Dissecting the Role of Substrate on the Morphology and Separation Properties of Thin Film Composite Polyamide Membranes: Seeing Is Believing

Upcycling End-of-Life Polyvinylidene Fluoride Membranes into Reverse Osmosis Membranes for Sustainable Water Purification

Membrane technology has been increasingly applied in water purification to address global water scarcity. However, commercial membranes inevitably reach the end-of-life (EoL) after long-term operation, which constrains the sustainability of membrane technology. Herein, we demonstrated the feasibility of upcycling real EoL poly(vinylidene fluoride) (PVDF) microfiltration (MF) membranes into reverse osmosis (RO) membranes with higher separation precision via the interfacial polymerization (IP) reaction. We highlighted that the EoL MF membrane, with a fouling-induced narrowed pore size and relatively hydrophobic properties, is preferred for upcycling. The resultant upcycled RO membrane exhibited a satisfactory NaCl rejection (98.6 ± 0.4%) with favorable water permeance (2.3 ± 0.7 L m-2 h-1 bar-1), comparable to the performance of commercial RO membranes. Real wastewater treatment evaluations confirmed the membrane stability and permeate safety. Life-cycle assessment and techno-economic analysis showed that this upcycling process promises environmental and economic benefits, potentially reducing CO2-eq emissions by 18.6% and costs by 76.5%-92.2% compared with the conventional membrane approach. This proof-of-concept study paves the way for creating a closed eco-loop of membrane recycling for sustainable water purification.

Design Ultrathin Polyamide Membranes against Funnel Effect: A Novel Zone-of-Influence-Based Approach

Ultrathin polyamide membranes have gained significant attention due to their potential to achieve high water permeance. Nevertheless, their water permeance is constrained by the substrate-induced funnel effect. For years, researchers have been investigating how substrates impact membrane water permeance. However, these studies generally rely on a trial-and-error approach to find the optimal substrate porosity, which is often time-consuming and offers limited insights. To establish a more intuitive framework for membrane design, we introduced a novel zone-of-influence (ZOI)-based approach for the first time. We first analyze the distinctively different funnel behaviors for thin and thick films through numerical simulations. Thin films, characterized by small ratios of film thickness over substrate pore size (i.e., aspect ratio θ ≤ 0.5), show a highly localized influence of substrate pores and present a more severe funnel effect than thick films with θ ≫ 1. This analysis leads to the concept of ZOI-a region of polyamide over a single substrate pore with water permeation efficiency exceeding a predefined threshold value. A linear relationship between ZOI and θ was observed, which enables an intuitive design to achieve a target water permeance by simply overlapping ZOIs of multiple pores, making it far more efficient than the traditional trial-and-error approach. We further developed an analytical model based on the superposition principle to unravel the fundamental structure-performance relationship between water permeation efficiency, aspect ratio and substrate porosity. This study provides convenient design tools for optimizing ultrathin membrane structure, offering critical guidance and deep insights for the advancement of high-performance membranes.

Nodular networks in hydrated polyamide desalination membranes enhance water transport

For nearly half a century, thin-film composite reverse osmosis membranes have served as key separation materials for desalination. However, the precise structure of their polyamide selective layer under hydrated conditions and its relationship to membrane transport remain poorly understood. Using cryo-electron tomography, we successfully reconstructed the three-dimensional structure of six commercial polyamide membranes under hydrated conditions, revealing a fully swollen nodular network. The highly heterogeneous nodules, measuring 17.2 ± 2.8 nanometer in thickness, were directly connected to the pores of the underlying polysulfone substrate. The nodules occupied most of the surface area compared to the 75.9 ± 26.8-nanometer-thick dense layer of the polyamide film. Key structural parameters of the nodules, including surface area index and wall thickness, were correlated with the water permeance of an additional 16 polyamide membranes, validating the major role of these nodules in water transport. This study enhances our understanding of the heterogeneous structure of desalination membranes and its role in membrane transport.

Nanomorphogenesis of interlayered polyamide membranes for precise ion sieving in lithium extraction

Nanofiltration (NF) offers a scalable and energy-efficient method for lithium extraction from salt lakes. However, the selective separation of lithium from magnesium, particularly in brines with high magnesium concentrations, remains a significant challenge due to the close similarity in their hydrated ionic radii. The limited Li+/Mg2+selectivity of current NF membranes is primarily attributed to insufficient control over pore size and surface charge. In this study, we report the development of an interlayered thin-film composite (iTFC) membrane incorporating functionalized sulfonated carrageenan to regulate the interfacial polymerization process. This integrated interlayer plays a crucial role in controlling the diffusion and spatial distribution of amine monomers, leading to the formation of dense, nano-striped polyamide networks. These structural improvements including refined pore size and reduced negative charge significantly enhanced Li+/Mg2+selectivity (133.5) and increased permeance by 2.5 times compared to conventional TFC membranes. Additionally, the nano-striped structure optimized the membrane filtration area while minimizing ion transport resistance, effectively overcoming the traditional trade-off between ion selectivity and permeability. This study highlights the potential of iTFC membranes for achieving both high lithium purity and recovery, offering a promising avenue for large-scale lithium extraction from brines.

Effects of Latent Solvent Content on Tuning the Nanofiltration Performance of Nanofibrous Composite Membranes

This study aims to optimize the application of electrospun nanofibrous substrates in thin-film composite (TFC) nanofiltration (NF) membranes for enhanced liquid separation efficiency by employing a method of effective welding between fibers using latent solvents. Polyacrylonitrile (PAN) nanofiber substrates were fabricated via electrospinning, and a dense polyamide selective layer was formed on their surface through interfacial polymerization (IP). The investigation focused on the effects of different solvent systems, particularly the role of dimethyl sulfoxide (DMSO) as a latent solvent, on the nanostructure and final membrane performance. The results indicate that increasing the DMSO content can enhance the greenness of the fabrication process, the substrate hydrophilicity, and the mechanical strength, while also influencing the thickness and morphology of the polyamide layer. At a DMSO rate of 30%, the composite membrane achieves optimal pure water permeability and high rejection rates; when the DMSO content exceeds 40%, structural inhomogeneity in the substrate membrane leads to an increase in defects, significantly deteriorating membrane performance. These findings provide theoretical insights and technical guidance for the application of electrospinning technology in designing efficient and stable NF membranes.

Lignin alkali regulated interfacial polymerization towards ultra-selective and highly permeable nanofiltration membrane

Thin-film composite polyamide (TFC PA) membranes hold promise for energy-efficient liquid separation, but achieving high permeance and precise separation membrane via a facile approach that is compatible with present manufacturing line remains a great challenge. Herein, we demonstrate the use of lignin alkali (LA) derived from waste of paper pulp as an aqueous phase additive to regulate interfacial polymerization (IP) process for achieving high performance nanofiltration (NF) membrane. Various characterizations and molecular dynamics simulations revealed that LA can promote the diffusion and partition of aqueous phase monomer piperazine (PIP) molecules into organic phase and their uniform dispersion on substrate, accelerating the IP reaction and promoting greater interfacial instabilities, thus endowing formation of TFC NF membrane with an ultrathin, highly cross-linked, and crumpled PA layer. The optimal membrane exhibited a remarkable water permeance of 26.0 L m-2 h-1 bar-1 and Cl-/SO42- selectivity of 191.0, which is superior to the state-of-the-art PA NF membranes. This study provides a cost-effective scalable strategy for fabricating ultra-selective and highly permeable NF membrane for precise ion-ion separation and small organic compounds removal.

Nanofoamed Polyamide Membranes: Mechanisms, Developments, and Environmental Implications

Thin film composite (TFC) polyamide membranes have been widely applied for environmental applications, such as desalination and water reuse. The separation performance of TFC polyamide membranes strongly depends on their nanovoid-containing roughness morphology. These nanovoids not only influence the effective filtration area of the polyamide film but also regulate the water transport pathways through the film. Although there have been ongoing debates on the formation mechanisms of nanovoids, a nanofoaming theory─stipulating the shaping of polyamide roughness morphology by nanobubbles of degassed CO2 and the vapor of volatile solvents─has gained much attention in recent years. In this review, we provide a comprehensive summary of the nanofoaming mechanism, including related fundamental principles and strategies to tailor nanovoid formation for improved membrane separation performance. The effects of nanovoids on the fouling behaviors of TFC membranes are also discussed. In addition, numerical models on the role of nanovoids in regulating the water transport pathways toward improved water permeance and antifouling ability are highlighted. The comprehensive summary on the nanofoaming mechanism in this review provides insightful guidelines for the future design and optimization of TFC polyamide membranes toward various environmental applications.

Ultra-permeable silk-based polymeric membranes for vacuum-driven nanofiltration

Nanofiltration (NF) membranes are commonly supplied in spiral-wound modules, resulting in numerous drawbacks for practical applications (e.g., high operating pressure/pressure drop/costs). Vacuum-driven NF could be a promising and low-cost alternative by utilizing simple components and operating under an ultra-low vacuum pressure (<1 bar). Nevertheless, existing commercial membranes are incapable of achieving practically relevant water flux in such a system. Herein, we fabricated a silk-based membrane with a crumpled and defect-free rejection layer, showing water permeance of 96.2 ± 10 L m-2 h-1 bar-1 and a Na2SO4 rejection of 96.0 ± 0.6% under cross-flow filtration mode. In a vacuum-driven system, the membrane demonstrates a water flux of 56.8 ± 7.1 L m-2 h-1 at a suction pressure of 0.9 bar and high removal rate against various contaminants. Through analysis, silk-based ultra-permeable membranes may offer close to 80% reduction in specific energy consumption and greenhouse gas emissions compared to a commercial benchmark, holding great promise for advancing a more energy-efficient and greener water treatment process and paving the avenue for practical application in real industrial settings.

Research on Reverse Osmosis (RO)/Nanofiltration (NF) Membranes Based on Thin Film Composite (TFC) Structures: Mechanism, Recent Progress and Application

The global shortage of clean water is a major problem, even in water-rich regions. To solve this problem, low-cost and energy-efficient water treatment methods are needed. Membrane separation technology (MST), as a separation method with low energy consumption, low cost, and good separation effect, has been widely used to deal with seawater desalination, resource recovery, industrial wastewater treatment, and other fields. With the continuous progress of scientific and technological innovation and the increasing demand for use, NF/RO membranes based on the TFC structure are constantly being upgraded. This paper presents the recent research progress of NF and RO membranes based on TFC structures and their applications in different fields, especially the formation mechanism and regulation of selective layer structures and the modification methods of selective layers. Our summary provides fundamental insights into the understanding of NF and RO membrane processes and hopefully triggers further thinking on the development of membrane filtration process optimization.

Distinct Efficacies of Interlayers in Tailoring Polyamide Nanofiltration Membrane Performance for Organic Micropollutant Removal: Dependent on Substrate Characteristics

Interlayered thin-film nanocomposite (TFN) membranes have shown the potential to boost nanofiltration performance for water treatment applications including the removal of organic micropollutants (OMPs). However, the effects of substrates have been overlooked when exploiting and evaluating the efficacy of certain kinds of interlayers in tailoring membrane performance. Herein, a series of TFN membranes were synthesized on different porous substrates with identical interlayers of metal-organic framework nanosheets. It was revealed that the interlayer introduction could narrow but not fully eliminate the difference in the properties among the polyamide layers formed on different substrates, and the membrane performance variation was prominent in distinct aspects. For substrates with small pore sizes exerting severe water transport hindrance, the introduced interlayer mainly enhanced membrane water permeance by affording the gutter effect, while it could be more effective in reducing membrane pore size by improving the interfacial polymerization platform and avoiding PA defects when using a large-pore-size substrate. By matching the selected substrates and interlayers well, superior TFN membranes were obtained with simultaneously higher water permeance and OMP rejections compared to three commercial membranes. This study helps us to objectively understand interlayer efficacies and attain performance breakthroughs of TFN membranes for more efficient water treatment.

Enhanced water treatment performance of ceramic-based forward osmosis membranes via MOF interlayer

Forward osmosis (FO) membrane processes could operate without hydraulic pressures, enabling the efficient treatment of wastewaters with mitigated membrane fouling and enhanced efficiency. Designing a high-performance polyamide (PA) layer on ceramic substrates remains a challenge for FO desalination applications. Herein, we report the enhanced water treatment performance of thin-film nanocomposite ceramic-based FO membranes via an in situ grown Zr-MOF (UiO-66-NH2) interlayer. With the Zr-MOF interlayer, the ceramic-based FO membranes exhibit lower thickness, higher cross-linking degree, and increased surface roughness, leading to higher water flux of 27.38 L m-2 h-1 and lower reverse salt flux of 3.45 g m-2 h-1. The ceramic-based FO membranes with Zr-MOF interlayer not only have an application potential in harsh environments such as acidic solution (pH 3) and alkaline solution (pH 11), but also exhibit promising water and reverse salt transport properties, which are better than most MOF-incorporated PA membranes. Furthermore, the membranes could reject major species (ions, oil and organics) with rejections ＞94 % and water flux of 22.62-14.35 L m-2 h-1 in the treatment of actual alkaline industrial wastewater (pH 8.6). This rational design proposed in this study is not only applicable for the development of a high-quality ceramic-based FO membrane with enhanced performance but also can be potentially extended to more challenging water treatment applications.

Leveraging Janus Substrates as a Confined "Interfacial Reactor" to Synthesize Ultrapermeable Polyamide Nanofilms

Porous substrates act as open "interfacial reactors" during the synthesis of polyamide composite membranes via interfacial polymerization. However, achieving a thin and dense polyamide nanofilm with high permeance and selectivity is challenging when using a conventional substrate with uniform wettability. To overcome this limitation, we propose the use of Janus porous substrates as confined interfacial reactors to decouple the local monomer concentration from the total monomer amount during interfacial polymerization. By manipulating the location of the hydrophilic/hydrophobic interface in a Janus porous substrate, we can precisely control the monomer solution confined within the hydrophilic layer without compromising its concentration. The hydrophilic surface ensures the uniform distribution of monomers, preventing the formation of defects. By employing Janus substrates fabricated through single-sided deposition of polydopamine/polyethyleneimine, we significantly reduce the thickness of the polyamide nanofilms from 88.4 to 3.8 nm by decreasing the thickness of the hydrophilic layer. This reduction leads to a remarkable enhancement in water permeance from 7.2 to 52.0 l/m2·h·bar while still maintaining ~96% Na2SO4 rejection. The overall performance of this membrane surpasses that of most reported membranes, including state-of-the-art commercial products. The presented strategy is both simple and effective, bringing ultrapermeable polyamide nanofilms one step closer to practical separation applications.

Engraving Polyamide Layers by In Situ Self-Etchable CaCO3 Nanoparticles Enhances Separation Properties and Antifouling Performance of Reverse Osmosis Membranes

Nanovoids within a polyamide layer play an important role in the separation performance of thin-film composite (TFC) reverse osmosis (RO) membranes. To form more extensive nanovoids for enhanced performance, one commonly used method is to incorporate sacrificial nanofillers in the polyamide layer during the exothermic interfacial polymerization (IP) reaction, followed by some post-etching processes. However, these post-treatments could harm the membrane integrity, thereby leading to reduced selectivity. In this study, we applied in situ self-etchable sacrificial nanofillers by taking advantage of the strong acid and heat generated in IP. CaCO3 nanoparticles (nCaCO3) were used as the model nanofillers, which can be in situ etched by reacting with H+ to leave void nanostructures behind. This reaction can further degas CO2 nanobubbles assisted by heat in IP to form more nanovoids in the polyamide layer. These nanovoids can facilitate water transport by enlarging the effective surface filtration area of the polyamide and reducing hydraulic resistance to significantly enhance water permeance. The correlations between the nanovoid properties and membrane performance were systematically analyzed. We further demonstrate that the nCaCO3-tailored membrane can improve membrane antifouling propensity and rejections to boron and As(III) compared with the control. This study investigated a novel strategy of applying self-etchable gas precursors to engrave the polyamide layer for enhanced membrane performance, which provides new insights into the design and synthesis of TFC membranes.

High performance forward osmosis membrane with ultrathin hydrophobic nanofibrous interlayer

The novel thin film composite (TFC) forward osmosis (FO) membrane with electrospinning nanofibers as support layer can alleviate internal concentration polarization (ICP). While the macropores of the nanofiber support layer cause defects in the polyamide (PA) layer. Therefore, hydrophobic polyvinylidene fluoride (PVDF) fine nanofibers were used as an interlayer to modulate the process of interfacial polymerization (IP) in this study. The results showed that the introduction of the interlayer improved the hydrophobicity of the support layer for achieving uniform, thin and defect-free selective polyamide (PA) layer. The water flux of TFC-PVDF was 58.26 LMH in the FO mode of 2 M NaCl, which was two times higher than that of the unmodified FO membrane. Lower reverse salt flux (4.91 gMH) and structural parameter (179.43 μm) alleviated the ICP. In addition, TFC-PVDF membrane showed good anti-fouling performance for SA (flux recovery ratio of 93.97%) due to high hydrophilicity, low zeta potential and low roughness. This study provides an easy and promising method to prepare defect-free PA selective layer on the macropores nanofiber support layer. The novel FO membrane shows high desalination performance and anti-fouling properties.

NaHCO3 addition enhances water permeance and Ca/haloacetic acids selectivity of nanofiltration membranes for drinking water treatment

The existence of disinfection by-products such as haloacetic acids (HAAs) in drinking water severely threatens water safety and public health. Nanofiltration (NF) is a promising strategy to remove HAAs for clean water production. However, NF often possesses overhigh rejection of essential minerals such as calcium. Herein, we developed highly selective NF membranes with tailored surface charge and pore size for efficient rejection of HAAs and high passage of minerals. The NF membranes were fabricated through interfacial polymerization (IP) with NaHCO3 as an additive. The NaHCO3-tailored NF membranes exhibited high water permeance up to ∼24.0 L m - 2 h - 1 bar-1 (more than doubled compared with the control membrane) thanks to the formation of stripe-like features and enlarged pore size. Meanwhile, the tailored membranes showed enhanced negative charge, which benefitted their rejection of HAAs and passage of Ca and Mg. The higher rejection of HAAs (e.g., > 90%) with the lower rejection of minerals (e.g., < 30% for Ca) allowed the NF membranes to achieve higher minerals/HAAs selectivity, which was significantly higher than those of commercially available NF membranes. The simultaneously enhanced membrane performance and higher minerals/HAAs selectivity would greatly boost water production efficiency and water quality. Our findings provide a novel insight to tailor the minerals/micropollutants selectivity of NF membranes for highly selective separation in membrane-based water treatment.

Lyotropic Liquid Crystal (LLC)-Templated Nanofiltration Membranes by Precisely Administering LLC/Substrate Interfacial Structure

Mesoporous materials based on lyotropic liquid crystal templates with precisely defined and flexible nanostructures offer an alluring solution to the age-old challenge of water scarcity. In contrast, polyamide (PA)-based thin-film composite (TFC) membranes have long been hailed as the state of the art in desalination. They grapple with a common trade-off between permeability and selectivity. However, the tides are turning as these novel materials, with pore sizes ranging from 0.2 to 5 nm, take center stage as highly coveted active layers in TFC membranes. With the ability to regulate water transport and influence the formation of the active layer, the middle porous substrate of TFC membranes becomes an essential player in unlocking their true potential. This review delves deep into the recent advancements in fabricating active layers using lyotropic liquid crystal templates on porous substrates. It meticulously analyzes the retention of the liquid crystal phase structure, explores the membrane fabrication processes, and evaluates the water filtration performance. Additionally, it presents an exhaustive comparison between the effects of substrates on both polyamide and lyotropic liquid crystal template top layer-based TFC membranes, covering crucial aspects such as surface pore structures, hydrophilicity, and heterogeneity. To push the boundaries even further, the review explores a diverse array of promising strategies for surface modification and interlayer introduction, all aimed at achieving an ideal substrate surface design. Moreover, it delves into the realm of cutting-edge techniques for detecting and unraveling the intricate interfacial structures between the lyotropic liquid crystal and the substrate. This review is a passport to unravel the enigmatic world of lyotropic liquid crystal-templated TFC membranes and their transformative role in global water challenges.

Does Surface Roughness Necessarily Increase the Fouling Propensity of Polyamide Reverse Osmosis Membranes by Humic Acid?

Surface roughness has crucial influence on the fouling propensity of thin film composite (TFC) polyamide reverse osmosis (RO) membranes. A common wisdom is that rougher membranes tend to experience more severe fouling. In this study, we compared the fouling behaviors of a smooth polyamide membrane (RO-s) and a nanovoid-containing rough polyamide membrane (RO-r). Contrary to the traditional belief, we observed more severe fouling for RO-s, which can be ascribed to its uneven flux distribution caused by the "funnel effect". Additional tracer filtration tests using gold nanoparticles revealed a more patchlike particle deposition pattern, confirming the adverse impact of "funnel effect" on membrane water transport. In contrast, the experimentally observed lower fouling propensity of the nanovoid-containing rough membrane can be explained by: (1) the weakened "funnel effect" thanks to the presence of nanovoids, which can regulate the water transport pathway through the membrane and (2) the decreased average localized flux over the membrane surface due to the increased effective filtration area for the nanovoid-induced roughness features. The current study provides fundamental insights into the critical role of surface roughness in membrane fouling, which may have important implications for the future development of high-performance antifouling membranes.

Demystifying the Role of Surfactant in Tailoring Polyamide Morphology for Enhanced Reverse Osmosis Performance: Mechanistic Insights and Environmental Implications

Surfactant-assisted interfacial polymerization (IP) has shown strong potential to improve the separation performance of thin film composite polyamide membranes. A common belief is that the enhanced performance is attributed to accelerated amine diffusion induced by the surfactant, which can promote the IP reaction. However, we show enhanced membrane performance for Tween 80 (a common surfactant), even though it decreased the amine diffusion. Indeed, the membrane performance is closely related to its polyamide roughness features with numerous nanovoids. Inspired by the nanofoaming theory that relates the roughness features to nanobubbles degassed during the IP reaction, we hypothesize that the surfactant can stabilize the generated nanobubbles to tailor the formation of nanovoids. Accordingly, we obtained enlarged nanovoids when the surfactant was added below its critical micelle concentration (CMC). In addition, both the membrane permeance and selectivity were enhanced, thanks to the enlarged nanovoids and reduced defects in the polyamide layer. Increasing the concentration above CMC resulted in shrunken nanovoids and deteriorated performance, which can be ascribed to the decreased stabilization effect caused by micelle formation. Interestingly, better antifouling performance was also observed for the surfactant-assisted membranes. Our current study provides mechanistic insights into the critical role of surfactant during the IP reaction, which may have important implications for more efficient membrane-based desalination and water reuse.

A novel conductive carbon-based forward osmosis membrane for dye wastewater treatment

Forward osmosis (FO) membrane fouling is one of the main reasons that hinder the further application of FO technology in the treatment of dye wastewater. To alleviate membrane fouling, a conductive coal carbon-based substrate and polydopamine nanoparticles (PDA NPs) interlayer composite FO membrane (CPFO) was prepared by interfacial polymerization (IP). CPFO-10 membrane prepared by depositing 10 mL of PDA NPs solution exhibited an optimum performance with water flux of 7.56 L/(m²h) for FO mode and 10.75 L/(m²h) for pressure retarded osmosis (PRO) mode, respectively. For rhodamine B and chrome black T dye wastewater treatment, the water flux losses were reduced by 21.6%, and 14.5% under the voltages of +1.5 V, and -1.5 V, respectively, compared with no voltage applied after the device was operated for 8 h. The applied voltage had little effect on the fouling mitigation performance of the CPFO membrane for neutral charged cresol red. After the device was operated for 4 cycles, the rejection rates of dyes wastewater treated by the CPFO membranes with applied voltage were close to 100%. The flux decline rate and flux recovery rate of CPFO membrane for rhodamine B and chrome black T wastewater treatment under application of +1.5 V and -1.5 V voltage after 4 cycles were 11.6%, 99.2%, and 16.7%, 98.9%, respectively. Therefore, the voltage-applied CPFO membrane still maintained good rejection and antifouling performance in long-term operation. This study provides a new insight into the preparation of conductive FO membranes for dye wastewater treatment and membrane fouling control.

Facile monomer interlayered MOF based thin film nanocomposite for efficient arsenic separation

The thin film nanocomposites (TFN) based membranes are sensitive to the synergy between the polymer and nanoparticles. TFN incorporating metal-organic frameworks (MOFs) have shown tremendous enhancement in permeability. This study investigates alternate MOF positioning during TFC fabrication for a highly selective membrane. Co-Zn-based mixed metal-organic framework (mMOF) was interlayered between m-phenylenediamine (MPD) and trimesoyl chloride (TMC) to form a polyamide (PA) selective layer. The practiced method conveniently allowed exact loading of mMOF and thus prevented the loss. Owing to the mMOF's placement between MPD and TMC, an increase in PA cross-linking was observed. The mMOF-MPD monomer compatibility allowed homogeneous distribution and formation of a defect-free PA layer. The surface morphology showed a more pronounced formation of leaves-like features due to interfacial degassing. Neutral solute-based filtration tests determined mean pore size, probability distribution, and MWCO. The incorporation of mMOF led to formation of additional nanochannels in the membrane surface. The perm-selectivity studies performed on a dead-end filtration unit resulted in 94% As⁵⁺ retention with 2.5 times higher permeance than the control. The current study pronounced the viability of the monomer interlayer method to form a highly selective TFN for water separation and related applications.

Development and Investigation of Hierarchically Structured Thin-Film Nanocomposite Membranes from Polyamide/Chitosan Succinate Embedded with a Metal-Organic Framework (Fe-BTC) for Pervaporation

Thin-film composite membranes (TFC) obtained by the formation of a selective layer on a porous membrane-substrate via interfacial polymerization (IP) are indispensable for separation procedures in reverse osmosis, nanofiltration, pervaporation, and gas separation. Achieving high selectivity and permeability for TFC membranes is still one of the main challenges in membrane science and technology. This study focuses on the development of thin film nanocomposite (TFN) membranes with a hierarchically structured polyamide (PA)/chitosan succinate (ChS) selective layer embedded with a metal-organic framework of iron 1,3,5-benzenetricarboxylate (Fe-BTC) for the enhanced pervaporation dehydration of isopropanol. The aim of this work was to study the effect of Fe-BTC incorporation into the ChS interlayer and PA selective layer, obtained via IP, on the structure, properties, and performance of pervaporation TFN membranes. The structure and hydrophilicity of the developed TFN membranes were investigated using scanning electron microscopy (SEM) and atomic force microscopy (AFM), along with water contact angle measurements. The developed TFN membranes were studied in the pervaporation dehydration of isopropanol (12-30 wt % water). It was found that incorporation of Fe-BTC into the ChS interlayer yielded the formation of a smoother, more uniform, and defect-free PA ultrathin selective layer via IP, due to the amorpho-crystalline structure of particles serving as the amine storage reservoir and led to an increase in membrane selectivity toward water, and a slight decrease in permeation flux compared to the ChS interlayered TFC membranes. The best pervaporation performance was demonstrated by the TFN membrane with a ChS-Fe-BTC interlayer and the addition of 0.03 wt % Fe-BTC in the PA layer, yielding a permeation flux of 197-826 g·m^-2·h^-1 and 98.50-99.99 wt % water in the permeate, in the pervaporation separation of isopropanol/water mixtures (12-30 wt % water).

Nanofiltration Membranes with Crumpled Polyamide Films: A Critical Review on Mechanisms, Performances, and Environmental Applications

Nanofiltration (NF) membranes have been widely applied in many important environmental applications, including water softening, surface/groundwater purification, wastewater treatment, and water reuse. In recent years, a new class of piperazine (PIP)-based NF membranes featuring a crumpled polyamide layer has received considerable attention because of their great potential for achieving dramatic improvements in membrane separation performance. Since the report of novel crumpled Turing structures that exhibited an order of magnitude enhancement in water permeance ( Science 2018, 360 (6388), 518-521), the number of published research papers on this emerging topic has grown exponentially to approximately 200. In this critical review, we provide a systematic framework to classify the crumpled NF morphologies. The fundamental mechanisms and fabrication methods involved in the formation of these crumpled morphologies are summarized. We then discuss the transport of water and solutes in crumpled NF membranes and how these transport phenomena could simultaneously improve membrane water permeance, selectivity, and antifouling performance. The environmental applications of these emerging NF membranes are highlighted, and future research opportunities/needs are identified. The fundamental insights in this review provide critical guidance on the further development of high-performance NF membranes tailored for a wide range of environmental applications.

Removing miscellaneous heavy metals by all-in-one ion exchange-nanofiltration membrane

The composition of wastewater containing heavy metal mixtures is often complex and poses a serious threat to human and environmental health. Effective removal of a variety of heavy metal ions with a single technology is challenging, and the conventional split integrated technologies require multi-step processing and a massive footprint. For the first time, we achieve hierarchically integrating ion exchange and nanofiltration into all-in-one "iNF" membranes. The iNF membrane has a hierarchical structure with an interfacial polymerization layer and an ion exchange layer, which can achieve highly efficient indiscriminate heavy metal ion removal, overcoming the defect that traditional nanofiltration membranes can only remove single metal cations or oxyanions. The ion exchange layer can remove heavy metal ions through sulfonic acid groups and quaternary amine groups. In addition, the ion exchange layer can be regenerated by electro-deionization, which is meaningful for sustainable membrane usage. This facile, scalable, and compact integrated process shows outstanding potential and universal applicability in complex wastewater treatment.

Linear versus Nonlinear Aromatic Polyamides: The Role of Backbone Geometry in Thin Film Salt Exclusion Membranes

Two aromatic polyamides─poly(3,3'-dihydroxybenzidine terephthalamide) (DHTA) and poly(3,3'-dihydroxybenzidine isophthalamide) (DHIA)─are compared for their ability to remove salts from water. DHTA is linear and rigid whereas DHIA is nonlinear and semirigid. DHTA and DHIA were selected as they allow us to investigate the effect of polymer backbone geometry on salt exclusion in a non-crosslinked thin film membrane, independently of the backbone chemistry. Because of their differences in solution viscosity, spin coating parameters for DHTA and DHIA solutions were optimized separately to produce thin film composites (TFCs) with reproducible membrane properties. The resulting DHTA TFCs displayed salt rejections of 87.8% (NaCl), 97.0% (MgSO4), and 80.3% (CaCl2). In comparison, DHIA TFCs demonstrated poor salt rejections of 21.0% (NaCl), 29.3% (MgSO4), and 15.4% (CaCl2). Cross-sectional SEM images of DHTA and DHIA films reveal that DHTA has a stratified (layered) morphology whereas DHIA exhibits a dense, featureless morphology. Both DHTA and DHIA TFCs exhibit similar surface morphology, contact angle, surface charge, and water uptake. PEG rejection experiments indicate that the average pore size of DHTA TFCs is ∼2 nm while DHIA TFCs have an average pore size of ∼3 nm. Our findings illustrate that using a rigid, linear aromatic polyamide gives an active layer with a stratified morphology, uniplanar orientation, smaller pores, and higher salt rejection, whereas the nonlinear aromatic polyamide analogue results in an isotropic active layer with larger pores and lower salt rejection.

Cosolvent-Assisted Interfacial Polymerization toward Regulating the Morphology and Performance of Polyamide Reverse Osmosis Membranes: Increased m-Phenylenediamine Solubility or Enhanced Interfacial Vaporization?

Cosolvent-assisted interfacial polymerization (IP) can effectively enhance the separation performance of thin film composite (TFC) reverse osmosis (RO) membranes. However, the underlying mechanisms regulating the formation of their polyamide (PA) rejection films remain controversial. The current study reveals two essential roles of cosolvents in the IP reaction: (1) directly promoting interfacial vaporization with their lower boiling points and (2) increasing the solubility of m-phenylenediamine (MPD) in the organic phase, thereby indirectly promoting the IP reaction. Using a series of systematically chosen cosolvents (i.e., diethyl ether, acetone, methanol, and toluene) with different boiling points and MPD solubilities, we show that the surface morphologies of TFC RO membranes were regulated by the combined direct and indirect effects. A cosolvent favoring interfacial vaporization (e.g., lower boiling point, greater MPD solubility, and/or higher concentration) tends to create greater apparent thickness of the rejection layer, larger nanovoids within the layer, and more extensive exterior PA layers, leading to significantly improved membrane water permeance. We further demonstrate the potential to achieve better antifouling performance for the cosolvent-assisted TFC membranes. The current study provides mechanistic insights into the critical roles of cosolvents in IP reactions, providing new tools for tailoring membrane morphology and separation properties toward more efficient desalination and water reuse.

Unveiling the Growth of Polyamide Nanofilms at Water/Organic Free Interfaces: Toward Enhanced Water/Salt Selectivity

The permeance and selectivity of a reverse osmosis (RO) membrane are governed by its ultrathin polyamide film, yet the growth of this critical film during interfacial polymerization (IP) has not been fully understood. This study investigates the evolution of a polyamide nanofilm at the aqueous/organic interface over time. Despite its thickness remaining largely constant (∼15 nm) for the IP reaction time ranging from 0.5 to 60 min, the density of the polyamide nanofilm increased from 1.25 to 1.36 g cm^-3 due to the continued reaction between diffused m-phenylenediamine and dangling acyl chloride groups within the formed polyamide film. This continued growth of the polyamide nanofilm led to a simultaneous increase in its crosslinking degree (from 50.1 to 94.3%) and the healing of nanosized defects, resulting in a greatly enhanced rejection of 99.2% for NaCl without sacrificing water permeance. Using humic acid as a molecular probe for sealing membrane defects, the relative contributions of the increased crosslinking and reduced defects toward better membrane selectivity were resolved, which supports our conceptual model involving both enhanced size exclusion and healed defects. The fundamental insights into the growth mechanisms and the structure-property relationship of the polyamide nanofilm provide crucial guidance for the further development and optimization of high-performance RO membranes.

Enhancing the Permselectivity of Thin-Film Composite Membranes Interlayered with MoS2 Nanosheets via Precise Thickness Control

The demand for highly permeable and selective thin-film composite (TFC) nanofiltration membranes, which are essential for seawater and brackish water softening and resource recovery, is growing rapidly. However, improving and tuning membrane permeability and selectivity simultaneously remain highly challenging owing to the lack of thickness control in polyamide films. In this study, we fabricated a high-performance interlayered TFC membrane through classical interfacial polymerization on a MoS₂-coated polyethersulfone substrate. Due to the enhanced confinement effect on the interface degassing and the improved adsorption of the amine monomer by the MoS₂ interlayer, the MoS₂-interlayered TFC membrane exhibited enhanced roughness and crosslinking. Compared to the control TFC membrane, MoS₂-interlayered TFC membranes have a thinner polyamide layer, with thickness ranging from 60 to 85 nm, which can be tuned by altering the MoS₂ interlayer thickness. A multilayer permeation model was developed to delineate and analyze the transport resistance and permeability of the MoS₂ interlayer and polyamide film through the regression of experimental data. The optimized MoS₂-interlayered TFC membrane (0.3-inter) had a 96.8% Na₂SO₄ rejection combined with an excellent permeability of 15.9 L m^-2 h^-1 bar^-1 (LMH/bar), approximately 2.4 times that of the control membrane (6.6 LMH/bar). This research provides a feasible strategy for the rational design of tunable, high-performance NF membranes for environmental applications.

A novel ceramic-based thin-film composite nanofiltration membrane with enhanced performance and regeneration potential

The rational design of a ceramic-based nanofiltration membrane remains a significant challenge due to its performance and fabrication cost. Herein, we report a high-performance ceramic-based thin-film composite (TFC) membrane fabricated via a typical interfacial polymerization on an interwoven net substrate assembled by titanium dioxide (TiO₂) nanowires. The chemical properties and morphologies were systematically investigated for ceramic substrates and their corresponding TFC membranes. Due to the significantly improved hydrophilicity of the TiO₂ framework, more reactive amine monomers were uniformly adsorbed on the modified surface of the ceramic substrate, yielding an ultrathin polyamide layer with less resistance. In addition, the smooth surface and decreased pore size of the TiO₂ framework contributed to forming a defect-free polyamide layer. As a result, the obtained ceramic-based TFC membrane evinced high permeance of 26.4 L m^-2 h^-1 bar^-1 and excellent salt rejection efficiency, leading to simultaneous improvements compared with the control TFC membrane without the TiO₂ framework. Notably, the potential regeneration ability of the ceramic-based TFC membrane could be achieved via facile low-temperature calcination and re-polymerization process due to the varied thermostability between the polyamide layer and the robust ceramic substrate. The operation of regeneration helped to prolong the lifetime and decrease the cost for the ceramic-based TFC membrane. This research provides a feasible protocol to fabricate sustainable ceramic-based nanofiltration membranes with enhanced performance for water treatment.

Mechanism and performance relevance of nanomorphogenesis in polyamide films revealed by quantitative 3D imaging and machine learning

Biological morphogenesis has inspired many efficient strategies to diversify material structure and functionality using a fixed set of components. However, implementation of morphogenesis concepts to design soft nanomaterials is underexplored. Here, we study nanomorphogenesis in the form of the three-dimensional (3D) crumpling of polyamide membranes used for commercial molecular separation, through an unprecedented integration of electron tomography, reaction-diffusion theory, machine learning (ML), and liquid-phase atomic force microscopy. 3D tomograms show that the spatial arrangement of crumples scales with monomer concentrations in a form quantitatively consistent with a Turing instability. Membrane microenvironments quantified from the nanomorphologies of crumples are combined with the Spiegler-Kedem model to accurately predict methanol permeance. ML classifies vastly heterogeneous crumples into just four morphology groups, exhibiting distinct mechanical properties. Our work forges quantitative links between synthesis and performance in polymer thin films, which can be applicable to diverse soft nanomaterials.

Molecular Methods for Assessing the Morphology, Topology, and Performance of Polyamide Membranes

The molecular-scale morphology and topology of polyamide composite membranes determine the performance characteristics of these materials. However, molecular-scale simulations are computationally expensive and morphological and topological characterization of molecular structures are not well developed. Molecular dynamics simulation and analysis methods for the polymerization, hydration, and quantification of polyamide membrane structures were developed and compared to elucidate efficient approaches for producing and analyzing the polyamide structure. Polymerization simulations that omitted the reaction-phase solvent did not change the observed hydration, pore-size distribution, or water permeability, while improving the simulation efficiency. Pre-insertion of water into the aggregate pores (radius ≈ 4 Å) of dry domains enabled shorter hydration simulations and improved simulation scaling, without altering pore structure, properties, or performance. Medial axis and Minkowski functional methods were implemented to identify permeation pathways and quantify the polyamide morphology and topology, respectively. Better agreement between simulations and experimentally observed systems was accomplished by increasing the domain size rather than increasing the number of ensemble realizations of smaller systems. The largest domain hydrated was an order of magnitude larger by volume than the largest domain previously reported. This work identifies methods that can enable more efficient and meaningful fundamental modeling of membrane materials.

Accessing greater thickness and new morphology features in polyamide active layers of thin-film composite membranes by reducing restrictions in amine monomer supply

Polyamide formation, via interfacial polymerization (IP) during thin-film composite (TFC) membrane fabrication, is regarded as self-limiting-in the sense that the polyamide film limits its own growth as it forms. During IP, trimesoyl chloride (TMC) and m-phenylenediamine (MPD) react rapidly to form an incipient polyamide film that densifies and slows the diffusion of the more permeable monomer (MPD), thereby limiting polyamide growth and yielding films that typically exhibit thicknesses <350 nm. The morphology of these polyamide films is characterized by a basal layer of void nodular and leaf-like features that is sometimes overlaid by a secondary layer of overlapping flat features. Here, we present evidence showing that polyamide active layers are substantially permeable to MPD, and that minimizing certain restrictions in the MPD supply conditions during IP can result in polyamide active layers of thicknesses several times greater (>1 μm) than those typically reported in the literature. In addition to the basal layer of void nodular features and secondary layer of overlapping flat features that characterize typical polyamide active layers, the thicker films also exhibited three additional morphological features: blanket-like layers atop the basal layer or other void features, multi-layer void structures, and/or void mega-nodules (up to over a micron in diameter). Overall, the results indicate that reducing restrictions in the MPD supply conditions during IP: (1) overcomes the limited polyamide growth observed in conventional TFC membrane fabrication and (2) leads to film morphologies with a more prominent void structure. This latter observation is consistent with recent literature describing the role of CO₂ degassing and nanobubble confinement in the development of polyamide active layer morphology. Future studies could vary MPD supply conditions as a new tool to expand the range of achievable thicknesses in active layer casting, regulate active layer morphology and optimize nanobubble confinement conditions independently of MPD supply. Such capabilities could aid in the development of novel supports and TFC structures.