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Salvinno groundbraking technology focuses in the technological achievements of the EIC Transition project “SuperClean”, that NCSR Demokritos has developed and supports the ambitions set in the project through the use of a novel type of plasma reactor equipment and a novel plasma nanotexturing process that produces SSbD next generation superhydrophobic / superhydrophilic membranes, with enhanced fouling and scaling resistance, exceptional chemical durability, and compatibility with circular economy principles offering a direct, scalable replacement for conventional wet coating methods. This work has been patented[1]  and published in Nanotechnology in 2021[2] and Micro and Nano Engineering in 2024[3].

The new plasma reactor is essentially plasma etching equipment coupled with controlled sputtering of etch inhibitors from a metallic surface. The new reactor design allows for simultaneous arrival on the polymer surface of etching ions and radicals as well as etching inhibitors. Their synergistic action causes the formation of micro-nanoscale roughness on the surface. The SEM images in Fig. 1 demonstrate the difference in topography on the surface of polyethersulfone (PES) membranes after plasma nanotexturing in the new plasma reactor. This rough topography (micro-nanotexture) exhibits a high surface air fraction, which is crucial to achieve superhydrophobicity.

Figure 1: SEM images of the PES membrane morphology A) Untreated top down (x5000 magnification), B) Untreated at 45◦ angle (x2000 magnification), C) After treatment for 2:00 min with O2 top down (x5000 magnification) and D) After treatment for 2:00 min with O2 at 45◦ angle (x2000 magnification).

Many industries generate highly variable waste streams both air and liquid with extreme pH conditions (ranging from 0 to 14), which can degrade membranes over time, leading to system failures, increased maintenance costs, and environmental concerns. There is also a growing need to replace traditional fluorocarbon-based membranes, such as polytetrafluoroethylene (PTFE) and PVDF, due to concerns about per- and polyfluoroalkyl substances (PFAS), which pose environmental and health risks. The degradation of these membranes during the filtration process in such extreme conditions is resulting in the contamination of air, water and soil posing a significant health risk for humans and the environment. 

The goal of this is to identify and develop alternative non-fluorinated membranes that can withstand harsh wastewater conditions without compromising performance.

1. Variable Faraday shield for a substrate holder, a clamping ring, or an electrode, or their combination in a plasma reactor

2. A. Zeniou et al, Nanotechnology, vol. 32, no. 23, 2021.

3. E. Manouras, Micro and Nano Engineering, Vol. 24, 2024, 00269, ISSN 2590-0072