Mechanical Strength for Backwash Operations
  The tube endures 6 bar reverse‑pressure backwashing, allowing operators to restore >85 % of original flux in a single cycle. Its mechanical stability reduces filter‑change frequency by 50 % in continuous wastewater systems.

  ✅ ️Problem Solved

  A textile wastewater plant in South Korea experienced rapid clogging and chemical degradation of polymer membranes, causing unplanned downtime every two weeks. After integrating ADCERAX® Zirconia Ceramic Membrane Tube, COD levels in discharge fell from 900 mg/L to <80 mg/L, while cleaning frequency was extended to once every 45 days. Operational uptime improved by 35 %, and annual maintenance costs dropped by 28 %, demonstrating the tube’s durability and cleaning efficiency in high‑COD effluent treatment.

To ensure stable performance, long service life, and optimal separation results, Zirconia Ceramic Membrane Tube users must follow proper operational and maintenance guidelines. This section outlines key precautions and best practices during installation, cleaning, storage, and system integration for industrial process users.

• Installation Guidelines

  1. Support Structure: A rigid frame or housing must be used to secure the membrane without bending stress. Improper alignment may lead to hairline cracks or seal failure under pressure.
  2. Sealing Integrity: Use compatible gaskets or O-rings that withstand CIP chemicals and elevated temperatures. Avoid metal-to-ceramic point loads which may cause microfractures.
  3. Orientation & Flow: Install with correct flow direction marked on the module. Reverse installation may disrupt pore gradient performance and reduce filtration efficiency.

• Cleaning and Maintenance

  1. Cleaning Agents: Use alkaline (NaOH) or oxidizing agents (NaClO ≤500 ppm) for periodic flushing. Avoid strong acids which degrade seals and mounting.
  2. Backflushing Frequency: Apply reverse pressure pulses every 8–12 hours of continuous use. This restores flux performance and minimizes membrane compaction.
  3. Drying Process: Before storage, dry membranes with filtered compressed air or ambient heat under 60°C. Avoid direct flame or sunlight exposure.

• Operation Parameters

  1. Pressure Control: Keep transmembrane pressure (TMP) below 0.4 MPa during normal operation. Overpressure can cause crack propagation within the ceramic layer.
  2. Temperature Range: Operate within 5–80°C for typical aqueous solutions. Higher temperatures may accelerate thermal expansion mismatch with housing materials.
  3. pH Compatibility: Zirconia membranes tolerate pH 3–10 continuously. For extreme pH cycles, monitor seal degradation and replace accordingly.

• Storage and Handling

  1. Protective Packaging: Always store the membrane in its original foam-lined crate. Avoid unprotected contact with hard objects during handling.
  2. Moisture Prevention: Keep in a dry, ventilated environment to prevent microbial growth inside pores. Use desiccant packs if humidity >60%.
  3. Inventory Rotation: Follow FIFO (First-In, First-Out) principle to minimize long-term storage exposure, especially in coastal or high-humidity areas.

FAQs about Zirconia Ceramic Membrane Tube

1. Q1: Can Zirconia Ceramic Membrane Tube maintain performance under high-temperature CIP cycles?
   Yes. The tube structure is thermally stable up to 400°C, allowing repeated steam sterilization or hot chemical cleaning without deformation or degradation. This ensures longer service intervals in hygienic industries like dairy and biotech.

2. Q2: How does Zirconia Ceramic Membrane Tube improve dairy filtration compared to polymer membranes?
   It provides a chemically inert and thermally stable filtration surface, preventing fouling and flavor loss in cold-processed milk, whey, and yogurt. Its non-reactive properties preserve nutritional and sensory profiles during repeated runs.
3. Q3: Is the membrane resistant to aggressive solvents in chemical applications?
   Yes. The zirconia structure tolerates strong acids, alkalis, and organic solvents, ensuring stable permeation rates in fine chemical and pharmaceutical solvent recovery. This reduces the frequency of shutdowns due to membrane failure.
4. Q4: How does the membrane perform in oily wastewater treatment?
   It provides excellent oil rejection rates and anti-fouling performance, even under high-COD or emulsified oil conditions. Its compatibility with oxidizing cleaners like NaClO ensures stable flux during high-load operation.
5. Q5: Can the Zirconia Ceramic Membrane Tube be used for continuous operation?
   Yes. With its mechanical strength exceeding 120 MPa and low membrane flux decline (<5% over 1000h), it supports continuous flow operations without loss of integrity, making it suitable for automated industrial systems.

• ⭐️⭐️⭐️⭐️⭐️

  “The Zirconia Ceramic Membrane Tube has dramatically improved our juice clarification line.” It delivers stable cold filtration without compromising aroma or color even after multiple CIP cycles. Maintenance time was reduced by over 40%, and no membrane swelling was observed under daily cleaning with NaClO.
  — Samantha L., Senior Process Engineer, Cypress Valley Beverage Technologies

• ⭐️⭐️⭐️⭐️⭐️
  “We use these tubes for solvent recovery in batch pharmaceutical synthesis.” Their resistance to aggressive solvents and temperature cycling is unmatched. We ran 2,000 hours without flux drop, which helped us reduce our cartridge replacement frequency significantly.
  — Lukas M., Plant Director, DeltaChem Research GmbH
• ⭐️⭐️⭐️⭐️⭐️
  “This is the only ceramic membrane we’ve tested that tolerates our high-COD, oil-rich wastewater.” Even under NaOH and high-pressure backwash, it retains consistent flux and high oil rejection. Downtime for module cleaning dropped from weekly to bi-monthly.
  — Erik J., Utilities Manager, Midshore Paper & Pulp Co.
• ⭐️⭐️⭐️⭐️⭐️
  “Installation was easy, and the support team gave us great guidance on process optimization.” We’ve achieved precise protein separation in dairy filtration without thermal denaturation, which wasn’t possible with polymer membranes.
  — Mira T., Technical Director, Northgate Dairy Solutions