Multi-Layer Filter Material with a Superoleophobic Pore Size Gradient for the Coalescence Separation of Surfactant-Stabilized Oil-in-Water Emulsions

The performance of oil–water coalescence separation elements currently fails to meet the increasing demands of the oily wastewater treatment industry. To address this challenge, a series of fiber coalescing filters were developed through an underwater superoleophobic modification process using a simple impregnation technique. The effect of varying surface wettability on the separation efficiency of oil-in-water (O/W) emulsions stabilized with surfactants was investigated. The results demonstrate that, after undergoing underwater superoleophobic modification, the separation efficiency of the fiber filter material improved by 33.9%, the pressure drop was reduced by 46.1%, and the steady-state quality factor increased by 83.3%. Building upon these findings, an oil-repellent pore size gradient structure was introduced for the coalescence separation of surfactant-stabilized oil-in-water emulsions. This structure exhibited outstanding characteristics, including a low pressure drop and a high-quality factor. Furthermore, when processing emulsions stabilized with surfactants such as OP-10 (nonionic), CTAB (cationic), and SDS (anionic), the structure maintained high separation efficiencies of 93.6%, 96.4%, and 97.2%, respectively, after 10 cycles. Finally, based on experimental data and theoretical analysis, a separation mechanism for oil–water coalescence using superoleophobic pore size gradient filtration materials is proposed. This structure demonstrates significant potential for widespread application in liquid–liquid separation technologies.