Scale Up and Validation of Novel Tri-Bore PVDF Hollow Fiber Membranes for Membrane Distillation Application in Desalination and Industrial Wastewater Recycling.

Novel tri-bore polyvinylidene difluoride (PVDF) hollow fiber membranes (TBHF) were scaled-up for fabrication on industrial-scale hollow fiber spinning equipment, with the objective of validating the membrane technology for membrane distillation (MD) applications in areas such as desalination, resource recovery, and zero liquid discharge. The membrane chemistry and spinning processes were adapted from a previously reported method and optimized to suit large-scale production processes with the objective of translating the technology from lab scale to pilot scale and eventual commercialization. The membrane process was successfully optimized in small 1.5 kg batches and scaled-up to 20 kg and 50 kg batch sizes with good reproducibility of membrane properties. The membranes were then assembled into 0.5-inch and 2-inch modules of different lengths and evaluated in direct contact membrane distillation (DCMD) mode, as well as vacuum membrane distillation (VMD) mode. The 0.5-inch modules had a permeate flux >10 L m−2 h−1, whereas the 2-inch module flux dropped significantly to <2 L m−2 h−1 according to testing with 3.5 wt.% NaCl feed. Several optimization trials were carried out to improve the DCMD and VMD flux to >5 L m−2 h−1, whereas the salt rejection consistently remained ≥99.9%.

Development and Industrial-Scale Fabrication of Next-Generation Low-Energy Membranes for Desalination.

Spiral-wound modules have been the most common configuration of packing flat-sheet membranes since the early development of polyamide (PA) membranes for water treatment applications. Conventional spiral-wound modules (SWMs) for desalination applications typically consist of several leaf sets, with each leaf set comprising feed spacers, membranes, and a permeate carrier (PC) wrapped around a permeate-collecting tube. The membrane area that can be packed into a given module diameter is limited by the overall leaf set thickness, restricting module productivity for a given membrane permeability. We describe here a novel industrial-scale method for successfully coating the polysulfone (PSf) ultrafiltration (UF) support layer directly onto a permeate carrier, instead of conventional non-woven fabric, as a precursor to the polyamide TFC coating, resulting in twofold benefits: (a) drastically simplifying the membrane fabrication process by eliminating the use of non-woven fabric and (b) increasing the throughput of each membrane module by facilitating the packing of a larger membrane area in a standard module housing. By combining the permeate carrier and membrane into a single sheet, the need for the non-woven support layer was eliminated, leading to a significantly reduced leaf set thickness, enabling a much larger membrane area to be packed in a given volume, leading to lower energy consumption per cubic meter of produced water. Molecular-weight cutoff (MWCO) values in the range of 36-96 kDa were found to be dependent on PC thickness and material. Nevertheless, the reinforced membranes were successfully fabricated with a ~9% reduction in membrane leaf thickness compared to a conventional membrane. Preliminary trials of coating a thin-film composite PA layer resulted in defect-free reverse osmosis (RO) membranes with a salt rejection of 94% and a flux of 40 L m-2 h-1 when tested against a 2000 mg/L NaCl feed solution at an operating pressure of 15 bar. Results from the testing of the 1812 and 2514 elements validated the novel concept and paved the way for further improvements towards full-scale RO membranes with the potential to be the next low-energy workhorse of the water industry.

Novel Sandwich-Structured Hollow Fiber Membrane for High-Efficiency Membrane Distillation and Scale-Up for Pilot Validation.

Hollow fiber membranes were produced from a commercial polyvinylidene fluoride (PVDF) polymer, Kynar HSV 900, with a unique sandwich structure consisting of two sponge-like layers connected to the outer and inner skin layers while the middle layer comprises macrovoids. The sponge-like layer allows the membrane to have good mechanical strength even at low skin thickness and favors water vapor transportation during vacuum membrane distillation (VMD). The middle layer with macrovoids helps to significantly reduce the trans-membrane resistance during water vapor transportation from the feed side to the permeate side. Together, these novel structural characteristics are expected to render the PVDF hollow fiber membranes more efficient in terms of vapor flux as well as mechanical integrity. Using the chemistry and process conditions adopted from previous work, we were able to scale up the membrane fabrication from a laboratory scale of 1.5 kg to a manufacturing scale of 50 kg with consistent membrane performance. The produced PVDF membrane, with a liquid entry pressure (LEPw) of >3 bar and a pure water flux of >30 L/m2·hr (LMH) under VMD conditions at 70−80 °C, is perfectly suitable for next-generation high-efficiency membranes for desalination and industrial wastewater applications. The technology translation efforts, including membrane and module scale-up as well as the preliminary pilot-scale validation study, are discussed in detail in this paper.

Time-dependent polymerization kinetic study and the properties of hybrid polymers with functional silsesquioxanes.

Methacrylate-functionalized cubic silsesquioxane homopolymers [p(MA-CSSQ)] were synthesized by reversible addition-fragmentation chain transfer (RAFT)-mediated living radical polymerization in the presence of dodecyl(dimethylacetic acid)trithiocarbonate (DDTA) chain transfer agent, and their polymerization kinetics were studied. The DDTA-terminated p(MA-CSSQ) was then employed as a macro-RAFT agent in the polymerization of methylmethacrylate (MMA) for the synthesis of a brushlike p(MA-CSSQ)-b-PMMA block copolymer. The kinetics study of p(MA-CSSQ) showed that the monomer to polymer conversion, evaluated by (1)H NMR, was found to be approximately 80% with the maximum number average molecular weight (M(n)) of 24000 and 32300 Da, for the [MA-CSSQ]/[DDTA] ratios of 100 and 200, respectively, as determined by gel permeation chromatography (GPC). The broadening of molecular weight distributions in p(MA-CSSQ) homopolymer GPC traces was observed, presumably due to the presence of the radical-radical termination products. The resultant homopolymer and block copolymer exhibited excellent thermal stability as evidenced by thermogravimetric and differential scanning calorimetric analyses. The surface properties of p(MA-CSSQ) homopolymer and p(MA-CSSQ)-b-PMMA block copolymer, determined by water contact angle and atomic force microscopy (AFM) measurements, strongly indicated the surface enrichment of the hydrophobic silsesquioxane groups. The AFM images showed the microsized granular domains of p(MA-CSSQ) homopolymer, whereas the islandlike phase-separated domains were observed in p(MA-CSSQ)-b-PMMA block copolymer.

Self-assembly of block copolymer micelles: synthesis via reversible addition-fragmentation chain transfer polymerization and aqueous solution properties.

Poly(hexafluorobutyl methacrylate) (PHFBMA) homopolymer was synthesized by reversible addition-fragmentation chain transfer (RAFT)-mediated living radical polymerization in the presence of cyano-2-propyl dithiobenzoate (CPDB) RAFT agent. A block copolymer of PHFBMA-poly(propylene glycol acrylate) (PHFBMA-b-PPGA) with dangling poly(propylene glycol) (PPG) side chains was then synthesized by using CPDB-terminated PHFBMA as a macro-RAFT agent. The amphiphilic properties and self-assembly of PHFBMA-b-PPGA block copolymer in aqueous solution were investigated by dynamic and static light scattering (DLS and SLS) studies, in combination with fluorescence spectroscopy and transmission electron microscopy (TEM). Although PPG shows moderately hydrophilic character, the formation of nanosize polymeric micelles was confirmed by fluorescence and TEM studies. The low value of the critical aggregation concentration exhibited that the tendency for the formation of copolymer aggregates in aqueous solution was very high due to the strong hydrophobicity of the PHFBMA(145)-b-PPGA(33) block copolymer. The combination of DLS and SLS measurements revealed the existence of micellar aggregates in aqueous solution with an association number of approximately 40 +/- 7 for block copolymer micelles. It was also found in TEM observation that there are 40-50 micelles accumulated into one aggregate and these micelles are loosely packed inside the aggregate.

Multilayer buildup and biofouling characteristics of PSS-b-PEG containing films.

Thin films exhibiting protein resistance are of interest in diverse areas, ranging from low fouling surfaces in biomedicine to marine applications. Herein, we report the preparation of low protein and cell binding multilayer thin films, formed by the alternate deposition of a block copolymer comprising polystyrene sulfonate and poly(poly(ethylene glycol) methyl ether acrylate) (PSS-b-PEG), and polyallylamine hydrochloride (PAH). Film buildup was followed by quartz crystal microgravimetry (QCM), which showed linear growth and a high degree of hydration of the PSS-b-PEG/PAH films. Protein adsorption studies with bovine serum albumin using QCM demonstrated that multilayer films of PSS/PAH with a terminal layer of PSS-b-PEG were up to 5-fold more protein resistant than PSS-terminated films. Protein binding was dependent on the ionic strength at which the terminal layer of PSS-b-PEG was adsorbed, as well as the pH of the protein solution. It was also possible to control the protein resistance of the films by coadsorption of the final layer with another component (PSS), which showed an increase in protein resistance as the proportion of PSS-b-PEG in the adsorption solution was increased. In addition, protein resistance could also be controlled by the location of a single PSS-b-PEG layer within a PSS/PAH film. Finally, the buildup of PSS-b-PEG/PAH films on colloidal particles was demonstrated. PSS-b-PEG-terminated particles exhibited a 6.5-fold enhancement in cell binding resistance compared with PSS-terminated particles. The stability of PSS-b-PEG films combined with their low protein and cell binding characteristics provide opportunities for the use of the films as low fouling coatings in devices and other surfaces requiring limited interaction with biological interfaces.

Synthesis and Self-Assembly of pH-Responsive Amphiphilic Poly(dimethylaminoethyl methacrylate)-block-Poly(pentafluorostyrene) Block Copolymer in Aqueous Solution.

We report the synthesis of a novel pH-responsive amphiphilic block copolymer poly(dimethylaminoethyl methacrylate)-block-poly(pentafluorostyrene) (PDMAEMA-b-PPFS) using RAFT-mediated living radical polymerization. Copolymer micelle formation, in aqueous solution, was investigated using fluorescence spectroscopy, static and dynamic light scattering (SLS and DLS), and transmission electron microscopy (TEM). DLS and SLS measurements revealed that the diblock copolymers form spherical micelles with large aggregation numbers, N(agg) ≈ 30 where the dense PPFS core is surrounded by dangling PDMAEMA chains as the micelle corona. The hydrodynamic radii, R(h) of these micelles is large, at pH 2-5 as the protonated PDMAEMA segments swell the micelle corona. Above pH 5, the PDMAEMA segments are gradually deprotonated, resulting in a lower osmotic pressure and enhanced hydrophobicity within the micelle, thus decreasing the R(h) . However, the radius of gyration, R(g) remains independent of pH as the dense PPFS cores predominate.

Synthesis, multilayer film assembly, and capsule formation of macromolecularly engineered acrylic acid and styrene sulfonate block copolymers.

We report the use of copolymers synthesized with specific block ratios of weakly and strongly charged groups for the preparation of stable, pH-responsive multilayers. In this study, we utilized reversible addition-fragmentation chain transfer (RAFT) polymerization in the synthesis of novel pH-sensitive copolymers comprising block domains of acrylic acid (AA) and styrene sulfonate (SS) groups. The PAA x- b-SS y copolymers, containing 37%, 55%, and 73% of AA groups by mass (denoted as PAA 37- b-SS 63, PAA 55- b-SS 45, and PAA 73- b-SS 27, respectively), were utilized to perform stepwise multilayer assembly in alternation with poly(allylamine hydrochloride), PAH. The ratio of AA to SS groups, and the effect of the pH of both anionic and cationic adsorption solutions, on multilayer properties, were investigated using ellipsometry and atomic force microscopy. The presence of SS moieties in the PAA x- b-SS y copolymers, regardless of the precise composition, lead to films with a relatively consistent thickness. Exposure of these multilayers to acidic conditions postassembly revealed that these multilayers do not exhibit the characteristic large swelling that occurs with PAA/PAH films. The film stability was attributed to the presence of strongly charged SS groups. PAA x- b-SS y/PAH films were also formed on particle substrates under various adsorption conditions. Microelectrophoresis measurements revealed that the surface charge and isoelectric point of these core-shell particles are dependent on assembly pH and the proportion of AA groups in PAA x- b-SS y. These core-shell particles can be used as precursors to hollow capsules that incorporate weak polyelectrolyte functionality. The role of AA groups in determining the growth profile of these capsules was also examined. The multilayer films prepared may find applications in areas where pH-responsive films are required but large film swelling is unfavorable.

The antifouling and fouling-release performance of hyperbranched fluoropolymer (HBFP)-poly(ethylene glycol) (PEG) composite coatings evaluated by adsorption of biomacromolecules and the green fouling alga Ulva.

Cross-linked hyperbranched fluoropolymer (HBFP) and poly(ethylene glycol) (PEG) amphiphilic networks with PEG weight percentages of 14% (HBFP-PEG14), 29% (HBFP-PEG29), 45% (HBFP-PEG45), and 55% (HBFP-PEG55) were prepared on 3-aminopropyl)triethoxysilane (3-APS) functionalized microscope glass slides for marine antifouling and fouling-release applications. The surface-free energies (gamma(s)), polar (gamma(s)(p) and gamma(s)(AB)), and dispersion (gamma(s)(d) and gamma(s)(LW)) components were evaluated using advancing contact angles by two-liquid geometric-mean and three-liquid Lifshitz-van der Waals acid-base approaches. The HBFP coating exhibited a low surface energy of 22 mJ/m(2), while the gamma(s) and gamma(s)(p) of the cross-linked HBFP-PEG coatings increased proportionally with the PEG weight percentages in the networks. The adsorption of bovine serum albumin (BSA), lectin from Codium fragile (CFL), lipopolysaccharides from Escherichia coli (LPSE) and Salmonella minnesota (LPSS) upon glass, APS-glass, HBFP, PEG, and the cross-linked HBFP-PEG network coatings were investigated by fluorescence microscopy. The marine antifouling and fouling-release properties of the cross-linked HBFP-PEG coatings were evaluated by settlement and release assays involving zoospores of green fouling alga Ulva (syn. Enteromorpha; Hayden, H. S.; Blomster, J.; Maggs, C. A.; Silva, P. C.; Stanhope, M. J.; Waaland, J. R. Eur. J. Phycol. 2003, 38, 277). The growth and release of Ulva sporelings were also investigated upon the HBFP-PEG45 coating in comparison to a poly(dimethylsiloxane) elastomer (PDMSE) standard material. Of the heterogeneous cross-linked network coatings, the maximum resistances to protein, lipopolysaccharide, and Ulva zoospore adhesion, as well as the best zoospore and sporeling release properties, were recorded for the HBFP-PEG45 coating. This material also exhibited better performance than did a standard PDMSE coating, suggesting its unique applicability in fouling-resistance applications.