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.