Case Study: Mizu Ultrafiltration Membranes Delivering Long-Term Reliable Performance at Sembcorp, Andhra Pradesh for Power Plant Water Treatment
- Theway Scholar
- Jan 31
- 3 min read
Introduction
Water plays a vital role in power generation facilities, where it is extensively used for boiler feed preparation, cooling systems, and utility operations. Process water in power plants often contains turbidity, suspended solids, colloidal silica, organic matter, BOD, and COD, which can adversely impact downstream treatment systems such as RO membranes if not effectively removed.
At Sembcorp, Andhra Pradesh, maintaining consistent feed water quality for the RO system was critical to ensure uninterrupted plant operations and long membrane life. To meet these requirements, Sembcorp partnered with Theway Membranes to implement Mizu Ultrafiltration (UF) Membranes. This case study highlights the proven durability, consistency, and long-term performance of Mizu UF membranes in a demanding power plant application.
The Challenge
Process water at Sembcorp, Andhra Pradesh presented several operational challenges due to fluctuating quality and fine contaminants. The key challenges identified were:
High Turbidity & Suspended Solids: Feed water contained turbidity levels up to 15 NTU with TSS up to 10 ppm, increasing fouling potential.
Colloidal Silica Presence: Fine colloidal particles posed a risk to RO membranes and downstream equipment.
Organic Load (BOD & COD): Organic matter increased fouling stress on membrane systems.
Operational Cost Control: Frequent membrane replacement or excessive cleaning would significantly increase O&M costs.
Long-Term Reliability: Continuous power plant operation demanded a robust UF system capable of stable performance over several years.
The plant required a dependable UF solution that could consistently protect the RO system while operating under variable feed conditions.
The Solution: Mizu Ultrafiltration Membranes
Following technical evaluation, Mizu UF Membranes from Theway Membranes were selected for their high fouling resistance, durability, and proven performance in industrial water treatment applications.
Key Features of Mizu UF Membranes
Advanced Ultrafiltration Technology: Efficient removal of suspended solids, colloidal silica, and organic contaminants.
Consistent Permeate Quality: Produces low-turbidity water suitable for RO pretreatment.
High Fouling Resistance: Designed to operate reliably under fluctuating process water conditions.
Robust & Durable Construction: Engineered for long service life in industrial environments.
Low Maintenance Operation: Reduced cleaning frequency and stable long-term performance.
Deployment at Sembcorp, Andhra Pradesh
The Mizu UF system was commissioned in 2019 at the Sembcorp power plant in Andhra Pradesh as a pretreatment system for RO. The system treats process water with a capacity of 2 m³/hr, ensuring consistent RO feed quality.
Key Deployment Details
Location: Sembcorp, Andhra Pradesh
Industry Segment: Power Plant
Technology: Mizu – Ultrafiltration
Source Water: Process Water
User Application: RO Pretreatment
Capacity: 2 m³/hr
Commissioning: 2019
Results and Impact
Field validation of Mizu Ultrafiltration Membranes at Sembcorp has demonstrated exceptional long-term performance and operational stability.
Key Results Achieved
Consistent Permeate Quality:
Turbidity: < 1 NTU
Suspended Solids: < 1 ppm
SDI: < 3Achieved consistently over 72 months, even with feed turbidity up to 15 NTU, TSS up to 10 ppm, and SDI < 6.
Extended Membrane Life:No membrane replacement required as of August 2025, confirming excellent durability.
Reliable RO Protection:Stable UF permeate quality ensured effective protection of downstream RO membranes.
Reduced Operational Costs:Long membrane life and low fouling characteristics minimized cleaning frequency and maintenance expenses.
Operational Continuity:Consistent UF performance supported uninterrupted power plant operations.
Conclusion
The successful long-term operation of Mizu Ultrafiltration Membranes at Sembcorp, Andhra Pradesh highlights Theway Membranes’ expertise in delivering robust and reliable filtration solutions for power plant applications. The UF system consistently handled turbidity, suspended solids, colloidal silica, and organic matter while delivering high-quality permeate for RO pretreatment.
By adopting Mizu UF technology, Sembcorp achieved enhanced system reliability, extended membrane life, reduced operating costs, and stable water quality—reinforcing the importance of advanced ultrafiltration in power plant water management.
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