Interfacial polymerization membrane

Interfacial polymerization membranes are less appHcable to gas separation because of the water swollen hydrogel that fills the pores of the support membrane. In reverse osmosis, this layer is highly water swollen and offers Httle resistance to water flow, but when the membrane is dried and used in gas separations the gel becomes a rigid glass with very low gas permeabiUty. This glassy polymer fills the membrane pores and, as a result, defect-free interfacial composite membranes usually have low gas fluxes, although their selectivities can be good. 

UF Membranes as a Substrate for RO An important use of UF membranes is as a substrate for composite reverse-osmosis membranes. After the UF membrane (usually polysulfone) is prepared, it is coated with an aqueous solution of an amine, then dipped in an organic solution of an acid chloride to produce an interfacially polymerized membrane coating. 

Interfacial polymerization membranes. This type of anisotropic membrane is made by polymerizing an extremely thin layer of polymer at the surface of a microporous support polymer. 

L.E. Black, Interfacially polymerized membranes and reverse-osmosis of organic solvent solutions using them, EP 421676, 1991. 

Black, L. E. 1991. Interfacially polymerized membranes for reverse osmosis separation of organic solvent solutions. U.S. Patent No. 5173191. 

Commercial application of nanofiltration membrane and reverse osmosis membrane is not yet realized for the removal of As from drinking water. The high energy consumption as well as low removal rate for the As(III) is the maj or obstacle. Classical interfacial polymerization membranes are negatively charged, but of low charge density, leading to low rejection of As (Seidel et al, 2001). 

Zhao, Y., Qiu, C., Li, X., Vararattanavech, A., Shen, W., Torres, J., Helix-Nielsen et al. 2012, Synthesis of robust and high-performance aquaporin-based biomimetic membranes by interfacial polymerization-membrane preparation and RO performance characterization, J Memb Sci 423-424 422-428. 

Interfdci l Composite Membra.nes, A method of making asymmetric membranes involving interfacial polymerization was developed in the 1960s. This technique was used to produce reverse osmosis membranes with dramatically improved salt rejections and water fluxes compared to those prepared by the Loeb-Sourirajan process (28). In the interfacial polymerization method, an aqueous solution of a reactive prepolymer, such as polyamine, is first deposited in the pores of a microporous support membrane, typically a polysulfone ultrafUtration membrane. The amine-loaded support is then immersed in a water-immiscible solvent solution containing a reactant, for example, a diacid chloride in hexane. The amine and acid chloride then react at the interface of the two solutions to form a densely cross-linked, extremely thin membrane layer. This preparation method is shown schematically in Figure 15. The first membrane made was based on polyethylenimine cross-linked with toluene-2,4-diisocyanate (28). The process was later refined at FilmTec Corporation (29,30) and at UOP (31) in the United States, and at Nitto (32) in Japan. 

Membranes made by interfacial polymerization have a dense, highly cross-linked interfacial polymer layer formed on the surface of the support membrane at the interface of the two solutions. A less cross-linked, more permeable hydrogel layer forms under this surface layer and fills the pores of the support membrane. Because the dense cross-linked polymer layer can only form at the interface, it is extremely thin, on the order of 0.1 p.m or less, and the permeation flux is high. Because the polymer is highly cross-linked, its selectivity is also high. The first reverse osmosis membranes made this way were 5—10 times less salt-permeable than the best membranes with comparable water fluxes made by other techniques. 

An excellent review of composite RO and nanofiltration (NE) membranes is available (8). These thin-fHm, composite membranes consist of a thin polymer barrier layer formed on one or more porous support layers, which is almost always a different polymer from the surface layer. The surface layer determines the flux and separation characteristics of the membrane. The porous backing serves only as a support for the barrier layer and so has almost no effect on membrane transport properties. The barrier layer is extremely thin, thus allowing high water fluxes. The most important thin-fHm composite membranes are made by interfacial polymerization, a process in which a highly porous membrane, usually polysulfone, is coated with an aqueous solution of a polymer or monomer and then reacts with a cross-linking agent in a water-kniniscible solvent. 

The predominant RO membranes used in water applications include cellulose polymers, thin film oomposites (TFCs) consisting of aromatic polyamides, and crosslinked polyetherurea. Cellulosic membranes are formed by immersion casting of 30 to 40 percent polymer lacquers on a web immersed in water. These lacquers include cellulose acetate, triacetate, and acetate-butyrate. TFCs are formed by interfacial polymerization that involves coating a microporous membrane substrate with an aqueous prepolymer solution and immersing in a water-immiscible solvent containing a reactant [Petersen, J. Memhr. Sol., 83, 81 (1993)]. The Dow FilmTec FT-30 membrane developed by Cadotte uses 1-3 diaminobenzene prepolymer crosslinked with 1-3 and 1-4 benzenedicarboxylic acid chlorides. These membranes have NaCl retention and water permeability claims. 

Geong and coworkers reported a new concept for the formation of zeolite/ polymer mixed-matrix reverse osmosis (RO) membranes by interfacial polymerization of mixed-matrix thin films in situ on porous polysulfone (PSF) supports [83]. The mixed-matrix films comprise NaA zeoHte nanoparticles dispersed within 50-200 nm polyamide films. It was found that the surface of the mixed-matrix films was smoother, more hydrophilic and more negatively charged than the surface of the neat polyamide RO membranes. These NaA/polyamide mixed-matrix membranes were tested for a water desalination application. It was demonstrated that the pure water permeability of the mixed-matrix membranes at the highest nanoparticle loadings was nearly doubled over that of the polyamide membranes with equivalent solute rejections. The authors also proved that the micropores of the NaA zeolites played an active role in water permeation and solute rejection. 

Using different polymeric materials in the chromatographic columns and LSC data on retention times (t) of suitably chosen reference solutes, three interfacial parameters (o(p, Ojj, and S), defined below, have been generated for characterizing polymeric membrane materials (53,56)... 

Phase separation controlled by diffusion exchange often results in a skin which is composed of a micellar assembly of nodules, as will be discussed below. When extremely hydrophobic polymers (e.g., modifled-PPO) are cast from dioxane into water (pg = p = p ) a dense polymer layer is formed at the solution s interface that somewhat resembles the type of layer formed by Interfacial polymerization. There is almost no inward contraction of the interfacial skin, and the coagulation process is controlled by diffusion through the dense, interfacial thin film. These result in an anisotropic membrane with a very fine "coral" structure (Figures 9 and 10). 

Relationship Between Nodular and Rejecting Layers. Nodular formation was conceived by Maler and Scheuerman (14) and was shown to exist in the skin structure of anisotropic cellulose acetate membranes by Schultz and Asunmaa ( ), who ion etched the skin to discover an assembly of close-packed, 188 A in diameter spheres. Resting (15) has identified this kind of micellar structure in dry cellulose ester reverse osmosis membranes, and Panar, et al. (16) has identified their existence in the polyamide derivatives. Our work has shown that nodules exist in most polymeric membranes cast into a nonsolvent bath, where gelation at the interface is caused by initial depletion of solvent, as shown in Case B, which follows restricted Inward contraction of the interfacial zone. This leads to a dispersed phase of micelles within a continuous phase (designated as "polymer-poor phase") composed of a mixture of solvents, coagulant, and a dissolved fraction of the polymer. The formation of such a skin is delineated in the scheme shown in Figure 11. 

A new variation of interfacial polymerization was developed by Russell and Emrick in which functionalized nanoparticles or premade oligomers self-assemble at the interface of droplets, stabilizing them against coalescence. The functional groups are then crosslinked, forming permanent capsule shells around the droplets to make water-in-oil (Lin et al. 2003 Skaff et al. 2005) and oil-in-water (Breitenkamp and Emrick 2003 Glogowski et al. 2007) microcapsules with elastic membranes. 

Extractant leakage from the pores of the polymeric membrane in SLM is due to osmotic flow of massive quantities of water through the membrane. Membrane stability decreases with increasing osmotic pressure gradient and depends upon composition of the SLM system. A high tendency to solubilize water, low extractant/aqueous interfacial tension, and high wettability of polymeric membrane leads to less stable SLMs. The following measures have been proposed for improvement of stability ... 

Nanofiltration membranes usually have good rejections of organic compounds having molecular weights above 200—500 (114,115). NF provides the possibility of selective separation of certain organics from concentrated monovalent salt solutions such as NaCl. The most important nanofiltration membranes are composite membranes made by interfacial polymerization. Polyamides made from piperazine and aromatic acyl chlorides are examples of widely used nanofiltration membrane. Nanofiltration has been used in several commercial applications, among which are demineralization, oiganic removal, heavy-metal removal, and color removal (116). 

Although these composite fibers were developed lor reverse osmosis lltcir acceptance in the desalinatiun industry has been limited due to insufficient selectivity and oxidative stability. The concept, however, is extremely viable composite membrane fiat films made from interfacial polymerization have gained wide industry approval. Hollow libers using Ibis technique to give equivalent properties and life, yet lo be developed, should be market tested during the 1990s. 

The stability of various niosomal formulations depends on factors such as preparation methods, storage temperature, the encapsulated drug, the surfactants, and additive mixture [41,52,64,65], It may be possible to stabilize niosomes by a variety of methods such as the use of membrane-spanning lipids, the interfacial polymerization of surfactant monomers in situ, addition of polymerized surfactants, cholesterol, steric and electrostatic stabilizers to the formulation [41,52]. In general, vesicle aggregation may be prevented by inclusion of... 

Enzyme micro-encapsulation is another alternative for sensor development, although in most cases preparation of the microcapsules may require extremely well-controlled conditions. Two procedures have usually been applied to microcapsule preparation, namely interfacial polymerization and liquid drying [80]. Polyamide, collodion (cellulose nitrate), ethylcellulose, cellulose acetate butyrate or silicone polymers have been employed for preparation of permanent micro capsules. One advantage of this method is the double specificity attributed to the presence of both the enzyme and the semipermeable membrane. It also allows the simultaneous immobilization of many enzymes in a single step, and the contact area between the substrate and the catalyst is large. However, the need for high protein concentration and the restriction to low molecular weight substrates are the important limitations to this approach. 

Membranes made by the Loeb-Sourirajan process consist of a single membrane material, but the porosity and pore size change in different layers of the membrane. Anisotropic membranes made by other techniques and used on a large scale often consist of layers of different materials which serve different functions. Important examples are membranes made by the interfacial polymerization process discovered by Cadotte [15] and the solution-coating processes developed by Ward [16], Francis [17] and Riley [18], The following sections cover four types of anisotropic membranes ... 

Figure 3.20 Schematic of the interfacial polymerization process. The microporous film is first impregnated with an aqueous amine solution. The film is then treated with a multivalent crosslinking agent dissolved in a water-immiscible organic fluid, such as hexane or Freon-113. An extremely thin polymer film forms at the interface of the two solutions [47]. Reprinted from L.T. Rozelle, J.E. Cadotte, K.E. Cobian, and C.V. Knopp, Jr, Nonpolysaccharide Membranes for Reverse Osmosis NS-100 Membranes, in Reverse Osmosis and Synthetic Membranes, S. Sourirajan (ed.), National Research Council Canada, Ottawa, Canada (1977) by permission from NRC Research Press...

Most anisotropic membranes are produced by solution precipitation, interfacial polymerization or solution coating. A number of other techniques developed in the laboratory are reviewed briefly below none are used on a large scale. 

Since the discovery by Cadotte and his co-workers that high-flux, high-rejection reverse osmosis membranes can be made by interfacial polymerization [7,9,10], this method has become the new industry standard. Interfacial composite membranes have significantly higher salt rejections and fluxes than cellulose acetate membranes. The first membranes made by Cadotte had salt rejections in tests with 3.5 % sodium chloride solutions (synthetic seawater) of greater than 99 % and fluxes of 18 gal/ft2 day at a pressure of 1500 psi. The membranes could also be operated at temperatures above 35 °C, the temperature ceiling for Loeb-Sourirajan cellulose acetate membranes. Today s interfacial composite membranes are significantly better. Typical membranes, tested with 3.5 % sodium chloride solutions,... 

For a few years after the development of the first interfacial composite membranes, it was believed that the amine portion of the reaction chemistry had to be polymeric to obtain good membranes. This is not the case, and the monomeric amines, piperazine and phenylenediamine, have been used to form membranes with very good properties. Interfacial composite membranes based on urea or amide bonds are subject to degradation by chlorine attack, but the rate of degradation of the membrane is slowed significantly if tertiary aromatic amines are used and the membranes are highly crosslinked. Chemistries based on all-aromatic or piperazine structures are moderately chlorine tolerant and can withstand very low level exposure to chlorine for prolonged periods or exposure to ppm levels... 

---