Performance assessment of the indigenous ceramic UF membrane in bioreactor process for highly polluted tannery wastewater treatment

The present study evaluates the performance of an indigenously developed ceramic ultrafiltration (UF) membrane in a lab-scale membrane bioreactor (MBR) process to treat real tannery effluent with varying organic loading (1500–6000 mg/L). UF membrane was prepared by the coating of bentonite clay on tubular clay-alumina macroporous support. The membrane surface was characterized by scanning electron microscopy, Fourier transform infrared spectroscopy, X-ray diffraction, X-ray photoelectron spectroscopy, BET adsorption–desorption, contact angle measurement, and atomic force microscopy. In the side-stream MBR process, sewage sludge from a local sewage treatment plant was used as an activated sludge source with a constant sludge retention time of 30 days. Membrane filtration was performed in cross-flow mode using a single-channel membrane module. Artificial neural network (ANN) modeling tool was used to analyze the influence of various independent input variables, namely, the hydraulic retention time (4–10 h), mixed liquor suspended solid (MLSS) concentration (2–8 g/L), and influent COD concentration (1500–6000 mg/L) on COD removal (%) with feed-forward backpropagation method. Membrane study was done at a transmembrane pressure of 4.3 bar and feed flow rate of 7.5 L/min to observe the flux declination and fouling of the UF membrane with time. Average COD and BOD concentrations obtained in the treated effluent were 147.56 and 31 mg/L, respectively, and chromium concentration was < 0.1 mg/L; thus, treated effluent quality was found to be suitable for industrial recycling purposes apart from the safe environmental discharge. An in-depth study was undertaken to understand the removal mechanism in the MBR process, nature and extent of membrane fouling, changes in the morphology of the UF membrane, surface wettability, and surface topology by detailed surface characterization of the membrane pre- and post-filtration.