Integrated In Situ Fabrication of CuO Nanorod-Decorated Polymer Membranes for the Catalytic Flow-Through Reduction of p-Nitrophenol

We developed a novel method to fabricate copper nanorods in situ in a poly(ether sulfone) (15 wt %) casting solution by a sonochemical reduction of Cu2+ ions with NaBH4. The main twist is the addition of ethanol to remove excess NaBH4 through Cu(0) catalyzed ethanolysis. This enabled the direct use of the resulting copper-containing casting dispersions for membrane preparation by liquid nonsolvent-induced phase separation and led to full utilization of the copper source, generating zero metal waste. We characterized the copper nanorods as presented in the membranes via scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS), X-ray diffraction (XRD), and UV/vis spectroscopy. We could demonstrate that the rapid immobilization from reducing conditions led to the membrane incorporation of copper nanorods in a state of high reactivity, which also promoted the complete oxidation to CuO after fabrication. We further observed a large aspect ratio and crystal straining of the nanorods, likely resulting from growth around the matrix polymer. The entanglement with poly(ether sulfone) further facilitated a selective presentation at the pore surface of the final CuO-decorated membranes. The membranes also exhibit high water permeances of up to 2800 L/m2hbar. Our catalytic membranes achieved exceptionally high activities in the aqueous flow-through reduction of p-nitrophenol (p-NP), with turnover frequencies of up to 115 h–1, even surpassing those of other state-of-the-art catalytic membranes that incorporate Pd or Ag. Additionally, we demonstrated that catalytic hydrolysis of the reducing agent in water can lead to hydrogen gas formation and blocking of active sites during continuous catalytic p-NP hydrogenation. We illustrated that the accompanying conversion loss can be mitigated by facilitated gas transport in the water-filled pores, which is dependent on the orientation of the pore size gradient and the flow direction.