Transferring bulk chemistry to interfacial synthesis of TFC-membranes to create chemically robust poly(epoxyether) films

Polymerization of Epoxides at a Static Oil-Alkaline Water Interface

'On-water' catalysis entails the significant enhancement of a chemical reaction by water, even when those reactions are known to be water-sensitive. Here, the findings about the anionic ring opening polymerization of epoxides at the static interface between oil and alkaline water are shared. Unexpectedly, high molar mass fractions are observed with the interfacial system presented herein, albeit at very low conversions (< 5%). Styrene oxide, a notably unreactive epoxide, is chosen as the model compound to investigate the influence of several reaction parameters (i.e., pH, type of the initiator salt, polymerization time, interfacial area, solvent, shaking) on the polymerization. Poly(styrene oxide) (PSO) with an Mn of 5300 g mol-1 is observed via MALDI-ToF MS, with species of at least 8000 g mol-1. The feasibility of expanding the system to (cyclic) aliphatic and aromatic epoxides, and glycidyl ethers is also explored. The system appears to promote polymerization of epoxides that position at the interface, in such a way that initiation and propagation can occur. A mechanistic interpretation of the interfacial polymerization is suggested. The surprising results obtained in this work urge to revisit the role of water in ionic polymerizations.

Monolithic Polyepoxide Membranes for Nanofiltration Applications and Sustainable Membrane Manufacture

The present work details the development of carbon fiber-reinforced epoxy membranes with excellent rejection of small-molecule dyes. It is a proof-of-concept for a more sustainable membrane design incorporating carbon fibers, and their recycling and reuse. 4,4'-methylenebis(cyclohexylamine) (MBCHA) polymerized with either bisphenol-A-diglycidyl ether (BADGE) or tetraphenolethane tetraglycidylether (EPON Resin 1031) in polyethylene glycol (PEG) were used to make monolithic membranes reinforced by nonwoven carbon fibers. Membrane pore sizes were tuned by adjusting the molecular weight of the PEG used in the initial polymerization. Membranes made of BADGE-MBCHA showed rejection of Rose Bengal approaching 100%, while tuning the pore sizes substantially increased the rejection of Methylene Blue from ~65% to nearly 100%. The membrane with the best permselectivity was made of EPON-MBCHA polymerized in PEG 300. It has an average DI flux of 4.48 LMH/bar and an average rejection of 99.6% and 99.8% for Rose Bengal and Methylene Blue dyes, respectively. Degradation in 1.1 M sodium hypochlorite enabled the retrieval of the carbon fiber from the epoxy matrix, suggesting that the monolithic membranes could be recycled to retrieve high-value products rather than downcycled for incineration or used as a lower selectivity membrane. The mechanism for epoxy degradation is hypothesized to be part chemical and part physical due to intense swelling stress leading to erosion that leaves behind undamaged carbon fibers. The retrieved fibers were successfully used to make another membrane exhibiting similar performance to those made with pristine fibers.

Use of Ionic Liquids and Co-Solvents for Synthesis of Thin-Film Composite Membranes

Polyamide (PA) thin-film composite (TFC) membranes are commonly applied in reversed osmosis (RO) and nanofiltration (NF) applications due to their thin, dense top-layer, and high selectivity. Recently, the conventional organic phase (i.e., hexane) during interfacial polymerization (IP) was replaced by less toxic ionic liquids (ILs) which led to excellent membrane performances. As the high price of most ILs limits their up-scaling, the potential use of inexpensive Aliquat was investigated in this study. The thin-film composite (TFC) membranes were optimized to remove flavor compounds, i.e., ethyl acetate (EA) and isoamyl acetate (IA), from a fermentation broth. A multi-parameter optimization was set-up involving type of support, reaction time for IP, water content of Aliquat, and concentration of both monomers m-phenylenediamine (MPD) and trimesoylchloride (TMC). The membranes prepared using Aliquat showed similar fluxes as those prepared from a reference IL 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide ([C₄mpyr][Tf₂N]) but with better EA and IA retentions, even better than for a commercial RO membrane (GEA type AF). Finally, the recently introduced epoxide-curing of Bisphenol A diglycidyl ether (BADGE) with 1,6-hexanediamine (HDA) was investigated using Aliquat as organic phase. It is the first time this type of IP was performed in combination with an IL as organic phase. The resulting membrane was used in the filtration of a 35 µM Rose Bengal (RB) in 20 wt% dimethylformamide/ water (DMF/H₂O) feed mixture. A well-crosslinked poly(β-alkanolamine) film was obtained with a > 97% retention.

Mesoporous Silica Thin Membrane with Tunable Pore Size for Ultrahigh Permeation and Precise Molecular Separation

We report on our use of a thin-layered vertical mesoporous silica thin film (MSTF) with tunable pore size overlaid on an anodic aluminum oxide (AAO) membrane for advancing water purification. The features of ultrathin thickness (about 20 nm), a uniform vertical pore orientation, low tortuosity, high porosity, and a hydrophilic surface endow the MSTF membranes with ultrahigh water permeability compared with that of state-of-the-art membranes. The modified E-MSTF membrane with a small pore diameter of 2.1 ± 0.1 nm demonstrates superior nanofiltration performance for dye molecules with a cutoff of 520 Da and ultrahigh water permeability of 310 ± 8 L m^-2 h^-1 bar^-1. Furthermore, the precise molecular sieving of dye/salt mixtures was realized with outstanding salt permeation (97.5% NaCl, 96.0% Na₂SO₄) and a high retention of dye (99.0%). The water permeance and selectivity of the modified E-MSTF membrane are higher than that of reported membranes with similar dye rejections. This work opens up new avenues for constructing tailor-made membranes with tunable pore size and remarkable separation performance.