Investigation of the performance behavior of a forward osmosis membrane system using various feed spacer materials fabricated by 3D printing technique

3D-Printed Materials for Wastewater Treatment

The increasing levels of water pollution pose an imminent threat to human health and the environment. Current modalities of wastewater treatment necessitate expensive instrumentation and generate large amounts of waste, thus failing to provide ecofriendly and sustainable solutions for water purification. Over the years, novel additive manufacturing technology, also known as three-dimensional (3D) printing, has propelled remarkable innovation in different disciplines owing to its capability to fabricate customized geometric objects rapidly and cost-effectively with minimal byproducts and hence undoubtedly emerged as a promising alternative for wastewater treatment. Especially in membrane technology, 3D printing enables the designing of ultrathin membranes and membrane modules layer-by-layer with different morphologies, complex hierarchical structures, and a wide variety of materials otherwise unmet using conventional fabrication strategies. Extensive research has been dedicated to preparing membrane spacers with excellent surface properties, potentially improving the membrane filtration performance for water remediation. The revolutionary developments in membrane module fabrication have driven the utilization of 3D printing approaches toward manufacturing advanced membrane components, including biocarriers, sorbents, catalysts, and even whole membranes. This perspective highlights recent advances and essential outcomes in 3D printing technologies for wastewater treatment. First, different 3D printing techniques, such as material extrusion, selective laser sintering (SLS), and vat photopolymerization, emphasizing membrane fabrication, are briefly discussed. Importantly, in this Perspective, we focus on the unique 3D-printed membrane modules, namely, feed spacers, biocarriers, sorbents, and so on. The unparalleled advantages of 3D printed membrane components in surface area, geometry, and thickness and their influence on antifouling, removal efficiency, and overall membrane performance are underlined. Moreover, the salient applications of 3D printing technologies for water desalination, oil-water separation, heavy metal and organic pollutant removal, and nuclear decontamination are also outlined. This Perspective summarizes the recent works, current limitations, and future outlook of 3D-printed membrane technologies for wastewater treatment.

Evaluation of vibratory shear-enhanced processing module-integrated three-dimensional printed spacers for enhanced wastewater ultrafiltration

The article evaluates the effectiveness of two new designed module-integrated three-dimensional (3D) printed spacers in enhancing wastewater ultrafiltration efficiencies using vibratory shear-enhanced processing (VSEP). The study investigates the star-shaped spacer filled module channel (star spacer) and the column-shaped herringbone spacer filled module channel with the same position as the flow direction (column spacer) and with the opposite position as the flow direction (rev column spacer). It compares the VSEP module-integrated spacers with membrane module vibration (module vibration) and empty membrane module channel (control) configurations. The results show that the module integration of the 3D printed spacers can greatly improve the specific, average, and constant permeate fluxes and can contribute to reducing the total, reversible and irreversible resistance values, and specific energy consumption of the ultrafiltration membrane separation experiments. Overall, this study provides valuable insights into improving the performance of wastewater ultrafiltration systems and fouling mitigation through the module integration of 3D printed spacers and membrane module vibration. PRACTITIONER POINTS: Vibratory shear-enhanced processing (VSEP) ultrafiltration module-integrated 3D printed spacers were successfully fabricated and evaluated for improved wastewater treatment. Two spacer designs, a star-shaped and a column-shaped herringbone, were compared with an empty membrane module channel with and without vibration. Two configurations of the column-shaped spacer, in the same and reversed flow direction, were tested. Specific energy consumption was calculated and compared for all configurations. Significant improvements in ultrafiltration performance were observed with the use of spacers compared with an empty module channel, including enhanced permeate fluxes and reductions in both total and reversible, as well as irreversible, resistance.

Custom-designed 3D printed feed spacers and TFN membranes with MIL-101(Fe) for water recovery by forward osmosis

ABSTRACTIn this work, a dual-pronged approach- (i) novel thin-film nanocomposite polyether sulfone (PES) membrane with MIL-101 (Fe) and (ii) 3D printed spacers were explored to enhance water recovery by forward osmosis. The concentration of PES, pore former, draw solution, and MIL-101(Fe) was optimized for maximum pure water flux (PWF) and minimum specific reverse solute flux (SRSF). The best membrane exhibited a PWF of 7.52 Lm^-2h^-1 and an SRSF of 0.33 ± 0.03 gL^-1 using 1.5 M NaCl. The M₂₂ membrane with the diamond-type spacer demonstrated a PWF of 2.53 Lm^-2h^-1 and SRF of 0.75 gL^-1. The novel spacer design imparted significant turbulence to the feed flow and a lower foulant resistance of 1.3 m^-1 as compared to the ladder type (1.5 m^-1) or commercial spacer (1.7 m^-1). This arrangement could recover 19% pure water within 12 h of operation (98% oil rejection) with a ∼ 94% flux recovery after water wash.

Designing sustainable membrane-based water treatment via fouling control through membrane interface engineering and process developments

Membrane-based water treatment processes have been established as a powerful approach for clean water production. However, despite the significant advances made in terms of rejection and flux, provision of sustainable and energy-efficient water production is restricted by the inevitable issue of membrane fouling, known to be the major contributor to the elevated operating costs due to frequent chemical cleaning, increased transmembrane resistance, and deterioration of permeate flux. This review provides an overview of fouling control strategies in different membrane processes, such as microfiltration, ultrafiltration, membrane bioreactors, and desalination via reverse osmosis and forward osmosis. Insights into the recent advancements are discussed and efforts made in terms of membrane development, modules arrangement, process optimization, feed pretreatment, and fouling monitoring are highlighted to evaluate their overall impact in energy- and cost-effective water treatment. Major findings in four key aspects are presented, including membrane surface modification, modules design, process integration, and fouling monitoring. Among the above mentioned anti-fouling strategies, a large part of research has been focused on membrane surface modifications using a number of anti-fouling materials whereas much less research has been devoted to membrane module advancements and in-situ fouling monitoring and control. At the end, a critical analysis is provided for each anti-fouling strategy and a rationale framework is provided for design of efficient membranes and process for water treatment.

Meta-analyzing the efficacy of 3D printed models in anatomy education

Three-dimensional printing models (3DPs) have been widely used in medical anatomy training. However, the 3DPs evaluation results differ depending on such factors as the training objects, experimental design, organ parts, and test content. Thus, this systematic evaluation was carried out to better understand the role of 3DPs in different populations and different experimental designs. Controlled (CON) studies of 3DPs were retrieved from PubMed and Web of Science databases, where the participants were medical students or residents. The teaching content is the anatomical knowledge of human organs. One evaluation indicator is the mastery of anatomical knowledge after training, and the other is the satisfaction of participants with 3DPs. On the whole, the performance of the 3DPs group was higher than that of the CON group; however, there was no statistical difference in the resident subgroup, and there was no statistical difference for 3DPs vs. 3D visual imaging (3DI). In terms of satisfaction rate, the summary data showed that the difference between the 3DPs group (83.6%) vs. the CON group (69.6%) (binary variable) was not statistically significant, with p > 0.05. 3DPs has a positive effect on anatomy teaching, although there are no statistical differences in the performance tests of individual subgroups; participants generally had good evaluations and satisfaction with 3DPs. 3DPs still faces challenges in production cost, raw material source, authenticity, durability, etc. The future of 3D-printing-model-assisted anatomy teaching is worthy of expectation.

Miniaturized 3D printed electrochemical platform with optimized Fibrous carbon electrode for non-interfering hypochlorite sensing

3D printing technology based electrochemical device can provide ease of fabrication, cost effectiveness, rapid detection and lower limit of detection. Herein, a novel, customized, portable and inexpensive 3D printed electrochemical device, has been presented. Fibrous carbon Toray paper, deposited with gold nanoparticles through electrodeposition, used as a working electrode which Further device was tested with 1 mM sodium hypochlorite using cyclic voltammetry (CV) and square wave voltammetry (SWV) in 0.1 M PBS. Hypochlorite has a pivotal role in supporting the growing chemical and paper industries and finds diverse uses in several clinical applications. It is primarily used for disinfecting food, water and surfaces. The scan rate study was carried out from 20 mVs^-1 to 250 mVs^-1 using cyclic voltammetry technique. The diffusion coefficient obtained from scan rate effect was 1.39 × 10^-6 cm²s^-1. The concentration range was evaluated with SWV technique, in a linear range of 0.6 μM-40 μM, with a detection limit of 0.7 μM. The device was further analyzed to ensure non-interference from co-existing chemicals like sodium chloride, potassium nitrate, sodium carbonate, sodium nitrite. Real sample analysis was done with sea, artificial sea and tap water with impressive recovery values. In summary, the developed working electrode can be customized and modified based on testing analyte; thus, the proposed device can be used for various other biochemical analytes.

Enhancement of wastewater treatment performance using 3D printed structures: A major focus on material composition, performance, challenges, and sustainable assessment

In order to enhance the performance and sustainability of wastewater treatment technologies, researchers are showing keen interest in the development of novel materials which can overcome the drawbacks associated with conventional materials. In this context, 3D printing gained significant attention due to its capability of fabricating complex geometrics using different material compositions. The present review focuses on recent advancements of 3D printing applications in various physicochemical and biological wastewater treatment techniques. In physicochemical treatment methods, substantial research has been aimed at fabricating feed spacers and other membrane parts, photocatalytic feed spacers, catalysts, scaffolds, monoliths, and capsules. Several advantages, such as membrane fouling mitigation, enhanced degradation efficiency, and recovery and reusability potential, have been associated with the aforementioned 3D printed materials. While in biofilm-based biological treatment methods, the use of 3D printed bio-carriers has led to enhanced mass transfer efficiency and microbial activities. Moreover, the application of these bio-carriers has shown better removal efficiency of chemical oxygen demand (∼90%), total nitrogen (∼73%), ammonia nitrogen (95%), and total phosphorous (∼100%). Although the removal efficiencies were comparable with conventional carriers, 3D printed carriers led to ∼40% reduction in hydraulic retention time, which could significantly save capital and operational expenditures. This review also emphasizes the challenges and sustainability aspects of 3D printing technology and outlines future recommendations which could be vital for further research in this field.

The emerging role of 3D printing in water desalination

Unmatched flexibility in terms of material selection, design and scalability, along with gradually decreasing cost, has led 3D printing to gain significant attention in various water treatment and desalination applications. In desalination, 3D printing has been applied to improve the energy efficiency of existing technologies. For thermal desalination, this involves the use of 3D printed components that enhance water evaporation and energy harvesting with new materials and designs. For membrane-based desalination, 3D printing offers membranes and other module components with customized materials and geometries for better fouling resistance and productivity. This review highlights the current status, advances and challenges associated with 3D printing in both thermal and membrane-based desalination technologies. Other unique benefits offered by 3D printing for water desalination along with the associated challenges are also discussed in this review. Finally, the future prospects and research directions are highlighted related to the application of 3D printing in the water desalination industry.

Roles and performance enhancement of feed spacer in spiral wound membrane modules for water treatment: A 20-year review on research evolvement

Membrane technologies have been widely applied in water treatment, wastewater reclamation and seawater desalination. Feed spacer present in spiral wound membrane (SWM) modules plays a pivotal role in creating flow channels, promoting fluid mixing and enhancing mass transfer. However, it induces the increase of feed channel pressure (FCP) drop and localized stagnant zones that provokes membrane fouling. For the first time, we comprehensively review the research evolvement on feed spacer in SWM modules for water treatment over the last 20 years, to reveal the impacts of feed spacer on the hydrodynamics and biofouling in the spacer-filled channel, and to discuss the potential approaches and current limitations for the modification of feed spacer. The research process can be divided into three phases, with research focus shifting from hydrodynamics in Phase Ⅰ (the year of 2001-2008), to biofouling in Phase Ⅱ (the year of 2009-2015), and then to novel spacer designs in Phase Ⅲ (the year of 2016-2020). The spacer configuration has a momentous impact on the hydraulic performance regarding flow velocity field, shear stress, mass transfer and FCP drop. Biofouling initially occurs on feed spacer, especially around spacer filaments and the contact zones with membrane surface, and ultimately degrades the overall membrane performance indicating the importance of controlling spacer biofouling. The modification of feed spacer is mainly achieved by altering surface chemistry or introducing novel configurations. However, the stability of spacer coating and the economy and practicality of 3D-printed spacer remain a predicament to be tackled. Future studies are suggested to focus on the standardization of testing conditions for spacer evaluation, the effect of hydrodynamics on membrane fouling control, the design and fabrication of novel feed spacer adaptable for SWM modules, the application of feed spacer for drinking water production, organic fouling control in spacer-filled channel and the role of permeate spacer on membrane performance.

Electrically Polarized Graphene-Blended Spacers for Organic Fouling Reduction in Forward Osmosis

In membrane processes, a spacer is known to play a key role in the mitigation of membrane fouling. In this study, the effect of electric polarization on a graphene-blended polymer spacer (e.g., poly(lactic acid), PLA) for organic fouling on membrane surfaces was investigated. A pristine PLA spacer (P-S), a graphene-blended spacer (G-S), and an electrically polarized graphene-blended spacer (EG-S) were successfully fabricated by 3D printing. Organic fouling tests were conducted by the 5-h filtration of CaCl₂ and a sodium alginate solution through commercially available membranes, which were placed together with the fabricated spacers. Membranes utilizing P-S, G-S, and EG-S were characterized in terms of the fouling amount on the membrane surface and fouling roughness. Electrostatic forces of EG-S provided 70% less and 90% smoother fouling on the membrane surface, leading to an only 14% less water flux reduction after 5 h of fouling. The importance of nanomaterial blending and polarization was successfully demonstrated herein.

A review on spacers and membranes: Conventional or hybrid additive manufacturing?

Over the past decade, 3D printing or additive manufacturing (AM) technology has seen great advancement in many aspects such as printing resolution, speed and cost. Membranes for water treatment experienced significant breakthroughs owing to the unique benefits of additive manufacturing. In particular, 3D printing's high degree of freedom in various aspects such as material and prototype design has helped to fabricate innovative spacers and membranes. However, there were conflicting reports on the feasibility of 3D printing, especially for membranes. Some research groups stated that technology limitations today made it impossible to 3D print membranes, but others showed that it was possible by successfully fabricating prototypes. This paper will provide a critical and comprehensive discussion on 3D printing specifically for spacers and membranes. Various 3D printing techniques will be introduced, and their suitability for membrane and spacer fabrication will be discussed. It will be followed by a review of past studies associated with 3D-printed spacers and membranes. A new category of additive manufacturing in the membrane water industry will be introduced here, known as hybrid additive manufacturing, to address the controversies of 3D printing for membrane. As AM technology continues to advance, its possibilities in the water treatment is limitless. Some insightful future trends will be provided at the end of the paper.

Boron Nitride Nanotube (BNNT) Membranes for Energy and Environmental Applications

Owing to their extraordinary thermal, mechanical, optical, and electrical properties, boron nitride nanotubes (BNNTs) have been attracting considerable attention in various scientific fields, making it more promising as a nanomaterial compared to other nanotubes. Recent studies reported that BNNTs exhibit better properties than carbon nanotubes, which have been extensively investigated for most environment-energy applications. Irrespective of its chirality, BNNT is a constant wide-bandgap insulator, exhibiting thermal oxidation resistance, piezoelectric properties, high hydrogen adsorption, ultraviolet luminescence, cytocompatibility, and stability. These unique properties of BNNT render it an exceptional material for separation applications, e.g., membranes. Recent studies reported that water filtration, gas separation, sensing, and battery separator membranes can considerably benefit from these properties. That is, flux, rejection, anti-fouling, sensing, structural, thermal, electrical, and optical properties of membranes can be enhanced by the contribution of BNNTs. Thus far, a majority of studies have focused on molecular simulation. Hence, the requirement of an extensive review has emerged. In this perspective article, advanced properties of BNNTs are analyzed, followed by a discussion on the advantages of these properties for membrane science with an overview of the current literature. We hope to provide insights into BNNT materials and accelerate research for environment-energy applications.

High performance nanofiber-supported thin film composite forward osmosis membranes based on continuous thermal-rolling pretreated electrospun PES/PAN blend substrates

One of the major challenges facing the practical application of forward osmosis (FO) membranes is the need for high performance. Thus, the fabrication of highly permselective FO membranes is of great importance. The objective of this study was to improve the wettability/hydrophilicity of electrospun nanofiber (ESNF)-based substrates for the fabrication of nanofiber-supported thin film composite (NTFC) membranes for FO application. This study explored the impact of electrospun polyethersulfone/polyacrylonitrile (PES/PAN) nanofibers as the blend support to produce NTFC membranes. The blending of PES/PAN in the spinning dope was optimized. The blending of hydrophilic PAN (0-10 wt%) in PES affects the fiber diameter, hydrophilicity, water uptake, and roughness of the ESNF membrane substrates. Continuous thermal-rolling pretreatment was performed on the ESNF substrates prior to interfacial polymerization for polyamide active layer deposition. The results indicated that the fabricated NTFC membrane achieved significantly greater water flux (L/m² h) while retaining a low specific salt flux (g/L) compared to traditional TFC membranes. The NTFC membrane flux increased with an increase in PAN content in the ESNF substrate. According to the FO performance results, the NTFC-10 (PES/PAN blend ratio of 90:10) exhibited optimal performance: a high water flux of 42.1 and 52.2 L/m² h for the FO and PRO modes, respectively, and low specific salt flux of 0.27 and 0.24 g/L for the FO and PRO modes, respectively, using 1 M NaCl as the draw solution. This demonstrated the higher selectivity and water flux achieved by the developed NTFC membranes compared to the traditional TFC membranes.

Antibacterial rGO-CuO-Ag film with contact- and release-based inactivation properties

To reduce the high operational costs of water treatment because of membrane biofouling, next-generation materials are being developed to counteract microbial growth. These modern anti-biofouling strategies are based on new membrane materials or membrane surface modifications. In this study, antimicrobial films comprising rGO, rGO-CuO, rGO-Ag, and rGO-CuO-Ag were synthesized, evaluated, and tested for potential biofouling control using Pseudomonas aeruginosa PAO1 as the model bacterium. The combined rGO-CuO-Ag film displayed enhanced reduction (10-log reduction) in biofouling in comparison to the rGO film (control), followed by the rGO-Ag film (8-log reduction) and rGO-CuO film (0-log reduction). This demonstrated that the use of mixed antimicrobial agents is more effective in reducing biofouling than that of a single agent. The rGO-CuO-Ag film exhibited consistent, controlled, and moderate release of silver (Ag) ions. The release of Ag ions produced a long-lasting antimicrobial effect. These results underscore the potential applications of combined antimicrobial surface-based agents in practice and further research.

Influence of draw solution type and properties on the performance of forward osmosis process: Energy consumption and sustainable water reuse

Single and multi-component fertilizers were used as a draw solution (DS) in forward osmosis (FO) to produce high-quality water from synthetic and seawater solution, eliminating the need for DS regeneration and reducing the operational energy. The effect of DS type, concentration, circulation flow rates on the FO water flux (WF), specific water flux (SWF), percentage water recovery (%W_recovery), reverse salt flux (RSF) and percentage salt rejection (%R) were studied. The results showed that single fertilizer draw solution (SFDSs) produced higher WF (4.43 L/m².h), %W_recovery (30%) and RSF (60%) in comparison with multi-component draw solution (MCDS) with WF, %W_recovery and RSF of 2.57 L/m².h, 17% and 46%, respectively. DS with higher concentration produced the highest SWF and %W_recovery and consumed less energy. MCDS with concentration of 200 g/L showed SWF in the range of 14.0 to 10.4 L/m²h and energy consumption of 0.312 kW/h m³ in comparison with 10 to 7.8 L/m²h and 0.23 kW/h m³ for MCDS with concentration of 100  g/L. Increasing the recirculation flow rate showed minimum effect on WF and up to 35% energy saving. Pure water extracted using liquid fertilizers utilizing the unique FO mass transport properties balanced nutrient requirement and the water quality parameters, thereby sustaining the aquaponics industry.

Capillary effect in Janus electrospun nanofiber membrane for oil/water emulsion separation

Janus electrospun nanofiber membranes (J-ENMs) have attracted considerable interest as membranes for oil-in-water emulsion separation due to the opposite properties on each side of the membrane. Such properties can provide capillary effect and achieve water unidirectional transportation. However, the capillary effect on performances of the J-ENMs is still obscure. Therefore, it is highly important to investigate the relation of pore size, capillary pressure, and fluid flux of them. For this study, J-ENMs, which have a dual-layer structure with hydrophilic polyacrylonitrile (PAN) and hydrophobic polystyrene (PS) nanofibrous membranes simultaneously, were fabricated via the electrospinning process. Among the fabricated membranes, the large pore sizes of the PS layer of J-ENMs affected capillary pressure leading to a pure water flux increase of nine times that of the small pore size. For emulsion flux, oil droplets can pass through a large pore of the PS layer easily and can cause a decrease in emulsion flux. Nevertheless, the emulsion flux of J-ENMs was 1.7 times higher than that of single layer membrane, which showed a promising application for the oil/water separation field.

Modeling and Simulation Studies Analyzing the Pressure-Retarded Osmosis (PRO) and PRO-Hybridized Processes

Pressure-retarded osmosis (PRO) is viewed as a highly promising renewable energy process that generates energy without carbon emissions in the age of the climate change regime. While many experimental studies have contributed to the quest for an efficiency that would make the PRO process commercially viable, computational modeling and simulation studies have played crucial roles in investigating the efficiency of PRO, particularly the concept of hybridizing the PRO process with reverse osmosis (RO). It is crucial for researchers to understand the implications of the simulation and modeling works in order to promote the further development of PRO. To that end, the authors collected many relevant papers and reorganized their important methodologies and results. This review, first of all, presents the mathematical derivation of the fundamental modeling theories regarding PRO including water flux and concentration polarization equations. After that, those theories and thermodynamic theories are then applied to depict the limitations of a stand-alone PRO process and the effectiveness of an RO-PRO hybridized process. Lastly, the review diagnoses the challenges facing PRO-basis processes which are insufficiently resolved by conventional engineering approaches and, in response, presents alternative modeling and simulation approaches as well as novel technologies.