ZnO-coated nickel-copper foams for dual-function photocatalytic degradation of pharmaceuticals and pathogen inactivation in water

ZnO nanoparticles were coated onto nickel (Ni) and copper (Cu) foams via electrophoretic deposition (EPD) to fabricate dual-functional photocatalytic materials for advanced water treatment applications. The 3D porous metallic foams enhanced the ZnO layer’s light utilization, mechanical robustness, high electrical conductivity, and high-water permeability. Extensive characterization using SEM, HR-TEM, XRD, XPS, BET analysis, and EIS confirmed uniform ZnO deposition without compromising the structural integrity of the foams. Under UVA-visible irradiation (peak wavelength 385 nm, LED), the ZnO-coated foams exhibited high photocatalytic activity towards three recalcitrant pharmaceuticals, carbamazepine (CBZ), bezafibrate (BZF), and sulfamethoxazole (SMX), achieving near-complete degradation in both batch and continuous-flow configurations within a short irradiation time. Additionally, these materials demonstrated effective disinfection performance, achieving 2.75-log inactivation of MS2 bacteriophage, approaching the 3-log benchmark. In addition, the catalyst maintained stable performance over multiple cycles and was easily regenerated between runs using ethanol and deionized water rinsing. This integrated photocatalytic–disinfection approach enables simultaneous removal of micropollutants and pathogens in a single high-permeability reactor, demonstrating the potential of ZnO–metal foam composites as scalable and durable materials for next-generation water and wastewater treatment systems. • ZnO was coated on Ni/Cu foams by EPD to form durable, high-permeability photocatalysts. • Material analysis confirmed uniform ZnO layers and intact foam structure. • Under 385 nm light, the foams rapidly degraded CBZ, BZF, and SMX. • They achieved 2.75-log MS2 inactivation for combined treatment. • The catalysts were easily regenerated and showed stable multi-cycle performance.