At a former copper mine in Salt Lake City, Utah, a groundwater remediation effort is demonstrating how innovation can transform water treatment in the mining sector. The site, contaminated after 140 years of mining operations, faces high levels of total dissolved solids and sulphate concentrations exceeding US Environmental Protection Agency (EPA) limits. The water treatment plant (WTP) relies on reverse osmosis (RO) technology to meet EPA regulations, but high flow rates and challenging feed waters led to rapid membrane fouling, frequent cleanings, and increased operating costs. Enter Aqua Membranes’ Printed Spacer Technology®, a solution that has reduced membrane cleaning frequency by a staggering 83%.
The heart of the issue lies in feed spacer fouling. Traditional mesh netting spacers in spiral wound RO membranes trap solids and biological growth, necessitating frequent cleanings. At the Utah site, monthly cleanings were the norm to maintain system performance. Aqua Membranes’ innovation lies in its 3D-printed spacers, built directly on the membrane surface. The WTP team retrofitted their system with Aqua Membranes’ ECOBW505 membrane design, completing the process in just three days in October 2024.
The results speak for themselves. After eight months of operation, the first membrane cleaning occurred 170 days post-installation, a stark contrast to the previous monthly cleanings. This 83% reduction in cleaning frequency translated into significant savings. Chemical usage decreased, downtime reduced by 15 days annually, and membrane life extended, lowering replacement costs. The plant expects a 16-month return on investment from cleaning-related savings alone, with total lifetime savings projected to reach hundreds of thousands of dollars.
Craig Beckman, CEO of Aqua Membranes, highlights the broader implications: “This isn’t just about cleaning less often. It’s about rethinking what’s possible with RO technology. We’re seeing higher performance, greater energy efficiency, and more compact, scalable solutions.” The 3D-printed spacer technology increases water flow rates by up to 20%, delivers up to 30% energy savings through lower pressure drops, and offers standard dimensions for seamless integration into existing systems.
The Utah case study underscores a shift in the mining industry’s approach to water treatment. As mines grapple with stricter environmental regulations and the need for sustainable practices, innovations like Aqua Membranes’ technology are gaining traction. The potential to reduce operational costs, improve efficiency, and extend the life of critical equipment is a compelling proposition.
Moreover, the success at the Utah site raises questions about the broader application of 3D-printed spacer technology. Could this innovation revolutionize water treatment not just in mining, but in other industries facing similar challenges? The mining sector, often at the forefront of adopting cutting-edge technologies, is once again setting a precedent for others to follow.
In a field where reliability, cost control, and compliance are paramount, Aqua Membranes is challenging the status quo. The Utah mine’s experience serves as a testament to the power of innovation in driving operational excellence and sustainability. As the industry continues to evolve, such advancements will be crucial in meeting the demands of a changing regulatory landscape and a growing focus on environmental stewardship.