Fabrication of non-fluorinated hydrophilic-oleophobic stainless steel mesh for oil-water separation

A review of various dimensional superwetting materials for oil-water separation

In recent years, the application and fabrication technologies of superwetting materials in the field of oil-water separation have become a research hotspot, aiming to address challenges in marine oil spill response and oily wastewater treatment. Simultaneously, the fabrication technologies and related applications of superwetting materials have been increasingly diversified. This paper systematically reviews the sources and hazards of oily wastewater and oil-water emulsions, several traditional oil-water separation methods, and their limitations, thereby highlighting the advantages of superwetting materials. Additionally, this paper provides an overview of the fundamental theories of wetting and conducts a microanalysis of the penetration mechanism based on Laplace pressure at the gas-liquid-solid three-phase interface. Following this, the latest advances in superwetting oil-water separation materials are elucidated, focusing on five categories: (i) superhydrophobic-superoleophilic materials; (ii) superhydrophilic-underwater superoleophobic materials; (iii) superhydrophobic-superoleophobic materials; (iv) "special" superwetting materials; and (v) smart switchable superwetting materials. This paper innovatively discusses these materials from the perspectives of two-dimensional and three-dimensional materials, deeply studying the mechanisms of oil-water separation and using data to quantify the separation efficiency. Comparative discussions are conducted on the materials from various dimensions, including different substrates, innovations in existing technologies, and fabrication methods as discussed in various articles, followed by corresponding summaries. Finally, the existing shortcomings and challenges of current superwetting materials are summarized, and prospects are proposed. We firmly believe that developing low-cost, stable, environmentally friendly, and practical large-scale superwetting oil-water separation materials will have broad application prospects and potential in the future.

Special wettable Azadirachta indica leaves like microarchitecture mesh filtration membrane produced by galvanic replacement reaction for layered oil/water separation

The oil/water separation has received significant attention due to its critical environmental impact. The special wettable surfaces are highly desired to deal with the oil/water mixtures. This work demonstrates a simple two-step method to develop a superhydrophobic Azadirachta indica leaves like Ag-decorated electrochemically copper-coated stainless-steel mesh (SH-AIL-Ag-EC-Cu-Mesh) for efficient separation of oil/water mixtures. In the first step, the electrodeposition of the copper took place on the mesh surface at a suitable applied potential. In the second step, the galvanic replacement reaction between the Ag⁺ and electrodeposited Cu produced the fascinating superhydrophobic Ag leaves on the mesh surface. The SH-AIL-Ag-EC-Cu-Mesh was thoroughly characterized by the X-ray photoelectron spectroscopy (XPS), Energy Dispersive X-Ray Spectroscopy (EDX), elemental mapping, surface wettability analysis, and the contact analyzer. The morphological analysis has shown the unique leafy structures of the reduced Ag on the surface of the mesh. The XPS analysis has confirmed that most of the Ag present on the surface is in zerovalent form. The combination of the electrodeposition and the displacement reaction between the copper and the silver turned the surface superhydrophobic, and the water contact angle was significantly improved from 115° to 158°. The designed SH-AIL-Ag-EC-Cu-Mesh has shown excellent selectivity for oil in oil/water mixtures with a separation efficiency of 99.1% with an exceptionally high flux of 8963 L m^-2h^-1. The SH-AIL-Ag-EC-Cu-Mesh has shown excellent reusability, and after 15 cycles of separation, no significant decrease in the oil/water separation efficiency was observed.

Pressure-Driven Phase Separation Based on Modified Porous Mesh for Liquid Management in Microgravity

Surface tension becomes the main force influencing the gas-liquid interface in microgravity environment. The instability of the gas-liquid distribution is a menace for spacecraft missions. Passive phase separation based on porous material is a promising technique for microgravity liquid management and advanced life support systems. Here, the mechanism of pressure-driven phase separation based on porous material is experimentally investigated, highlighting the synergistic influence of single-phase flow, breakthrough failure, and self-healing ability on liquid acquisition capability. The major parameters characterizing the separation efficiency are the breakthrough threshold pressure and the flow resistance. A fabrication strategy which elicits the surface wettability and maintains the original surface morphology is proposed and verified to increase the critical breakthrough threshold pressure without introducing extra flow resistance. Moreover, the modified mesh is integrated into a screen channel liquid acquisition device. The improvement of the overall separation performance is evaluated in an antigravity delivery experiment, where the acceleration of liquid is -g₀. It has been demonstrated that the fabrication strategy increases the achievable flow rate over 80% and the reseal flow rate over 200% for gas-free water delivery. This work enriches the understanding of phase separation based on porous material and provides an alternative method for liquid management in microgravity.

A Materials Science Perspective of Midstream Challenges in the Utilization of Heavy Crude Oil

An increasing global population and a sharply upward trajectory of per capita energy consumption continue to drive the demand for fossil fuels, which remain integral to energy grids and the global transportation infrastructure. The oil and gas industry is increasingly reliant on unconventional deposits such as heavy crude oil and bitumen for reasons of accessibility, scale, and geopolitics. Unconventional deposits such as the Canadian Oil Sands in Northern Alberta contain more than one-third of the world's viscous oil reserves and are vital linchpins to meet the energy needs of rapidly industrializing populations. Heavy oil is typically recovered from subsurface deposits using thermal recovery approaches such as steam-assisted gravity drainage (SAGD). In this perspective article, we discuss several aspects of materials science challenges in the utilization of heavy crude oil with an emphasis on the needs of the Canadian Oil Sands. In particular, we discuss surface modification and materials' design approaches essential to operations under extreme environments of high temperatures and pressures and the presence of corrosive species. The demanding conditions for materials and surfaces are directly traceable to the high viscosity, low surface tension, and substantial sulfur content of heavy crude oil, which necessitates extensive energy-intensive thermal processes, warrants dilution/emulsification to ease the flow of rheologically challenging fluids, and engenders the need to protect corrodible components. Geopolitical reasons have further led to a considerable geographic separation between extraction sites and advanced refineries capable of processing heavy oils to a diverse slate of products, thus necessitating a massive midstream infrastructure for transportation of these rheologically challenging fluids. Innovations in fluid handling, bitumen processing, and midstream transportation are critical to the economic viability of heavy oil. Here, we discuss foundational principles, recent technological advancements, and unmet needs emphasizing candidate solutions for thermal insulation, membrane-assisted separations, corrosion protection, and midstream bitumen transportation. This perspective seeks to highlight illustrative materials' technology developments spanning the range from nanocomposite coatings and cement sheaths for thermal insulation to the utilization of orthogonal wettability to engender separation of water-oil emulsions stabilized by endogenous surfactants extracted during SAGD, size-exclusion membranes for fractionation of bitumen, omniphobic coatings for drag reduction in pipelines and to ease oil handling in containers, solid prills obtained from partial bitumen solidification to enable solid-state transport with reduced risk of damage from spills, and nanocomposite coatings incorporating multiple modes of corrosion inhibition. Future outlooks for onsite partial upgradation are also described, which could potentially bypass the use of refineries for some fractions, enable access to a broader cross-section of refineries, and enable a new distributed chemical manufacturing paradigm.

Highly Effective Anti-Organic Fouling Performance of a Modified PVDF Membrane Using a Triple-Component Copolymer of P(Stx-co-MAAy)-g-fPEGz as the Additive

In this study, a triple-component copolymer of P(St_x-co-MAA_y)-g-fPEG_z containing hydrophobic (styrene, St), hydrophilic (methacrylic acid, MAA), and oleophobic (perfluoroalkyl polyethylene glycol, fPEG) segments was synthesized and used as an additive polymer to prepare modified PVDF membrane for enhanced anti-fouling performance. Two compositions of St:MAA at 4:1 and 1:1 for the additive and two blending ratios of the additive:PVDF at 1:9 and 3:7 for the modified membranes were specifically examined. The results showed that the presence of the copolymer additive greatly affected the morphology and performance of the modified PVDF membranes. Especially, in a lower ratio of St to MAA (e.g., St:MAA at 1:1 versus 4:1), the additive polymer and therefore the modified PVDF membrane exhibited both better hydrophilic as well as oleophobic surface property. The prepared membrane can achieve a water contact angle at as low as 48.80° and display an underwater oil contact angle at as high as 160°. Adsorption experiments showed that BSA adsorption (in the concentration range of 0.8 to 2 g/L) on the modified PVDF membrane can be reduced by as much as 93%. From the filtration of BSA solution, HA solution, and oil/water emulsion, it was confirmed that the obtained membrane showed excellent resistance to these organic foulants that are often considered challenging in membrane water treatment. The performance displayed slow flux decay during filtration and high flux recovery after simple water cleaning. The developed membrane can therefore have a good potential to be used in such applications as water and wastewater treatment where protein and other organic pollutants (including oils) may cause severe fouling problems to conventional polymeric membranes.

Delamination-Free In-Air and Underwater Oil-Repellent Filters for Oil-Water Separation: Gravity-Driven and Cross-Flow Operations

Separating oil-water mixtures is critical in a variety of practical applications, including the treatment of industrial wastewater, oil spill cleanups, as well as the purification of petroleum products. Among various methodologies that have been utilized, membranes are the most attractive technology for separating oil-water emulsions. In recent years, selective wettability membranes have attracted particular attention for oil-water separations. The membrane surfaces with hydrophilic and in-air oleophobic wettability have demonstrated enhanced effectiveness for oil-water separations in comparison with underwater oleophobic membranes. However, developing a hydrophilic and in-air oleophobic surface for a membrane is not a trivial task. The coating delamination process is a critical challenge when applying these membranes for separations. Inspired by the above, in this study we utilize poly(ethylene glycol)diacrylate (PEGDA) and 1H,1H,2H,2H-heptadecafluorodecyl acrylate (F-acrylate) to fabricate a hydrophilic and in-air oleophobic coating on a filter. We utilize methacryloxypropyl trimethoxysilane (MEMO) as an adhesion promoter to enhance the adhesion of the coating to the filter. The filter demonstrates robust oil repellency preventing oil adhesion and oil fouling. Utilizing the filter, gravity-driven and continuous separations of surfactant-stabilized oil-water emulsions are demonstrated. Finally, we demonstrate that the filter can be reused multiple times upon rinsing for further oil-water separations.

Superwetting materials for hydrophilic-oleophobic membrane in oily wastewater treatment

The vast amount of oily wastewater released to the environment through industrialization has worsened the water quality in recent years, posing adverse impacts on general human health. Oil emulsified in water is one of the most difficult mixtures to be treated, making it imperative for new technology to be explored to address this issue. The use of conventional water treatment such as flotation, coagulation, precipitation, adsorption, and chemical treatment have low separation efficiencies and high energy costs, and are not applicable to the separation of oil/water emulsions. Therefore, there is a demand for more efficient methods and materials for the separations of immiscible oil/water mixtures and emulsions. Superwetting materials that can repel oil, while letting water pass through have been widely explored to fit into this concern. These materials usually make use of simultaneous hydrophilic/oleophobic mechanisms to allow a solid surface to separate oily emulsion with little to no use of energy. Also, by integrating specific wettability concepts with appropriate pore scale, solid surfaces may achieve separation of multifarious oil/water mixtures namely immiscible oil/water blends and consolidated emulsions. In this review, materials used to impart superwetting in solid surfaces by focusing on superhydrophilic/superoleophobic wetting properties of the materials categorized into fluorinated and non-fluorinated surface modification are summarized. In each material, its background, mechanism, fabricating processes, and their effects on solid surface's wetting capability are elaborated in detail. The materials reviewed in this paper are mainly organic and green, suggesting the alternative material to replace the fluorine group that is widely used to achieve oleophobicity in oily wastewater treatment.

Cellulose-based special wetting materials for oil/water separation: A review

Oil spill accidents and oily wastewater discharged by petrochemical industries have severely wasted water resources and damaged the environment. The use of special wetting materials to separate oil and water is efficient and environment-friendly. Cellulose is the most abundant renewable resource and has natural advantages in removing pollutants from oily wastewater. The application and modification of cellulose as special wetting materials have attracted considerable research attention. Therefore, we summarized cellulose-based superlipophilic/superhydrophobic and superhydrophilic/superoleophobic materials exhibiting special wetting properties for oil/water separation. The treatment mechanism, preparation technology, treatment effect, and representative projects of oil-bearing wastewater are discussed. Moreover, cellulose-based intelligent-responsive materials for application to oil/water separation and the removal of other pollutants from oily wastewater have also been summarized. The prospects and potential challenges of all the materials have been highlighted.

Durable Superhydrophobic Wood via One-Step Immersion in Composite Silane Solution

A superhydrophobic coating endows pristine hydrophilic wood with excellent water/moisture repellency and thus prolongs its service life. Generally, the superhydrophobic coating on wood is fabricated by a two-step process in which the nanoparticles are first introduced onto the surface and then modified by low-surface-energy molecules. Herein, for the first time, we have fabricated the superhydrophobic wood via a one-step process free of nanoparticles by immersing the pristine hydrophilic wood, such as pine, balsawood, and basswood, into a composite silane solution of hexadecyltrimethoxysilane and methyltrimethoxysilane. The wood remains superhydrophobic or highly hydrophobic after long-term exposure to mechanical damage (such as abrading, knife-cutting, and tape-peeling), chemical damage (such as immersion in acid, alkali, or ethanol), and environmental impacting (such as UV irradiation and low/high-temperature exposure).

Protocol for Preparing Synthetic Solutions Mimicking Produced Water from Oil and Gas Operations

Produced water (PW) is the water associated with hydrocarbons during the extraction of oil and gas (O&G) from either conventional or unconventional resources. Existing efforts to enhance PW management systems include the development of novel membrane materials for oil-water separation. In attempting to evaluate these emerging physical separation technologies, researchers develop various formulations of test solutions aiming to represent actual PW. However, there is no clear scientific guideline published in the literature about how such a recipe should be prepared. This article develops a protocol for preparing synthetic solutions representing the characteristics and behavior of actual PW and enabling the performance comparisons of different oil-water separation membranes at the bench scale level. In this study, two different brine recipes were prepared based on salts present in actual PW, crude oil was used as the hydrocarbon source, and a surfactant was added to disperse the oil into the aqueous phase. The recipe is accessible to the wider scientific community and was proven to be reproduceable, homogenous, stable, and comparable to actual PW field samples through analytical monitoring measurements and bench scale evaluations.

Durable, cost-effective and superhydrophilic chitosan-alginate hydrogel-coated mesh for efficient oil/water separation

Hydrogels with low-adhesive superoleophobicity are ideal candidates for modifying filtration substrates to achieve efficient and antifouling oil/water separation. However, there are still some unfavorable factors hindering their practical application, including expensive raw materials, complex fabrication process, poor stability and durability. In this work, a durable, cost-effective and superhydrophilic chitosan-alginate (CS-ALG) hydrogel coated mesh was developed by a facile, two-step dip-coating method for efficient oil/water separation in hypersaline environments. By integrating polysaccharide-based superhydrophobic surfaces and the hierarchical micro-/nanostructures, the as-fabricated CS-ALG hydrogel coated mesh exhibits excellent underwater superoleophobicity and anti-oil-fouling performance. Benefiting from that, the mesh could separate various oil/water mixtures with high separation efficiency (> 99%). It is worth mentioning that the double-cross-linked CS-ALG hydrogel based on sequential electrostatic interaction and ionic cross-linking shows excellent durability in hypersaline environments. All these attractive advantages make the hydrogel-coated mesh a promising candidate for oily wastewater treatment and oil spill cleanup.

Fabrication of Tween-20 coated PVDF membranes for wastewater treatment: optimization of preparation parameters, removal and membrane fouling control performance

In the present study, polyoxyethylene (20) sorbitan monolaurate (Tween-20) was employed as a surface coating agent for hydrophilic modification of poly(vinylidene fluoride) microfiltration membranes. The optimized parameters for membrane preparation (i.e., coating temperature, coating concentration, coating time and drying time) were systematically investigated. Contact angle and transmembrane pressure were employed to evaluate the efficiency of the modified membranes, and the optimized parameters were proposed. The removal of chemical oxygen demand (COD) and suspended solids (SS), as well as fouling control performance, was further evaluated. The results showed that the optimized parameters were 40 °C, 4.5 mmol L-1, 45 min and 45 min for coating temperature, coating concentration, coating time and drying time, respectively. Under these conditions, a hydration layer on the surface was formed, resulting in a more hydrophilic membrane surface. During domestic wastewater treatment in membrane bioreactor (MBR), the Tween-20 modified membrane exhibited better performance with rejection efficiencies of 94.56% and 97.53% for COD and SS, respectively. Tween-20 coating could mitigate the increase of transmembrane pressure and reduce the concentration of proteins accumulated on the membrane surface, which was effective for membrane fouling control. Simultaneously, the operation time of MBR was extended from 25 to 46 days. Furthermore, the stability of Tween-20 coated PVDF membrane was also verified. The results indicated that surface coating with Tween-20 is efficient and easy to be carried out, showing a great potential for application in MBR during wastewater treatment.

Graphene Array-Based Anti-fouling Solar Vapour Gap Membrane Distillation with High Energy Efficiency

Photothermal membrane distillation (MD) is a promising technology for desalination and water purification. However, solar-thermal conversion suffers from low energy efficiency (a typical solar-water efficiency of ~ 50%), while complex modifications are needed to reduce membrane fouling. Here, we demonstrate a new concept of solar vapour gap membrane distillation (SVGMD) synergistically combining self-guided water transport, localized heating, and separation of membrane from feed solution. A free-standing, multifunctional light absorber based on graphene array is custom-designed to locally heat the thin water layer transporting through graphene nanochannels. The as-generated vapour passes through a gap and condenses, while salt/contaminants are rejected before reaching the membrane. The high solar-water efficiency (73.4% at 1 sun), clean water collection ratio (82.3%), excellent anti-fouling performance, and stable permeate flux in continuous operation over 72 h are simultaneously achieved. Meanwhile, SVGMD inherits the advantage of MD in microorganism removal and water collection, enabling the solar-water efficiency 3.5 times higher compared to state-of-the-art solar vapour systems. A scaled system to treat oil/seawater mixtures under natural sunlight is developed with a purified water yield of 92.8 kg m^-2 day^-1. Our results can be applied for diverse mixed-phase feeds, leading to the next-generation solar-driven MD technology.

Review: Porous Metal Filters and Membranes for Oil-Water Separation

In recent years, oil-water separation has been widely researched to reduce the influences of industrial wastewater and offshore oil spills. A filter membrane with special wettability can achieve the separation because of its opposite wettability for water phase and oil phase. In the field of filter membrane with special wettability, porous metal filter membranes have been much investigated because of the associated high efficiency, portability, high plasticity, high thermal stability, and low cost. This article provides an overview of the research progress of the porous metal filter membrane fabrication and discusses the future developments in this field.

Application of a triblock copolymer additive modified polyvinylidene fluoride membrane for effective oil/water separation

A hollow fibre membrane was fabricated by blending polyvinylidene fluoride (PVDF) with a triblock copolymer additive polymer that has both hydrophilic and oleophobic surface properties. The novel membrane was characterized and examined for oil/water separation under various system conditions, including different cross-flow rate, feed temperature, trans-membrane pressure, and its rejection and cleaning efficiency, etc. By applying the membrane into the filtration of synthesized oil/water emulsion, the membrane constantly achieved an oil rejection rate of above 99%, with a relatively constant permeate flux varied in the range of 68.9-59.0 l m^-2 h^-1. More importantly, the fouling of the used membrane can be easily removed by simple water flushing. The membrane also demonstrated a wide adaptability for different types of real oily wastewater, even at very high feed oil concentration (approx. 115 000 mg l^-1 in terms of chemical oxygen demand (COM)). Hence, the novel triblock copolymer additive-modified PVDF membrane can have a great prospect in the continuing effort to expand the engineering application of polymeric membranes for oily wastewater treatment.

A glucose modified filter paper for effective oil/water separation

Toluene/water emulsion cannot be separated by the un-treated filter paper. In comparison, toluene/water emulsion could be efficiently separated by the glucose (GLC) treated filter paper.