The morphology and performance of polyamide active layer can be controlled by the pore size and surface porosity of support layer. Nevertheless, further investigation is required to elucidate the impact of pore distribution and the specific role of each pore. Therefore, by introducing polyetherimide (PEI) as a sacrificial top layer, the support layer with a wide pore distribution was prepared by co-casting method. A mathematical model was developed to enable the estimation of the impact of each pore radius and pore distribution on the structure and performance of the active layer. During interfacial polymerization process, the surface pore size and distribution of the support layer influenced the incipient film which consists of the polyamide colloids and dominates the successive growth of polyamide layer. It was suggested that both average pore radius and pore distribution contributed to the composite of incipient film. The overall η of 1.77 for S75 corresponded to an incipient film composed of linear polyamide terminated with MPD and fully cross-linked polyamide, resulting in the best performing membrane (C75) with DC of 0.75 and structural parameter as low as 230 μm. A comparison of C75 with C0 revealed an increase in water flux of 138 % and a minor increase in salt flux of 6.37 %. This work presents a novel approach to enhancing the performance of FO membranes and offers a new perspective on the structure-effect relationship.
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