Recovering valuable raw materials from liquid waste streams for our global customers is a key area to Xtract’s business.
Xtract has enjoyed international success with the installation of its Glaze and Slip Reclamation Systems within the ceramics industry for more than 20 years.
Xtract’s technology, which is based on crossflow filtration using specially designed robost ceramic membranes, has also been employed to recover valuable Zircona from waste slurry for the manufacture of metal pour filters within the investment casting industry. The technology can also be used for many other industrial liquid waste streams, either for material recovery or for the concentration of waste for disposal.
Glaze Reclamation Systems
Many ceramics manufacturers around the world are using Xtract’s advanced technology to meet the highest of process standards and efficiencies. They are consistently enjoying significant cost savings by recovering glaze from their manufacturing process and contributing ultimately to a ‘zero waste policy’.
Xtract’s glaze reclamation systems are designed to process dilute washings containing glaze overspray, delivering two liquid streams.
The first stream is the recovered glaze at such a density and consistency that it can be blended with virgin glaze for re-use, providing the customer with tangible savings from the moment the system is commissioned.
The second stream is filtered water which can be used as clean process water within the factory, or can be safely disposed of.
Xtract offers its customers the opportunity to save money by reclaiming up to 100% of the raw material within the captured waste stream by integrating an Xtract system into the manufacturing process. The Xtract system provides precise density control in a reliable and simple to operate single process. High reliability and low maintenance costs give high plant availability which is essential to the customer’s process.
The Xtract Process can significantly reduce waste handling and processing through conventional and expensive waste water treatment process plant. The Xtract system removes the necessity to discharge harmful constituents to drain and provides an assured quality of its recycled water enabling efficient re-use. The Xtract system significantly improves the environmental standing and accreditation of any company employing its technology.
Oil Water Separation
In some cases oil/water separation can reduce soluble oil disposal costs by as much as 75%, making the installation of an Xtract filter – either static or mobile – an extremely attractive prospect. These units are of particular benefit to chemical, gas, refining and petroleum process plants.
Xtract’s innovative filtration solutions can also be applied to the treatment of contaminated water stored at licenced waste sites for treatment and safe disposal. Disposal of large quantities of waste is a growing problem for owners and operators as increasingly severe global legislation is focusing their attention on finding a cost effective and environmentally acceptable answer.
Xtract employs a unique ceramic membrane which operates as a crossflow filter, whereby the incoming contaminated flow passes along the length of the filter rather than at right angles to the filtration surface. Driven by a difference in pressure, the filtered feedstock passes through the body of the filter to create a clean permeate phase. In the meantime, the retentate phase, including oil, bacteria and suspended solids, is kept in the flow and passes to the filter outlet. The fine pore size of the ceramic media means that sub-micron particles can be removed to give a better than 10mg/l oil and suspended solids in the resulting cleaned water.
In independent verification trials, these ceramic membranes were put through their paces on oily formation water onshore. These trials resulted in consistently reduced oil-in-water to less than 5 mg/l, removed all sulphate reducing bacteria and kept total suspended solids below 10 mg/l.
The technology can be used to filter a variety of waste materials, waste oil and water emulsions and waste coolants.
Slip Reclamation Systems
Slip reclamation is a major issue in the ceramic industry, particularly in the traditional sector, and Xtract has a proven track record in delivering outstanding results.
The Xtract slip recovery system can be operated as either a batch or continuous process. Excess slip is concentrated to much higher density levels which greatly increases solids recovery. The resulting concentrated suspension is reintroduced into the slip making process, thus significantly reducing raw material inventory and purchasing costs.
The benefits of the Xtract process are clear. We have already demonstrated more than a three-fold increase in solids recovery while these installations mean a big reduction in waste disposal to landfill. The combined cost savings quickly make an impact. A payback period of 12-18 months is not uncommon.
There are many Xtract installations worldwide delivering the real and tangible cost savings and process benefits. It is normal for Xtract’s customers that, following commissioning and integration of the Xtract system, they immediately expect to achieve 100% Slip utilisation, together with a significant amount of clean re-usable process quality water.
Zirconia Reclamation Systems
The reclamation of zirconia lost within industrial processes can offer significant savings to the manufacturer. However, due to the viscous nature of the slurry, the reclamation process is enormously challenging.
Xtract has used its experience in the reclamation of submicron viscous slurries from industrial processes to develop a zirconia reclamation system, saving money every day for its clients.
Liquid Waste processing Systems
The Xtract systems are sufficiently robust and technically capable of facing up to today’s demanding liquid waste processing protocols.
Pre-treatment, large particle separation and Xtract crossflow filtration combine to achieve efficient waste concentration, reducing disposal volumes and costs. Produced filtrate is recycled into the process to reduce water consumption.