Robust zirconia ceramic membrane with exceptional performance for purifying nano-emulsion oily wastewater

Doping heteroatoms to form multiple hydrogen bond sites for enhanced interfacial reconstruction and separations

Interfacial challenges in unconventional oil extraction include heavy oil-water-solid multiphase separation and corrosion inhibition. Herein, a novel strategy based on interfacial hydrogen bonding reconstruction is proposed for constructing multifunctional interfacially active materials (MIAMs) to address multi-interfacial separation needs. A simple one-pot method is applied to successfully synthesize four different MIAM varieties, integrating site groups (-NH2, OSO, -COOH, and Si-O-Si) with multiple hydrogen bonds (HBs) into allyl polyether chains. The results indicate that all synthesized MIAMs excel in demulsification, detergency, and corrosion inhibition simultaneously, even at 25 °C. Their dehydration efficiency for different water-in-oil emulsions (even heavy oil emulsion) surpasses 99.9 % even at 16 °C, showing their excellent energy-saving potential for field applications. Furthermore, they demonstrate effective, nondestructive static cleaning (up to 86 %) of adhered oil from solid surfaces at 25 °C and provide corrosion inhibition effects (up to 92.09 %) on mild steel immersed in saturated brine. Mechanistic tests reveal that incorporating multiple HB sites in MIAMs dramatically enhances their effectiveness in interfacial separations. Based on these findings, an HB-dominated noncovalent interaction reconstruction strategy is tentatively proposed to develop advanced materials for low-carbon, efficient interfacial separations.

Prevention is better than a cure: A 'zero residual nanoadsorbent toxicity' downstream from its effluent exit point

Here, we offer thoughts concerning a 'zero residual nanoadsorbent toxicity' environmental policy which we strongly advocate. Our discussions in support of this policy are based on the adage 'Prevention is better than cure'. Besides emphasizing the need for strict regulations (regional and international), research and development avenues are highlighted for the technology that can achieve 'zero tolerance' for residual nanoadsorbent levels escaping and building up in receiving ecosystems. We do not oppose nanoadsorbents. On the contrary, their water and wastewater purification potentials are well recognized. However, they should not be permitted to translocate downstream from the exit point of a final effluent.

Scalable weaving of resilient membranes with on-demand superwettability for high-performance nanoemulsion separations

This study leverages the ancient craft of weaving to prepare membranes that can effectively treat oil/water mixtures, specifically challenging nanoemulsions. Drawing inspiration from the core-shell architecture of spider silk, we have engineered fibers, the fundamental building blocks for weaving membranes, that feature a mechanically robust core for tight weaving, coupled with a CO2-responsive shell that allows for on-demand wettability adjustments. Tightly weaving these fibers produces membranes with ideal pores, achieving over 99.6% separation efficiency for nanoemulsions with droplets as small as 20 nm. They offer high flux rates, on-demand self-cleaning, and can switch between sieving oil and water nanodroplets through simple CO2/N2 stimulation. Moreover, weaving can produce sufficiently large membranes (4800 cm2) to assemble a module that exhibits long-term stability and performance, surpassing state-of-the-art technologies for nanoemulsion separations, thus making industrial application a practical reality.

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.

Highly efficient ceramic membrane synthesized from sugar scum and fly ash as sustainable precursors for dyes removal

Recycling solid industrial wastes into valuable materials is always the priority solution in waste management. In this perspective, sugar scum and fly ash were used to produce an effective low-cost porous ceramic membrane. The impacts of the sintering temperature, amount of sugar scum, and sintering time on the properties of the prepared ceramic membrane were investigated and optimized using experimental design. A simultaneous rise in both the sintering temperature and the amount of sugar scum leads to a notable increase in porosity. Moreover, the simultaneous increase or decrease in the time and the amount of sugar scum causes a significant decrease in the compressive strength. The optimal conditions have been determined as a sintering temperature of 1197 °C, a sugar scum amount of 12.06 %, and a sintering time of 253 min. Under these conditions, the density, porosity, and compressive strength were found to be 2.16 g/cm³, 34.66 %, and 28.24 MPa, respectively. In addition, the obtained ceramic membrane has a water permeability of 2356.68 L/h m2 bar, a pore size in the range 0-4.5 μm, and excellent chemical resistance in both acidic and basic media. Finally, the performance of the prepared ceramic membrane was evaluated by the filtration of methylene blue. The results indicate that sugar scum and fly ash are suitable precursors to manufacture an effective ceramic membrane for the treatment of wastewater.

Fe(II)-Modulated Microporous Electrocatalytic Membranes for Organic Microcontaminant Oxidation and Fouling Control: Mechanisms of Regulating Electron Transport toward Enhanced Reactive Oxygen Species Activation

Regulation of the fast electron transport process for the generation and utilization of reactive oxygen species (ROS) by achieving fortified electron "nanofluidics" is effective for electrocatalytic oxidation of organic microcontaminants. However, limited available active sites and sluggish mass transfer impede oxidation efficiency. Herein, we fabricated a conductive electrocatalytic membrane decorated with hierarchical porous vertically aligned Fe(II)-modulated FeCo layered double hydroxide nanosheets (Fe(II)-FeCo LDHs) in an electro-Fenton system to maximize exposure of active sites and expedite mass transfer. The nanospaced interlayers of Fe(II)-FeCo LDHs within the microconfined porous structure formed by its vertical nanosheets highly boost the micro/nanofluidic distribution of target pollutants to active centers/species, achieving accelerated mass transferability. Aliovalent substitution by Fe(II) activates in-plane metallics to maximize the available active sites and makes each Fe(II)-FeCo LDH nanosheet a geometrical nanocarrier for constructing a fast electron "nanofluidic" to accelerate Fe(II) regeneration in Fe(III)/Fe(II) cycles. As a result, the Fe(II)-FeCo LDHs exhibited improved reactivity in catalyzing H2O2 to •OH and 1O2. Accordingly, the membrane exhibited a higher atrazine degradation kinetic (0.0441 min-1) and degradation rate (93.2%), which were 4.7 and 2.1 times more than those of the bare carbon nanotube membrane, respectively. Additionally, the enhanced hydrophilic and strongly oxidized reactivity synergistically mitigated the organic fouling occurring in the pores and surface of the membrane. These findings clarify the activation mechanism of ROS over an innovative electrocatalytic membrane reactor design for organic microcontaminant treatment.

Silicon carbide catalytic ceramic membranes with nano-wire structure for enhanced anti-fouling performance

Membrane fouling is a critical challenge for current ceramic membranes, which suffer from low flux and insufficient removal. Development of self-cleaning catalytic ceramic membranes is promising to address this challenge. Herein, we design heterogeneous silicon carbide ceramic membranes featuring a novel structure of g-C₃N₄-decorated β-SiC nano-wire catalytic functional layer, which enables enhanced anti-fouling self-cleaning performance. At chemical harsh (alkaline or especially acidic) conditions, the nano-wire membrane exhibits catalysis-enhanced removal performance for organic contaminants. Unlike conventional particle-packing membrane structure, such a nano-wire network membrane structure has not only high porosity (56.1%), but exceptional water permeance (110 L·m^-2·h^-1·bar^-1) and removal (100%) of organic substance under simulated sunlight, outperforming state-of-the-art organic membranes and ceramic membranes. Superoxide radical (∙O₂^-) was experimentally confirmed to be major reactive species responsible for self-cleaning function. We also propose a catalytic mechanism model with radical formation pathway, enabled by the as-formed g-C₃N₄@β-SiC heterojunction structure with reduced electron-hole recombination. This work would provide new insights into not only rational design of next-generation ceramic membranes with self-cleaning function but also more applications of efficient treatment of refractory wastewaters containing degradable organic substances by using such membranes.

Progress in alumina ceramic membranes for water purification: Status and prospects

Ceramic membranes have gained increasing attention in recent years for the removal of various contaminants from water. Alumina membrane is considered as one of the most important ceramic membranes, which plays important roles not only in separation processes such as microfiltration, ultrafiltration, and nanofiltration, but also in catalysis- and adsorption- enhanced separation applications in water purification and wastewater treatment. However, there is currently still lack of a comprehensive critical review about alumina membranes for water purification. In this review, we first discuss recent developments of alumina membranes, and then critically introduce the state-of-the-art strategies for lowering fabrication cost, improving membrane performances and mitigating membrane fouling. Especially, aiming to improve membrane performance, some emerging methods are summarized such as tailoring membrane structure, developing flexible membranes, designing nano-pores for precise separation, and enhancing multi-functionalities. In addition, engineering applications of alumina membranes for water purification are also briefly introduced. Finally, the prospects for future research on alumina membranes are proposed, such as economic preparation/application, challenging precise separation, enriching multi-functionalities, and clarifying separation mechanisms.

A passive-active combined strategy for ultrafiltration membrane fouling control in continuous oily wastewater purification

Membrane-based technology has been confirmed as an effective way to treat emulsified oily wastewater, however, membrane fouling is still one of practical challenges in long-term operation. Herein, a novel passive-active combined strategy was proposed to control membrane fouling in continuous oily wastewater purification, where the δ-MnO₂ decoration layer helped to reduce the total fouling ratio (passive strategy for fouling mitigation) and the catalytic cleaning effectively removed the irreversible oil fouling (active strategy for fouling removal). The functional membrane was prepared via in-situ modification, referred to as δ-MnO₂@TA-PES. The morphology, crystalline phase, chemical structure and surface properties of the membranes were systematically characterized. Compared with PES, the δ-MnO₂@TA-PES possessed superhydrophilicity, enhanced electronegativity and narrowed pore size. The δ-MnO₂@TA-PES achieved high water permeation flux of 723.9 L·m ^- 2·h ^- 1·bar^-1, excellent oil rejection with separation efficiency above 98.5% for various emulsions, and durable anti-oil-fouling performance with FRR_b of 98.0%. Notably, the oil cake layer fouling on δ-MnO₂@TA-PES was greatly alleviated owing to its enhanced surface properties. In addition, δ-MnO₂@TA-PES showed high cleaning efficiency in the peroxymonosulfate (PMS) cleaning process, where the radical and nonradical pathways occurred simultaneously. And the active substances generated in the nonradical process (especially ¹O₂) were considered as the main contributor to the reduction of irreversible fouling. Overall, the novel strategy of fouling control ensured the efficient operation of ultrafiltration membranes for the continuous oily wastewater purification.

Cost and efficiency perspectives of ceramic membranes for water treatment

More robust ceramic membranes with tailorable structures and functions are increasingly employed for water treatment, particularly in some harsh applications for their ultra-long service lifespan due to their high mechanical, structural, chemical and thermal stability and anti-fouling properties. Decreasing cost and enhancing efficiency are two key but quite challenging application-oriented issues for broader and larger-scale engineering application of current ceramic membranes, and are required to make ceramic membranes a highly efficient and economic water treatment technique. In this review, we critically discuss these two significant concerns of both cost and efficiency for water treatment ceramic membranes, focusing on an overview of various advanced strategies and mechanism insights. A brief up-to-date discussion is first introduced about recent developments of ceramic membranes covering the major advances of novel membranes and applications. Then some promising strategies for decreasing the cost of ceramic membranes are discussed, including membrane material cost and processing cost. To fully address the issue of moderate efficiency with single separation function, valuable and considerable insights are provided into recent major progress and mechanism understandings in application with other unit processes, such as advanced oxidation and electrochemistry techniques, to significantly enhance treatment efficiency. Subsequently, a review of recent ceramic membrane applications emphasizing harsh operating environments is presented, such as oil-water separation, saline water, refractory organic and emerging contaminant wastewater treatment. Finally, engineering application, conclusions, and future perspectives of ceramic membrane for water treatment applications are critically discussed offering new insight based on understanding the issues of cost and efficiency.

Peracetic acid integrated catalytic ceramic membrane filtration for enhanced membrane fouling control: Performance evaluation and mechanism analysis

Endowing ceramic membrane (CM) catalytic reactivity can enhance membrane fouling control in the aid of in situ oxidation process. Peracetic acid (PAA) oxidant holds great prospect to integrate with CM for membrane fouling control, owing to the prominent advantages of high oxidation efficacy and easy activation. Herein, this study, for the first time, presented a PAA/CM catalytic filtration system achieving highly-efficient protein fouling alleviation. A FeOCl functionalized CM (FeOCl-CM) was synthesized, possessing high hydrophilicity, low surface roughness, and highly-efficient activation towards PAA oxidation. Using bovine serum albumin (BSA) as the model protein foulant, the PAA/FeOCl-CM catalytic filtration notably alleviated fouling occurring in both membrane pores and surface, and halved the flux reduction degree as compared with the conventional CM filtration. The PAA/FeOCl-CM catalytic oxidation allows quick and complete disintegration of BSA particles, via the breakage of the amide I and II bands and the ring opening of the aromatic amino acids (e.g., Tryptophan, Tyrosine). In-depth investigation revealed that the in situ generated ^•OH and ¹O₂ were the key reactive species towards BSA degradation during catalytic filtration, while the organic radical oxidation and the direct electron transfer pathway from BSA to PAA via FeOCl-CM played minor roles. Overall, our findings highlight a new PAA/CM catalytic filtration strategy for achieving highly-efficient membrane fouling control and provide an understanding of the integrated PAA catalytic oxidation - membrane filtration behaviors.

Oil-in-water emulsion separation: Fouling of alumina membranes with and without a silicon carbide deposition in constant flux filtration mode

Ceramic membranes have drawn increasing attention in oily wastewater treatment as an alternative to their traditional polymeric counterparts, yet persistent membrane fouling is still one of the largest challenges. Particularly, little is known about ceramic membrane fouling by oil-in-water (O/W) emulsions in constant flux filtration modes. In this study, the effects of emulsion chemistry (surfactant concentration, pH, salinity and Ca²⁺) and operation parameters (permeate flux and filtration time) were comparatively evaluated for alumina and silicon carbide (SiC) deposited ceramic membranes, with different physicochemical surface properties. The original membranes were made of 100% alumina, while the same membranes were also deposited with a SiC layer to change the surface charge and hydrophilicity. The SiC-deposited membrane showed a lower reversible and irreversible fouling when permeate flux was below 110 L m^-2 h^-1. In addition, it exhibited a higher permeance recovery after physical and chemical cleaning, as compared to the alumina membranes. Increasing sodium dodecyl sulfate (SDS) concentration in the feed decreased the fouling of both membranes, but to a higher extent in the alumina membranes. The fouling of both membranes could be reduced with increasing the pH of the emulsion due to the enhanced electrostatic repulsion between oil droplets and membrane surface. Because of the screening of surface charge in a high salinity solution (100 mM NaCl), only a small difference in irreversible fouling was observed for alumina and SiC-deposited membranes under these conditions. The presence of Ca²⁺ in the emulsion led to high irreversible fouling of both membranes, because of the compression of diffusion double layer and the interactions between Ca²⁺ and SDS. The low fouling tendency and/or high cleaning efficiency of the SiC-deposited membranes indicated their potential for oily wastewater treatment.

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.

A Methyl-Modified Silica Layer Supported on Porous Ceramic Membranes for the Enhanced Separation of Methyl Tert-Butyl Ether from Aqueous Solution

As a kind of volatile organic compound (VOC), methyl tert-butyl ether (MTBE) is hazardous to human health and destructive to the environment if not handled properly. MTBE should be removed before the release of wastewater. The present work supported the methyl-modified silica layer (MSL) on porous α-Al₂O₃ ceramic membranes with methyltrimethoxysilane (MTMS) as a precursor and pre-synthesized mesoporous silica microspheres as dopants by the sol-gel reaction and dip-coating method. MTMS is an environmentally friendly agent compared to fluorinated alkylsilane. The MSL-supported Al₂O₃ ceramic membranes were used for MTBE/water separation by pervaporation. The NMR spectra revealed that MTMS evolves gradually from an oligomer to a highly cross-linked methyl-modified silica species. Methyl-modified silica species and pre-synthesized mesoporous silica microspheres combine into hydrophobic mesoporous MSL. MSL makes the α-Al₂O₃ ceramic membranes transfer from amphiphilic to hydrophobic and oleophilic. The MSL-supported α-Al₂O₃ ceramic membranes (MSL-10) exhibit an MTBE/water separation factor of 27.1 and a total flux of 0.448 kg m⁻² h⁻¹, which are considerably higher than those of previously reported membranes that are modified by other alkylsilanes via the post-grafting method. The mesopores within the MSL provide a pathway for the transport of MTBE molecules across the membranes. The presence of methyl groups on the external and inner surface is responsible for the favorable separation performance and the outstanding long-term stability of the MSL-supported porous α-Al₂O₃ ceramic membranes.

Electro-Enhanced Separation of Microsized Oil-in-Water Emulsions via Metallic Membranes: Performance and Mechanistic Insights

Conventional separation membranes suffer from evitable fouling and flux decrease for water treatment applications. Herein, a novel protocol of electro-enhanced membrane separation is proposed for the efficient treatment of microsized emulsions (∼1 μm) by rationally designing robust electroresponsive copper metallic membranes, which could mitigate oil fouling and coenhance permeance (from ∼1026 to ∼2516 L·m^-2·h^-1·bar^-1) and rejection (from ∼87 to ∼98%). High-flux Cu membranes exhibit superior ductility and electrical conductivity, enabling promising electroactivity. Separation performance and the fouling mechanism were studied under different electrical potentials and ionic strengths. Application of negative polarization into a large-pore (∼2.1 μm) Cu membrane is favorable to not only almost completely reject smaller-sized oil droplets (∼1 μm) but also achieve antifouling and anticorrosion functions. Moreover, surfactants around oil droplets might be redistributed due to electrostatic repulsion, which effectively enhances the steric hindrance effect between neighboring oil droplets, mitigating oil coalescence and consequently membrane fouling. Furthermore, due to the screening effect of surfactants, the presence of low-concentration salts increases the adsorption of surfactants at the oil-water interface, thus preventing oil coalescence via decreasing oil-water interfacial tension. However, under high ionic strengths, the fouling mechanism converts from cake filtration to a complete blocking model due to the reduced electrostatic repulsion between the Cu membrane and oil droplets. This work would provide mechanistic insights into electro-enhanced antifouling for not only oil emulsion separation but also more water treatment applications using rationally designed novel electroresponsive membranes.

Treatment of oily wastewaters by highly porous whisker-constructed ceramic membranes: Separation performance and fouling models

Efficient treatment of challenging oily emulsion wastewater can alleviate water pollution to provide more chances for water reuse and resource recovery. Despite their promising application potential, conventional porous ceramic membranes have challenging bottleneck issues such as high cost and insufficient permeance. This study presents a new strategy for highly efficient treatment of not only synthetic but real oily emulsions via unexpensive whisker-constructed ceramic membranes, exhibiting exceptional permeance and less energy input. Compared with common ceramic membranes, such lower-cost mullite membranes with a novel whisker-constructed structure show higher porosity and water permeance, and better surface oleophobicity in water. Treatment performance such as permeate flux and oil rejection was explored for the oily emulsions with different properties under key operating parameters. Furthermore, classical Hermia models were used to reveal membrane fouling mechanism to well understand the microscopic interactions between emulsion droplets and membrane interface. Even for real acidic oily wastewater, such membranes also exhibit high permeance and less energy consumption, outperforming most state-of-the-art ceramic membranes. This work provides a new structure concept of highly permeably whisker-constructed porous ceramic membranes that can efficiently enable more water separation applications.

Robust ultrathin nanoporous MOF membrane with intra-crystalline defects for fast water transport

Rational design of high-performance stable metal–organic framework (MOF) membranes is challenging, especially for the sustainable treatment of hypersaline waters to address critical global environmental issues. Herein, a molecular-level intra-crystalline defect strategy combined with a selective layer thinning protocol is proposed to fabricate robust ultrathin missing-linker UiO-66 (ML-UiO-66) membrane to enable fast water permeation. Besides almost complete salt rejection, high and stable water flux is achieved even under long-term pervaporation operation in hash environments, which effectively addresses challenging stability issues. Then, detailed structural characterizations are employed to identify the type, chemical functionality, and density of intra-crystalline missing-linker defects. Moreover, molecular dynamics simulations shed light on the positive atomistic role of these defects, which are responsible for substantially enhancing structural hydrophilicity and enlarging pore window, consequently allowing ultra-fast water transport via a lower-energy-barrier pathway across three-dimensional sub-nanochannels during pervaporation. Unlike common unfavorable defect effects, the present positive intra-crystalline defect engineering concept at the molecular level is expected to pave a promising way toward not only rational design of next-generation MOF membranes with enhanced permeation performance, but additional water treatment applications.

The development of highly water-permeable membranes is key for the treatment of high salinity waters. Here the authors enhance the water permeability of a metal-organic framework nanoporous membrane via an intra-crystalline defect engineering strategy.