Fabrication and Optimization of Low-Cost Clay–Marble Membranes for Textile Effluent Microfiltration

This study presents the development of an innovative flat ceramic microfiltration membrane produced from low-cost and environmentally friendly raw materials. The approach is based on the valorization of marble waste powder in combination with natural clay, thereby addressing both the need for effective wastewater treatment and the sustainable reuse of industrial by-products. The fabrication process was carefully optimized through a statistical strategy using the Doehlert experimental design within the response surface methodology framework. This allowed for the systematic evaluation of key synthesis parameters, including marble waste content, sintering temperature, and dwell time, in order to identify conditions leading to high-performance membranes.

The optimized membranes exhibited a well-balanced combination of structural, mechanical, and functional characteristics, making them suitable for microfiltration applications. Their porosity and microstructural uniformity ensured efficient liquid–solid separation, while their mechanical strength provided stability under operating conditions. In addition, the materials demonstrated strong resistance to aggressive chemical environments, particularly under alkaline conditions, thus confirming their durability for long-term use.

Performance tests with real industrial wastewater further confirmed the effectiveness of the membranes. Substantial improvements in water clarity and notable reductions in organic load indicators were observed, highlighting their ability to remove suspended solids and partially reduce dissolved contaminants.

Overall, this research demonstrates the potential of sustainable ceramic membranes based on natural clay and marble waste as viable, eco-friendly alternatives to conventional filtration materials. By combining waste valorization, low production costs, and efficient water purification capacity, these membranes represent a promising solution for industrial wastewater treatment and resource-efficient water management.