Experimental Study and Optimization of Low-Cost Clay–Carbonate Waste Membranes for Textile Effluent Microfiltration

This study focuses on the design and development of a novel flat ceramic microfiltration membrane produced from low-cost and environmentally sustainable raw materials. The approach relies on the valorization of carbonate waste, a by-product generated in large quantities by industrial processes, in combination with natural clay, which serves as a suitable binding and structural component. The integration of carbonate waste into the membrane composition not only provides an effective strategy for waste recycling but also reduces production costs, thereby addressing both environmental and economic concerns.

The fabrication process was systematically optimized through a statistical design methodology, which allowed the simultaneous evaluation of key synthesis parameters, namely the waste content, sintering temperature, and sintering duration. This methodological framework facilitated the identification of optimal processing conditions while minimizing the number of experimental trials required. The prepared membranes exhibited favorable physicochemical characteristics and satisfactory mechanical strength, making them suitable for practical applications. In addition, they demonstrated high chemical stability, particularly under harsh operating conditions, which is a crucial requirement for long-term use in wastewater treatment.

When tested with real textile effluents, the ceramic membranes showed efficient purification performance, confirming their capacity to reduce turbidity and organic load. These results highlight the potential of carbonate waste–clay ceramic membranes as a promising and sustainable alternative for industrial wastewater treatment and as a valuable contribution to the advancement of circular economy strategies in environmental engineering.