Advancing Membrane Technology: High‐Flux PES/ZnO‐Nanoclay Composites for Dye Wastewater Treatment

Industrial wastewater containing synthetic dyes presents environmental and health hazards. Ultrafiltration membranes can address this problem but often suffer from low flux and fouling issues. Incorporating suitable additives can improve their efficiency in removing dyes. In this study, polyethersulfone (PES) membranes embedded with green‐synthesized ZnO‐nanoclay nanoparticles at 1 wt% and 2 wt% were produced through phase inversion to effectively eliminate methylene blue dye. Characterization techniques, such as SEM, FTIR, AFM, and contact angle measurements, examined the nanoparticles and membranes. Tensile testing assessed the mechanical properties, while filtration performance was evaluated using a dead‐end cell. The addition of nanoparticles increased pore size, hydrophilicity, and surface roughness, especially at 2 wt%. Tensile strength increased by 12% at 1 wt% and 25% at 2 wt%, although elongation decreased. Compared to pure membranes, flux tests showed MB rejection rates of 98.01% (1 wt%) and 99.85% (2 wt%), with water flux improving by 500% and 250%, respectively. These results indicate that integrating green‐synthesized ZnO‐nanoclay into PES membranes substantially improves their structural, mechanical, and filtration capabilities, leading to excellent dye rejection and notable flux enhancement. The membranes developed offer a scalable, effective solution for wastewater treatment and show strong potential for industrial use.