Retrofit/ Replacement Toray TMR140-100S Flat MBR Membrane Module In Airport By JX Purification

Replacement Toray TMR140-100S Flat MBR Membrane Module In airport  By JX Purification

1. Project Background

As a major international aviation hub, an international airport’s wastewater treatment system originally employed Toray flat sheet membrane modules (TMR140-100S), which were responsible for treating wastewater generated by daily airport operations. As the equipment reached the end of its design service life, replacement became urgent. Meanwhile, the original product was officially discontinued, leaving the airport with no access to OEM spare parts. A reliable replacement solution was urgently needed to ensure stable operation of the wastewater treatment system and avoid disruptions to normal airport operations.

2. Project Challenges

1. OEM Discontinuation and Spare Part Shortage: Toray flat sheet membrane modules were discontinued, making OEM spare parts unavailable, and the project timeline was tight.

2. Strict Government Approval: As public infrastructure, airport projects are subject to stringent government approval requirements for compliance, safety, and stability. Approval authorities were particularly cautious about non-OEM equipment due to liability concerns.

3. Seamless Replacement Requirement: To minimize renovation costs and downtime, the new membrane modules were required to be directly installed on the existing Toray aeration tanks without any modifications to the existing basins, pipelines, or aeration systems.

4. Highly Corrosive Environment: Located in a coastal area, the airport falls under ISO 12944 C5-M (marine, extremely high corrosion) conditions, imposing extremely high requirements on the corrosion resistance of equipment materials.

3. Core Membrane Module Parameter Comparison

We can see frome the picture our MBR module can be adapted on the orignal Toray aeration box 1:1.   

4. Solution

To address the above challenges, we proposed the following customized solution:

Precise Dimension Matching for Seamless Connection

1. The existing Toray aeration tanks were precisely measured to ensure the new membrane tank’s bottom interface, hole positions, and height fully matched Toray standards.

2. Additional connection screw holes were added only at the interface between the membrane tank bottom and the aeration tank, in accordance with Toray drawings, ensuring seamless physical installation without any extra modifications.

3. The main body of the membrane tank retained our original design, guaranteeing structural strength and long-term operational stability.

Material Upgrade for High Corrosion Resistance

The new membrane module frame and interfaces were entirely constructed from SUS316L stainless steel. Compared to the original SUS316, its lower carbon content (≤0.03%) provides superior resistance to intergranular and pitting corrosion, perfectly adapting to the airport’s coastal, high-salt environment and extending service life.

Technical Equivalence with Enhanced Performance

1. The new modules utilized high-performance membrane sheets with an area of 1.5㎡ each, totaling 94 sheets, resulting in a total membrane area of 141㎡—nearly identical to the original Toray system’s 140㎡, ensuring equivalent treatment capacity.

2. The membrane pore size was optimized to 0.08 μm, delivering higher retention accuracy and more stable effluent quality. Through optimized membrane sheet arrangement and aeration system design, the new modules exhibited lower trans-membrane pressure (TMP), reduced energy consumption, and lower operational and maintenance costs.

Compliant Documentation to Facilitate Approval

1. A complete set of documentation was provided, including Material Test Reports (MTR), salt spray test reports (≥1000 hours), and third-party performance test reports, verifying compliance with relevant international standards.

2. Detailed technical equivalence and installation validation reports were issued, clarifying that the new modules represented a continuation of the original technology rather than entirely new equipment, effectively alleviating concerns among government approval authorities.

5. Project Outcomes

Successful Replacement and Stable Operation: The new membrane modules were successfully installed and commissioned, with key performance indicators such as system flux and TMP meeting or exceeding those of the original system, ensuring stable and compliant wastewater treatment.

Seamless Integration with Zero Modifications: Seamless connection to the existing Toray aeration tanks was achieved without any modifications to the existing basins, pipelines, or aeration systems, minimizing downtime and renovation costs.

Approval Granted with Controlled Risks: The project successfully passed government review through comprehensive technical documentation and compliance certifications, resolving the airport’s urgent needs and providing a successful model for similar future projects.

Cost Optimization for Long-term Benefits: Compared to purchasing an entirely new system, the replacement solution reduced costs by approximately 30%. The use of 316L stainless steel significantly extended equipment lifespan, lowering long-term maintenance costs.

6. Project Summary

The success of this project hinged on accurately addressing the client’s core pain points: “seamless replacement” and “compliant approval.” Through precise dimension matching, material upgrades, and comprehensive compliance documentation, we not only resolved the urgent issue of OEM discontinuation but also helped government authorities mitigate risks through professional technical solutions and services, enabling smooth project implementation. This case demonstrates that, even when OEM equipment is discontinued, professional replacement solutions can ensure stable system operation and effective cost control.

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