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Despite the emergence of eco-friendly solvents and scalable methods for polymeric membrane fabrication, studies on the impacts of solvent synthesis and manufacturing scale-up have not been conducted. To this end, a life cycle assessment (LCA) was developed with the goal of determining the global environmental and health impacts of producing polysulfone (PSf) membranes with the solvents PolarClean and γ-valerolactone (GVL) via doctor blade extrusion (DBE) and slot die coating (SDC). Along with PolarClean and GVL, dimethylacetamide (DMAc) and N-methyl-2-pyyrolidone (NMP) were included in the LCA as conventional solvents for comparison. The dope solution viscosity had a major influence on the material inventories; to produce a normalized membrane unit on a surface area basis, a larger quantity of PSf-PolarClean-GVL materials was required due to its high viscosity. The life cycle impact assessment found electricity and PolarClean to be major contributing parameters to multiple impact categories during membrane fabrication. The commercial synthesis route of PolarClean selected in this study required hazardous materials derived from petrochemicals, which increased its impact on membrane fabrication. Due to more materials being required to fabricate membranes via SDC to account for tool fluid priming, the PSf-PolarClean-GVL membrane fabricated via SDC exhibited the highest impacts. The amount of electricity and concentration of PolarClean were the most sensitive parameters according to Spearman’s rank coefficient analysis. A scenario analysis in which the regional energy grid was substituted found that using the Swedish grid, which comprises far more renewable technologies than the global and US energy grids, significantly lowered impacts in most categories. Despite the reported eco-friendly benefits of using PolarClean and GVL as alternatives to conventional organic solvents, the results in this study provide a wider perspective of membrane fabrication process impacts, highlighting that upstream impacts can counterbalance the beneficial properties of alternative materials. 

Next-generation polymeric membranes must be derived from more environmentally friendly materials that have similar solubility and miscibility properties as their predecessors to form permeable and selective membranes. Bio-derived polymers, recycled plastics, and eco-friendly solvents have been demonstrated to produce membranes with similar permeability and selectivity as conventional counterparts, though matching membrane durability and cost-effectiveness remain as future research challenges. Slot die coating and 3D printing have been demonstrated to show the scalability of membrane fabrication. Life cycle assessments have become valuable tools in estimating the total environmental impacts of the manufacturing process and characterizing the sustainability of new materials. Recent advances have shortened the gap between materials innovation research and commercial application. 

Water contamination resulting from coal spills is one of the largest environmental problems affecting communities in the Appalachia Region of the United States. This coal slurry contains potentially toxic substances, such as hydrocarbons, heavy metals, and coal cleaning chemicals, and its leakage into water bodies (lakes, rivers, and aquifers) can lead to adverse health effects not only for freshwater bodies and plant life but also for humans. This study focused on two major experiments. The first experiment involved the use of biochar to create a biochar–polysulfone (BC-PSf) flat-sheet multifunctional membrane to remove organic contaminants, and the other major experiment compared eco-friendly (gamma-valerolactone—GVL; Rhodiasolv® PolarClean—PC) and petroleum-derived solvents (i.e., N-methyl-pyrrolidone—NMP) in the fabrication of the biochar–polysulfone membranes. The resulting membranes were tested for their efficiency in removing both positively and negatively charged organic contaminants from the collected water at varying pH values. A comparative life cycle assessment (LCA) with accompanying uncertainty and sensitivity analyses was carried out to understand the global environmental impacts of incorporating biochar, NMP, GVL, and PC in the synthesis of PSf/NMP, BC-PSf/NMP, PSf/GVL, BC-PSf/GVL, PSf/PC, and BC-PSf/PC membranes at a set surface area of 1000 m2. The results showed that the addition of biochar to the membrane matrix increased the surface area of the membranes and improved both their adsorptive and mechanical properties. The membranes with biochar incorporated in their matrix showed a higher potential for contaminant removal than those without biochar. The environmental impacts normalized to the BC-PSf/GVL membrane showed that the addition of biochar increased global warming impacts, eutrophication, and respiratory impacts by over 100% in all the membrane configurations with biochar. The environmental impacts were highly sensitive to biochar addition (Spearman’s coefficient > 0.8). The BC/PSf membrane with Rhodiasolv® PolarClean had the lowest associated global environmental impacts among all the membranes with biochar. Ultimately, this study highlighted potential tradeoffs between functional performance and global environmental impacts regarding choices for membrane fabrication. 

Abstract In this study, loose nanofiltration membranes made of polysulfone dissolved in co-solvents PolarClean and gamma-Valerolactone were prepared via slot die coating (SDC) on a roll-to-roll (R2R) system by directly coating them onto a support layer or free standing. A solution flow rate of 20 mL/min, substrate speed of 17.1 mm/s, and coating gap of 0.1 mm resulted in the formation of membranes without structural defects. Pre-wetting the support layer with dope solution minimized shrinkage of membrane layer thickness and improved interfacial adhesion. Membrane samples produced using SDC exhibited properties and performance consistent with bench-scale doctor blade extruded samples; pre-wetted and uncompressed samples (SDC-3) exhibited the highest rejection of bovine serum albumin (99.20% ± 1.31%) and along with adequate mean permeability during filtration (70.5 ± 8.33 LMH/bar). This study shows that combining sustainable materials development with SDC provides a holistic approach to membrane separations to bridge materials discovery and membrane formation. 

Abstract Membranes serve as important components for modern manufacturing and purification processes but are conventionally associated with excessive solvent usage. Here, for the first time, a procedure for fabricating large area polysulfone membranes is demonstrated via the combination of direct ink writing (DIW) with non-solvent induced phase inversion (NIPS). The superior control and precision of this process allows for complete utilization of the polymer dope solution during membrane fabrication, thus enabling a significant reduction in material usage. Compared to doctor blade fabrication, a 63% reduction in dope solution volume was achieved using the DIW technique for fabricating similarly sized membranes. Cross flow filtration analysis revealed that, independent of the manufacturing method (DIWvs.doctor blade), the membranes exhibited near identical separation properties. The separation properties were assessed in terms of bovine serum albumin (BSA) rejection and permeances (pressure normalized flux) of pure water and BSA solution. This new manufacturing strategy allows for the reduction of material and solvent usage while providing a large toolkit of tunable parameters which can aid in advancing membrane technology. 

Protection against airborne viruses has become very relevant since the outbreak of SARS-CoV-2. Nonwoven face masks along with heating, ventilation, and air conditioning (HVAC) filters have been used extensively to reduce infection rates; however, some of these filter materials provide inadequate protection due to insufficient initial filtration efficiency (FE) and FE decrease with time. Flat sheet porous membranes, which have been used extensively to filter waterborne microbes and particulate matter due to their high FE have the potential to filter air pollutants without compromising its FE over time. Therefore, in this study, single layer polysulfone (PSf) membranes were fabricated via non-solvent induced phase separation (NIPS) and were tested for airflow rate, pressure drop and FE. Polyethylene glycol (PEG) and glycerol were employed as pore-forming agents, and the effect of the primary polymer and pore-forming additive molecular weights (MW) on airflow rate and pressure drop were studied at different concentrations. The thermodynamic stability of dope solutions with different MWs of PSf and PEG in N-methylpyrrolidone (NMP) at different concentrations was determined using cloud-point measurements to construct a ternary phase diagram. Surface composition of the fabricated membranes was characterized using contact angle and X-ray photoelectron spectroscopy (XPS), while membrane morphology was characterized by SEM, and tensile strength experiments were performed to analyze the membrane mechanical strength (MS). It was observed that an increase in PSf and PEG molecular weight and concentration increased airflow and decreased pressure drop. PSf60:PEG20:NMP (15:15:70)% w/w showed the highest air flow rate and lowest pressure drop, but at the expense of the mechanical strength, which was improved significantly by attaching the membrane to a 3D-printed polypropylene support. Lastly, the FE values of the membranes were similar to those of double-layer N95 filters and significantly higher than those of single layer of N95, surgical mask and HVAC (MERV 11) filters. 

Microcystin-LR (MC-LR) is a toxin produced by cyanobacteria that can bloom in freshwater supplies. This study describes a new strategy for remediation of MC-LR that combines linearization of the toxin using microcystinase A, MlrA, enzyme with rejection of linearized byproducts using membrane filtration. The MlrA enzyme was expressed in Escherichia coli (E. coli) and purified via a His-tag with 95% purity. Additionally, composite membranes made of 95% polysulfone and 5% sulfonated polyether ether ketone (SPEEK) were fabricated and used to filter a solution containing cyclic and linearized MC-LR. Tests were also performed to measure the adsorption and desorption of MC-LR on polysulfone/SPEEK membranes. Liquid chromatography-mass spectrometry (LC-MS) was used to characterize the progress of linearization and removal of MC-LR. Results indicate that the MlrA was successful at linearizing MC-LR. Membrane filtration tests showed rejection of 97% of cyclic MC-LR and virtually all linearized MC-LR, with adsorption to the membranes being the main rejection mechanism. Adsorption/desorption tests indicated that methanol could be used to strip residual MC-LR from membranes to regenerate them. This study demonstrates a novel strategy of remediation of microcystin-tainted water, combining linearization of MC-LR to a low-toxicity byproduct along with removal by membrane filtration. 

The outbreak of the COVID-19 pandemic, in 2020, has accelerated the need for personal protective equipment (PPE) masks as one of the methods to reduce and/or eliminate transmission of the coronavirus across communities. Despite the availability of different coronavirus vaccines, it is still recommended by the Center of Disease Control and Prevention (CDC), World Health Organization (WHO), and local authorities to apply public safety measures including maintaining social distancing and wearing face masks. This includes individuals who have been fully vaccinated. Remarkable increase in scientific studies, along with manufacturing-related research and development investigations, have been performed in an attempt to provide better PPE solutions during the pandemic. Recent literature has estimated the filtration efficiency (FE) of face masks and respirators shedding the light on specific targeted parameters that investigators can measure, detect, evaluate, and provide reliable data with consistent results. This review showed the variability in testing protocols and FE evaluation methods of different face mask materials and/or brands. In addition to the safety requirements needed to perform aerosol viral filtration tests, one of the main challenges researchers currently face is the inability to simulate or mimic true aerosol filtration scenarios via laboratory experiments, field tests, and in vitro/in vivo investigations. Moreover, the FE through the mask can be influenced by different filtration mechanisms, environmental parameters, filtration material properties, number of layers used, packing density, fiber charge density, fiber diameter, aerosol type and particle size, aerosol face velocity and concentration loadings, and infectious concentrations generated due to different human activities. These parameters are not fully understood and constrain the design, production, efficacy, and efficiency of face masks.