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Pilot-Scale Polysulfone Ultrafiltration Patterned Membranes: Phase-Inversion Parametric Optimization on a

Ayesha Ilyas¹, Ivo F J Vankelecom¹

¹Membrane Technology Group (MTG), Division cMACS, Faculty of Bioscience Engineering, KU Leuven, Celestijnenlaan 200F, P.O. Box 2454, 3001 Leuven, Belgium.

|August 27, 2025

Summary

This summary is machine-generated.

This study optimized pilot-scale production of patterned polysulfone (PSf) ultrafiltration membranes using spray-modified non-solvent-induced phase separation (s-NIPS). The upscaled membranes show significantly increased water flux, advancing membrane technology for water treatment.

Keywords:

fouling control patterned membranes phase inversion pilot-scale preparation roll-to-roll membrane production upscaling

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Area of Science:

Materials Science
Chemical Engineering
Environmental Science

Background:

Scalability and processability of high-performance membranes are key challenges.
Previous research on patterned membranes using spray-modified non-solvent-induced phase separation (s-NIPS) was primarily lab-scale.
Scaling up membrane production can alter performance characteristics.

Purpose of the Study:

To optimize pilot-scale production of patterned polysulfone (PSf) ultrafiltration membranes via s-NIPS.
To identify optimal phase inversion parameters for roll-to-roll manufacturing.
To bridge the gap between lab-scale and pilot-scale membrane preparation.

Main Methods:

Systematic variation of phase inversion parameters (polymer concentration, molecular weight, additive type/concentration) on a 12-inch wide roll-to-roll pilot line.
Utilized spray-modified non-solvent-induced phase separation (s-NIPS) method.
Characterization of membranes for pure water permeance, BSA rejection, casting solution viscosities, and morphology.

Main Results:

Achieved defect-free, high-performance patterned PSf membranes at pilot scale.
s-NIPS patterned membranes demonstrated a 150-350% increase in water flux compared to flat membranes.
High pattern heights (up to 825 µm) and finger-like macrovoids contributed to enhanced flux.

Conclusions:

Successfully optimized s-NIPS for upscaled production of patterned PSf ultrafiltration membranes.
The developed membranes exhibit significantly enhanced water flux, suitable for water treatment applications.
This work validates the potential of pilot-scale s-NIPS for producing advanced membranes.