Preparation of Superwetting Porous Materials for Ultrafast Separation of Water-in-Oil Emulsions

Study on Demulsification via Vacuum Filtration with Superamphiphilic Diatomite/G-C3N4/Rice Husk Charcoal Composite Filter Layer

The primary extraction way for unconventional oil/gas resources is hydraulic fracturing to alter the reservoir for commercial production. However, hydraulic fracturing technology consumes a large amount of water, and the flowback water can easily be mixed with hydrocarbon substances to form emulsions. To achieve the recycling of water, it is necessary to develop an efficient continuous demulsification method for treating the flowback fluid. In this study, a composite filtration layer with superhydrophilic and superoleophilic properties was successfully prepared using water-based polyurethane as a binder. The g-C3N4 was used to improve the affinity of the filtration layer to water and oil. The diatomite and rice husk carbon were used as an adsorbent and a filter aid, respectively. The contact angles (CA) of both oil and water on the surface of the filtration layer were measured to be 0°. During the demulsification process, vacuum filtration was employed to increase the pressure difference across the filtration layer, thereby improving the treatment flux of flowback fluid. The experimental results showed that the filtration flux with the addition of rice husk charcoal increased from 160.58 L∙m-2∙h-1 to 174.68 L∙m-2∙h-1 compared to the filter layer without rice husk charcoal. Based on the composite filtration layer, the apparent demulsification efficiency exceeded 90.6% for various types of emulsion. The mechanism of demulsification was investigated by the molecular dynamics method. The results showed that the adsorption layer density of water molecules reached 1.5 g/cm3, and the adsorption layer density of oil molecules exceeded 2.5 g/cm3. The porous structure wall has a strong adsorption effect on both oil and water molecules, resulting in deformation and destruction of the oil-water interface, so that the dispersed phase is adsorbed and aggregated by the filter layer at the same time and permeates from the filter layer after reaching saturation, thus separating the two phases.

Dual-bionic superwetting gears with liquid directional steering for oil-water separation

Developing an effective and sustainable method for separating and purifying oily wastewater is a significant challenge. Conventional separation membrane and sponge systems are limited in their long-term usage due to weak antifouling abilities and poor processing capacity for systems with multiple oils. In this study, we present a dual-bionic superwetting gears overflow system with liquid steering abilities, which enables the separation of oil-in-water emulsions into pure phases. This is achieved through the synergistic effect of surface superwettability and complementary topological structures. By applying the surface energy matching principle, water and oil in the mixture rapidly and continuously spread on preferential gear surfaces, forming distinct liquid films that repel each other. The topological structures of the gears facilitate the overflow and rapid transfer of the liquid films, resulting in a high separation flux with the assistance of rotational motion. Importantly, this separation model mitigates the decrease in separation flux caused by fouling and maintains a consistently high separation efficiency for multiple oils with varying densities and surface tensions.

Multifunctional starch-based material for contaminated emulsions separation and purification

Stable water-in-oil (W/O) emulsions can produce at many industrial production occasions. However, most materials for its separation have serious fouling problems. To overcome this shortcoming, we fabricated an easy cleaning multifunctional starch-based material with unique wetting behavior which could realize efficient separation and purification of W/O emulsions. This material has a hierarchical structure and superoleophilic and under oil superhydrophobic surfaces which could separate various W/O emulsions in a high separation efficiency and flux without external pressure. In addition, the decrease of separation flux was not observed for this material, which can be reused more than 10 times after washing with ethanol and drying after each separation cycle. Furthermore, this material also could realize efficient removal of dyes and heavy-metal and rare-earth ions simultaneously during a separation process. The material shows great potential for separating and purifying stable W/O emulsions produced during the industrial production.

Hyper-Cross-Linked Polymer-Decorated Surfaces with Ultrahigh Efficiency for Oil/Water Emulsion Separation and Recovery

A novel superhydrophobic/superoleophilic surface has been developed by direct surface condensation of dichloroxylene that results in a controlled coating of hyper-cross-linked polymers. Specifically, the coating was successfully applied to a melamine formaldehyde sponge and optimized by fine-tuning the reaction variables. The resulting hierarchical porous sorbents stabilized by polydimethylsiloxane exhibited an increased surface area, good physiochemical stability, high selectivity, and adsorption capacities for a variety of oils and solvents. The composite can separate oil in water emulsions with ultrahigh separation efficiency >99% over 10 cycles in liter-scale experiments, wherein the highest separation efficiency was as low as 2 ppm even with a short period of filtration, suggesting strong potential for oil/water separation and recovery.

Effect of silylating agents on the superhydrophobic and self-cleaning properties of siloxane/polydimethylsiloxane nanocomposite coatings on cellulosic fabric filters for oil-water separation

A new facile approach for preparing two nonfluorinated hybrid organic-inorganic siloxane/polydimethylsiloxane nanocomposite coatings for cotton fabrics is presented using two distinct silylating agents. The first coated fabric was prepared predominantly via trimethylsilyl modification using hexamethyldisilazane (HMDS) while higher amounts of trimethoxy(octadecyl)silane (TMOS) further enhanced the superhydrophobicity of the second coating matrix. Unlike HMDS with substituted silyl (Me3Si) groups, TMOS consists of hydrolysable trimethoxy silyl ((MeO)3Si) chemical groups that allowed for the formation of nanosilica with Si-O-Si linkages needed to foster stable coatings. After characterization and testing, these coated fabrics demonstrated varying responses to harsh solvents and thermal conditions. Both sets of coated fabrics exhibited unique capacities for self-cleaning and oil-water separation as superhydrophobic filters due to (a) their low surface energy silylated hybrid polysiloxane chemical groups, (b) their highly reduced surface wettability and (c) nanopatterned surface morphologies. In this study, coated superhydrophobic cotton fabrics revealed a higher static aqueous contact angle of more than 150° and sliding hysteresis angle of less than 5°. Coated fabrics with 30 mg TMOS/10 mg HMDS (CMF3) and 30 mg HMDS/10 mg TMOS (CTF3) exhibited optimal superhydrophobicity. Both fabrics also retained percentage separation efficiencies over 90% for both chloroform-water and toluene-water mixtures. However, CTF3 displayed with a recorded separation efficiency less than 90° after five filtration cycles.

New superhydrophobic and self-cleaning zirconia/polydimethylsiloxane nanocomposite coated cotton fabrics

Zirconia/polydimethylsiloxane nanocomposite coated fabric demonstrates unique stability with tendencies toward self-cleaning and oil–water separations due to its nanopatterned morphologies and adhering superhydrophobic polysiloxane chemical groups.

Simulation Study on the Dynamic Behaviors of Water-in-Oil Emulsified Droplets on Coalescing Fibers

Although increasing superwetting membranes have been developed for separating oil-water emulsions based on the "size-sieving" mechanism, their pores are easily blocked and fouled by the intercepted emulsified droplets, which would result in a severe membrane fouling issue and a sharp decline in flux. Instead of droplet interception, a fiber-based coalescer separates oil/water emulsions by inducing the emulsified droplets to coalesce and transform into layered oil/water mixtures, exhibiting an ability to work continuously for a long time with high throughput, which makes it a promising technology for emulsion treatment. However, the underlying mechanism of the separation process is not well understood, which makes it difficult to further improve the separation performance. Hence, in this work, the dynamic behaviors of water-in-oil emulsified droplets on the surface of the coalescing fiber were numerically investigated based on the phase-field model. The attachment, transport, and detachment behaviors of droplets on fibers were directly observed, and the effects of fiber wettability, orientation, arrangement, and fluid speed were studied in detail. First, it was observed that the droplets will move downstream along the fiber surface under the effect of fluid shear, and the large droplets tend to coalesce with their downstream small droplets on the same fiber surface because they move faster compared to the small droplets. Second, it was found that the emulsified droplet will spontaneously transport to the intersection of two angled fibers under the drive of asymmetric Laplace pressure, which demonstrated that the emulsified droplets tend to gather at the intersection of fibers when permeating through a coalescing medium. Third, it was found that the detachment behaviors of droplets from the fiber surface are strongly affected by their size, fiber wettability, and fluid velocity. In addition, the results of our simulation show that the backside of two closely attached fibers can further inhibit the detachment of droplets. We truly believe that our research results are of significance to optimize the parameters of a fiber-based coalescer for separating oil-water emulsions and to develop novel oil/water separators.

Separation Mechanism and Construction of Surfaces with Special Wettability for Oil/Water Separation

Oil leakage and the discharge of oil/water mixtures by domestic and industrial consumers have caused not only severe environmental pollution and a threat to all species in the ecosystem but also a huge waste of precious resources. Therefore, the separation of oil/water mixtures, especially stable emulsion, has become an urgent global issue. Recently, materials containing a special wettability feature for oil and water have drawn immense attention because of their potential applications for oil/water separation application. In this paper, we systematically summarize the fundamental theories, separation mechanism, design strategies, and recent developments in materials with special wettability for separating stratified and emulsified oil/water mixtures. The related wetting theories that unveil the physical underlying mechanism of the oil/water separation mechanism are proposed, and the practical design criteria for oil/water separation materials are provided. Guided by the fundamental design criteria, various porous materials with special wettability characteristics, including those which are superhydrophilic/underwater superoleophobic, superhydrophobic/superoleophilic, and superhydrophilic/in-air superoleophobic, are systemically analyzed. These superwetting materials are widely employed to separate oil/water mixtures: from stratified oil/water to emulsified ones. In addition, the materials that implement the demulsification of emulsified oil/water mixtures via the ingenious design of the multiscale surface morphology and construction of special wettability are also discussed. In each section, we introduce the design ideas, base materials, preparation methods, and representative works in detail. Finally, the conclusions and challenges for the oil/water separation research field are discussed in depth.

Decomposable Polyvinyl Alcohol-Based Super-Hydrophobic Three-Dimensional Porous Material for Effective Water/Oil Separation

The development of the oil industry brings the critical problem of ocean pollution by oil spill or fossil fuels. The use of materials for water/oil separation is one of the effective approaches to solve this crisis. Polyvinyl alcohol (PVA) has been used  to prepare water/oil separation materials. Currently, glutaraldehyde has been employed as the cross-linking agent, which is well known to be toxic and environmentally unfriendly. Moreover, it is difficult to deal with the disposal of the Across-linked material. Here, we propose a strategy of fabricating macroporous material which was prepared by PVA and sodium silicate (Na₂SiO₃) in aqueous solution. Following through with the one-step method of sol-gel reaction of hydroxyl groups with trimethoxy(octadecyl)silane, the low surface energy substance was grafted on the macroporous material and a super-hydrophobic macroporous membrane for water/oil separation was prepared. As oil sorbent, the as-prepared dried super-hydrophobic PVA/Na₂SiO₃ porous materials (PSD6S) have the adsorption capacity of 1.8-7.0 g/g for oil uptake, which depends on the type of oil liquid. Typically, the separation efficiency of this material could reach more than 99% even after 10 times of use without the help of ambient pressure. It is noteworthy that the as-prepared samples could be easily decomposable and dissolvable completely in acidic medium at a rapid rate.

Biocompatible Meshes with Appropriate Wettabilities for Underwater Oil Transportation/Collection and Highly Effective Oil/Water Separation

In this study, we prepared biocompatible superhydrophilic and underwater superoleophobic tannic acid (TA)/polyvinylpyrrolidone (PVP)-coated stainless-steel meshes that mediated extremely efficient separations of mixtures of oil and water. These TA/PVP-coated stainless-steel meshes displayed excellent antifouling properties and could be used to separate oil/water mixtures continuously for up to 24 h. Moreover, a funnel-like TA/PVP-coated stainless-steel mesh device could be used for underwater oil transportation and collection. In conjunction with our continuous oil removal system, this device allowed for the continuous collection and removal of oil pollutants from underwater environments. The high performance of these TA/PVP-coated stainless-steel meshes and their green, low-energy, cost-effective preparation suggests great potential for practical applications.

Effective Separation of a Water in Oil Emulsion from a Direct Contact Latent Heat Storage System

The problem of emulsification between Phase Change Material (PCM) and Heat Transfer Fluid (HTF) in direct contact latent heat storage systems has been reported in various studies. This issue causes the PCM to flow out of the storage tank and crystallize at unwanted locations and thus presents a major limitation for the proper operation of such systems. These anomalies become more pronounced when high HTF flow rates are employed with the aim to achieve fast heat transfer rates. The goal of this paper is to find a method which will enable the fast separation of the formed emulsion and thus the uninterrupted operation of the storage unit. In this study, three separation methods were examined and the use of superhydrophobic filters was chosen as the best candidate for the demulsification of the PCM and HTF mixtures. The filter was produced by processing of a melamine sponge with different superhydrophobic adhesives and was tested with emulsions closely resembling the ones formed in a real direct contact setup. The superhydrophobic filter obtained, was able to separate the emulsions effectively while presenting a very high permeability (up to 1,194,980 kg h−1 m−2 bar−1). This is the first time the use of a superhydrophobic sponge has been investigated in the context of demulsification in direct contact latent heat storage.

Rational design of materials interface at nanoscale towards intelligent oil-water separation

Oil-water separation is critical for the water treatment of oily wastewater or oil-spill accidents. The oil contamination in water not only induces severe water pollution but also threatens human beings' health and all living species in the ecological system. To address this challenge, different nanoscale fabrication methods have been applied for endowing biomimetic porous materials, which provide a promising solution for oily-water remediation. In this review, we present the state-of-the-art developments in the rational design of materials interface with special wettability for the intelligent separation of immiscible/emulsified oil-water mixtures. A mechanistic understanding of oil-water separation is firstly described, followed by a summary of separation solutions for traditional oil-water mixtures and special oil-water emulsions enabled by self-amplified wettability due to nanostructures. Guided by the basic theory, the rational design of interfaces of various porous materials at nanoscale with special wettability towards superhydrophobicity-superoleophilicity, superhydrophilicity-superoleophobicity, and superhydrophilicity-underwater superoleophobicity is discussed in detail. Although the above nanoscale fabrication strategies are able to address most of the current challenges, intelligent superwetting materials developed to meet special oil-water separation demands and to further promote the separation efficiency are also reviewed for various special application demands. Finally, challenges and future perspectives in the development of more efficient oil-water separation materials and devices by nanoscale control are provided. It is expected that the biomimetic porous materials with nanoscale interface engineering will overcome the current challenges of oil-water emulsion separation, realizing their practical applications in the near future with continuous efforts in this field.

An easy preparation of photo-response TiO2@copper wire mesh with quick on/off switchable superwetting for high efficiency oil–water separation

A photo-response superwetting was easily fabricated using a hydrothermal method and titanium dioxide (TiO₂) on a copper wire mesh (CWM).

Calcium Sulfate Hemihydrate Nanowires: One Robust Material in Separation of Water from Water-in-Oil Emulsion

Here we report a facile and cost-effective wet-chemical approach to the synthesis of calcium sulfate hemihydrate nanowires (HH NWs, CaSO₄·0.5H₂O), and their robust performance in immobilizing water molecules to the crystal lattice of CaSO₄ and then separating them from a surfactant-stabilized water-in-oil emulsion (mean droplet size of around 1.2 μm). Every gram of HH NWs are capable of treating 20 mL emulsion (water content: 10.00 mg mL^-1) with a separation efficiency of 99.23% at room temperature, and this efficiency can be further improved by tuning the surface charge density of HH. Along with the water immobilization, HH NWs are converted to large cubic-like calcium sulfate dihydrate microparticles (DH, CaSO₄·2H₂O, mean size: 50 μm), and the accompanied size increment enables efficient collection of the solid phase from oil. DH microparticles can be regenerated into HH NWs, which retain the high performance of the original NWs. Such a unique renewable feature improves the economics of our method and simultaneously prevents the secondary pollution. Further economic evaluation finds that purification of every cubic meters of emulsion (water content: 10.00 mg mL^-1) will cost about $34.18 for HH NWs, much lower than the $490.78 for the previously reported HH NPs, and $11 052.05-$23 420.32 Fe₃O₄ NP-based adsorbents, respectively. With the high efficiency, easy collection, low cost, and renewable feature, HH NWs show highly promising applications in the field of oil purification and recycle.

Vapor-Liquid Sol-Gel Approach to Fabricating Highly Durable and Robust Superhydrophobic Polydimethylsiloxane@Silica Surface on Polyester Textile for Oil-Water Separation

Large-scale fabrication of superhydrophobic surfaces with excellent durability by simple techniques has been of considerable interest for its urgent practical application in oil-water separation in recent years. Herein, we proposed a facile vapor-liquid sol-gel approach to fabricating highly durable and robust superhydrophobic polydimethylsiloxane@silica surfaces on the cross-structure polyester textiles. Scanning electron microscopy and Fourier transform infrared spectroscopy demonstrated that the silica generated from the hydrolysis-condensation of tetraethyl orthosilicate (TEOS) gradually aggregated at microscale driven by the extreme nonpolar dihydroxyl-terminated polydimethylsiloxane (PDMS(OH)). This led to construction of hierarchical roughness and micronano structures of the superhydrophobic textile surface. The as-fabricated superhydrophobic textile possessed outstanding durability in deionized water, various solvents, strong acid/base solutions, and boiling/ice water. Remarkably, the polyester textile still retained great water repellency and even after ultrasonic treatment for 18 h, 96 laundering cycles, and 600 abrasion cycles, exhibiting excellent mechanical robustness. Importantly, the superhydrophobic polyester textile was further applied for oil-water separation as absorption materials and/or filter pipes, presenting high separation efficiency and great reusability. Our method to construct superhydrophobic textiles is simple but highly efficient; no special equipment, chemicals, or atmosphere is required. Additionally, no fluorinated slianes and organic solvents are involved, which is very beneficial for environment safety and protection. Our findings conceivably stand out as a new tool to fabricate organic-inorganic superhydrophobic surfaces with strong durability and robustness for practical applications in oil spill accidents and industrial sewage emission.