Growth dynamics of interfacially polymerized polyamide layers by diffuse reflectance spectroscopy and Rutherford backscattering spectrometry

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.

Functionalized-MXene Thin-Film Nanocomposite Hollow Fiber Membranes for Enhanced PFAS Removal from Water

Due to adverse health effects and the broad sources of per- and polyfluoroakyl substances (PFAS), PFAS removal is a critical research area in water purification. We demonstrate the functionalization of thin-film composite (TFC) hollow fiber nanofiltration (HFN) membranes by MXene nanosheets during the interfacial polymerization (IP) process for enhanced removal of perfluorooctane sulfonic acid (PFOS) from water. A MXene-polyamide (PA) selective layer was fabricated on top of a polysulfone (PSF) hollow fiber support via IP of trimesoyl chloride (TMC) and a mixture of piperazine (PIP) and MXene nanosheets to form MXene-PA thin-film nanocomposite (TFN) membranes. Incorporating MXene nanosheets during the IP process tuned the morphology and negative surface charge of the selective layer, resulting in enhanced PFOS rejection from 72% (bare TFC) to more than 96% (0.025 wt % MXene TFN), while the water permeability was also increased from 13.19 (bare TFC) to 29.26 LMH/bar (0.025 wt % MXene TFN). Our results demonstrate that both electrostatic interaction and size exclusion are the main factors governing the PFOS rejection, and both are determined by PA selective layer structural and chemical properties. The lamella structure and interlayer of MXene nanosheets inside the PA layer provided different transport mechanisms for water, ions, and PFAS molecules, resulting in enhanced water permeability and PFAS rejection due to traveling through the membrane by both diffusions through the PA layer and the MXene intralayer channels. MXene nanosheets showed very promising capability as a 2D additive for tuning the structural and chemical properties of the PA layer at the permeability-rejection tradeoff.

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.

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.

Visualizing and monitoring interfacial polymerization by aggregation-induced emission

The aggregation-induced emission effect is used to visualize and monitor interfacial polymerization at the alkane–ionic liquid interface by virtue of the quantitative fluorescence of arylamine luminogens.

A Novel Approach To Optimize the Fabrication Conditions of Thin Film Composite RO Membranes Using Multi-Objective Genetic Algorithm II

This work focuses on developing a novel method to optimize the fabrication conditions of polyamide (PA) thin film composite (TFC) membranes using the multi-objective genetic algorithm II (MOGA-II) method. We used different fabrication conditions for formation of polyamide layer—trimesoyl chloride (TMC) concentration, reaction time (t), and curing temperature (Tc)—at different levels, and designed the experiment using the factorial design method. Three functions (polynomial, neural network, and radial basis) were used to generate the response surface model (RSM). The results showed that the radial basis predicted good results (R² = 1) and was selected to generate the RSM that was used as the solver for MOGA-II. The experimental results indicate that TMC concentration and t have the highest influence on water flux, while NaCl rejection is mainly affected by the TMC concentration, t, and Tc. Moreover, the TMC concentration controls the density of the PA, whereas t confers the PA layer thickness. In the optimization run, MOGA-II was used to determine optimal parametric conditions for maximizing water flux and NaCl rejection with constraints on the maximum acceptable levels of Na₂SO₄, MgSO₄, and MgCl₂ rejections. The optimized solutions were obtained for longer t, higher Tc, and different TMC concentration levels.

Monitoring the Interfacial Polymerization of Piperazine and Trimesoyl Chloride with Hydrophilic Interlayer or Macromolecular Additive by In Situ FT-IR Spectroscopy

The interfacial polymerization (IP) of piperazine (PIP) and trimesoyl chloride (TMC) has been extensively utilized to synthesize nanofiltration (NF) membranes. However, it is still a huge challenge to monitor the IP reaction, because of the fast reaction rate and the formed ultra-thin film. Herein, two effective strategies were applied to reduce the IP reaction rate: (1) the introduction of hydrophilic interlayers between the porous substrate and the formed polyamide layer, and (2) the addition of macromolecular additives in the aqueous solution of PIP. As a result, in situ Fourier transform infrared (FT-IR) spectroscopy was firstly used to monitor the IP reaction of PIP/TMC with hydrophilic interlayers or macromolecular additives in the aqueous solution of PIP. Moreover, the formed polyamide layer growth on the substrate was studied in a real-time manner. The in situ FT-IR experimental results confirmed that the IP reaction rates were effectively suppressed and that the formed polyamide thickness was reduced from 138 ± 24 nm to 46 ± 2 nm according to TEM observation. Furthermore, an optimized NF membrane with excellent performance was consequently obtained, which included boosted water permeation of about 141-238 (L/m2·h·MPa) and superior salt rejection of Na2SO4 > 98.4%.

Controlled Growth of Polyamide Films atop Homogenous and Heterogeneous Hydrogels using Gel-Liquid Interfacial Polymerization

Controlled growth of crosslinked polyamide (PA) thin films is demonstrated at the interface of a monomer-soaked hydrogel and an organic solution of the complementary monomer. Termed gel-liquid interfacial polymerization (GLIP), the resulting PA films are measured to be chemically and mechanically analogous to the active layer in thin film composite membranes. PA thin films are prepared using the GLIP process on both a morphologically homogeneous hydrogel prepared from poly(2-hydroxyethylmethacrylate) (PHEMA) and a phase-separated, heterogeneous hydrogel prepared from poly(acrylamide) (PAAm). Two monomer systems are examined: trimesoyl chloride (TMC) reacting with m-phenylene diamine (MPD) and TMC reacting with piperazine (PIP). Unlike the self-limiting growth behavior in TFC membrane fabrication, diffusion-limited, continuous growth of the PA films is observed, where both the thickness and roughness of the PA layers increase with reaction time. A key morphological difference is found between the two monomer systems using the GLIP process: TMC/MPD produces a ridge-and-valley surface morphology whereas TMC/PIP produces nodule/granular structures. The GLIP process represents a unique opportunity to not only explore the pore characteristics (size, spacing, and continuity) on the resulting structure and morphology of interfacially polymerized thin films, but also a method to modify the surface of (or encapsulate) hydrogels.

A Novel Thin-Film Nanocomposite Nanofiltration Membrane by Incorporating 3D Hyperbranched Polymer Functionalized 2D Graphene Oxide

In order to develop a high-performance thin-film nanocomposite (TFN) nanofiltration (NF) membrane, the functionalized graphene-based nanomaterial (GO-HBE-COOH) was synthesized by combining two-dimensional graphene oxide (GO) with a three-dimensional hyperbranched polymer, which was used as the novel nanofiller and successfully embedded into the polypiperazine-amide (PPA) active layers on polysulfone (PSU) substrates via interfacial polymerization (IP) process. The resultant NF membranes were characterized using ATR-FTIR, SEM, and AFM, while their performance was evaluated in terms of water flux, salt rejection, antifouling ability, and chlorine resistance. The influence of GO-HBE-COOH concentration on the morphologies, properties, and performance of TFN NF membranes was investigated. With the addition of 60 ppm GO-HBE-COOH, the TFN-GHC-60 NF membrane exhibited the optimal water flux without a sacrifice of the salt rejection. It was found that the introduction of GO-HBE-COOH nanosheets favored the formation of a thinner and smoother nanocomposite active layer with an enhanced hydrophilicity and negative charge. As a result, TFN NF membranes demonstrated a superior permeaselectivity, antifouling ability, and chlorine resistance over the conventional PPA thin-film composite (TFC) membranes.

Water Transport through Ultrathin Polyamide Nanofilms Used for Reverse Osmosis

Thin-film composite membranes comprising a polyamide nanofilm separating layer on a support material are state of the art for desalination by reverse osmosis. Nanofilm thickness is thought to determine the rate of water transport through the membranes; although due to the fast and relatively uncontrolled interfacial polymerization reaction employed to form these nanofilms, they are typically crumpled and the separating layer is reported to be ≈50-200 nm thick. This crumpled structure has confounded exploration of the independent effects of thickness, permeation mechanism, and the support material. Herein, smooth sub-8 nm polyamide nanofilms are fabricated at a free aqueous-organic interface, exhibiting chemical homogeneity at both aqueous and organic facing surfaces. Transfer of these ultrathin nanofilms onto porous supports provides fast water transport through the resulting nanofilm composite membranes. Manipulating the intrinsic nanofilm thickness from ≈15 down to 8 nm reveals that water permeance increases proportionally with the thickness decrease, after which it increases nonlinearly to 2.7 L m^-2 h^-1 bar^-1 as the thickness is further reduced to ≈6 nm.

Measuring Interfacial Polymerization Kinetics Using Microfluidic Interferometry

A range of academic and industrial fields exploit interfacial polymerization in producing fibers, capsules, and films. Although widely used, measurements of reaction kinetics remain challenging and rarely reported, due to film thinness and reaction rapidity. Here, polyamide film formation is studied using microfluidic interferometry, measuring monomer concentration profiles near the interface during the reaction. Our results reveal that the reaction is initially controlled by a reaction-diffusion boundary layer within the organic phase, which allows the first measurements of the rate constant for this system.

Utilization of the Donnan potential induced by reverse salt flux in pressure retarded osmosis systems

Pressure retarded osmosis (PRO) generates energy from salinity gradients. Reverse salt flux through a semi-permeable PRO membrane reduces the energy efficiency. We demonstrate for the first time the direct conversion of the reverse salt flux into electrochemical potential, recovering >7% positive net power using a single electrochemical PRO membrane.

Sustainable Process for the Preparation of High-Performance Thin-Film Composite Membranes using Ionic Liquids as the Reaction Medium

A new form of interfacial polymerization to synthesize thin-film composite membranes realizes a more sustainable membrane preparation and improved nanofiltration performance. By introducing an ionic liquid (IL) as the organic reaction phase, the extremely different physicochemical properties to those of commonly used organic solvents influenced the top-layer formation in several beneficial ways. In addition to the elimination of hazardous solvents in the preparation, the m-phenylenediamine (MPD) concentration could be reduced 20-fold, and the use of surfactants and catalysts became redundant. Together with the more complete recycling of the organic phase in the water/IL system, these factors resulted in a 50 % decrease in the mass intensity of the top-layer formation. Moreover, a much thinner top layer with a high ethanol permeance of 0.61 L m(-2)  h(-1)  bar(-1) [99 % Rose Bengal (RB, 1017 Da) retention; 1 bar=0.1 MPa] was formed without the use of any additives. This EtOH permeance is 555 and 161 % higher than that for the conventional interfacial polymerization (without and with additives, respectively). In reverse osmosis, high NaCl retentions of 97 % could be obtained. Finally, the remarkable decrease in the membrane surface roughness indicates the potential for reduced fouling with this new type of membrane.