Ceramic Membrane Filtration System (CMFS)

A large, Fortune-500 Company had a metal parts washer application and they were not pleased with the results they were getting. The oil on the metal parts was systematically washed off, removing the oil, and residual surfactant remained on the parts. The particle contaminants in the solution and the residual surfactant fouled the polymeric membrane of the filtration system being used.

Polymer Membrane System

Continued clogging slowed down the overall process, increased disposal costs, increased operating costs, compromised product quality, and increased the need to shut down to clean and de-sludge. Not only did the suspended solids and surfactant foul the membrane, but also the temperature and pH became troubling issues that needed to be addressed.

The solids and surfactant build-up created additional waste disposal costs. The problematic filtration system was generating roughly 8000 gallons/week of waste oil and the company was spending 32 cents/gallon to haul away the hazardous material collected during the filtration process.

The high disposal costs that accrued were not a welcome result. Something had to change. When the automotive parts manufacturer contacted The Hilliard Corporation, Hilliard knew that they could reduce those costs and help the company gain other benefits as well.

The customer was hoping to either improve upon or eliminate some of the shortcomings of their current system. Their primary objective was to reduce the need to haul spent cleaner solution off-site for further treatment. Removal of emulsified oil and grease to less than 10 PPM was achieved.

When Hilliard analysed the company's problem, results, and objectives, they suggested using the Hilco Ceramic Membrane Filtration System (CMFS), which would work much more effectively over the polymer membrane system, a system that was not performing to their satisfaction.

Hilco Ceramic Membrane Filtration System (CMFS)

The Hilliard Corporation also manufactures a line of wastewater and filtration equipment under its Star Filters division, which was considered for use in this particular application. However, the Hilco Ceramic Membrane provided a more suitable remedy, given the customer goals and product capabilities.

The Hilco CMFS is very effective at dramatically lowering oily wastewater disposal costs. The ultra-filtration system uses high-velocity fluid "crossflow" technology across the face of the membrane. The oil-free water passes through the ceramic membrane while the oily waste is concentrated in a process reservoir.

Waste Stream Disposal

Depending on the particular waste stream disposal, volumes can be reduced as much as 20 times. The system is designed to accept three different micron-rated membranes (0.2 μm, 0.01 μm, and 0.005 μm) in order to meet all specific local discharge ordinances. The 0.01-μm membrane was employed for this inorganic membrane waste application.

Use of the Hilco CMFS reduced operating costs by eliminating the frequent need to dump the tanks, cut down on hazardous waste, reduced chemical use, and lowered administrative compliance costs. The Ceramic Membrane Filter can accept a pH up to 13 and tolerates temperatures up to 190°F.

The processed stream still approaching influent temperature is returned directly to the parts washer machine, resulting in significant energy savings by eliminating the need to reheat the solution.

Hilco Ceramic Membrane Filtration System, nominal 7,000 gal/day capacity model.

Labor and maintenance costs were reduced because the system only needed to be cleaned after 5-7 days of operation. The Hilco Ceramic Membrane System is well suited for other applications, performing micro-filtration and ultra-filtration tasks involving wastewater, mop water, and other harsh solvent- and chemical-based applications. With its versatility and multi-functionality, payback occurs in a short timeframe.

A complete, integrated filter assembly system with a very high packing density (membrane area/module volume) is one of the many benefits of this ultrafiltration system.

Also, fewer membrane modules are needed which results in lower capital and operating costs, as well as reduced floor space requirements. Metal part product quality is significantly improved and rework frequency has been reduced. Hilco Ceramic Membrane Filtration System, nominal 7,000 gal/day capacity model.