Facile one-step fabrication of superhydrophobic melamine sponges by poly(phenol-amine) modification method for effective oil-water separation

Bioinspired interlaced wetting surfaces for continuous on-demand emulsion separation

Maintaining high separation performance during continuous emulsion separation remains a challenge. Herein, based on biomimetic coupling ideas, hole array interlaced wetting surfaces (HAIWSs) and mastoid array interlaced wetting surfaces (MAIWSs) were prepared by laser processing, electroless silver deposition, thiol modification, and spraying for on-demand emulsion separation. When the separation is going on, randomly moving emulsion droplets are prone to being captured by holes or mastoids due to interlaced wettability. Under this unique interface behavior, the occurrence of filter cake and pore clogging is reduced, thus achieving both high efficiency (∼99.5 and ∼99.3 %). Meanwhile, the high flux can also be maintained (∼3212 and ∼3458 L m-2 h-1). Significantly better than surfaces without pores or mastoid structures. Further, the as-prepared surfaces also exhibit excellent recyclability. After 50 separation cycles, optimized HAIWS and MAIWS still maintained high efficiency (∼96.2 and ∼95.8 %) and high flux (∼3042 and ∼3164 L m-2 h-1), exceeding other surfaces without hole or mastoid structure. Notably, complex physical/chemical cleaning processes are avoided. Besides, even in harsh conditions, HAIWS and MAIWS still maintain excellent stability. The above strategy provides a novel mechanism for effective on-demand emulsion separation and is expected to encourage the creation of new-class separation devices for oily wastewater treatment in industry.

Biomass-activated carbon-based superhydrophobic sponge with photothermal properties for adsorptive separation of waste oil

The increasing discharge of oily wastewater from life poses a serious threat to the ecological environment and human health. To develop green, efficient, and low-cost materials for oil-water separation, a superhydrophobic photothermal oil-absorbing sponge (CAC-PDA@MF) was prepared by using nanoscale coconut shell activated carbon (CAC) loaded on a melamine sponge in this study. The sponge had excellent superhydrophobicity (WCA of 159.53°) due to the reduction of surface energy by grafting long-chain silanes. The adsorption capacity of the sponge was 69.04 g/g-158.27 g/g for a wide range of oils and organic solvents, and the sponge had excellent mechanical properties for multiple adsorption and recovery of oil. After 50 cycles of oil-water separation, its separation efficiency was maintained at over 98 %. In addition, the material had high acid, alkali, and salt resistance as well as excellent photothermal conversion properties. Its surface temperature rose rapidly to 100 °C and above, at a light intensity of 1.0 kW/m2. The material was capable of adsorbing and recovering high-viscosity oils that were solid or semi-solid at room temperature. Its versatility and commercial value made it a promising candidate for a wide range of applications.

Internal Superwettability Inversion of a COF-Encapsulated Melamine Sponge Prepared by a One-Step Synthesis at Room Temperature

Superwettable materials have been attracting attention due to their unique properties, showing great application prospects in a variety of fields including oil-water separation. Herein, a kind of covalent organic framework (COF)-encapsulated melamine sponge (MS) capable of internal superwettability inversion is prepared by a one-step synthesis at room temperature. COF is produced in situ on the skeleton of MS, which is favorable for practical application, and the prepared COF-encapsulated sponge (MS@COF) exhibits superhydrophobicity (water contact angle of about 157.0°) due to the rough surface provided by the micro/nanostructure of COF. More importantly, MS@COF displays reversibly superhydrophilicity by simple prewetting, achieving superwettability inversion conveniently, unlike the previous switchable materials that rely on external conditions. This facile intrinsic superwettability inversion greatly enriches the application prospects of this kind of smart sponge.

Magnetic Hyperporous Elastic Material with Excellent Fatigue Resistance and Oil Retention for Oil-Water Separation

Oily wastewater has caused serious threats to the environment; thus, high-performance absorbing materials for effective oil-water separation technology have attracted increasing attention. Herein, we develop a magnetic, hydrophobic, and lipophilic hyperporous elastic material (HEM) templated by high internal phase emulsions (HIPE), in which free-radical polymerization of butyl acrylate (BA) and divinylbenzene (DVB) is employed in the presence of poly(dimethylsiloxane) (PDMS), lecithin surfactant, and modified Fe3O4 nanoparticles. The adoption of the emulsion template with nanoparticles as both stabilizers and cross-linkers endows the HEM with biomimetic hierarchical open-cell micropores and elastic cross-linked networks, generating an oil absorbent with outstanding mechanical stability. Compressive fatigue resistance of the HEM is demonstrated to endure 2000 mechanical cycles without plastic deformation or strength degradation. By exploiting the synergistic effect of hierarchical structures and low-surface-energy components, the resulting HEM also possesses excellent and robust hydrophobicity (water contact angle of 164°) and good oil absorption capacity, in which Fe3O4 nanoparticles lead to convenient magnetically controlled oil recyclability as well. Notably, the unique biomimetic microporous structure demonstrates superior oil retention capacity (>95% at 1000 rpm and >60% at 10,000 rpm) over the state-of-the-art porous materials for a diverse variety of oils to reduce the risk of secondary oil leakage, along with good recoverability by squeezing owing to the excellent compression resilience. These excellent performances of our HEM provide broad prospects for practical applications in oil-water separation, energy conversion, and smart soft robotics.

Hierarchical 0D CuO Wrapped by Petal-like 2D ZnO: A Strategic Approach of Superhydrophobic Melamine Sponge toward Wastewater Treatment

In addressing the pressing environmental challenges posed by frequent oil spills, this work presents a novel approach of synthesizing a superhydrophobic three-dimensional (3D) porous melamine sponge (MS). CuO and ZnO nanoparticles were grown on the MS via a hydrothermal method to create MS/CuO/ZnO with multiscale hierarchical nanostructures. The resulting material exhibited a stable water contact angle of 155° through various tests. MS/CuO/ZnO demonstrated exceptional oil absorption capacities (40-145 g/g and 0.83-0.99 mL.cm-3), surpassing 98% efficiency in oil separation, and retained reusability for 10 cycles. Impressively, the sponge achieved successful separation of oil/water emulsions with a permeation flux of 14870 L m-2 h-1. The composite sponge, distinguished by its high photodegradation ability, can degrade both water- and oil-targeted pollutants under visible light irradiation from light-emitting diode (LED). With its remarkable attributes including superior oil absorption, excellent oil/water separation, mechanical resistance, and excellent photocatalytic ability, it exhibits considerable potential for applications in both wastewater treatment and large-scale marine oil spill response. The easily prepared MS/CuO/ZnO emerges as a versatile solution capable of addressing pressing challenges and marking a significant leap toward sustainable and impactful environmental remediation.

Activated carbon fibers functionalized with superhydrophilic coated pDA/TiO2/SiO2 with photoluminescent self-cleaning properties for efficient oil-water separation

The adhesion of high-viscosity oil contamination poses limitations on three-dimensional (3D) materials' practical use in treating oilfield-produced water (OPW). In this study, we developed a hybrid pDA/TiO2/SiO2 coating (PTS) on the surface of hydrophilic activated carbon (ACF1) through a combination of dopamine (DA) polymerization, ethyl orthosilicate (TEOS) hydrolysis, and the condensation of TiO2 nanoparticles (NPs) with SiO2 NPs. This coating was designed for gravity-based oil-water separation. The inherent porosity and generous pore size of ACF1-PTS conferred it an ultra-high permeation flux (pure water flux of 3.72 × 105 L∙m-2∙h-1), allowing it to effectively separate simulated oil-water mixtures and oil-water emulsions while maintaining exceptional permeation flux and oil rejection efficiency. When compared to cleaning methods involving ethanol aqueous solutions and NaClO, ultraviolet (UV) illumination cleaning proved superior, enabling oil-contaminated ACF1-PTS to exhibit remarkable flux recovery efficiency and oil-removal capabilities during cyclic separation of actual OPW. Furthermore, the ACF1-PTS material demonstrated impressive stability and durability when exposed to acidic environments (acid, alkali, and salt), robust hydraulic washout conditions, and 25-cycle tests. This study offers valuable insights and research avenues for the development of highly efficient and environmentally friendly 3D oil-water separation materials for the actual treatment of OPW.

A comprehensive review on anticorrosive/antifouling superhydrophobic coatings: Fabrication, assessment, applications, challenges and future perspectives

Superhydrophobicity (SHP) is an incredible phenomenon of extreme water repellency of surfaces ubiquitous in nature (E.g. lotus leaves, butterfly wings, taro leaves, mosquito eyes, water-strider legs, etc). Historically, surface exhibiting water contact angle (WCA) > 150° and contact angle hysteresis <10° is considered as SHP. The SHP surfaces garnered considerable attention in recent years due to their applications in anti-corrosion, anti-fouling, self-cleaning, oil-water separation, viscous drag reduction, anti-icing, etc. As corrosion and marine biofouling are global problems, there has been focused efforts in combating these issues using innovative environmentally friendly coatings designs taking cues from natural SHP surfaces. Over the last two decades, though significant progress has been made on the fabrication of various SHP surfaces, the practical adaptation of these surfaces for various applications is hampered, mainly because of the high cost, non-scalability, lack of simplicity, non-adaptability for a wide range of substrates, poor mechanical robustness and chemical inertness. Despite the extensive research, the exact mechanism of corrosion/anti-fouling of such coatings also remains elusive. The current focus of research in recent years has been on the development of facile, eco-friendly, cost-effective, mechanically robust chemically inert, and scalable methods to prepare durable SHP coating on a variety of surfaces. Although there are some general reviews on SHP surfaces, there is no comprehensive review focusing on SHP on metallic and alloy surfaces with corrosion-resistant and antifouling properties. This review is aimed at filling this gap. This review provides a pedagogical description with the necessary background, key concepts, genesis, classical models of superhydrophobicity, rational design of SHP, coatings characterization, testing approaches, mechanisms, and novel fabrication approaches currently being explored for anticorrosion and antifouling, both from a fundamental and practical perspective. The review also provides a summary of important experimental studies with key findings, and detailed descriptions of the evaluation of surface morphologies, chemical properties, mechanical, chemical, corrosion, and antifouling properties. The recent developments in the fabrication of SHP -Cr-Mo steel, Ti, and Al are presented, along with the latest understanding of the mechanism of anticorrosion and antifouling properties of the coating also discussed. In addition, different promising applications of SHP surfaces in diverse disciplines are discussed. The last part of the review highlights the challenges and future directions. The review is an ideal material for researchers practicing in the field of coatings and also serves as an excellent reference for freshers who intend to begin research on this topic.

Hydrophobic organogel sorbent and its coated porous substrates for efficient oil/water emulsion separation and effective spilled oil remediation

Frequent offshore oil leakage accidents and large quantities of oily-wastewater produced in industry and daily life bring huge challenges to global water purification. The adaptability and stability of organogels as adsorbent materials have shown wide application prospects in the field of oil-water separation. Herein, the organogels displayed stable hydrophobic/lipophilic properties with high absorption ability (1200 wt./wt%), efficient sorption of multiple emulsions (>99.0%), and good reusability. More importantly, the organogels were successfully assembled with 2D/3D substrates to achieve excellent sorption capacity (102.5 g/g) and recycling performance (50 cycles). The gel-carbon black assembled on MS (GCB-MS) sorbent with excellent photothermal conversion performance, and can rapidly heat the surface to 70.4 °C under 1.0 sunlight radiation (1.0 kW/m2) and achieved an ultra-high sorption capacity of about 103 g/g for viscous crude oil. Meanwhile, the GCB-MS was combined with a pump to build continuous oil spill cleaning equipment to achieve a super-fast cleanup rate of 6.83 g/min. The developed hydrophobic organogels had been expanded unprecedentedly to realize the comprehensive treatment of oily-wastewater in complex environments, including layered oils, emulsions, and viscous crude oil spill, which provided an effective path for the comprehensive treatment of oily wastewater in complex environments.

Super-amphiphobic arabic gum-based coatings on textile for on-demand oily and dye wastewater treatment

Different membrane materials have broadly been constructed for oil-containing water separation, but most of preparation routes involve corrosive or toxic chemicals and especially many materials have only single superwetting property. Herein, a novel and eco-friendly cellulose-based textile membrane is developed by incorporating the composite coating consisting of arabic gum (AG), attapulgite (APT), and iron (Fe) onto cellulose textiles. The functionalized textile is superoleophobic underwater and superhydrophobic underoil. As a result, the textile prewetted with water or oil can be employed to separate light oil layer/water and heavy oil layer/water mixtures, respectively, and the separation efficiency to the two types of mixtures is larger than 98.3 %. Results also reveal that the decorated textile possesses superior stability and recyclability in purifying oily wastewater. More importantly, such coated textile is capable of filtrating water-soluble contaminants (dyes) from polluted water. Due to the versatility and environmental compatibility of product as well as the accessibility as agricultural and forestry product as raw materials, the advanced textiles may offer effective solutions to oily wastewater purification and water-soluble contaminant removal.

Biomimetic materials in oil/water separation: Focusing on switchable wettabilities and applications

Clean water resources are crucial for human society, as the leakage and discharge of oily wastewater not only harm the economy but also disrupt our living environment. Therefore, there is an urgent need for efficient oil-water separation technology. Surfaces with switchable superwetting behavior have garnered significant attention due to their importance in both fundamental research and practical applications. This review introduces the fundamental principles of wettability in the oil-water separation process, the basic theory of switchable wettability, and the mechanisms involved in oil-water separation. Subsequently, the review discusses the research progress, challenges, and issues associated with three conventional types of special wettability materials: superhydrophobic/superoleophilic materials, superhydrophilic/superoleophobic materials, and superhydrophilic/underwater superoleophobic materials. Most importantly, it provides a detailed exploration of recent advancements in switchable wettability smart materials, which combine elements of traditional special wettability materials. These include stimulus-responsive smart materials, pre-wetting-induced materials, and Janus materials. The discussion covers key response factors, detailed examples of representative works, design concepts, and fabrication strategies. Finally, the review offers a comprehensive summary of switchable superwetting smart materials, encompassing their advantages and disadvantages, persistent challenges, and future prospects.

Scalable Fabrication of Superhydrophobic Coating with Rough Coral Reef-Like Structures for Efficient Self-Cleaning and Oil-Water Separation: An Experimental and Molecular Dynamics Simulation Study

Superhydrophobic coating has a great application prospect in self-cleaning and oil-water separation but remains challenging for large-scale preparation of robust and weather-resistant superhydrophobic coatings via facile approaches. Herein, this work reports a scalable fabrication of weather-resistant superhydrophobic coating with multiscale rough coral reef-like structures by spraying the suspension containing superhydrophobic silica nanoparticles and industrial coating varnish on various substrates. The coral reef-like structures effectively improves the surface roughness and abrasion resistance. Rapid aging experiments (3000 h) and the outdoor building project application (3000 m2 ) show that the sprayed superhydrophobic coating exhibits excellent self-cleaning properties, weather resistance, and environmental adaptability. Moreover, the combined silica-coating varnish-polyurethane (CSCP) superhydrophobic sponge exhibits exceptional oil-water separation capabilities, selectively absorbing the oils from water up to 39 times of its own weight. Furthermore, the molecular dynamics (MD) simulation reveals that the combined effect of higher surface roughness, smaller diffusion coefficient of water molecules, and weaker electrostatic interactions between water and the surface jointly determines the superhydrophobicity of the prepared coating. This work deepens the understanding of the anti-wetting mechanism of superhydrophobic surfaces from the perspective of energetic and kinetic properties, thereby paving the way for the rational design of superhydrophobic materials and their large-scale applications.

Eco-Friendly Fluorine Functionalized Superhydrophobic/Superoleophilic Zeolitic Imidazolate Frameworks-Based Composite for Continuous Oil-Water Separation

Superhydrophobic metal-organic framework (MOF)-based sponges have received increasing attention in terms of treating oil-water mixtures. However, highly fluorinated substances, commonly used as modifiers to improve the hydrophobicity of MOFs, have aroused much environmental concern. Developing a green hydrophobic modification is crucial in order to prepare superhydrophobic MOF-sponge composites. Herein, we report the preparation of a porous composite sponge via a polydopamine (PDA)-assisted growth of zeolitic imidazolate frameworks (ZIF-90) and eco-friendly hydrophobic short-chain fluorinated substances (trifluoroethylamine) on a melamine formaldehyde (MF) sponge. The composite sponge (F-ZIF-90@PDA-MF) exhibited superhydrophobicity (water contact angle, 153°) and superoleophilicity (oil contact angle, 0°), which is likely due to the combination of the low surface energy brought on by the grafted CF₃ groups, as well as the rough surface structures that were derived from the in situ growth of ZIF-90 nanoparticles. F-ZIF-90@PDA-MF showed an excellent adsorption capacity of 39.4-130.4 g g^-1 for the different organic compounds. The adsorbed organic compounds were easily recovered by physical squeezing. Continuous and selective separation for the different oil-water mixtures was realized by employing the composite sponge as an absorbent or a filter. The separation efficiency and flux reached above 99.5% and went up to 7.1 ×10⁵ L m^-2 h^-1, respectively. The results illustrate that the superhydrophobic and superoleophilic F-ZIF-90@PDA-MF sponge has potential in the field of water-oil separation, especially for the purposes of large-scale oil recovery in a water environment.

MOF-derived LDH modified flame-retardant polyurethane sponge for high-performance oil-water separation: Interface engineering design based on bioinspiration

Frequent petrochemical spill accidents and secondary fire hazards have threatened the ecological environment and environmental safety. The traditional purification technology has the problems of high energy consumption and secondary pollution, which also brings new challenges to spill disposal. Herein, we demonstrate a biomimetic structure-based flame-retardant polyurethane (PU) sponge (FPUF@MOF-LDH@HDTMS) for continuous oil-water separation. Inspired by desert beetle and lotus leaf, the biomimetic micro-nano composite structure was constructed by in-situ growth of metal-organic framework-derived layered double hydroxide (MOF-LDH) on the surface of the PU sponge. After grafting MOF-LDH with hexadecyltrimethoxysilane, FPUF@MOF-LDH@HDTMS showed excellent superhydrophobic/superoleophilic performance (water contact angle=153° and oil contact angle=0°). FPUF@MOF-LDH@HDTMS can easily and quickly adsorb oily liquids suspended/settled in the water thanks to the unique bionic structure. FPUF@MOF-LDH@HDTMS has excellent oil/organic solvents absorption capacity; even after 20 cycles of use still maintains high adsorption capacity. More importantly, the continuous oil-water separation through FPUF@MOF-LDH@HTMS has achieved a separation efficiency of up to 99.1%. In addition, the bionic superhydrophobic sponge has excellent flame retardancy, which reduces the possibility of secondary fire caused by PU sponges. Thus, the biomimetic micro-nano composite structure provides a new design strategy for the more high-performance oil-water separation sponges.

Rosin acid and SiO2 modified cotton fabric to prepare fluorine-free durable superhydrophobic coating for oil-water separation

Currently, fluorides and long-chain aliphatic compounds are the most frequent low surface energy chemicals utilized in the preparation of superhydrophobic coatings, but associated environmental risks and instability restrict their potential application in oil-water separation. This research described a superhydrophobic coating based on rosin acid and SiO₂ modified cotton fabric to overcome this challenge. By means of spray impregnation and UV-assisted click reaction, sulfhydryl modified rosin acid (RA), Octavinyl-POSS, and SiO₂ were grafted onto the surface of cotton fabric to obtain RA-SiO₂ superhydrophobic coating with rough surfaces such as lotus leaf and low surface energy. The RA-SiO₂ superhydrophobic coating had favorable self-cleaning ability, and also adsorbed various light and heavy oils to achieve efficient separation of oil-water mixtures. The separation efficiency was 96.3% and the permeate flux was 6110.84 (L⋅m^-2⋅h^-1) after 10 repetitions. The RA-SiO₂ superhydrophobic coating was found to be effective in separating oil-in-water and oil-in-water emulsions, and the separation mechanism was elaborated. In addition, it could effectively separate emulsions even after mechanical abrasion and chemical immersion, and had excellent stability. The fluorine-free and environmentally friendly low-cost superhydrophobic coating based on rosin acid is expected to play a significant potential in oil-water separation applications due to its excellent separation performance.

Novel Magnetically Driven Superhydrophobic Sponges Coated with Asphaltene/Kaolin Nanoparticles for Effective Oil Spill Cleanup

Fast and effective cleanup of oil spills remains a global challenge. A modified commercial sponge with superhydrophobicity, strong absorption capacity, outstanding magnetic response, and fire resistance were fabricated by a facile and inexpensive route of dip-coated melamine sponge carbonization. The low-cost petroleum asphaltene and kaolin nanoparticles were used as the dip-coating reagent. High absorption capacity of the fabricated sponges allowed rapid and continuous removal of oil contaminants. Taking advantage of the good refractory property, the sponges can be used in burning conditions and directly reused after burning out of the absorbed oil. Reusability tests showed that the modified sponges still maintained high absorption capacity (>85%) after six regeneration and reuse cycles. These characteristics make the fabricated sponge a promising aid to promote effective in situ burning cleanup of oil spills, contributing as a magnetic oil collector and a fire-resistant flexible boom. An example usage scenario of the sponges applied to in situ burning cleanup of oil spills is described.

Solar-Assisted Superhydrophobic MoS2/PDMS/MS Sponge for the Efficient Cleanup of Viscous Oil

Industrialization releases many high-viscosity oil pollutants into the environment, requiring a hydrophobic recyclable oil-absorbing material. Therefore, a self-heating and superhydrophobic melamine sponge (MS) by connecting polydimethylsiloxane (PDMS) was coated with functionalized molybdenum disulfide (MoS₂) nanosheets on a three-dimensional microstructure of a commercial MS (MoS₂/PDMS/MS) via a simple and low-cost dip-coating method. The prepared sponge showed a water contact angle of 151.8°, indicating that the modified sponge exhibited superhydrophobicity. Due to the addition of MoS₂, the modified sponge can convert light into heat, and its surface could be heated to 59.7 °C within 30 s. Because of the excellent MoS₂/PDMS/MS photothermal performance, the sponge could decrease the viscosity of the high-viscosity oil, absorbing the high-viscosity oil efficiently. After simultaneous thermal analysis and repeated compression tests, the modified sponge exhibited high thermochemical stability, mechanical property, and reusability. This superhydrophobic multifunctional sponge shows excellent potential for high-viscosity oil absorption.