Oil-in-water emulsion separation: Fouling of alumina membranes with and without a silicon carbide deposition in constant flux filtration mode

Durable Nano-Flower Structured Foam Coupled with Electrically-Driven in Situ Aeration Enable High-Flux Oil/Water Emulsion Separation with Dynamic Antifouling Ability

The conventional membranes used for separating oil/water emulsions are typically limited by the properties of the membrane materials and the impact of membrane fouling, making continuous long-term usage unachievable. In this study, a filtering electrode with synchronous self-cleaning functionality is devised, exhibiting notable antifouling ability and an extended operational lifespan, suitable for the continuous separation of oil/water emulsions. Compared with the original Ti foam, the in situ growth of NiTi-LDH (Layered double hydroxide) nano-flowers endows the modified Ti foam (NiTi-LDH/TF) with exceptional superhydrophilicity and underwater superoleophobicity. Driven by gravity, a rejection rate of over 99% is achieved for various emulsions containing oil content ranging from 1% to 50%, as well as oil/seawater emulsions. The flux recovery rate exceeds 90% after one hundred cycles and a 4-h filtration period. The enhanced separation performance is realized through the "gas bridge" effect during in situ aeration and electrochemical anodic oxidation. The internal aeration within the membrane pores contributes to the removal of oil foulants. This study underscores the potential of coupling foam metal filtration materials with electrochemical technology, providing a paradigm for the exploration of novel oil/water separation membranes.

Effect of Long-Term Sodium Hypochlorite Cleaning on Silicon Carbide Ultrafiltration Membranes Prepared via Low-Pressure Chemical Vapor Deposition

Sodium hypochlorite (NaClO) is widely used for the chemical cleaning of fouled ultrafiltration (UF) membranes. Various studies performed on polymeric membranes demonstrate that long-term (>100 h) exposure to NaClO deteriorates the physicochemical properties of the membranes, leading to reduced performance and service life. However, the effect of NaClO cleaning on ceramic membranes, particularly the number of cleaning cycles they can undergo to alleviate irreversible fouling, remains poorly understood. Silicon carbide (SiC) membranes have garnered widespread attention for water and wastewater treatment, but their chemical stability in NaClO has not been studied. Low-pressure chemical vapor deposition (LP-CVD) provides a simple and economical route to prepare/modify ceramic membranes. As such, LP-CVD facilitates the preparation of SiC membranes: (a) in a single step; and (b) at much lower temperatures (700-900 °C) in comparison with sol-gel methods (ca. 2000 °C). In this work, SiC ultrafiltration (UF) membranes were prepared via LP-CVD at two different deposition temperatures and pressures. Subsequently, their chemical stability in NaClO was investigated over 200 h of aging. Afterward, the properties and performance of as-prepared SiC UF membranes were evaluated before and after aging to determine the optimal deposition conditions. Our results indicate that the SiC UF membrane prepared via LP-CVD at 860 °C and 100 mTorr exhibited excellent resistance to NaClO aging, while the membrane prepared at 750 °C and 600 mTorr significantly deteriorated. These findings not only highlight a novel preparation route for SiC membranes in a single step via LP-CVD, but also provide new insights about the careful selection of LP-CVD conditions for SiC membranes to ensure their long-term performance and robustness under harsh chemical cleaning conditions.

Enhancing membrane separation performance in the conditions of different water electrical conductivity and fouling types via surface grafting modification of a nanofiltration membrane, NF90

A commercialized and widely applied nanofiltration membrane, NF90, was in-situ modified through a surface grafting modification method by using 3-sulfopropyl methacrylate potassium salt and initiators. The effects of water electrical conductivity (EC) and fouling types on membrane separation efficiency were examined before and after membrane modification. Results reveal that both the pristine membrane (PTM) and surface grafting modification membrane (SGMM) had a declining permeate flux and salt (NaCl) removal efficiency but an increasing trend of pharmaceuticals and personal care products (PPCPs) removal with increasing water EC from 250 to 10,000 μs cm-1. However, SGMM exhibited a slightly declining permeate flux but 13%-17% and 1%-42% higher rejection of salt and PPCPs, respectively, compared with PTM, due to electrostatic repulsion and size exclusion provided by the grafted polymer. After sodium alginate (SA) and humic acid (HA) fouling, SGMM had 17%-26% and 16%-32% higher salt rejection and 1%-12% and 1%-51% greater PPCP removal, respectively, compared with PTM due to the additional steric barrier layer contributed by the foulants. The successful grafting and increasing hydrophilicity of the SGMM were confirmed by contact angle analysis, which was beneficial for mitigating membrane fouling. Overall, the proposed in-situ surface grafting modification of NF90 can considerably mitigate organic and biological fouling while raising the rejection of salt and PPCPs at different background water EC, which is beneficial for practical applications in producing clean and high quality water for consumers.

Constructing a composite microfiltration carbon membrane by TiO2 and Fe2O3 for efficient separation of oil-water emulsions

Membrane-based separation technology has attracted enormous attention for oil/water emulsion treatment. Here, composite microfiltration carbon membranes (MCMs) were prepared from the precursor of phenolic resin doping with TiO2 and Fe2O3 via the processes of stereotype and pyrolysis. The functional groups, thermal stability, porous structure, microstructure, morphology, and hydrophilicity of the membrane samples were analyzed by Fourier-transform infrared spectroscopy, thermogravimetric analysis, bubble pressure method, X-ray diffraction, scanning electron microscope, and water contact angle, respectively. The effect of dopant amount on the separation performance of MCMs was investigated. The results show that a mixed matrix system is constructed by TiO2 and Fe2O3 in MCMs, which is beneficial for further optimizing the pore size, porosity, and hydrophilicity of MCMs for oily wastewater treatment by varying the dopant amount. The maximum oil rejections are achieved at 98.9% and 99.6% for MCMs with a dopant content of TiO2 and Fe2O3 at 25%, respectively. In brief, this study offers an attractive strategy for improving the separation performance of MCMs for oily wastewater.

A solar-driven degradation-evaporation strategy for membrane self-cleaning in the efficient separation of viscous crude oil/water emulsions

Membrane separation techniques are promising methods for effectively treating hazardous emulsified oily wastewater, but membrane fouling remains a serious challenge because the high viscosity and complex composition of crude oil make it easy to adhere to membranes and difficult to be removed by conventional physical or chemical cleaning means. Herein, a two-stage solar-driven (photo-Fenton degradation/evaporation) strategy was proposed to realize the self-cleaning of membranes fouled by viscous crude oil (>60,000 mPa s), wherein the photo-Fenton process helped to degrade the heavy components into light components, and all light components removed during the solar-driven evaporation process. A 1D/2D heterostructure membrane with photo-Fenton activity and anti-crude-oil-fouling performance was prepared via a facile self-assembly vacuum-assist method. The addition of rod-like g-C₃N₄ (RCN) increased the interlayer distance of α-FeOOH/porous g-C₃N₄ (FPCN) nanosheets, resulting in a high permeation flux. The FPCN-RCN membrane exhibited both high permeation flux of 779 ± 19 L m^-2h^-1bar^-1 and a separation efficiency of 99.4% for highly viscous crude oil-in-water emulsion. Importantly, the viscous crude oil fouled on the membrane was completely removed by the photo-Fenton degradation/solar-driven evaporation strategy, and the flux recovery rate of the membrane was ∼100%. Therefore, the FPCN-RCN membrane combined with the novel self-cleaning strategy exhibits great potential for practical emulsified oily wastewater treatment.

Fabrication of a Zircon Microfiltration Membrane for Culture Medium Sterilization

Multilayer ceramic membranes to be used for bacteria removal by filtration were prepared from ceramic materials. They consist of a macro-porous carrier, an intermediate layer and a thin separation layer at the top. Tubular and flat disc supports were prepared from silica sand and calcite (natural raw materials), using extrusion and uniaxial pressing methods, respectively. Making use of the slip casting technique, the silica sand intermediate layer and the zircon top-layer were deposited on the supports, in this order. The particle size and the sintering temperature for each layer were optimized to achieve a suitable pore size for the deposition of the next layer. Morphology, microstructures, pore characteristics, strength and permeability were also studied. Filtration tests were conducted to optimize the permeation performance of the membrane. Experimental results show that the total porosity and average pore size of the porous ceramic supports sintered at different temperatures within the range (1150-1300 °C), and lie in the ranges of 44-52% and 5-30 μm, respectively. For the ZrSiO₄ top-layer, after firing at 1190 °C, a typical average pore size of about 0.3 μm and a thickness of about 70 μm were measured, while water permeability is estimated to a value of 440 lh^-1m^-2bar^-1. Finally, the optimized membranes were tested in the sterilization of a culture medium. Filtration results show the efficiency of the zircon-deposited membranes for bacteria removal; indeed, the growth medium was found to be free of all microorganisms.

Outstanding Separation Performance of Oil-in-Water Emulsions with TiO2/CNT Nanocomposite-Modified PVDF Membranes

Membrane filtration is an effective technique for separating micro- and nano-sized oil droplets from harmful oil-contaminated waters produced by numerous industrial activities. However, significant flux reduction discourages the extensive application of this technology; therefore, developing antifouling membranes is necessary. For this purpose, various titanium dioxide/carbon nanotube (TiO₂/CNT) nanocomposites (containing 1, 2, and 5 wt.% multi-walled CNTs) were used for the modification of polyvinylidene fluoride (PVDF) ultrafilter (250 kDa) membrane surfaces. The effects of surface modifications were compared in relation to the flux, the filtration resistance, the flux recovery ratio, and the purification efficiency. TiO₂/CNT_2% composite modification reduced both irreversible and total filtration resistances the most during the filtration of 100 ppm oil emulsions. The fluxes were approximately 4-7 times higher compared to the unmodified PVDF membrane, depending on the used transmembrane pressure (510, 900, and 1340 L/m²h fluxes were measured at 0.1, 0.2, and 0.3 MPa pressures, respectively). Moreover, the flux recovery ratio (up to 68%) and the purification efficiency (95.1-99.8%) were also significantly higher because of the surface modification, and the beneficial effects were more dominant at higher transmembrane pressures. TiO₂/CNT_2% nanocomposites are promising to be applied to modify membranes used for oil-water separation and achieve outstanding flux, cleanability, and purification efficiency.

A multifunctional heterogeneous superwettable coating for water collection, oil/water separation and oil absorption

Herein, inspired by desert beetles, we fabricated a multifunctional heterogeneous superwettable coating (MHSC) for water collection and oily wastewater cleanup. The selective modifications of 1-octadecanethiol (ODT) treated CoO and P25 TiO₂ nanoparticles (NPs) were prepared, so hydrophobic CoO NPs and superhydrophilic P25 NPs were combined on the MHSC, showing the water contact angle (WCA) of 156.5° and rolling-off angle (RA) of 6.4°. With the aid of waterborne polyurethane (WPU), five kinds of substrates (i.e., glass slide, dish, wood, fabric, sponge) spray-coated by MHSC displayed high-efficiency water collection rates (WCRs) of 18.1 ± 0.7 mg min^-1 cm^-2. Moreover, MHSC coated fabric manifested robust oil/water separations with separation efficiencies (SEs) > 99.7 % and fluxes ranged from 9.7 to 11.0 L m^-2 s^-1. Efficient oil sorption from oily water was obtained by MHSC coated sponge with oil absorption capacities (OACs) of 6.5-29.5 g g^-1. Further, even dealt with the treatments of mechanical destructions, extreme temperature and UV illumination, the coated materials remained stable performances.

Impact of pre-coagulation on the ceramic membrane process during oil-water emulsion separation: Fouling behavior and mechanism

Coagulation has been evaluated as an economical and effective pre-treatment method for controlling membrane fouling. We investigated the influence of the pre-coagulation of oil-water (O/W) emulsions on the formation of membrane fouling in the ceramic membrane process. The results confirmed that pre-coagulation effectively mitigated the fouling formation on the ceramic membrane surface during the O/W emulsion separation. The mechanism of mitigating membrane fouling by pre-coagulation was proposed, owing to the reduction in the zeta potential value of oil droplets by pre-coagulation, resulting in weak electrostatic attraction between oil droplets and ceramic membrane surfaces, and an increase in the size of the oil droplets by pre-coagulation, leading the formation of a cake layer fouling. In addition, the decrease in the hydrophobicity of oil droplets by pre-coagulation resulted in alleviating the hydrophobic interaction between oil droplets and membrane surface. The proposed fouling mechanism was supported by the characterization of the virgin and fouled membrane surfaces and the analysis of the fouling resistance ability of the membranes. Our study could be indicative of mitigation protocols that can be used to alleviate membrane fouling on ceramic membranes during oily wastewater treatment.

Designing of nanotextured inorganic-organic hybrid PVDF membrane for efficient separation of the oil-in-water emulsions

The separation of the emulsified oil/water is one of the critical environmental challenges. The PVDF membranes have been found helpful for separation, but rapid fouling makes them less attractive in treating oil-in-water emulsions. The design of antifouling membranes has become an area of deep interest. Herein, developing a novel modified PVDF ultrafiltration membrane was reported by doping the pyrrole and solidifying it in a ferric-containing coagulation bath, resulting in a unique nanotextured PVDF membrane (CCB-Fe/PP_np-PVDF) to separate the oil/water emulsions. The resultant CCB-Fe/PP_np-PVDF membrane was thoroughly characterized using the FTIR, FE-SEM, EDX, mapping, AFM, and contact analyzer. The hydrophilicity of the CCB-Fe/PP_np-PVDF was substantially improved, and the water contact angle was reduced from 81֯ ± 0.9֯ to 44֯ ± 1.7֯. The CCB-Fe/PPnp-PVDF membrane flux increased by 121% compared to the pristine PVDF membrane, with high separation efficiency of 99%. The hydrophilic nanotextured surface of the CCB-Fe/PP_np-PVDF membrane showed good antifouling behavior, with a flux recovery ratio (FRR) of more than 96%. Irreversible flux was just less than 4%. The high flux recovery ratio indicated that the nanotextured surface produced by the Fe/PP_np had prevented the blockage of the membrane pores and compact cake layer formation, which makes it an excellent membrane for oil/water emulsion separation. This strategy can be adopted for designing advanced membranes for separation applications.

Silicon carbide catalytic ceramic membranes with nano-wire structure for enhanced anti-fouling performance

Membrane fouling is a critical challenge for current ceramic membranes, which suffer from low flux and insufficient removal. Development of self-cleaning catalytic ceramic membranes is promising to address this challenge. Herein, we design heterogeneous silicon carbide ceramic membranes featuring a novel structure of g-C₃N₄-decorated β-SiC nano-wire catalytic functional layer, which enables enhanced anti-fouling self-cleaning performance. At chemical harsh (alkaline or especially acidic) conditions, the nano-wire membrane exhibits catalysis-enhanced removal performance for organic contaminants. Unlike conventional particle-packing membrane structure, such a nano-wire network membrane structure has not only high porosity (56.1%), but exceptional water permeance (110 L·m^-2·h^-1·bar^-1) and removal (100%) of organic substance under simulated sunlight, outperforming state-of-the-art organic membranes and ceramic membranes. Superoxide radical (∙O₂^-) was experimentally confirmed to be major reactive species responsible for self-cleaning function. We also propose a catalytic mechanism model with radical formation pathway, enabled by the as-formed g-C₃N₄@β-SiC heterojunction structure with reduced electron-hole recombination. This work would provide new insights into not only rational design of next-generation ceramic membranes with self-cleaning function but also more applications of efficient treatment of refractory wastewaters containing degradable organic substances by using such membranes.

A passive-active combined strategy for ultrafiltration membrane fouling control in continuous oily wastewater purification

Membrane-based technology has been confirmed as an effective way to treat emulsified oily wastewater, however, membrane fouling is still one of practical challenges in long-term operation. Herein, a novel passive-active combined strategy was proposed to control membrane fouling in continuous oily wastewater purification, where the δ-MnO₂ decoration layer helped to reduce the total fouling ratio (passive strategy for fouling mitigation) and the catalytic cleaning effectively removed the irreversible oil fouling (active strategy for fouling removal). The functional membrane was prepared via in-situ modification, referred to as δ-MnO₂@TA-PES. The morphology, crystalline phase, chemical structure and surface properties of the membranes were systematically characterized. Compared with PES, the δ-MnO₂@TA-PES possessed superhydrophilicity, enhanced electronegativity and narrowed pore size. The δ-MnO₂@TA-PES achieved high water permeation flux of 723.9 L·m ^- 2·h ^- 1·bar^-1, excellent oil rejection with separation efficiency above 98.5% for various emulsions, and durable anti-oil-fouling performance with FRR_b of 98.0%. Notably, the oil cake layer fouling on δ-MnO₂@TA-PES was greatly alleviated owing to its enhanced surface properties. In addition, δ-MnO₂@TA-PES showed high cleaning efficiency in the peroxymonosulfate (PMS) cleaning process, where the radical and nonradical pathways occurred simultaneously. And the active substances generated in the nonradical process (especially ¹O₂) were considered as the main contributor to the reduction of irreversible fouling. Overall, the novel strategy of fouling control ensured the efficient operation of ultrafiltration membranes for the continuous oily wastewater purification.