Recycled Polystyrene as a Sustainable Material for Hollow Fiber Membranes in Dye Filtration

Expanded polystyrene (EPS) waste was chemically modified by sulfonation to obtain sulfonated EPS (sEPS), which was subsequently blended with virgin polyphenylsulfone (PPSU) at concentrations ranging from 10 to 50% to elaborate hollow fiber membranes for dye removal. The membranes were elaborated by non-solvent-induced phase separation and characterized by scanning electron microscopy, mechanical properties, antifouling, water flux measurements, and dye rejection performance. Scanning electron microscopy images of PPSU/sEPS blends showed well-defined membrane cross-sections with no polymer segregation up to 30% recycled EPS content, indicating improved compatibility due to EPS sulfonation. The HFMs present mean pore radii ranging from 4.2 ± 0.5 to 11.1 ± 1.0 nm with porosity up to 80%. Water flux improved significantly from 3.1 to 21.2 L m−2 h−1 at 2 bar as sEPS content increased. Dye rejection performance was promising, with Reactive Black 5 rejection ranging from 77% to 99%. The 80/20s PPSU/sEPS membrane showed the highest Reactive Black 5 rejection at 98.3% and revealed a 70.3% rejection in a 24 h dye mixture test. Furthermore, the 70/30s displayed superior anti-fouling properties, achieving a 99.3% flux recovery ratio in a xanthan gum solution at 2 bar. This study demonstrates a novel approach to transform EPS waste into high-performance hollow fiber membrane with competitive antifouling and dye separation properties.