Separation of oil-in-water emulsions stabilized by different types of surfactants using electrospun fiber membranes

Electrochemical coalescence of oil-in-water droplets in microchannels of TiO2-x/Ti anode via polarization eliminating electrostatic repulsion and ·OH oxidation destroying oil-water interface film

Electrochemistry is a sustainable technology for oil-water separation. In the common flat electrode scheme, due to a few centimeters away from the anode, oil droplets have to undergo electromigration to and electrical neutralization at the anodic surface before they coalesce into large oil droplets and rise to water surface, resulting in slow demulsification and easy anode fouling. Herein, a novel strategy is proposed on basis of a TiO2-x/Ti anode with microchannels to overcome these problems. When oil droplets with several microns in diameter flow through channels with tens of microns in diameter, the electromigration distance is shortened by three orders of magnitude, electrical neutralization is replaced by polarization coupling ·OH oxidation. The new strategy was supported by experimental results and theoretical analysis. Taking the suspension containing emulsified oil as targets, COD value dropped from initial 500 mg/L to 117 mg/L after flowing through anodic microchannels in only 58 s of running time, and the COD removal was 21 times higher than that for a plate anode. At similar COD removal, the residence time was 48 times shorter than that of reported flat electrodes. Coalescences of oil droplets in microchannels were observed by a confocal laser scanning microscopy. This new strategy opens a door for using microchannel electrodes to accelerate electrochemical coalescence of oil-in-water droplets.

A comprehensive review on the behavior and evolution of oil droplets during oil/water separation by membranes

Membrane separation technology has significant advantages for treating oil-in-water emulsions. Understanding the evolution of oil droplets could reveal the interfacial and colloidal interactions, facilitate the design of advanced membranes, and improve the separation performances. This review on the characteristic behavior and evolution of oil droplets focuses on the advanced analytical techniques, and the subsequent fouling as well as demulsification effects during membrane separation. A detailed introduction is provided on microscopic observations and numerical simulations of the dynamic evolution of oil droplets, featuring real-time in-situ visualization and accurate reconstruction, respectively. Characteristic behaviors of these oil droplets include attachment, pinning, wetting, spreading, blockage, intrusion, coalescence, and detachment, which have been quantified by specific proposed parameters and criteria. The fouling process can be evaluated using Hermia and resistance models. The related adhesion force and intrusion pressure as well as droplet-droplet/membrane interfacial interactions can be accurately quantified using various force analysis methods and advanced force measurement techniques. It is encouraging to note that oil coalescence has been achieved through various effects such as electrostatic interactions, mechanical actions, Laplace pressure/surface free energy gradients, and synergistic effects on functional membranes. When oil droplets become destabilized and coalesce into larger ones, the functional membranes can overcome the limitations of size-sieving effect to attain higher separation efficiency. This not only bypasses the trade-off between permeability and rejection, but also significantly reduces membrane fouling. Finally, the challenges and potential research directions in membrane separation are proposed. We hope this review will support the engineering of advanced materials for oil/water separation and research on interface science in general.

An Overview of Recent Progress in Nanofiber Membranes for Oily Wastewater Treatment

Oil separation from water becomes a challenging issue in industries, especially when large volumes of stable oil/water emulsion are discharged. The present short review offers an overview of the recent developments in the nanofiber membranes used in oily wastewater treatment. This review notes that nanofiber membranes can efficiently separate the free-floating oil, dispersed oil and emulsified oil droplets. The highly interconnected pore structure nanofiber membrane and its modified wettability can enhance the permeation flux and reduce the fouling. The nanofiber membrane is an efficient separator for liquid-liquid with different densities, which can act as a rejector of either oil or water and a coalescer of oil droplets. The present paper focuses on nanofiber membranes' production techniques, nanofiber membranes' modification for flux and separation efficiency improvement, and the future direction of research, especially for practical developments.

2D Nano-Mica Sheets Assembled Membranes for High-Efficiency Oil/Water Separation

Oil-polluted water has become one of the most important environmental concerns nowadays due to the increasing industrial oily wastewater and frequent oil spill accidents. Herein, a novel two-dimensional (2D) nano-mica sheets assembled composite membrane with underwater super-oleophobic properties was developed for effective oil/water separation. A 2D nano-mica sheet was synthesized by a facile solvent-assisted ultrasonic exfoliation and then the obtained 2D nano-mica sheets were co-deposited with dopamine on polyvinylidene fluoride substrate to prepare nano-mica composite membranes (NCM). The NCM is hydrophilic in air and super-oleophobic underwater (the water contact angle in the air is 37.6°, and the oil contact angle in water is 151.4°). Furthermore, the prepared NCM provided outstanding stability in different acid-base environments (pH = 1-11). Noteworthily, the oil removal rate is higher than 99.5% as the sodium dodecyl sulfate SDS-stabilized oil (soya-bean oil, mineral oil and pump oil) -in-water emulsions. Meanwhile, the NCM showed excellent reusability, as the oil removal efficiency kept at 99.0% after ten soya-bean oil-in-water or mineral oil-in-water emulsion filtration cycles. The present work paved a new way for developing a low-cost and environmentally friendly strategy for oily wastewater treatment and developed a high-increment utilization application field for natural minerals.

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

Ceramic membranes have drawn increasing attention in oily wastewater treatment as an alternative to their traditional polymeric counterparts, yet persistent membrane fouling is still one of the largest challenges. Particularly, little is known about ceramic membrane fouling by oil-in-water (O/W) emulsions in constant flux filtration modes. In this study, the effects of emulsion chemistry (surfactant concentration, pH, salinity and Ca²⁺) and operation parameters (permeate flux and filtration time) were comparatively evaluated for alumina and silicon carbide (SiC) deposited ceramic membranes, with different physicochemical surface properties. The original membranes were made of 100% alumina, while the same membranes were also deposited with a SiC layer to change the surface charge and hydrophilicity. The SiC-deposited membrane showed a lower reversible and irreversible fouling when permeate flux was below 110 L m^-2 h^-1. In addition, it exhibited a higher permeance recovery after physical and chemical cleaning, as compared to the alumina membranes. Increasing sodium dodecyl sulfate (SDS) concentration in the feed decreased the fouling of both membranes, but to a higher extent in the alumina membranes. The fouling of both membranes could be reduced with increasing the pH of the emulsion due to the enhanced electrostatic repulsion between oil droplets and membrane surface. Because of the screening of surface charge in a high salinity solution (100 mM NaCl), only a small difference in irreversible fouling was observed for alumina and SiC-deposited membranes under these conditions. The presence of Ca²⁺ in the emulsion led to high irreversible fouling of both membranes, because of the compression of diffusion double layer and the interactions between Ca²⁺ and SDS. The low fouling tendency and/or high cleaning efficiency of the SiC-deposited membranes indicated their potential for oily wastewater treatment.

Systematic Design of a Flow-Through Titanium Electrode-Based Device with Strong Oil Droplet Rejection Property for Superior Oil-in-Water Emulsion Separation Performance

Oily wastewater treatment has been restricted by the existence of stable oil-in-water (O/W) emulsions containing micrometer-sized oil droplets. However, the strong adhesion and stacking of emulsified oil droplets on the surface of current separation media cause serious fouling of the treatment unit and the rapid decline of treatment efficiency. Herein, a novel flow-through titanium (Ti) electrode-based filtration device with remarkable oil droplet rejection property was well designed for the continuously separating O/W emulsion. In contrast to the pristine Ti foam, the permeance of the TiO₂ nanoarray-coated Ti foam (NATF) increased from 2538 to 4364 L m^-2 h^-1 bar^-1 through gravity-driven flow. Further, more than ∼70% permeability can be maintained after 6 h of O/W emulsion filtration using the current device, the value of which was markedly higher than that of conventional oil/water separation filters (less than 5%). According to the results of wettability test, the super-oil-repellent surface endowed by this nanoarray structure primarily avoided the formation of a compact oil fouling layer. When the voltage was applied, accompanied by the electrophoresis effect, redistribution of surfactant molecules on the surface of oil droplets induced by an electric field made them readily captured by the microbubbles continuously generated from the electrode, thereby rapidly migrating these bubble-adhered oil droplets far from the filtration medium.

Recent Progress in Microfiltration/Ultrafiltration Membranes for Separation of Oil and Water Emulsions

Oily wastewater has become one of the leading causes of environmental pollution. A massive quantity of oily wastewater is released from industries, oil spills, and routine activities, endangering the ecosystem's sustainability. Due to the enormous negative impact, researchers put strenuous efforts into developing a sustainable solution to treat oily wastewater. Microfiltration/ultrafiltration membranes are considered an efficient solution to treat oily wastewater due to their low cost, small footprint, facile operation, and high separation efficiencies. However, membranes severely fouled during the separation process due to oil's adsorption and cake layer formation, which shortens the membranes' life. This review has critically discussed the microfiltration/ultrafiltration membrane synthesizing methods and their emulsion's separation performance. In the end, key challenges and their possible solutions are highlighted to provide future direction to synthesize next-generation membranes.

Recent Mitigation Strategies on Membrane Fouling for Oily Wastewater Treatment

The discharge of massive amounts of oily wastewater has become one of the major concerns among the scientific community. Membrane filtration has been one of the most used methods of treating oily wastewater due to its stability, convenience handling, and durability. However, the continuous occurrence of membrane fouling aggravates the membrane's performance efficiency. Membrane fouling can be defined as the accumulation of various materials in the pores or surface of the membrane that affect the permeate's quantity and quality. Many aspects of fouling have been reviewed, but recent methods for fouling reduction in oily wastewater have not been explored and discussed sufficiently. This review highlights the mitigation strategies to reduce membrane fouling from oily wastewater. We first review the membrane technology principle for oily wastewater treatment, followed by a discussion on different fouling mechanisms of inorganic fouling, organic fouling, biological fouling, and colloidal fouling for better understanding and prevention of membrane fouling. Recent mitigation strategies to reduce fouling caused by oily wastewater treatment are also discussed.

Mussel-Inspired Fabrication of PDA@PAN Electrospun Nanofibrous Membrane for Oil-in-Water Emulsion Separation

Emulsified oily wastewater threatens human health seriously, and traditional technologies are unable to separate emulsion containing small sized oil droplets. Currently, oil-water emulsions are usually separated by special wettability membranes, and researchers are devoted to developing membranes with excellent antifouling performance and high permeability. Herein, a novel, simple and low-cost method has been proposed for the separation of emulsion containing surfactants. Polyacrylonitrile (PAN) nanofibers were prepared via electrospinning and then coated by polydopamine (PDA) by using self-polymerization reactions in aqueous solutions. The morphology, structure and oil-in-water emulsion separation properties of the as-prepared PDA@PAN nanofibrous membrane were tested. The results show that PDA@PAN nanofibrous membrane has superhydrophilicity and almost no adhesion to crude oil in water, which exhibits excellent oil-water separation ability. The permeability and separation efficiency of n-hexane/water emulsion are up to 1570 Lm-2 h-1 bar-1 and 96.1%, respectively. Furthermore, after 10 cycles of separation, the permeability and separation efficiency values do not decrease significantly, indicating its good recycling performance. This research develops a new method for preparing oil-water separation membrane, which can be used for efficient oil-in-water emulsion separation.

Switchable wettability of grain-stacked filter layers from polyurethane plastic waste for oil/water separation

HYPOTHESIS

Polyurethane plastic waste (PUPW), a port-abundant solid waste, is difficult to degrade naturally and poses a severe threat to the environment. Hence, the effective recycling of PUPW remains a challenge.

EXPERIMENTS

Herein, a strategy of converting PUPW into stacked oil/water filtration layer grain through a layer-by-layer (LBL) assembly process is investigated. Notably, such PU-based, grain-stacked, and switchable wettability of the oil/water filter layer is first reported.

FINDINGS

The grain-stacked filter layers are flexible for separating immiscible oil/water mixtures, water-in-oil emulsions (WOE), and oil-in-water emulsions (OWE) under gravity over 10 cycle-usages. They can withstand strong acid/alkali solutions (pH = 1-14) and salt solutions over 12 h. Besides, 100-times scale-up experiments have indicated that the obtained filter layers exhibit an upper to 98.2 % separation efficiency for 10 L real industrial oil/water emulsion in the 24 h continuous operation. The demulsification mechanism for emulsions is that the electrostatic interaction along with adsorption between emulsion droplets and grains leads to the uneven distribution of surfactants on the interface film of the emulsion droplets, increasing the probability of tiny droplets colliding and coalescing into large droplets to achieve oil/water separation. This work proposes an effective and economical method of abundant plastic waste for industrial-scale oil-water separation rather than just on the laboratory-scale.

Instabilities and patterns in a submerged jelling jet

When a thin stream of aqueous sodium alginate is extruded into a reacting calcium chloride bath, it polymerizes into a soft elastic tube that spontaneously forms helical coils due to the ambient fluid drag. We quantify the onset of this drag-induced instability and its nonlinear evolution using experiments, and explain the results using a combination of scaling, theory and simulations. By co-extruding a second (internal) liquid within the aqueous sodium alginate jet and varying the diameter of the jet and the rates of the co-extrusion of the two liquids, we show that we can tune the local composition of the composite filament and the nature of the ensuing instabilities to create soft filaments of variable relative buoyancy, shape and mechanical properties. Altogether, by harnessing the fundamental varicose (jetting) and sinuous (buckling) instabilities associated with the extrusion of a submerged jelling filament, we show that it is possible to print complex three-dimensional filamentous structures in an ambient fluid.

One-pot facile synthesis of PDMS/PDMAEMA hybrid sponges for surfactant stabilized O/W emulsion separation

Hydrophobic/oleophilic sponges are excellent absorbent materials for oil contaminant removal. However, the application is limited in dealing with surfactant stabilized O/W emulsions. The water in the emulsion isolates the contact between the sponge and oil droplets. Consequently, the oil absorption efficiency is not ideal. Herein, to improve the oil absorption efficiency from anionic surfactant stabilized O/W emulsions, water responsive hybrid sponges were reported. To prepare such sponges, water soluble poly(N,N-dimethylaminoethylmethacrylate) (PDMAEMA) was introduced into polydimethylsiloxane (PDMS) sponges using table salt as a template and multi-walled carbon nanotubes (MWCNTs) as mechanical reinforcement in a one-pot method. Upon contact with an O/W emulsion, the water soluble PDMAEMA chain rose to the surface of the sponge, turning the hydrophobic surface into hydrophilic. Next, the tertiary amine groups in PDMAEMA ionized in water and carried positive charges which would cause the coagulation of oil droplets. Finally, the coagulated oil droplets were absorbed immediately by the oleophilic inner part of the sponge through the wicking effect. As a result, a Janus interface was generated in situ and sustained. Such material design synergistically contributed to a satisfactory hexadecane (HD) absorption efficiency of 178 ± 4% in 25 min. In contrast, the PDMS-MWCNT_1.0% sponge could only absorb 9.8 ± 0.2% HD. Moreover, these sponges also presented robust mechanical performance and reusability, offering a new route for oil/water separation and oil pollution remediation in open water.

Microfiltration of saline crude oil emulsions: Effects of dispersant and salinity

Dispersants reduce oil-water interfacial tension making the separation of oil-water emulsions challenging. In this study, crude oil stabilized by the dispersant, Corexit EC9500A, was emulsified in synthetic sea water using a range of Corexit/crude oil concentration ratios (up to 10% by volume). With an interfacial tension of only 8.0 mJ/m² at 0.5 mL(Corexit)/L, approximately 50% of the crude was dispersed into droplets <10 µm. Near complete rejection of oil in crossflow separation tests was accompanied by a precipitous flux decline attributable in part to dispersant- and salinity-induced decrease in membrane's oleophobicity (4.2 mJ/m² decrease in surface energy). Screening of electrostatic interactions prompted oil coalescence that occurred at the membrane surface but not in the bulk of the emulsion. Real-time in situ visualization by Direct Observation Through Membrane gave direct evidence of surface coalescence pointing to both its detrimental effects (spread of contiguous films) and possible advantages (removal of large droplets by crossflow shear).

Surfactant location and internal phase volume fraction dictate emulsion electrospun fiber morphology and modulate drug release and cell response

Emulsion electrospinning is a versatile technique used to create fibrous meshes for applications in drug delivery and tissue engineering. In this study, the effects of surfactant and increasing internal phase volume fraction on emulsion electrospun fiber morphology were investigated. The fiber diameter, surface topography, internal architecture, mesh hydrophobicity, and fiber volume fraction were all characterized and the resulting effects on model drug release and cell response were determined. Surfactant relocation to the fiber surface resulted in alterations to fiber surface topography and internal morphology, increased rate of water adsorption into the mesh, and reduced burst effects of drug release. Increasing the internal phase volume fraction within the emulsion resulted in minimal change to fiber diameter, surface morphology, fiber volume fraction, and rate of water adsorption illustrating the ability to increase drug loading without affecting fiber properties. Lastly, all meshes promoted cell adhesion and good viability with a trend of increased MTT absorbance from cells on the surfactant and emulsion fibers possibly suggesting that an increase in surface area via smaller fiber diameter and fiber volume fraction increases metabolic activity. Overall, these studies indicate that fiber morphology and mesh hydrophobicity can be tuned by controlling surfactant location within fibers and internal phase volume fraction. Modulating fiber properties within the emulsion electrospun mesh is important to achieve controlled drug release and cell response for tissue engineering applications.

Hierarchical structurized waste brick with opposite wettability for on-demand oil/water separation

Due to the variety of oily wastewater and complexity of separation system, it has put forward new challenge and requirement to separation materials for on-demand separation of various oil/water mixtures. Here, we reported a facile waste-to-resource strategy to rationally fabricate hierarchical ZnO nanopillars coating onto the surface of waste brick grains (ZnO/WBG) via simple physical process and in-situ growth technique. Specifically, the directly as-prepared ZnO/WBG possess superhydrophilic/underwater superoleophobic (UWSOB) properties and modified ZnO/WBG by organosilicon reagent possess quasi superhydrophobic/superoleophilic (SHOBI) properties. It is also worth noting that this discrete ZnO/WBG with opposite wettability can be accumulated into ZnO/WBG layer with numerous tortuous channel structure, making it feasible for on-demand separating various oil/water mixtures whether immiscible light- and heavy-oil/water mixtures or oil-in-water and water-in-oil emulsions. It has been demonstrated that the filter layers with opposite wettability exhibit high separation efficiency and flux, excellent chemical stability and admirable recyclability. Thus, this novel and cost-effective ZnO/WBG layer holds great promise for large-scale and versatile oil/water separation. Additionally, this work presents a sustainable perspective of effectively utilizing waste brick to construct workable functionalized materials with tremendous application potential, showing far-reaching value and significance in fundamental research and environmental protection.

Fabrication of a PAN–PA6/PANI membrane using dual spinneret electrospinning followed by in situ polymerization for separation of oil-in-water emulsions

A polyacrylonitrile–polyamide 6/polyaniline (PAN–PA6/PANI) doped membrane was prepared using dual spinneret simultaneous electrospinning of PAN and PA6 and in situ polymerization of aniline at low temperature.

Oil Deposition on Polymer Brush-Coated NF Membranes

Membrane-based processes are attractive for treating oily wastewaters. However, membrane fouling due to the deposition of oil droplets on the membrane surface compromises performance. Here, real-time observation of the deposition of oil droplets by direct confocal microscopy was conducted. Experiments were conducted in dead-end and crossflow modes. Base NF 270 nanofiltration membranes as well as membranes modified by grafting poly(N-isopropylacrylamide) chains from the membrane surface using atom transfer radical polymerization were investigated. By using feed streams containing low and high NaCl concentrations, the grafted polymer chains could be induced to switch conformation from a hydrated to a dehydrated state, as the lower critical solution temperature for the grafted polymer chains moved above and below the room temperature, respectively. For the modified membrane, it was shown that switching conformation of the grafted polymer chains led to the partial release of adsorbed oil. The results also indicate that, unlike particles such as polystyrene beads, adsorption of oil droplets can lead to coalescence of the adsorbed oil droplets on the membrane surface. The results provide further evidence of the importance of membrane properties, feed solution characteristics, and operating mode and conditions on membrane fouling.

Roles of surfactants in pressure-driven membrane separation processes: a review

Surfactants widely exist in various kinds of wastewaters which could be treated by pressure-driven membrane separation (PDMS) techniques. Due to the special characteristics of surfactants, they may affect the performance of membrane filtration. Over the last two decades, there are a number of studies on treating wastewaters containing surfactants by PDMS. The current paper gives a review of the roles of surfactants in PDMS processes. The effects of surfactants on membrane performance were discussed via two aspects: influence of surfactants on membrane fouling and enhanced removal of pollutants by surfactants. The characteristics of surfactants in solution and at solid-liquid interface were summarized. Surfactants in membrane filtration processes cause membrane fouling mainly through adsorption, concentration polarization, pore blocking, and cake formation, and fouling degree may be influenced by various factors (feed water composition, membrane properties, and operation conditions). Furthermore, surfactants may also have a positive effect on membrane performance. Enhanced removal of various kinds of pollutants by PDMS in the presence of surfactants has been summarized, and the removal mechanism has been revealed. Based on the current reports, further studies on membrane fouling caused by surfactants and enhanced removal of pollutants by surfactant-aided membrane filtration were also proposed.

Liquid-Infused Membranes with Oil-in-Water Emulsions

Liquid-infused membranes have been introduced to membrane technology recently. The infusion liquid can be expelled, opening the pore, in response to an immiscible feed liquid pressure. In the open state, the pore wall is still covered with the infusion liquid forming the so-called liquid-lined pores. Liquid lining is expected to give anti-fouling properties to these membranes. The pressure-responsive pores can be used for efficient sorting of fluids from a mixture based on interfacial tension. For example, in a two-phase mixture of immiscible liquids, the required liquid entry pressure is different for the constituent liquids. Here, we investigate the capability of liquid-infused membranes for selective permeation of the dispersed phase, that is, oil from an oil-in-water (O/W) emulsion. The separation experiments are conducted in a dead-end pressure-controlled filtration cell using liquid-infused and non-infused membranes. In order to permeate the dispersed phase, oil droplets should come in contact with the membrane surface which is accomplished here by gravity-driven creaming. Our results reveal that by setting the feed pressure between the entry pressure of oil and that of the surfactant solution, oil can be successfully permeated. For high concentrations of surfactants, water also permeated partly. The amount of water permeated through liquid-infused membranes is lower than that through non-infused membranes, caused by the corresponding interfacial tensions. The results suggest that the presence of the infusion liquid in the membrane gives rise to the formation of three-phase interfaces in the pore, namely, the interface between surfactant solution-oil (γ₁₂) and that between oil-infusion liquid (γ₂₃). Based on the interfacial energy contributions, the additional interface between oil and the infusion liquid gives rise to an increase in the liquid entry pressure for the surfactant solution based on the combined interfacial tension (γ₁₂ + γ₂₃) leading to less water permeation.

Direct Three-Dimensional Visualization of Membrane Fouling by Confocal Laser Scanning Microscopy

Membrane-based separation is an important technique for removing emulsified oil from water. However, the mechanisms of fouling are complex because of the deformability and potential for coalescence and break-up of the oil droplets. Here, we report for the first time direct, three-dimensional (3D) visualization of oil droplets on electrospun fiber microfiltration membranes after a period of membrane-based separation of oil-in-water emulsions. High-resolution 3D images were acquired by a dual-channel confocal laser scanning microscopy (CLSM) technique in which both the fibers and the oil (dodecane) were fluorescently labeled. The morphology of dodecane as the foulant was observed for two different types of fibers, an oleophobic nylon (PA6(3)T), and oleophilic polyvinylidene fluoride (PVDF). Through direct visualization, the rejected oil was found to form droplets of clam-shell shape on the PA6(3)T fibers, whereas the oil tended to wet the PVDF fibers and spread across the membrane. The morphology was also analyzed as a function of separation time (i.e., "4D" imaging), as the oil accumulated within and upon the membranes. The observations are qualitatively consistent with a transition from blocking of individual pores in the membrane to coalescence of oil droplets into coherent liquid films with increasing filtration time. Analysis of permeate flux using blocking filtration models corroborate the transition of fouling modes indicated by the 3D images. This direct, 3D visualization CLSM technique is a powerful tool for characterizing the mechanisms of fouling in membranes used for liquid emulsion separations.

Preparation of an electrospun tubular PU/GE nanofiber membrane for high flux oil/water separation

A simple, tubular structure polyurethane/graphene (PU/GE) nanofiber membrane for continuous oil/water separation has been prepared.