Advanced Treatment of Polyethylene Terephthalate (PET) Using SATOORNIK Gen-I

By: Dr.-Ing. Mitra Nikpay

Funded by SATOORNIK UG

© [21.03.2025] Dr. Mitra Nikpay and SATOORNIK UG. All rights reserved. No part of this report may be reproduced, distributed, or used without proper authorization.

INTRODUCTION

Microplastics (MPs), defined as plastic particles smaller than 5 mm, have become a significant environmental pollutant, contaminating terrestrial, freshwater, and marine ecosystems. Introduction. Polyethylene terephthalate (PET) is one of the most commonly used thermoplastic polymers globally, prized for its mechanical strength, thermal stability, chemical resistance, and moldability. It is known as polyester in the textile industry and PET in packaging applications. Its versatility has made it indispensable in the production of clothing fibers, food and beverage containers, and various consumer goods. In 2022, global PET production of 25.47 million metric tons with the packaging segment is about 69.5%, underscoring its widespread demand across numerous industries. However, the increasing consumption and often improper disposal of PET products have led to significant environmental concerns, particularly regarding their degradation into micro- and nanoplastics (MNPs). PET microplastics have been detected in marine and freshwater environments, agricultural soils, and even atmospheric samples, reflecting their pervasive distribution [1].

Emerging studies have highlighted the potential risks PET microplastics pose to both environmental health and biological systems. For instance, PET MPs have been observed to accumulate in the gastrointestinal tract, liver, kidneys, and gills of aquatic species such as Xenopus laevis tadpoles, where their presence has been linked to impaired immune function and heightened susceptibility to viral infections. In mammalian models, particularly swine, ingestion of PET MPs has been shown to cause notable histological changes in the duodenum and alterations in the enteric nervous system, especially at higher exposure doses. Additionally, PET MPs have been reported to negatively impact metabolic parameters in mice, reducing body weight and fecal output, possibly through disruptions in gut microbiota and hormonal imbalances [2,3,4].

On a cellular level, in vitro studies involving human brain vascular pericytes have demonstrated that PET micro- and nanoplastics can transiently disrupt mitochondrial functions, specifically impairing respiration and ATP production. Beyond organisms, PET MPs also interfere with soil microbiomes and nitrogen cycles, reducing bacterial diversity and altering greenhouse gas emissions. In wastewater treatment systems, their accumulation has been shown to impair microbial community structure and the performance of membrane bioreactors, with adverse effects on sludge properties [5,6,7].

Given these widespread ecological and physiological impacts, mitigating the release and accumulation of PET microplastics has become a critical environmental priority. Efficient separation and filtration technologies are key to addressing this challenge. In this context, the present study aims to evaluate the effectiveness of the SATOORNIK Gen-I filtration system in removing PET microplastics from contaminated water sources. Preliminary results demonstrate a significant removal efficiency, achieving an average reduction of 99.89% across three test conditions. The mass of microplastics captured through this process equates to levels commonly found in thousands of liters of polluted water, underscoring the potential scalability of this technology for industrial and municipal wastewater treatment applications.

MATERIALS AND METHODS

PET Particles:

Three distinct tests were conducted using different PET particle samples. The Tests utilized PET particles produced from 100% PET material. The quantities of PET particles used in each test are summarized in Table 1.

Table 1 Sample properties used in the tests

Figure 1 displays microscopic images of PET materials used in the tests. Figure 1a shows PET particles utilized in tests before applying the SATOORNIK Gen I, while Figure 1b shows the results of the test after applying filtration.

Figure 1 Microscopic images of PET materials used in testing. (a) Before applying the filter and (b) after applying the filter.

The size distribution of the PET particles applied in tests is shown in Figure 2. The mean particle size was 170 µm and the lowest size measured 18 µm. The densities of the PE particles, as a mean of HD and LD types, were 1.40 g/cm³, which were used to calculate mass and volume properties. Each test was conducted with 500 mL of tap water mixed with the respective PET particles to create a controlled medium for evaluating filtration efficiency. The water samples were agitated thoroughly to ensure uniform particle distribution before testing.

Figure 2 Graph of particle size distribution for PET samples used in tests

SATOORNIK Gen-I Filtration System:

The SATOORNIK Gen-I is a full-scale filtration unit specifically designed for the continuous separation of microplastics, including PET particles. Engineered for high efficiency, the system is optimized to capture even the smallest particles in water.

For each of the three tests, 500 mL water samples containing PET particles were processed through the SATOORNIK Gen-I system. The system operated continuously throughout the testing, with no washing or maintenance performed between tests. This approach aimed to evaluate the system's performance over multiple cycles, simulating real-world conditions of continuous operation.

Sampling and Analysis:

Samples were collected before and after filtration for each of the three tests. The pre-filtration sample represented the initial condition of the water, while the post-filtration sample represented the water after passing through the filtration unit.

The results were visually confirmed using a microscope. The comparison between the pre-and post-filtration samples allowed for the evaluation of the filtration efficiency in removing the PET particles.

Results

The filtration efficiency of SATOORNIK Gen-I was evaluated by measuring particle concentrations before and after filtration. The high-efficiency percentage mean of 99.76% demonstrates the device's effectiveness in removing two different particles from water (See Table 2).

Table 2 Summary of Filtration Efficiency for SATOORNIK Gen-I Across Tests T1, T2, and T3

Comparison to Real-World Wastewater Treatment Plant (WWTP) Concentrations

The filtration efficiency of the SATOORNIK Gen-I system was tested across three samples of PET particles, with masses of as Table 1. The system achieved high filtration efficiencies, ranging from 99.87% to 99.99%, with increasing particle concentrations reflecting real-world microplastic pollution levels.

In each test, PET particle concentrations were significantly higher than typical wastewater treatment plant (WWTP) influent concentrations, calculated up to a 1,836-fold increase relative to the real-world benchmark of 102 µg/L.

This cumulative test load equates to 3255.9 liters of real-world polluted water, indicating that the SATOORNIK Gen-I was able to handle continuous high-contamination levels effectively without requiring device maintenance or cleaning between tests. This result emphasizes the device’s robustness in treating PET pollution at elevated concentrations typically found in industrial wastewater.

The graph of Figure 3. demonstrates the robust filtration performance of the SATOORNIK Gen-I over three sequential high-concentration tests (T1, T2, T3), showcasing its ability to maintain or slightly improve efficiency under continuous operation. The data highlights the high filtration efficiency of the SATOORNIK Gen-I system, exceeding 99.99 % across all tests.

Figure 3. Efficiency of SATOORNIK Gen-I across three test samples. The graph demonstrates the consistent performance of the filtration system, with efficiency ranging from 99.87% to 99.99%, confirming its effectiveness in removing PET particles across multiple tests.

Conclusion

The findings of this study demonstrate that the SATOORNIK Gen-I filtration system, tested at full-scale operation, is a highly effective solution for mitigating PET microplastic pollution in both environmental and industrial contexts. Despite the use of PET particle concentrations far exceeding typical real-world pollution levels, the system consistently achieved outstanding filtration efficiencies, averaging over 99.92 %, and reduced particle concentrations to near undetectable levels across all tests. This exceptional performance was maintained under varying particle masses and test conditions, underscoring the reliability and robustness of the technology.

The full-scale testing offers valuable insights into the practical application of the SATOORNIK Gen-I system for addressing PET pollution, a growing concern in both industrial waste streams and environmental contamination. As PET microplastics present significant challenges to wastewater treatment facilities and ecosystems, the system's success highlights its potential to combat critical environmental and public health issues.

Furthermore, the tests confirmed the system’s ability to operate continuously without any decline in performance, emphasizing its suitability for long-term, uninterrupted use in a variety of real-world settings. In conclusion, the SATOORNIK Gen-I filtration system emerges as a transformative solution for addressing PET microplastic pollution, contributing to cleaner water, healthier ecosystems, and a more sustainable future.

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