Eco-friendly solvents and their mixture for the fabrication of polysulfone ultrafiltration membranes: An investigation of doctor blade and slot die casting methods

Calcium Silicate Promoting the Upcycling Potential of Polysulfone Medical Waste in Load-Bearing Applications

Polysulfone (PSF) medical waste can be effectively repurposed due to its excellent mechanical properties. Due to the increasing need for load-bearing bone implants, it is crucial to prioritize the development of biocompatible polymer-matrix composites. Calcium silicate (CaSi), known for its osteogenesis and antibacterial properties, is widely used in medical applications. In this study, recycled PSF plastics in fiber or nanoparticle forms and commercial PSF products were used to create PSF-based composites filled with three different amounts (10, 20, and 30 vol%) of CaSi. The green compact was heat-treated at various temperatures. Experimental results showed that the mechanical interlocking of the PSF matrix and CaSi filler occurred due to the liquefaction of PSF fibers or nanoparticles during heat treatment. When the composite contained 20% CaSi, the obtained three-point bending strength exceeded 60 MPa, falling within the reported strength of compact bone. There was a concurrent improvement in the biocompatibility and antibacterial activity of the PSF-based composites with the increasing amount of CaSi. Considering their mechanical properties and antibacterial activity, the 20% CaSi-containing PSF-based composites treated at 240 °C emerged as a promising candidate for bone implant applications. This study demonstrated the feasibility of upcycling medical waste such as PSF as a matrix, opening doors for its potential usage in the medical field.

Next-generation ultrafiltration membranes: A review of material design, properties, recent progress, and challenges

Membrane technology utilizing ultrafiltration (UF) processes has emerged as the most widely used and cost-effective simple process in many industrial applications. The industries like textiles and petroleum refining are promptly required membrane based UF processes to alleviate the potential environmental threat caused by the generation of various wastewater. At the same time, major limitations such as material selection as well as fouling behavior challenge the overall performance of UF membranes, particularly in wastewater treatment. Therefore, a complete discussion on material design with structural property relation and separation performance of UF membranes is always exciting. This state-of-the-art review has exclusively focused on the development of UF membranes, the material design, properties, progress in separation processes, and critical challenges. So far, most of the review articles have examined the UF membrane processes through a selected track of paving typical materials and their limited applications. In contrast, in this review, we have exclusively aimed at comprehensive research from material selection and fabrication methods to all the possible applications of UF membranes, giving more attention and theoretical understanding to the complete development of high-performance UF systems. We have discussed the methodical engineering behind the development of UF membranes regardless of their materials and fabrication mechanisms. Identifying the utility of UF membrane systems in various applications, as well as their mode of separation processes, has been well discussed. Overall, the current review conveys the knowledge of the present-day significance of UF membranes together with their future prospective opportunities whilst overcoming known difficulties in many potential applications.

Ultrafiltration Membranes Functionalized with Copper Oxide and Zwitterions for Fouling Resistance

Polymeric membrane fouling is a long-standing challenge for water filtration. Metal/metal oxide nanoparticle functionalization of the membrane surface can impart anti-fouling properties through the reactivity of the metal species and the generation of radical species. Copper oxide nanoparticles (CuO NPs) are effective at reducing organic fouling when used in conjunction with hydrogen peroxide, but leaching of copper ions from the membrane has been observed, which can hinder the longevity of the CuO NP activity at the membrane surface. Zwitterions can reduce organic fouling and stabilize NP attachment, suggesting a potential opportunity to combine the two functionalizations. Here, we coated polyethersulfone (PES) ultrafiltration membranes with polydopamine (PDA) and attached the zwitterionic compound, thiolated 2-methacryloyloxyethyl phosphorylcholine (MPC-SH), and CuO NPs. Functionalized membranes resulted in a higher flux recovery ratio (0.694) than the unfunctionalized PES control (0.599). Copper retention was high (>96%) for functionalized membranes. The results indicate that CuO NPs and MPC-SH can reduce organic fouling with only limited copper leaching.

Transmittance Control of a Water-Repellent-Coated Layer on a Tensioned Web in a Roll-to-Roll Slot-Die Coating System

Solar cells are important alternatives to fossil fuels for energy generation in today's world, where the demand for alternative, renewable sources of energy is increasing. However, solar cells, which are installed outdoors, are susceptible to pollution by environmental factors. A solution to overcome this limitation involves coating solar cell surfaces with functional coatings. In this study, we propose a transmittance control method for a tensioned web in a roll-to-roll, transparent, water-repellent film coating. First, we analyzed the effects of process conditions on the transmittance and contact angle of the transparent water-repellent film during roll-to-roll slot-die coating. It was confirmed that the tension was the most dominant factor, followed by the coating gap. Through the tension control, the transmittance was changed by 3.27%, and the contact angle of the DI water was changed by 17.7°. In addition, it was confirmed that the transmittance was changed by 0.8% and the contact angle of DI water by 3.9° via the coating gap control. Based on these results, a transmittance prediction model was developed according to the tension and coating gap, and was then verified experimentally. Finally, a water-repellent film with a high transmittance of 89.77% was obtained using this model.

Polymers and Solvents Used in Membrane Fabrication: A Review Focusing on Sustainable Membrane Development

(1) Different methods have been applied to fabricate polymeric membranes with non-solvent induced phase separation (NIPS) being one of the mostly widely used. In NIPS, a solvent or solvent blend is required to dissolve a polymer or polymer blend. N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAc), dimethylformamide (DMF) and other petroleum-derived solvents are commonly used to dissolve some petroleum-based polymers. However, these components may have negative impacts on the environment and human health. Therefore, using greener and less toxic components is of great interest for increasing membrane fabrication sustainability. The chemical structure of membranes is not affected by the use of different solvents, polymers, or by the differences in fabrication scale. On the other hand, membrane pore structures and surface roughness can change due to differences in diffusion rates associated with different solvents/co-solvents diffusing into the non-solvent and with differences in evaporation time. (2) Therefore, in this review, solvents and polymers involved in the manufacturing process of membranes are proposed to be replaced by greener/less toxic alternatives. The methods and feasibility of scaling up green polymeric membrane manufacturing are also examined.

Green and sustainable method of manufacturing anti-fouling zwitterionic polymers-modified poly(vinyl chloride) ultrafiltration membranes

The nonsolvent induced phase separation (NIPS) method for ultrafiltration (UF) membrane fabrication relies on the extensive use of traditional solvents, thus ranking first in terms of ecological impacts among all the membrane fabrication steps. Methyl-5-(dimethylamino)-2-methyl-5-oxopentanoate (PolarClean), as a green solvent, was utilized in this study to fabricate poly(vinyl chloride) (PVC) UF membranes. Subsequently, in post-treatment process, zwitterionic polymer, [2-(methacryloyloxy) ethyl] dimethyl-(3-sulfopropyl) ammonium hydroxide (DMAPS), was grafted onto the membrane surface to enhance its anti-fouling properties using a greener surface-initiated activator regenerated by electron transfer-atom transfer radical polymerization (ARGET-ATRP) reaction. This novel method used low toxicity chemicals, avoiding the environmental hazards of traditional ATRP, and greatly improving the reaction efficiency. We systematically studied the grafting time effect on the resulted membranes using sodium alginate as the foulant, and found that short grafting time (30 min) achieved excellent membrane performance: pure water permeability of 2872 L m^-2 h^-1 bar^-1, flux recovery ratio of 86.4% after 7-hour fouling test, and foulant rejection of 96.0%. This work discusses for the first time the greener procedures with lower environmental impacts in both fabrication and modification processes of PVC UF membranes.

Sustainable Fabrication of Organic Solvent Nanofiltration Membranes

Organic solvent nanofiltration (OSN) has been considered as one of the key technologies to improve the sustainability of separation processes. Recently, apart from enhancing the membrane performance, greener fabricate on of OSN membranes has been set as a strategic objective. Considerable efforts have been made aiming to improve the sustainability in membrane fabrication, such as replacing membrane materials with biodegradable alternatives, substituting toxic solvents with greener solvents, and minimizing waste generation with material recycling. In addition, new promising fabrication and post-modification methods of solvent-stable membranes have been developed exploiting the concept of interpenetrating polymer networks, spray coating, and facile interfacial polymerization. This review compiles the recent progress and advances for sustainable fabrication in the field of polymeric OSN membranes.

Influence of Sodium Hypochlorite Treatment on Pore Size Distribution of Polysulfone/Polyvinylpyrrolidone Membranes

This work was focused on the study of hypochlorite treatment on the pore size distribution of membranes. To this end, ultrafiltration membranes from a polysulfone/polyvinylpyrrolidone blend with a sponge-like structure were fabricated and exposed to hypochlorite solutions with different active chlorine concentrations for 4 h at ambient temperature. Liquid–liquid displacement and scanning electron microscopy were employed to study the limiting and surface pores, respectively. After treatment with 50 ppm hypochlorite solution at pH = 7.2, a five-fold increase in water permeance up to 1400 L/(m²·h·bar) was observed, accompanied by a 40% increase in the limiting pore sizes and almost a three-fold increase in the porosity. After 5000 ppm treatment at pH = 11.5, a 40% rise in the maximum limiting pore size and almost a two-fold increase in the porosity and permeance was observed, whereas the mean pore size was constant. Apparently, changes in the membrane structure at pH = 11.5 were connected with polyvinylpyrrolidone (PVP) degradation and wash-out, whereas at lower pH and despite lower active chlorine concentration, this process was coupled with polysulfone (PSf) destruction and removal.