Abstract In this study, low‐cost ceramic membranes were fabricated from industrial wastes (red mud and fly ash) for the removal of methylene blue (MB) dye from aqueous solutions. Ceramic membranes were produced using a uniaxial compaction approach and subsequently subjected to thermal treatment in the range of 600–900°C to examine the effect of sintering conditions on structural characteristics and filtration behaviour. A comprehensive set of analytical techniques, including thermogravimetric analysis (TGA), X‐ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), field emission scanning electron microscopy (FESEM), and energy‐dispersive X‐ray analysis (EDX), was employed to evaluate phase composition and microstructural features, confirming the formation of a stable aluminosilicate framework with a well‐connected pore structure. The membrane sintered at 700°C exhibited an optimal balance between porosity, mechanical integrity, and permeability. As the sintering temperature increased, porosity decreased due to progressive densification and grain growth. Filtration experiments performed at transmembrane pressures of 0.2–0.8 bar and MB concentrations of 10–110 mg · L −1 showed dye rejection exceeding 94% under low‐pressure and low‐concentration conditions. A slight decline in dye rejection at higher pressure and concentration was attributed to concentration polarization and partial pore blockage. The operating parameters, namely transmembrane pressure and feed concentration, were optimized using response surface methodology (RSM) based on a central composite design (CCD) to evaluate their effects on permeate flux and dye rejection. The results demonstrate that red mud–fly ash–derived ceramic membranes offer a sustainable and cost‐effective alternative for dye‐laden wastewater treatment.
Hirudkar et al. (Tue,) studied this question.