Textured ceramic membranes for desilting and deoiling of produced water in the Permian Basin

Oil production in the Permian Basin gives rise to large volumes of produced water contaminated by silt, emulsified oil, and additives used for enhanced oil recovery. There is intense interest in the design of membrane modules as sustainable alternatives for produced water treatment to enable the reuse of produced water for agricultural applications, injection into aquifers, and redeployment in oil recovery. Here, we report a hierarchically textured cement-based membrane exhibiting orthogonal wettability, specifically, superhydrophilic and underwater superoleophobic characteristics. The in situ formation of ettringite needles accompanied by embedding of glass spheres imbues multiscale texturation to stainless-steel mesh membranes, enabling the separation of silt and oil from produced water at high flux rates (1600 L h⁻¹۰m⁻², at ca. 2.7 bar). Oil concentration is reduced as low as 1 ppb with an overall separation efficiency of 99.7% in single-pass filtration. The membranes show outstanding mechanical resilience and retention of performance across multiple cycles.

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Multiscale 3D texturation of a metal mesh membrane engenders orthogonal wettability

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High separation efficiency of ca. 99% was achieved for produced water

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Oil concentration reduced to ≤1 ppb in a single pass at a high flux rate

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Desiliting and deoiling demonstrated for real produced water streams

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.

Superwetting Bi2MoO6/Cu3(PO4)2 Nanosheet-Coated Copper Mesh with Superior Anti-Oil-Fouling and Photo-Fenton-like Catalytic Properties for Effective Oil-in-Water Emulsion Separation

Superwetting materials with excellent anti-oil-fouling performance for the treatment of oily wastewater are urgently demanded in practice. In this work, aiming at effectively separating diverse oil-in-water emulsions, a multifunctional Bi₂MoO₆/Cu₃(PO₄)₂ nanosheet-coated copper mesh was successfully fabricated by the combination of chemical oxidation and ultrasonic irradiation deposition methods. The resultant copper mesh exhibited superior superhydrophilicity/underwater superoleophobicity and, more importantly, preferable anti-oil-fouling property benefitting from the stable and firm hydration layer. A series of oil/water separation experiments for the highly emulsified surfactant-free and surfactant-stabilized oil-in-water emulsions were conducted, with the respective permeation fluxes of up to 3000 and 700 L·m^-2·h^-1 and the corresponding separation efficiencies of 99.5 and 98.6% solely driven by gravity. Meanwhile, considering the photo-Fenton-like catalytic activity of Bi₂MoO₆, the as-fabricated copper mesh exhibited excellent degradation ability toward organic pollutants under visible light irradiation. More importantly, stability tests were performed to evaluate the ability to cope with the harsh environments for practical applications. With the outstanding performances of high separation efficiency, desirable photo-Fenton-like catalytic capacity, and strong stability, the Bi₂MoO₆/Cu₃(PO₄)₂ nanosheet-coated copper mesh holds promising potential for purifying emulsified wastewater.

Sacrifice Template Strategy to the Fabrication of a Self-Cleaning Nanofibrous Membrane for Efficient Crude Oil-in-Water Emulsion Separation with High Flux

The superhydrophilic/underwater superoleophobic membrane materials have attracted considerable attention in oil/water separation. However, most materials are extremely susceptible to pollution during oil-water separation, which drastically restricts their widespread applications. Herein, a momordica-charantia-like nanofibrous membrane (MCNM) with underwater superoleophobic performance was fabricated through a sacrifice template strategy by the electrospinning solution of zeolitic imidazolate framework-8 (ZIF-8) and polyacrylonitrile particles. The opened voids and wrinkles left after removing the template of nanocrystals ZIF-8 not only increased the porosity and roughness of the as-prepared fibrous membrane but also tremendously improved the underwater superoleophobicity. Therefore, the as-prepared MCNM showed excellent self-cleaning performance toward crude oil under water, avoiding the decrease of the separation efficiency and flux caused by membrane fouling during oil-water separation. Meanwhile, the separation efficiency of various surfactant-stabilized oil-in-water emulsions was higher than 99.6% with a flux up to 1580 ± 30 L m^-2 h^-1 solely driven by gravity. Moreover, no obvious wrinkles and cracks were observed on the resulted nanofibrous membrane after the sand impact and bent testing. More importantly, the as-prepared MCNM still maintained exceptional underwater superoleophobicity in harsh environment (3.5 wt % NaCl, 4 M HCl, 50 °C hot water) even after ultrasound for 1 h. The robust mechanical and chemical stability makes the antifouling MCNM exhibit tremendous potential for practical applications in dealing with oily wastewater in the future.

Bioinspired Anti-Oil-Fouling Hierarchical Structured Membranes Decorated with Urchin-Like α-FeOOH Particles for Efficient Oil/Water Mixture and Crude Oil-in-Water Emulsion Separation

Designing and constructing a stable water-retention layer acting as the isolation between the oil and membrane surface holds great significance for solving the membrane fouling problems in oil/water separation, including common layered oil/water mixtures, immiscible oil-in-water emulsions, and even high-viscosity crude oil-in-water emulsions. Inspired by the self-cleaning property of sea urchin thorns, a bioinspired anti-oil-fouling hierarchically structured membranes decorated with urchin-like α-FeOOH particles was successfully prepared via the layer-by-layer (LBL) self-assembly method, maintaining numerous effective micro-nanopores. The hierarchical structured membrane exhibited superior superhydrophilicity/underwater superoleophobicity, high water-retention ability, and preferable anti-oil-fouling properties. Furthermore, the biomimetic membrane with controllable pore sizes could not only separate common layered oil/water mixtures but also effectively separate immiscible surfactant-stabilized oil-in-water emulsions of both low-viscosity crude oil and high-viscosity crude oil with an ultrahigh water flux up to 2598.4 L m^-2 h^-1 and an outstanding separation efficiency of 98.5%, revealing its promising prospect in oily wastewater treatment.

Switchable superlyophobic zeolitic imidazolate framework-8 film-coated stainless-steel meshes for selective oil–water emulsion separation with high flux

A switchable superlyophobic ZIF-8 membrane can selectively remove oil droplets in oil-in-water emulsions via superoleophobicity and water droplets in water-in-oil emulsions via superhydrophobicity.