100 m³/D Integrated Skid-Mounted Ultrafiltration (UF) System

Introduction

Providing a safe, reliable, and hygienic supply of utility water for employee accommodations is a critical operational priority for modern industrial enterprises. Recently, Globaluf Water Treatment Co., Ltd. engineered, manufactured, and delivered an integrated 100 m³/day (5 m³/h) Skid-Mounted Ultrafiltration (UF) System with an Advanced Oil Separation System (OSS) for an enterprise worker hostel complex in Pasir Gudang, Malaysia.

The containerized, plug-and-play solution treats a challenging local pond water source heavily influenced by surface runoff and industrial discharge, converting it into high-quality domestic utility water optimized safely for employee showering, washing, and general facility cleaning.

The Challenge

The primary raw water source for this project is an open catchment basin known locally as “Lulu Pond,” which collects a mixture of tropical rainwater and surrounding industrial surface runoff. Water quality reports revealed significant seasonal spikes in total suspended solids (TSS) and, most critically, Oil & Grease concentrations peaking up to 9 mg/L.

Free and emulsified oils present a severe operational hazard to ultrafiltration membranes, causing rapid, irreversible fouling and severe flux decline if not thoroughly mitigated. To ensure safe domestic utilization at the worker hostels, the client required a robust, small-footprint system capable of consistently removing complex hydrocarbon chains, reducing turbidity, eliminating pathogens, and maintaining fully automated operation under tropical environmental conditions (25°C–30°C).

Globaluf Solution: Integrated Multi-Stage Treatment

Our engineering team designed an advanced process route split into two synchronized standalone blocks: an Advanced Dosing & Oil Separation Pretreatment System (OSS) and a Fully Automated Skid-Mounted Ultrafiltration (UF) System. By knocking down the high oil load during pretreatment, the downstream UF membranes remain highly protected, ensuring a long asset lifespan and stable operational efficiency.

The Optimized Process Route: Submersible Intake Pump → Coagulation Tank A (PAC + NaOH @ 64 rpm) → Flocculation Tank B (PAM @ 32 rpm) → Slanted-Plate Sedimentation Clarifier → Coalescing Oil Interceptor → Buffer Tank → Automated Sand Filter → Activated Carbon Filter → 100 μm Security Cartridge Filter → Out-to-In PVC Ultrafiltration (UF) Modules → Inline UV Sterilizer → Safe Product Water Storage

Watch the Project Walkthrough

Experience the 100 m³/D skid-mounted UF system in action, featuring integrated oil separation and fully automated PLC control.

Explore the Core Components of the Malaysian Project

1. Advanced Multi-Stage Oil Separation System (OSS)

To reduce Oil & Grease from 9 mg/L to under 1 mg/L, the wastewater undergoes dual-speed chemical conditioning. In Reaction Tank A, a rapid agitator running at 64 rpm quickly flashes PAC (30–50 mg/L) and NaOH to optimize coagulation and adjust pH. The water then flows into Reaction Tank B, where a slow-speed agitator running at 32 rpm meticulously builds heavy flocs using PAM (1–2 mg/L) without shearing them. Micro-flocs separate across a slanted-plate clarifier and drop into a sludge hopper for a periodic 8-to-12-hour purge, while surface hydrocarbons are skimmed out through a specialized coalescing oil interceptor baffle wall.

2. Integrated Skid-Mounted Ultrafiltration (UF) Core Unit

The heart of the advanced purification loop is our compact, highly integrated engineering skid housing the primary filtration modules and automated automation nodes.

Front profile of the Globaluf 5 m³/h integrated skid-mounted UF system, highlighting the robust structural framing, out-to-in membrane array, and the localized Siemens PLC automated control station.

3. Comprehensive Pre-filtration & Automated CIP Station

Positioned directly behind the ultrafiltration array is a high-efficiency multi-media block featuring dedicated automated multi-port valve manifolds alongside the systems supporting chemical maintenance infrastructure.

Rear engineering view showcasing the dual-tank multimedia filtration system (Sand & Activated Carbon), 100 μm heavy-duty security cartridge filter housing, and the integrated Chemical Clean-In-Place (CIP) storage tank.

4. Factory Acceptance Testing & Quality Assurance

Before overseas deployment to Southeast Asia, the entire system is subjected to a rigorous wet-testing protocol inside our assembly facility to guarantee field-readiness.

Side view of the system undergoing rigorous structural hydrostatic pressure testing, instrument calibration, and loop checks prior to dispatch.

5. Efficient Containerized FCL Export Logistics

Designed with absolute spatial efficiency in mind, both the complete UF skid and the accompanying OSS components were engineered to consolidate perfectly into a single freight package.

Secure maritime loading of the complete water treatment assembly into a single 20ft Full Container Load (FCL), eliminating external crating needs and lowering logistics overhead for our client.

Technical Process Engineering Highlights

• High-Performance Membranes: Built with 3 premium 54 m² out-to-in PVC hollow fiber ultrafiltration modules providing a total active filtration area of 162 m². It operates at a stable, conservative flux rate of 30.8 L/(h·m²) to prevent premature fouling from lingering hydrocarbons.
• Smart Automation Network: Controlled by a localized Siemens PLC and HMI touchscreen controller linked directly to continuous analog level sensors. The system automatically shifts between production, backwash cycles, and chemically enhanced backwashes (CEB) based on cross-membrane pressure (TMP) variations.
• Targeted CIP Chemistry: Due to the persistent tropical heat (25°C–30°C) and presence of organic oils, the automated clean-in-place maintenance loops feature an optimized recipe using 0.1% NaOH combined with 500 ppm NaClO to dissolve bio-films and greasy residues, supplemented by a quarterly 0.2% Citric Acid loop for scale removal.

The Result

The integrated 100 m³/D Skid-Mounted UF plant has successfully transformed local catchment runoff into a reliable, consistent, and exceptionally safe utility water asset. Final water analysis confirms a turbidity drop to below 0.1 NTU, a complete reduction of active grease and oils to non-detectable limits, and zero pathogen indicators following final UV sterilization.

By delivering this integrated treatment platform to our Malaysian partner, the worker hostel facility has achieved total utility independence from unreliable surface pools. The facility now provides clean, compliant, and odorless water for its workforce, demonstrating Globaluf’s signature focus on engineering robust solutions for demanding global environments.

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