Mathematical Model for the Formation of Thin-Film Composite Membranes by Interfacial Polymerization: Porous and Dense Films

Empowering ultrathin polyamide membranes at the water-energy nexus: strategies, limitations, and future perspectives

Membrane-based separation is one of the most energy-efficient methods to meet the growing need for a significant amount of fresh water. It is also well-known for its applications in water treatment, desalination, solvent recycling, and environmental remediation. Most typical membranes used for separation-based applications are thin-film composite membranes created using polymers, featuring a top selective layer generated by employing the interfacial polymerization technique at an aqueous-organic interface. In the last decade, various manufacturing techniques have been developed in order to create high-specification membranes. Among them, the creation of ultrathin polyamide membranes has shown enormous potential for achieving a significant increase in the water permeation rate, translating into major energy savings in various applications. However, this great potential of ultrathin membranes is greatly hindered by undesired transport phenomena such as the geometry-induced "funnel effect" arising from the substrate membrane, severely limiting the actual permeation rate. As a result, the separation capability of ultrathin membranes is still not fully unleashed or understood, and a critical assessment of their limitations and potential solutions for future studies is still lacking. Here, we provide a summary of the latest developments in the design of ultrathin polyamide membranes, which have been achieved by controlling the interfacial polymerization process and utilizing a number of novel manufacturing processes for ionic and molecular separations. Next, an overview of the in-depth assessment of their limitations resulting from the substrate membrane, along with potential solutions and future perspectives will be covered in this review.

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.

3D printed MOF-based mixed matrix thin-film composite membranes

MOF-based mixed-matrix membranes (MMMs) have attracted considerable attention due to their tremendous separation performance and facile processability. In large-scale applications such as CO₂ separation from flue gas, it is necessary to have high gas permeance, which can be achieved using thin membranes. However, there are only a handful of MOF MMMs that are fabricated in the form of thin-film composite (TFC) membranes. We propose herein the fabrication of robust thin-film composite mixed-matrix membranes (TFC MMMs) using a three dimensional (3D) printing technique with a thickness of 2-3 μm. We systematically studied the effect of casting concentration and number of electrospray cycles on membrane thickness and CO₂ separation performance. Using a low concentration of polymer of intrinsic microporosity (PIM-1) or PIM-1/HKUST-1 solution (0.1 wt%) leads to TFC membranes with a thickness of less than 500 nm, but the fabricated membranes showed poor CO₂/N₂ selectivity, which could be attributed to microscopic defects. To avoid these microscale defects, we increased the concentration of the casting solution to 0.5 wt% resulting in TFC MMMs with a thickness of 2-3 μm which showed three times higher CO₂ permeance than the neat PIM-1 membrane. These membranes represent the first examples of 3D printed TFC MMMs using the electrospray printing technique.

Interface-assisted synthesis: a gateway to effective nanostructure tuning of conducting polymers

The interface-assisted polymerization technique can be viewed as a powerful emerging tool for the synthesis of conducting polymers (CPs) on a large scale. Contrary to other bulk or single-phase polymerization techniques, interface-assisted synthesis strategies offer effective nanostructure control in a confined two-dimensional (2-D) space. This review focuses on the types of interfaces, mechanism at the interface, advantages and future perspectives of the interfacial polymerization in comparison to conventional polymerization techniques. Hence, the primary focus is on briefing the different types of the chemical methods of polymerization, followed by uniqueness in the reaction dynamics of interface polymerization. The classification of interfaces into four types (liquid/solid, gas/liquid, liquid/liquid, and gas/solid) is based on the versatility and underlying mechanistic pathway of the polymerization of each type. The role of interface in tuning the nanostructure of CPs and the performance evaluation of pristine CPs based on the electrical conductivity are also discussed. Finally, the future outlook of this emerging field is discussed and proposed in detail through some multifunctional applications of synthesized conducting polymers.

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.

Highly Permeable Reverse Osmosis Membranes via Molecular Layer-by-Layer Deposition of Trimesoyl Chloride and 3,5-Diaminobenzoic Acid

We present a series of polyamide membranes synthesized via molecular layer-by-layer (mLbL) deposition of trimesoyl chloride (TMC) and 3,5-diaminobenzoic acid (BA). These membranes exhibit superior NaCl rejection compared to previously reported TMC-BA membranes prepared via interfacial polymerization, with the improved performance of the mLbL films attributable to higher cross-link density facilitated by the stepwise deposition process in good solvents. We compare the TMC-BA series with membranes synthesized from TMC and m-phenylenediamine (MPD), a conventional reverse osmosis membrane chemistry. At the minimum thickness capable of 90 % NaCl rejection, mLbL TMC-BA membranes exhibit 50 % greater water permeance than mLbL TMC-MPD.

Poly(Homopiperazine-Amide) Thin-Film Composite Membrane for Nanofiltration of Heavy Metal Ions

The development of membrane-based technologies for the treatment of wastewater streams and resources containing heavy metal ions is in high demand. Among various technologies, nanofiltration (NF) membranes are attractive choices, and the continuous development of novel materials to improve the state-of-the-art NF membranes is highly desired. Here, we report on the synthesis of poly(homopiperazine-amide) thin-film composite (HTFC)-NF membranes, using homopiperazine (HP) as a monomer. The surface charge, hydrophilicity, morphology, cross-linking density, water permeation, solute rejection, and antifouling properties of the fabricated NF membranes were evaluated. The fabricated HTFC NF membranes demonstrated water permeability of 7.0 ± 0.3 L/(m2 h bar) and rejected Na2SO4, MgSO4, and NaCl with rejection values of 97.0 ± 0.6, 97.4 ± 0.5, and 23.3 ± 0.6%, respectively. The membranes exhibit high rejection values of 98.1 ± 0.3 and 96.3 ± 0.4% for Pb2+ and Cd2+ ions, respectively. The fouling experiment with humic acid followed by cross-flow washing of the membranes indicates that a flux recovery ratio (FRR) of 96.9 ± 0.4% can be obtained.

Interfacial Polymerization: From Chemistry to Functional Materials

Interfacial polymerization, where a chemical reaction is confined at the liquid-liquid or liquid-air interface, exhibits a strong advantage for the controllable fabrication of films, capsules, and fibers for use as separation membranes and electrode materials. Recent developments in technology and polymer chemistry have brought new vigor to interfacial polymerization. Here, we consider the history of interfacial polymerization in terms of the polymerization types: interfacial polycondensation, interfacial polyaddition, interfacial oxidative polymerization, interfacial polycoordination, interfacial supramolecular polymerization, and some others. The accordingly emerging functional materials are highlighted, as well as the challenges and opportunities brought by new technologies for interfacial polymerization. Interfacial polymerization will no doubt keep on developing and producing a series of fascinating functional materials.

Ultrafast Ion Sieving from Honeycomb-like Polyamide Membranes Formed Using Porous Protein Assemblies

Despite the commercial success of thin film composite polyamide membranes, further improvements to the water permeation of polyamide membranes without degradation in product water quality remain a great challenge. Herein, we report the fabrication of an interfacially polymerized polyamide nanofiltration membrane with a novel 3D honeycomb-like spatial structure, which is formed from a tobacco mosaic virus (TMV) porous protein nanosheet-coated microfiltration membrane support. TMV nanosheets with uniform pores and appropriate hydrophilicity deposited inside the support membrane pores facilitate the construction of a localized water-oil reaction interface with evenly distributed monomers and guide the formation of a defect-free polyamide layer with a spatial structure that copies the geometry of the membrane cavities. Such a 3D morphology possesses ultrahigh specific surface area, leading to unprecedented membrane water permeance as high as 84 L m^-2 h^-1 bar^-1, high MgSO₄ rejection of 98%, and monovalent/divalent ion sieving selectivity up to 89.

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%.

Thin-film composite membrane breaking the trade-off between conductivity and selectivity for a flow battery

A membrane with both high ion conductivity and selectivity is critical to high power density and low-cost flow batteries, which are of great importance for the wide application of renewable energies. The trade-off between ion selectivity and conductivity is a bottleneck of ion conductive membranes. In this paper, a thin-film composite membrane with ultrathin polyamide selective layer is found to break the trade-off between ion selectivity and conductivity, and dramatically improve the power density of a flow battery. As a result, a vanadium flow battery with a thin-film composite membrane achieves energy efficiency higher than 80% at a current density of 260 mA cm⁻², which is the highest ever reported to the best of our knowledge. Combining experiments and theoretical calculation, we propose that the high performance is attributed to the proton transfer via Grotthuss mechanism and Vehicle mechanism in sub-1 nm pores of the ultrathin polyamide selective layer.

Low-cost flow batteries with high power density are promising for energy storage, but membranes with simultaneously high ion conductivity and selectivity should be developed. Here the authors report a thin-film composite membrane that breaks the trade-off between ion conductivity and selectivity.

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.

Molecular dynamics simulation studies of the structure and antifouling performance of a gradient polyamide membrane

The structure and the antifouling performance of the first gradient polyamide layer model are systematically disclosed using molecular dynamics simulations.

Single-Walled Carbon Nanotube Film Supported Nanofiltration Membrane with a Nearly 10 nm Thick Polyamide Selective Layer for High-Flux and High-Rejection Desalination

Fabricating nanofiltration (NF) membranes with high permeating flux and simultaneous high rejection rate for desalination is rather significant and highly desired. A new avenue is reported in this work to design NF membrane by using polydopamine wrapped single-walled carbon nanotube (PD/SWCNTs) ultrathin film as support layer instead of the use of traditional polymer-based underlying layers. Thanks to the high porosity, smooth surface, and more importantly optimal hydrophilic surface of PD/SWCNTs film, a defect-free polyamide selective layer for NF membrane with thickness of as thin as 12 nm is achieved. The obtained NF membrane exhibits an extremely high performance with a permeating flux of 32 L m^-2 h^-1 bar^-1 and a rejection rate of 95.9% to divalent ions. This value is two to five times higher than the traditional NF membranes with similar rejection rate.

Topology and porosity modulation of polyurea films using interfacial polymerization

Polyurea films with controllable topologies and porosities were obtained by reacting different amines with hexamethyl diisocyanate at the liquid–liquid interface.

Visualization and characterization of interfacial polymerization layer formation

We present a microfluidic platform to visualize the formation of free-standing films by interfacial polymerization. A microfluidic device is fabricated, with an array of micropillars to stabilize an aqueous-organic interface that allows a direct observation of the films formation process via optical microscopy. Three different amines are selected to react with trimesoyl chloride: piperazine, JEFFAMINE(®)D-230, and an ammonium functionalized polyhedral oligomeric silsesquioxane. Tracking the formation of the free-standing films in time reveals strong effects of the characteristics of the amine precursor on the morphological evolution of the films. Piperazine exhibits a rapid reaction with trimesoyl chloride, forming a film up to 20 μm thick within half a minute. JEFFAMINE(®)D-230 displays much slower film formation kinetics. The location of the polymerization reaction was initially in the aqueous phase and then shifted into the organic phase. Our in situ real-time observations provide information on the kinetics and the changing location of the polymerization. This provides insights with important implications for fine-tuning of interfacial polymerizations for various applications.

Simulation of thin film membranes formed by interfacial polymerization

Interfacial polymerization is widely used today for the production of ultrathin films for encapsulation, chemical separations, and desalination. Polyamide films, in particular, are employed in manufacturing of reverse osmosis and nanofiltration membranes. While these materials show excellent salt rejection, they have rather low water permeability, both properties that apparently stem from the rigid cross-linked structure. An increasing amount of experimental research on membranes of different chemistries and membrane characterization suggests the importance of other factors (such as unreacted functional groups and surface roughness) in determining membrane performance. We developed a molecular simulation model to qualitatively study the effects of various synthesis conditions on membrane performance, in terms of its estimated porosity and permeability. The model is of an interfacial aggregation process of two types of functional monomers. Film growth with time and structural characteristics of the final film are compared with predictions of existing theories and experimental observations.

Kinetics of film formation by interfacial polycondensation

An approximate analytical model of film formation by interfacial polycondensation is presented. The analysis requires knowledge of a minimal set of certain kinetic parameters (monomer diffusivities and reaction rate constants) and reaction conditions (monomer concentrations and thickness of the unstirred layer). The process proceeds as a succession of two or three markedly different kinetic regimes. Each regime (insipient film formation, slowdown, and diffusion-limited growth) sets a different pattern of local polymer accumulation, with important implications for the structure of the emerging film. At the incipient stage, a loose polymer film begins to emerge in a fixed narrow region inside the boundary layer, followed by gradual densification of the middle part of the film. A condition for film formation is thus formulated on the basis of our analysis. The model predicts that two different scenarios are possible, which depend on the permeability of the polymer: films with a low permeability to both monomers pass through an abrupt slowdown of film growth, whereas permeable films undergo a smooth transition between the incipient film formation and diffusion-limited regimes. The model incorporates the highly important effects of the accumulation of reactive end groups and the decrease of monomer diffusion with the polymer concentration on the kinetics of the process and film characteristics. In addition, the validity of the utilized mean-field approach is analyzed, and the analysis suggests a direct correlation between the roughness and the thickness of the film. The results are in good agreement with an earlier numerical study and the direct structural studies of polyamide membrane films.

Theoretical model of interfacial polymerization

We present a theoretical description for the creation of a thin polymeric layer through the interfacial polymerization of two immiscible, low molecular weight liquids. The theory specifically takes into account the effects of polydispersity on the formation of the polymer film at the liquid-liquid interface. Consequently, we can describe the structure of the growing film and the molecular weight distribution of the resultant polymer chains. We focus on a model system where alternating AB copolymers are formed at the interface between phase-separated, low molecular weight species A and B. It is assumed that any A(B) unit can reversibly attach to any available B(A) unit or B(A)-ended chain. The formation of the copolymer layer is described by a system of reaction-diffusion equations, which detail the chemical evolution and diffusive dynamics of the polydisperse mixture of AB copolymers around the interface, and the evolution of the interface itself. Using this model, we determine the effects of the chemical reaction rates and the initial conditions on the kinetics of forming the AB copolymer layer and the structure of this film.