A review on polyamide thin film nanocomposite (TFN) membranes: History, applications, challenges and approaches

Nanovoid-Enhanced Thin-Film Composite Reverse Osmosis Membranes Using ZIF-67 Nanoparticles as a Sacrificial Template

In this work, nanovoid-enhanced thin-film composite (TFC) membranes have been successfully fabricated using ZIF-67 nanoparticles as the sacrificial template. By incorporating different amounts of ZIF-67 during interfacial polymerization, the resultant TFC membranes can have different degrees of nanovoids after self-degradation of ZIF-67 in water, consequently influencing their physiochemical properties and separation performance. Nanovoid structures endow the membranes with additional passages for water molecules. Thus, all the newly developed TFC membranes exhibit better separation performance for brackish water reverse osmosis (BWRO) desalination than the pristine TFC membrane. The membrane made from 0.1 wt % ZIF-67 shows a water permeance of 2.94 LMH bar^-1 and a salt rejection of 99.28% when being tested under BWRO at 20 bar. This water permeance is 53% higher than that of the pristine TFC membrane with the salt rejection well maintained.

Thin-Film Nanocomposite Membrane Incorporated with Porous Zn-Based Metal-Organic Frameworks: Toward Enhancement of Desalination Performance and Chlorine Resistance

Metal-organic framework (MOF) materials have received extensive attention for the design of advanced thin-film nanocomposite (TFN) membranes with excellent permselectivity. However, the relationship between the unique physicochemical properties and performance of engineered MOF-based membranes has yet to be extensively investigated. In this work, we investigate the incorporation of porous zinc-based MOFs (Zn-MOFs) into a polyamide active layer for the fabrication of TFN membranes on porous poly(phenylsulfone) (PPSU) support layers through an interfacial polymerization approach. The actual effects of varying the amount of Zn-MOF added as a nanofiller on the physicochemical properties and desalination performance of TFN membranes are studied. The presence and layout of Zn-MOFs on the top layer of the membranes were confirmed by X-ray photoelectron spectroscopy, scanning electron microscopy, and ζ potential analysis. The characterization results revealed that Zn-MOFs strongly bind with polyamide and significantly change the membrane chemistry and morphology. The results indicate that all four studied TFN membranes with incorporated Zn-MOFs enhanced the water permeability while retaining high salt rejection compared to a thin-film composite membrane. Moreover, the highest-performing membrane (50 mg/L Zn-MOF added nanofiller) not only exhibited a water permeability of 2.46 ± 0.12 LMH/bar but also maintained selectivity to reject NaCl (>90%) and Na₂SO₄ (>95%), similar to benchmark values. Furthermore, the membranes showed outstanding water stability throughout 72 h filtration and chlorine resistance after a 264 h chlorine-soaking test because of the better compatibility between the polyamide and Zn-MOF nanofiller. Therefore, the developed TFN membrane has potential to solve trade-off difficulties between permeability and selectivity. Our findings indicate that porous Zn-MOFs play a significant role in the development of a TFN membrane with high desalination performance and chlorine resistance.

Improving dispersive mixing in compatibilized polystyrene/polyamide-6 blends via extension-dominated reactive single-screw extrusion

Extensional mixing elements (EMEs) that impose extension-dominated flow via stationary single-plane or double-plane hyperbolic converging-diverging channels were previously designed for twin-screw and single-screw extruders (TSE and SSE, respectively). In a recently published work by the authors, reactive extrusion was performed on PS/PA6 polymer blends TSE using EMEs and a crystalline phase transition of the minor phase in these droplets was observed as the size of droplet decreases from micron to submicron. Herein, we expand upon this work to SSE and study: a) The ability of the EMEs to improve dispersive mixing in the same blends; b) Assess the possibility of achieving the same crystalline phase transition in SSEs. The final blends were characterized by DSC, rheologically and morphologically via SEM, and the results show that while EME-based SSE leads to much improved mixing, better than non-EME TSE, the reduction in size of the PA6 disperse phase is not enough to induce the phase transition observed in EME-based TSE.

PVA Films with Mixed Silver Nanoparticles and Gold Nanostars for Intrinsic and Photothermal Antibacterial Action

PVA films with embedded either silver nanoparticles (AgNP), NIR-absorbing photothermal gold nanostars (GNS), or mixed AgNP+GNS were prepared in this research. The optimal conditions to obtain stable AgNP+GNS films with intact, long lasting photothermal GNS were obtained. These require coating of GNS with a thiolated polyethylene glycol (PEG) terminated with a carboxylic acid function, acting as reticulant in the film formation. In the mixed AgNP+GNS films, the total noble metal content is <0.15% w/w and in the Ag films < 0.025% w/w. The slow but prolonged Ag⁺ release from film-embedded AgNP (8–11% of total Ag released after 24 h, in the mixed films) results in a very strong microbicidal effect against planktonic Escherichia coli and Staphylococcus aureus bacterial strains (the release of Au from films is instead negligible). Beside this intrinsic effect, the mixed films also exert an on-demand, fast hyperthermal bactericidal action, switched on by NIR laser irradiation (800 nm, i.e., inside the biotransparent window) of the localized surface plasmon resonance (LSPR) absorption bands of GNS. Temperature increases of 30 °C are obtained using irradiances as low as 0.27 W/cm². Moreover, 80–90% death on both strains was observed in bacteria in contact with the GNS-containing films, after 30 min of irradiation. Finally, the biocompatibility of all films was verified on human fibroblasts, finding negligible viability decrease in all cases.

Thin film nanocomposite membrane with triple-layer structure for enhanced water flux and antibacterial capacity

Triple-layered thin film composite (TFC) forward osmosis (FO) membranes prepared on interlayer-based supports have overcome the limitations of conventional porous substrates due to the formation of ultrathin and highly selective polyamide (PA) layers. However, mitigating the internal concentration polarization (ICP) and biofouling of TFC membranes remain a great challenge. Herein, we designed a novel triple-layered thin film nanocomposite (TFN) FO membrane with incorporation of silver (Ag) decorated graphene oxide quantum dots (GOQD) into PA layer via interfacial polymerization on a carbon nanotube (CNT) interlayer-based polyether sulfone substrate. By contrast with the TFC membranes, the newly developed GOQD/Ag incorporated triple-layered TFN membrane (TFN-GOQD/Ag) exhibited a great alleviation for ICP accompanied with a prominently enhanced water flux of 65.8 L·m^-2·h^-1 and decreased specific reverse salt flux of 1.4 g·m^-2·h^-1 by employing 1 M NaCl solution as draw solution. Moreover, the TFN-GOQD/Ag membrane possessed prominent antibacterial activity against both E. coli (99.8%) and S. aureus (97.3%). Noteworthy, the obtained TFN membrane demonstrated a controlled release of Ag⁺ along with long-term antibacterial potential and outstanding fouling resistance during the FO process. This work provides a new avenue to fabricate newly FO membranes with superior performance for water cleaning treatment.

Cross-Linked Covalent Organic Framework-Based Membranes with Trimesoyl Chloride for Enhanced Desalination

The rational design of continuous covalent organic framework (COF)-based membranes is challenging for desalination applications, mainly due to the larger intrinsic pore size of COFs and defects in the crystalline film, which lead to a negligible NaCl rejection ratio. In this work, we first demonstrated a COF-based desalination membrane with in situ cross-linking of a COF-TpPa layer by trimesoyl chloride (TMC) to stitch the defects between COF crystals and cross-link the COF cavity with high-cross-linking degree networks to enhance NaCl rejection. With the addition of TMC monomers, both small spherical nodules and some elongated "leaf-like" features were observed on the membrane surface due to the appearance of nanovoids during cross-linking. The resulting COF-based desalination membrane had a water permeability of approximately 0.81 L m^-2 h^-1 bar^-1 and offered substantial enhancement of the NaCl rejection ratio from being negligible to 93.3% at 5 bar. Mechanistic analysis indicated that the amidation reaction of the secondary amine in keto COF with TMC induced the formation of a highly porous network structure both in the cavity and on the exterior of COF, thereby successfully forming a continuous and nanovoid-containing selective layer for desalination. In addition, the membrane exhibited excellent desalting performance for real industrial wastewater with both low and high salinity. This study proposed that the introduction of a cross-linker to react with the terminal amine group and secondary amine in the backbone of the keto form of COF or its derivatives could provide a facile and scalable approach to fabricate a COF-based membrane with superior NaCl rejection. This opens a new fabrication route for COF-based desalination membranes, as well as extended applications in water desalination.

Frontiers of Membrane Desalination Processes for Brackish Water Treatment: A Review

Climate change, population growth, and increased industrial activities are exacerbating freshwater scarcity and leading to increased interest in desalination of saline water. Brackish water is an attractive alternative to freshwater due to its low salinity and widespread availability in many water-scarce areas. However, partial or total desalination of brackish water is essential to reach the water quality requirements for a variety of applications. Selection of appropriate technology requires knowledge and understanding of the operational principles, capabilities, and limitations of the available desalination processes. Proper combination of feedwater technology improves the energy efficiency of desalination. In this article, we focus on pressure-driven and electro-driven membrane desalination processes. We review the principles, as well as challenges and recent improvements for reverse osmosis (RO), nanofiltration (NF), electrodialysis (ED), and membrane capacitive deionization (MCDI). RO is the dominant membrane process for large-scale desalination of brackish water with higher salinity, while ED and MCDI are energy-efficient for lower salinity ranges. Selective removal of multivalent components makes NF an excellent option for water softening. Brackish water desalination with membrane processes faces a series of challenges. Membrane fouling and scaling are the common issues associated with these processes, resulting in a reduction in their water recovery and energy efficiency. To overcome such adverse effects, many efforts have been dedicated toward development of pre-treatment steps, surface modification of membranes, use of anti-scalant, and modification of operational conditions. However, the effectiveness of these approaches depends on the fouling propensity of the feed water. In addition to the fouling and scaling, each process may face other challenges depending on their state of development and maturity. This review provides recent advances in the material, architecture, and operation of these processes that can assist in the selection and design of technologies for particular applications. The active research directions to improve the performance of these processes are also identified. The review shows that technologies that are tunable and particularly efficient for partial desalination such as ED and MCDI are increasingly competitive with traditional RO processes. Development of cost-effective ion exchange membranes with high chemical and mechanical stability can further improve the economy of desalination with electro-membrane processes and advance their future applications.

Metal ferrite incorporated polysulfone thin-film nanocomposite membranes for wastewater treatment

Effluents from food, fermentation, and sugar industries contain a large quantity of glucose which has to be removed to limit the chemical oxygen demand (COD) of the water discharged. This work proposes novel thin-film nanocomposite (TFN) membranes incorporated with MgFe₂O₄ and ZnFe₂O₄ nanoparticles to address this concern. The nanoparticles synthesized by the sol-gel method was extensively characterized and then incorporated into the active polyamide layer of the thin-film composite polysulfone membranes. The change in membrane morphology, wettability, chemical structure, and mechanical strength with the incorporation of nanoparticles was studied in detail. Membranes with 0.005 wt.% MgFe₂O₄ nanoparticle exhibited highest glucose rejection (96.52 ± 2.35%) at 10 bar, 25 °C, and sufficiently high pure water flux (50.54 ± 1.92 L/m²h). This membrane also displayed 69.1 ± 5.12% salt rejection when challenged with 2000 ppm synthetic NaCl solution.

Differentiating Solutes with Precise Nanofiltration for Next Generation Environmental Separations: A Review

Selective removal or enrichment of targeted solutes including micropollutants, valuable elements, and mineral scalants from complex aqueous matrices is both challenging and pivotal to the success of water purification and resource recovery from unconventional water resources. Membrane separation with precision at the subnanometer or even subangstrom scale is of paramount importance to address those challenges via enabling "fit-for-purpose" water and wastewater treatment. So far, researchers have attempted to develop novel membrane materials with precise and tailored selectivity by tuning membrane structure and chemistry. In this critical review, we first present the environmental challenges and opportunities that necessitate improved solute-solute selectivity in membrane separation. We then discuss the mechanisms and desired membrane properties required for better membrane selectivity. On the basis of the most recent progress reported in the literature, we examine the key principles of material design and fabrication, which create membranes with enhanced and more targeted selectivity. We highlight the important roles of surface engineering, nanotechnology, and molecular-level design in improving membrane selectivity. Finally, we discuss the challenges and prospects of highly selective NF membranes for practical environmental applications, identifying knowledge gaps that will guide future research to promote environmental sustainability through more precise and tunable membrane separation.

Recent development of pressure retarded osmosis membranes for water and energy sustainability: A critical review

With the goal of zero-liquid discharge and green energy harvest, extraction of abundant green energy from saline water via pressure retarded osmosis (PRO) technology is a promising but challenging issue for water treatment technologies to achieve water and energy sustainability. Development of high performance PRO membranes has received increased concerns yet still under controversy in practical applications. In this review, a comprehensive and up-to-date discussion of some key historical developments is first introduced covering the major advances of PRO engineering applications and novel membranes especially made in recent years. Then the critical performance indicators of PRO membranes including water flux and power density are briefly discussed. Subsequently, sufficient discussion on four performance limiting factors in PRO membrane and process is presented including concentration polarization, reverse solute diffusion, membrane fouling and mechanical stability. To fully address these issues, an updated insight is provided into recent major progresses on advanced fabrication and modification techniques of novel PRO membranes featuring enhanced performance with different configurations and materials, which are also reviewed in detail based on the viewpoint of design rationales. Afterwards, antifouling strategies and engineering applications are critically introduced. Finally, conclusions and future perspective of PRO membrane for practical operation are briefly discussed.

Forward osmosis membrane technology for nutrient removal/recovery from wastewater: Recent advances, proposed designs, and future directions

In recent years, the concept of nutrient removal/recovery has been applied as a sustainable solution to develop and design various modern wastewater treatment technologies for recovering nutrients from waste streams and is one of the high-priority research areas. Forward osmosis (FO) technology has received increasing interests as a potential low-fouling membrane process and a new approach to remove/recover nutrients from wastewater and sludge. The main objective of this review is to summarize the state of FO technology for nutrient removal/recovery from wastewater and sludge in order to identify areas of future improvements. In this study, nutrient removal processes, FO membrane technology, main factors affecting the FO process performance, the source water for nutrient recovery, the previous studies on the FO membrane process for nutrient removal/recovery from wastewater and sludge, membrane fouling, and recent advances in FO membranes for nutrient removal/recovery were briefly and critically reviewed. Then, the proposed possible designs to apply FO process in conventional wastewater treatment plants (WWTPs) were theoretically presented. Finally, based on the gaps identified in the area, challenges ahead, future perspectives, and conclusions were discussed. Further investigations on the properties of FO associated with real wastewater, wastewater pre-treatment, the long-term low fouling operation, membrane cleaning strategies, water flux and the economic feasibility of the FO process are still desirable to apply FO technology for nutrient removal/recovery at full-scale (decentralized or centralized) in the future.

A Critical Review on Thin-Film Nanocomposite Membranes with Interlayered Structure: Mechanisms, Recent Developments, and Environmental Applications

The separation properties of polyamide reverse osmosis and nanofiltration membranes, widely applied for desalination and water reuse, are constrained by the permeability-selectivity upper bound. Although thin-film nanocomposite (TFN) membranes incorporating nanomaterials exhibit enhanced water permeance, their rejection is only moderately improved or even impaired due to agglomeration of nanomaterials and formation of defects. A novel type of TFN membranes featuring an interlayer of nanomaterials (TFNi) has emerged in recent years. These novel TFNi membranes show extraordinary improvement in water flux (e.g., up to an order of magnitude enhancement) along with better selectivity. Such enhancements can be achieved by a wide selection of nanomaterials, ranging from nanoparticles, one-/two-dimensional materials, to interfacial coatings. The use of nanostructured interlayers not only improves the formation of polyamide rejection layers but also provides an optimized water transport path, which enables TFNi membranes to potentially overcome the longstanding trade-off between membrane permeability and selectivity. Furthermore, TFNi membranes can potentially enhance the removal of heavy metals and micropollutants, which is critical for many environmental applications. This review critically examines the recent developments of TFNi membranes and discusses the underlying mechanisms and design criteria. Their potential environmental applications are also highlighted.

Covalent organic frameworks embedded membrane via acetic-acid-catalyzed interfacial polymerization for dyes separation: Enhanced permeability and selectivity

With the increasing demand of high water-quality, membrane filtration technologies are playing further important roles in water treatment owing to their small footprints, reduced use of chemicals and stable performances. However, the inherent permeability-selectivity trade-off is still a significant obstacle restricting the broad applications of membrane separation. Hydrophilic modification via doping nanoparticles into membranes is considered an effective solution to improve the permeability while maintaining selectivity. However, agglomeration of nanoparticles often results in inhomogeneity of the modified membranes. In this study, hybrid membranes with separated covalent organic framework (COF) particles that were uniformly embedded in the membrane surface pores were firstly fabricated via acetic-acid-catalyzed in situ synthesis. Owing to the ample hydrophilic chemical groups and tunable molecular transport channels in COFs, the modified membranes yielded almost twice higher water flux (about 200 L m^-2·h^-1·bar) than the pristine membranes with simultaneously enhanced rejection of water pollutants (i.e., dyes). In addition, the pure organic structure of COF improves the polymer-filler interaction of the mixed film, thereby reducing the risk of leakage. Therefore, the hybrid membranes also exhibited relatively high stability in long-term operations and different pH conditions, which makes them promising candidates in future membrane applications.

Enhancing nanofiltration performance by incorporating tannic acid modified metal-organic frameworks into thin-film nanocomposite membrane

Nanofiltration (NF) is an advanced environmental technology in water treatment. To thin film nanocomposite (TFN) membrane, good compatibility between nanofillers and polyamide (PA) layer is the guarantee of remarkable performance. Herein, tannic acid (TA) was employed as modifier of UIO-66-NH₂ prior to the interfacial polymerization (IP). With TA modification, more interaction can be formed so that the compatibility between nanofillers and PA layer can be promoted at the molecular level. Characterizations demonstrated the coating of TA on UIO-66-NH₂, together with successful introducing of nanofillers in TFN membranes. Compared to pristine thin film composite (TFC) membrane, both UIO-incorporated TFN (TFN-U) and TA modified UIO-incorporated TFN (TFN-TU) membranes showed higher permeance (111.2% and 93% enhancement, respectively). However, under the same nanofillers dose, TFN-TU exhibited slightly lower permeance and higher rejection than TFN-U since the bridging effect of TA healed non-selective voids in skin layer. With the increasing of nanofiller dose in IP, TFN-TU remained reasonable selectivity while TFN-U failed to. Moreover, TFN-TU showed better anti-fouling property due to TA modification. Introducing TA modified MOFs into IP can serve as an ingenious strategy for TFN membrane to achieve high-quality environmental applications.

Progress of Interfacial Polymerization Techniques for Polyamide Thin Film (Nano)Composite Membrane Fabrication: A Comprehensive Review

In this paper, we review various novel/modified interfacial polymerization (IP) techniques for the fabrication of polyamide (PA) thin film composite (TFC)/thin film nanocomposite (TFN) membranes in both pressure-driven and osmotically driven separation processes. Although conventional IP technique is the dominant technology for the fabrication of commercial nanofiltration (NF) and reverse osmosis (RO) membranes, it is plagued with issues of low membrane permeability, relatively thick PA layer and susceptibility to fouling, which limit the performance. Over the past decade, we have seen a significant growth in scientific publications related to the novel/modified IP techniques used in fabricating advanced PA-TFC/TFN membranes for various water applications. Novel/modified IP lab-scale studies have consistently, so far, yielded promising results compared to membranes made by conventional IP technique, in terms of better filtration efficiency (increased permeability without compensating solute rejection), improved chemical properties (crosslinking degree), reduced surface roughness and the perfect embedment of nanomaterials within selective layers. Furthermore, several new IP techniques can precisely control the thickness of the PA layer at sub-10 nm and significantly reduce the usage of chemicals. Despite the substantial improvements, these novel IP approaches have downsides that hinder their extensive implementation both at the lab-scale and in manufacturing environments. Herein, this review offers valuable insights into the development of effective IP techniques in the fabrication of TFC/TFN membrane for enhanced water separation.

Nanodiamond-Enabled Thin-Film Nanocomposite Polyamide Membranes for High-Temperature Water Treatment

Despite growing demands for high-temperature wastewater treatment, most available polymeric membranes are limited to mild operating temperatures (<50 °C) and become less efficient at high temperatures. Herein we show how to make thermally stable reverse osmosis thin-film nanocomposite (TFN) membranes by embedding nanodiamond (ND) particles. Polyamide composite layers containing different loadings of surface-modified ND particles were synthesized through interfacial polymerization. The reactive functional groups and the hydrophilic surface of the NDs intensified the interactions of the nanoparticles with the polymer matrix and increased the surface wettability of the TFN membranes. Contact angle measurement showed a maximum decrease from 88.4° for the pristine membrane to 58.3° for the TFN membrane fabricated with 400 ppm ND particles. The addition of ND particles and ethyl acetate created larger surface features on the polyamide surface of TFN membranes. The average roughness of the membranes increased from 108.4 nm for the pristine membrane to 177.5 nm for the TFN membrane prepared with highest ND concentration. The ND-modified TFN membranes showed a higher pure water flux (up to 76.5 LMH) than the pristine membrane (17 LMH) at ambient temperature at 220 psi and room temperature. The TFN membrane with the highest loading of ND particles overcame the trade-off relation between the water flux and NaCl rejection with 76.5 LMH and 97.3% when 2000 ppm of NaCl solution was filtered at 220 psi. Furthermore, with increasing ND concentration, the TFN membrane showed a lower flux decline at high temperatures over time. The TFN400 prepared with 400 ppm of m-phenylene diamine functionalized ND particles had a 13% flux decline over a 9 h filtration test at 75 °C. This research provides a promising path to the development of high-performance TFN membranes with enhanced thermal stability for the treatment of wastewaters at high temperatures.

High-performance nanofiltration membranes with a sandwiched layer and a surface layer for desalination and environmental pollutant removal

To overcome the permeability-selectivity limitation and improve the performance of desalination membranes, novel methods and design strategies are needed to prepare new types of thin film composite (TFC) nanofiltration (NF) membranes. In this work, a modified TFC membrane with a sandwiched layer and a surface layer was fabricated through a facile additional two-step approach. The microfiltration (MF) substrate and TFC surface were modified by a cellulose nanocrystal (CNC) sandwiched layer and a polydopamine (PDA) layer, respectively. Scanning electron microscopy (SEM) analysis indicated that the support modified by CNCs presented a more homogeneous surface than the control TFC. Cross-sectional SEM images showed that the underneath MF support, CNC interlayer, polyamide layer and PDA deposition layer were perfectly integrated. The surface charge was determined by an electrophoretic analyzer and revealed that the CNC interlayer increased the membrane electronegativity, while the PDA layer presented the opposite effect. Compared to the control TFC membrane, the solute permeability and rejection of the resultant CNC-TFC-PDA membrane were simultaneously increased, indicating a breakthrough in the trade-off limitation. The modified membranes exhibited a high removal rate for Congo red, Rose Bengal, sodium lignosulfonate and alkaline lignin, suggesting their excellent rejection performance for textile dyes and lignin derivatives. Fouling tests indicated that both the interlayer and surface layer exhibited positive effects on fouling alleviation. The effects of each functional layer were explored, and the main factors for performance improvement, including the modified hydrophilicity, surface charge, pore size and surface roughness, were discussed.