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Scalable Fabrication of Structured Covalent Organic Frameworks for Chemical Separation
Uppsala University, Disciplinary Domain of Science and Technology, Technology, Department of Materials Science and Engineering, Nanotechnology and Functional Materials.ORCID iD: 0009-0002-4231-4254
2025 (English)Doctoral thesis, comprehensive summary (Other academic)
Description
Abstract [en]

 Large-scale chemical separations underpin modern industry yet consume 10–15% of global energy, driving the need to replace thermal operations with membrane- and sorbent-based alternatives of higher efficiency. This thesis advances covalent organic frameworks (COFs) toward practical deployment by focusing on scalable fabrication and processing routes that preserve performance while enabling industrial integration. The intrinsic advantages of COFs—uniform porosity, tunability, and stability—are outlined alongside application-driven requirements for separation materials and processes. For membranes, this entails ultrathin, defect-free active layers on robust supports compatible with continuous manufacturing; for sorbents, it requires short diffusion pathways, macroscopic structure, and low-cost, high-throughput fabrication. A critical survey of fabrication strategies identifies nanosheet assembly and support-infusion liquid–liquid interfacial polymerization as promising continuous routes for COF membranes, while highlighting time and footprint reduction as key issues for structured COF sorbent fabrication. Two novel, scalable fabrication strategies are introduced: (i) a precursor-casting method yielding continuous sub-micron β-ketoenamine COF films, adapted to manufacture thin-film composite membranes on polymeric substrates; and (ii) a gel-based approach for imine and β-ketoenamine COFs, producing hierarchically porous sorbents with rapid adsorption kinetics. To enable robust membrane evaluation, a low-cost pressure-driven filtration system was designed and constructed to support extended nanofiltration studies. The findings suggest that near-term industrial impact is most likely in organic-solvent nanofiltration and selective metal-ion adsorption, where COFs’ robustness and modularity provide distinct benefits. Practical constraints—including monomer cost, solvent use, and heating requirements—are examined with potential mitigation pathways. Collectively, the results outline design and manufacturing considerations that chart a pragmatic route from laboratory scale to industrial implementation of COF membranes and sorbents.

Place, publisher, year, edition, pages
Uppsala: Acta Universitatis Upsaliensis, 2025. , p. 80
Series
Digital Comprehensive Summaries of Uppsala Dissertations from the Faculty of Science and Technology, ISSN 1651-6214 ; 2592
Keywords [en]
Covalent organic frameworks, Membrane separation, Scalable fabrication, Energy-efficient separations, COF synthesis, COF processing
National Category
Materials Chemistry Separation Processes
Research subject
Chemistry with specialization in Materials Chemistry
Identifiers
URN: urn:nbn:se:uu:diva-567805ISBN: 978-91-513-2600-9 (print)OAI: oai:DiVA.org:uu-567805DiVA, id: diva2:2000023
Public defence
2025-11-07, Ångström 4101, Regementsvägen 10, Uppsala, 09:15 (English)
Opponent
Supervisors
Available from: 2025-10-16 Created: 2025-09-22 Last updated: 2025-10-16
List of papers
1. Large-Scale, One-Pot Synthesis of Imine/ β-Ketoenamine-Linked COF Gels in Aqueous Systems for Wastewater Purification
Open this publication in new window or tab >>Large-Scale, One-Pot Synthesis of Imine/ β-Ketoenamine-Linked COF Gels in Aqueous Systems for Wastewater Purification
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(English)Manuscript (preprint) (Other academic)
Abstract [en]

Water contamination by organic dyes, heavy metal ions, and nanoscale particles poses a severe threat to ecosystems and human health, necessitating the development of versatile and robust filtration materials. Covalent organic frameworks (COFs), with their high porosity, tunable surface chemistry, and structural diversity, offer unique opportunities for multifunctional water purification. Here, we report a facile, one-pot, and scalable aqueous synthesis of imine- and β-ketoenamine-linked COFs in the form of freestanding, mechanically robust gels. A total of 31 freestanding COF gels with different molecular structures were successfully obtained, including 25 that are highly crystalline and 6 that are less crystalline or amorphous. Systematic investigation of synthesis conditions revealed that the type of linkage and reaction temperature significantly influenced the gelation process: room temperature favored imine-linked COF gels, whereas elevated temperature promoted β- ketoenamine-linked COF formation. The resulting COF gels exhibited high surface areas (up to 2127 m²/g), tunable pore sizes, and robust elastic networks. Taking advantage of their hierarchical porosity and high stability, the COF gels were employed in a filtration system, which enabled efficient removal of diverse pollutants, including Rhodamine B, Cr³⁺ ions, and ultrafine particles under continuous flow. These findings establish aqueous synthesis and shaping of COF materials as multifunctional platforms for next-generation water purification, capable of efficiently removing diverse pollutants and suitable for applications in industrial wastewater treatment, environmental remediation, and potable water production.

National Category
Materials Chemistry
Identifiers
urn:nbn:se:uu:diva-567643 (URN)
Available from: 2025-09-22 Created: 2025-09-22 Last updated: 2025-09-22
2. A Low-Cost Pressure Driven Filtration System for Nanofiltration Membrane Evaluation
Open this publication in new window or tab >>A Low-Cost Pressure Driven Filtration System for Nanofiltration Membrane Evaluation
(English)In: Hardware, E-ISSN 2813-6640Article in journal (Other academic) Accepted
Abstract [en]

membranes using novel materials and techniques, there is an increasing need to evaluate the practical viability of innovative membranes at the early stages of development. In many materials research laboratories, access to professionally manufactured membrane-evaluation systems may be limited. Here we present a pressure-driven filtration system for evaluation of nanofiltration membranes, that can be constructed from 3D-printed parts and widely available off-the-shelf components at a cost of approximately 60 €. The system uses a stirred cross-flow design capable of circulating the feed solution in the filter cell and maintaining a stable solute concentration during extended filtration experiments—as in conventional cross-flow cells. It is suitable for filtration of aqueous solutions containing dyes, inorganic salts, and dilute acids. Validation was performed by filtering a 2000 mg L-1 MgSO4 solution through a Veolia RL membrane at 7.6 bar, achieving a 96.5% rejection rate and a permeance of 7.5 L m-2 h-1 bar-1 after 24 hours of continuous operation.

National Category
Separation Processes
Identifiers
urn:nbn:se:uu:diva-567801 (URN)
Available from: 2025-09-22 Created: 2025-09-22 Last updated: 2025-09-28
3. Fabrication of Covalent Organic Framework Composite Membranes by Precursor Casting
Open this publication in new window or tab >>Fabrication of Covalent Organic Framework Composite Membranes by Precursor Casting
(English)Manuscript (preprint) (Other academic)
Abstract [en]

Covalent organic frameworks (COF) are promising active materials for pressure-driven separation membranes, owing to their high porosity, uniform pore structure, tunability and stability. Achieving scalable fabrication of COF layers on porous substrates in an essential step towards the large scale production and application of COF thin film composite (TFC) membranes. Here, we present a scalable precursor casting strategy for fabricating TpPa(SO3H)-COF on porous polytetrafluoroethylene (PTFE) substrates. While the COF layers exhibited inhomogeneous morphology and thickness, the membranes were robust and capable of fully rejecting Congo red dye from an aqueous solution. Thus, the fabrication strategy outlined here demonstrates potential for large scale production of COF-based TCF membranes by precursor casting.

National Category
Composite Science and Engineering Textile, Rubber and Polymeric Materials
Identifiers
urn:nbn:se:uu:diva-567641 (URN)
Available from: 2025-09-22 Created: 2025-09-22 Last updated: 2025-09-28
4. Scalable and Versatile Fabrication of Free-Standing Covalent Organic Framework Membranes with Tunable Microstructure for Molecular Separation
Open this publication in new window or tab >>Scalable and Versatile Fabrication of Free-Standing Covalent Organic Framework Membranes with Tunable Microstructure for Molecular Separation
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2025 (English)In: Journal of the American Chemical Society, ISSN 0002-7863, E-ISSN 1520-5126, Vol. 147, no 32, p. 29271-29281Article in journal (Refereed) Published
Abstract [en]

Covalent organic framework (COF) membranes hold significant promise for applications in separation, catalysis, and energy conversion; however, their industrial adoption has been hindered by the lack of scalable and efficient fabrication methods. Here, we present a fast, versatile, and broadly applicable strategy for fabricating free-standing and flexible COF membranes by casting precursor suspensions, followed by heat treatment under controlled humidity. This approach enables the fabrication of COF membranes with lateral dimensions up to several square decimeters and thicknesses that are tunable down to submicron levels within 1 h. It demonstrates remarkable versatility for producing a family of ketoenamine-linked COF membranes through the condensation of 1,3,5-triformylphloroglucinol with various amine monomers differing in length, side groups, and geometry. The resulting crack-free COF membranes exhibit high mechanical strength, with ultimate tensile strength up to 60 MPa and Young’s modulus up to 1.7 GPa, as well as exceptionally high porosity, with Brunauer–Emmett–Teller (BET) surface areas reaching up to 2226 m2 g–1. More importantly, the morphology, porosity, and crystallinity of the membranes can be finely tuned by modulating the heating conditions. The membranes with optimized microstructures demonstrate excellent separation performance, achieving over 99% rejection in nanofiltration of aqueous dye solutions, and a separation factor of 11 with an H2 permeance of 2857 GPU in H2/CO2 gas separation. This approach provides a scalable and effective pathway toward large-scale COF membrane manufacturing for advanced molecular separations and other membrane-based technologies.

Place, publisher, year, edition, pages
American Chemical Society (ACS), 2025
National Category
Nanotechnology
Research subject
Engineering Science with specialization in Nanotechnology and Functional Materials
Identifiers
urn:nbn:se:uu:diva-565436 (URN)10.1021/jacs.5c08788 (DOI)001540510200001 ()40735926 (PubMedID)2-s2.0-105013578719 (Scopus ID)
Available from: 2025-08-21 Created: 2025-08-21 Last updated: 2025-10-22Bibliographically approved

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