Optimization of interfacial polymerization to fabricate thin-film composite hollow fiber membranes in modules for brackish water reverse osmosis

The development of commercial-scale thin-film composite (TFC) hollow fiber membranes and modules for reverse osmosis (RO) has been lagging behind spiral wound TFC flat-sheet membranes and modules for many years. The delay arises from the challenges of synthesizing a defect-free polyamide selective layer on hollow fibers in modules. In order to solve this problem, a novel interfacial polymerization method is presented in this work to fabricate 1-inch TFC hollow fiber membrane modules for RO applications. By circulating the m-phenylenediamine (MPD) solution on the lumen side under a positive pressure and circulating the trimesoyl chloride (TMC) solution at the atmosphere pressure, a strong, uniform and defect-free polyamide selective layer is formed on the inner surface of hollow fiber membranes in modules. Under pressure, not only MPD monomers are evenly distributed on the inner surface of each hollow fiber substrate in modules, but also sufficient MPD monomers can retain in the substrate pores for further reaction with TMC monomers. The best RO performance obtained by this newly developed TFC hollow fiber membrane module has a water permeability of 4.49 L m(-2) h(-1) bar(-1) and a NaCl rejection of similar to 99%, using a feed solution of 1000 ppm NaCl under a transmembrane pressure of 20 bar. The novel interfacial polymerization method may provide useful insights to fabricate TFC hollow fiber membrane modules for desalination of brackish water.