Facile Fabrication of Superhydrophobic Sponge with Selective

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Facile fabrication of superhydrophobic sponge with selective absorption and collection of oil from water Xiaoyan Zhou, Zhaozhu Zhang, Xianghui Xu, Xuehu Men, and Xiaotao Zhu Ind. Eng. Chem. Res., Just Accepted Manuscript • DOI: 10.1021/ie400942t • Publication Date (Web): 13 Jun 2013 Downloaded from http://pubs.acs.org on June 21, 2013

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Industrial & Engineering Chemistry Research

Facile fabrication of superhydrophobic sponge with selective absorption and collection of oil from water

Xiaoyan Zhou 1,2, Zhaozhu Zhang 1*, Xianghui Xu 1, Xuehu Men 1 and Xiaotao Zhu 1,2

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State Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 730000, PR China

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Graduate School, Chinese Academy of Sciences, Beijing 100039, PR China

Corresponding Author * Fax: 86-931-4968098. E-mail: [email protected]

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ACS Paragon Plus Environment


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ABSTRACT A simple vapor phase deposition process has been developed to fabricate superhydrophobic and superoleophilic sponges by using ordinary commercial polyurethane sponges. The properties of simultaneous superhydrophobicity and superoleophilicity enabled the sponge to float on the water surface and selectively absorb oil from water. Its uptake capacities of different oils (motor oil, lubricating oil, pump oil, silicone oil and soybean oil) in the oil-water mixtures were all above 20. The absorbed oil could be collected by squeezing the sponge, and the recovered sponge could be reused in oil-water separation for many cycles while still keeping high capacity. This was helpful to realize the proper disposal of oil and avoid the secondary pollution. Similar experiment was performed by utilizing the as-prepared sponge to remove petroleum from the contaminated water. The results suggested that our material might find practical applications in the cleanup of oil spills and the removal of organic pollutants on water surface. KEYWORDS: Sponge; superhydrophobicity; selective absorption; recyclability

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1.

INTRODUCTION With the growth of offshore oil production and transportation, oil spillage and

chemical leakage have become the most important threat to the coastal environment and ecosystems of the sea.1-4 The clean up of these organic pollutants from water sources is a major environmental issue that continues to attract a great deal of attention.5-7 A variety of measures have been employed, such as physical absorption by oil-sorption materials,8 in-situ burning,9 dispersion,10 physics diffusion,11 enhanced bioremediation,12 and oil skimmer13,14. Among these existing techniques, using sorbent materials to remove oil from water is generally considered to be one of the most efficient countermeasures in marine oil-spill response.15,16 The widely used sorbent materials include zeolites,17 activated carbon,18 organoclays,19 straw,20 wool,21 sponges,22 and fibers23. Compared with other sorbent materials, sponges exhibit obvious superiority like high uptake capacity, high rate of uptake, low price, environmental friendliness, flexibility, and buoyancy.24,25 However, due to its hydrophilicity, sponge can also absorb water during the oil cleanup process, and this problem will greatly depress their actual oil absorption capacity. Consequently, for a large amount of oil/water mixture, such as oil leakage and spill, the ability of selective absorption of oils while repelling water completely is quite necessary. Recently, various superhydrophobic and superoleophilic materials applied in selective oil absorption from water have been prepared.26-28 For example, Seeger et al. developed superhydrophobic and superoleophilic polyester textiles via chemical vapor deposition of trichloromethylsilane, which could be used for oil/water separation and

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selective oil absorption.29 Shi et al. obtained a multifunctional superhydrophobic device by combining electroless metal deposition with self-assembled monolayers. This device successfully integrated the functions of oil-sorption materials, oil containment booms, oil skimmers, and water-oil separating devices.30 However, among those approaches, the fabrication procedures usually were complicated and time-consuming. The as-prepared materials showed low stability and flexibility, as well as poor absorption capacity and recyclability, which seriously restricted their practical applications. Therefore, producing materials with high absorption capacity and stable unusual wettability through simple and practical approaches is highly desirable. In this work, we proposed a facile approach to fabricate superhydrophobic and superoleophilic sponges coated with polypyrrole (PPy). This property of associated superhydrophobicity and superoleophilicity rendered the sponges able to selectively absorb oil from water. The oil-absorption capacity of the as-prepared sponge in different oil-water mixtures was investigated, and the long-term cycling performance was also studied. It was found that the fabricated sponge showed high oil-absorption capacity up to 20 and could be utilized many times, exhibiting excellent recyclability. Importantly, the absorbed oil can be extracted from the sponge by a simple squeezing method, which is helpful to realize the proper disposal of oil and avoid secondary pollution. The combination of extreme wettability and particular physicochemical features of sponges make them promising materials for removal and collection of oil from water.

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2.

EXPERIMENTAL SECTION

2.1 Materials Commercial polyurethane sponges (apparent density was 0.032 g/cm3, with the void volume of more than 97 percent) were obtained from a local furniture store. The pyrrole monomer was purchased from Shanghai Kefeng Chemical Reagents Co., Ltd., China. Ferric chloride was purchased from Xilong Chemical Co., Ltd., China. 1H, 1H, 2H, 2H-perfluorooctyltriethoxysilane (PTES) was obtained from Sigma-Aldrich. The motor oil, Mobil 1 ESP Formula 5W-30, was obtained from ExxonMobil Chemical. The petroleum sample was collected from the Shengli oilfield in Shandong, China. 2.2 Sample preparation The preparation procedure of the PPy–PTES–sponge is similar to the previous reports.31 The original sponges were ultrasonically cleaned in acetone and distilled water to remove possible impurities. Ferric chloride and PTES were dissolved in ethanol at a weight ratio of 5:1 to form a homogeneous orange solution including 0.3 M ferric chloride and 0.02 M PTES. Then this solution was applied onto the cleaned sponges by a dip-coating method. The sponge substrate was successively dipped into the solution and withdrawn at a constant speed below 1mm/s. After drying under ambient condition, the coated sponges were placed in a small sealed chamber, on the bottom of which was a layer of pyrrole liquid. There was a distance of 5 cm between the sponge and pyrrole liquid. The chamber was maintained at room temperature for an hour, and the volatilized pyrrole vapor polymerized and deposited on the sponge. Following the vapor-phase reaction, the sponges were rinsed with ethanol and water

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several times to remove un-reacted monomers or other byproducts, and dried in an oven at 100 °C for 30 minutes to obtain the dark superhydrophobic sponges. 2.3 Characterization Morphologies of the original and the as-prepared sponges were observed by a scanning electron microscope (SEM, JEOL JSM-5600LV).

Contact angle

measurements were carried out using a Krüss DSA 100 (Krüss Company, Ltd., Germany) apparatus at ambient temperature. Liquid droplets (about 5 µL) were dropped carefully onto the surface. The average contact angle value was determined by measuring five times at different positions of the same sample. The X-ray photoelectron spectroscopy (XPS) spectrum was conducted on a PHI-5702 electron spectrometer using an Al Kα line excitation source with the reference of C 1s at 285.0 eV. The takeoff angle of XPS was 90°. Fourier transform infrared (FTIR) spectrum was collected on a Bruker IFS66 V/S spectrometer. The images of the as-prepared sponges were captured with a digital camera (Canon). 3.

RESULTS AND DISCUSSION The fabrication process of the PPy-PTES sponge is schematically illustrated in

Figure 1. Figure 1a shows the typical photograph of the original sponge used in this study. After treated with the Ferric chloride/PTES solution, the sponge turned yellow in color as shown in Figure 1b. PTES was attached onto the sponge through hydrogen bonding interaction, while FeCl3 through simple physical adsorption. The vapor-phase polymerization of pyrrole occurred in a small reaction chamber (Figure 1c) and the sponge finally became black after the reaction (Figure 1d). The tiny amount of Fe3+

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included in the dipping solution plays an important role in the formation of PPy.

Figure 1. Photographic and schematic illustrations of the PPy-PTES-sponge fabrication process.

Fe3+ oxidizes the pyrrole monomer to give PPy and the Fe3+ ions are reduced to Fe2+ ions during the polymerization process (Figure 1e). SEM images of the original and the as-prepared PPy-PTES sponges are shown in Figure 2. The untreated sponge with a macroscopically rough surface is composed of three dimensional hierarchical porous structures, with pore sizes in the range of 100–400 µm (Figure 2a). This pristine porous structure allows high uptake capacity and provides large surface area as well as the roughness necessary for superwettability. After PPy-PTES treatment, the smooth sponge skeleton (inset of Figure 2a) was covered with a thin coating layer as shown in Figure 2b, which indicated the formation of PPy on the surface. The coated film was so thin that it had almost no effect on the pore size and high absorption

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capacity of the sponge. Besides, it has already been mentioned in previous work that ultrathin films of polymer could be formed through the gas-phase deposited polymerization.32 Pyrrole monomer has relatively high vapor pressure and can gradually turn into vapor phase even under ambient conditions. Once the pyrrole vapor encountered with oxidants like ferric chloride and ammonium persulfate, the polymerization could be readily initiated. Accordingly, and above all, PPy thin films were easily realized after the sponge substrate coated with oxidants was inserted into the reaction chamber filled with pyrrole vapor.

Figure 2. Typical SEM images of the pure sponge (a) and the PPy-PTES sponge (b). Insets are the higher magnification SEM images. (c) XPS survey spectra of the PPy-PTES treated and un-treated sponges. (d) FTIR spectra of the PPy-PTES treated and un-treated sponges.

In order to confirm the growth of PPy on the sponge surface, XPS and FTIR were conducted to explore the chemical components of the PPy-PTES treated sponges. The XPS survey spectra revealed that the element F (at 689.0eV) existed on the surface of the superhydrophobic sponges (Figure 2c). This suggested that PTES 8


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attached on the sponge surface after the PPy–PTES dip-coating treatment and thorough wash had not destroyed the interaction between PTES and the sponge. PTES played an important role in decreasing the surface energy of the sponge to achieve superhydrophobicity. From the FTIR spectra of the PPy-PTES treated sponge (Figure 2d), the bands at approximately 1560 and 1475 cm-1 may be attributed to the typical skeletal vibration and in-plane deformation vibration of the pyrrole rings. The band observed at around 1031 cm-1 was assigned to ﹦C–H in plane vibration. The peak at 972 cm-1 corresponded to the ﹦C–H out of plane vibration indicating the presence of PPy. The peak at 1263 cm-1 was the typical characteristic of C–F stretching vibration which was attributed to PTES. Thus, we concluded that the thin coating layer on the sponge skeleton was composed of PPy and PTES.

Figure 3. Time-dependent images of water (a-d) and oil (e-h) droplets on the surface of the as-prepared sponge in a room environment.

Contact angle measurement was carried out to investigate the wettability of the as-prepared black sponges. Images of a water droplet on the sponge surface were taken over time as presented in Figure 3a-d. The initial apparent water contact angle was as high as 153.7° and the droplet maintained the spherical shape until dryout, showing stable superhydrophobicity. Oil droplet could rapidly penetrate into the 9



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sponge in less than one second and the oil contact angle was measured to be 0° (Figure 3e-h), which revealed that the as-prepared sponge displayed simultaneous superhydrophobicity and superoleophilicity. As depicted in the photographic image in Figure 4a, water droplets attained in spherical shapes on any face of the as-prepared sponge. Even after cutting the sponge into two parts, the fresh faces also showed high repellency to water, indicating that the sponge exhibited a property of bulk superhydrophobicity (Figure 4b). Morphology of the cutting surface confirmed the coverage of PPy-PTES coating on the entire interconnected skeleton of the as-prepared sponge. This was attributed to the high mobility of reactive monomers in the gas phase and the porous structure of polyurethane sponges, enabling pyrrole to penetrate and polymerize through the whole sponge. In Figure 4c, the PPy-PTES treated sponge floated on the surface of water while the untreated one sank beneath the water surface after being placed on water. When the treated sponge was immersed in water by an external force, silver mirror-like surfaces appeared (Figure 4d). This bright surface was attributed to a continuous air layer trapped between the superhydrophobic surface and water, which was referred as the Cassie-Baxter nonwetting behavior.33-35 After the external force was released, the sponge instantaneously floated on the water surface, and no water absorption was observed by weighing it afterward. Moreover, the as-prepared sponge kept stable superhydrophobicity even after floating on 0.1 M NaCl solution for more than three months.

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Figure 4. Photographs of water droplets standing on the PPy-PTES sponge (a), and on the fresh faces of the as-prepared sponge after being cut into two parts (b). (c) Photograph of the original (white color) and the as-prepared (black color) sponges after being placed on water. (d) Photograph of the PPy-PTES sponge partially immersed in water by a force. Inset is the SEM image of the cutting surface of (b).

For FeCl3 and PTES in the dipping solution, their functions are to initiate polymerization and decrease the surface energy, respectively. Thus, the FeCl3 to PTES ratio within the mixture might affect the wettability of the resulting composite coatings. Figure 5a shows the wettability of the resulting surfaces with different mass ratios of FeCl3 to PTES. When the mass fraction of FeCl3 is small, the surface energy of the resulting coating is low enough to achieve superhydrophobicity, due to the existence of excess amount of PTES. When the mass ratio of FeCl3 to PTES is 7:1 and 9:1, the relative content of the obtained PPy is higher than PTES. They are not superhydrophobic surfaces, with contact angles of 144° and 127° for water. Besides, the vapor deposition time could also influence the wettability of the sponge. With the increase of deposition time, the color of the sponge substrate gradually turns black 11



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indicating the growth of PPy. The water contact angle on the surface increases as well, with the maximum value reaching 154° after 60 min of vapor phase deposition.

Figure 5. (a) Water contact angles of the as-prepared sponge with different mass ratios of FeCl3 to PTES. (b) The effect of deposition time on the wettability of the PPy-PTES sponge.

Figure 6. (a-d) Optical images for the removal of motor oil from water surface by the as-prepared sponge. The motor oil was labeled by oil red for clear observation. (e) Collection of motor oil from the as-prepared sponge by simple squeezing.

As mentioned above, the porous and interconnected framework of sponges provides huge space for the entrance and storage of liquids. However, the raw sponges are hydrophilic and absorb both water and oils without any selectivity. It is expected that the superhydrophobic and superoleophilic sponges can easily remove 12


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spreading oils on the water surface. After dipping the PPy-PTES sponge into a mixture of water and oil, it was observed that the thin oil layer kept shrinking and was quickly absorbed by the sponge within a few seconds. Then, the oil was completely removed from the mixture by pulling the sponge out of water (Figure 6 and Movie 1S, Supporting Information). The oil-absorption ability k of the sponge was calculated by the formula k = (M2-M1)/M1 according to previous reports.24,36 M1 and M2 represented the weights of the sponge before and after oil absorption, respectively. As illustrated in Figure 7a, the capacities k of the as-prepared sponges were 24 for motor oil, 23.5 for lubricating oil, 21.8 for pump oil, 31 for silicone oil, and 27.4 for soybean oil.

Figure 7. (a) Oil-absorption capacities k of the PPy-PTES sponges for the five different kinds of oils. (b) Absorption recyclability of the as-prepared sponges for different oils.

Additionally, the absorbed oils in the sponges were readily collected by a mechanical squeezing process (Figure 6e). After rinsed by alcohol and water thoroughly, the sponge recovered its original shape and could be reused for oil-water separation for many cycles (Figure 7b). The oil-absorption capacities k of the sponges for the five kinds of oils all kept above 17 even after 5 cycles of oil-water separation, exhibiting good recyclability. The decrease of oil absorption capacity was probably caused by the residual oils in the pores of the sponges. 13



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Figure 8. Process of removing petroleum from the petroleum-water mixture. (a) Brown mixture after dispersing petroleum into water; (b) the mixture after operating for 5 minutes; (c) the clear and transparent water phase left; (d) the final sponge filled with black viscous liquid.

After we successfully removed common oils from water, we wondered whether our material could be applied to oil spill cleanup, which meant absorbing petroleum from water. To study the oil spill cleanup behavior of the as-prepared sponges, we had imitated the petroleum-water mixture under natural conditions by dispersing petroleum into water and stirring to form a homogeneous brown mixture in a Petri dish (Figure 8a). When we put the superhydrophobic and superoleophilic sponge into the mixture, the petroleum was selectively absorbed by the sponge gradually (Movie S2, Supporting Information), following a similar process as that for motor oil-water separation. After handling with the mixture for about 5 minutes, we could observe that most of the petroleum had been absorbed and the color of the mixture faded as shown in Figure 8b. Finally, the water phase turned clear and transparent after about 7 minutes (Figure 8c and Movie S2, Supporting Information), and the sponge was filled with black viscous liquid in Figure 8d. It was obvious that the as-prepared sponge 14


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showed an excellent petroleum absorbent property, which made it an ideal candidate for oil spill cleanup and oil/water separation. 4.

CONCLUSIONS In summary, we have synthesized superhydrophobic and superoleophilic sponges

via facile vapor-phase polymerization of pyrrole. These novel sponges have advantages of high porosity, flexibility, easily scalable fabrication and especially the selective absorption of oil from water with high uptake capacity owing to their superhydrophobic property. Oils can be quickly removed from the water surface by dipping the as-prepared sponges into the oil-water mixtures. Absorption capacity of the sponge is measured up to above 20 times its own weight. After a simple mechanical squeezing and washing process, the oil contaminated sponges can be recovered and recycled in the oil-water separation for many times. The sponges can also hold a huge amount of petroleum in the petroleum-water mixture, and thus they are promising to be used as sorbent materials in the effective cleanup of oil spill and chemical leakage. ACKNOWLEDGMENT The authors acknowledged the financial support of the National Science Foundation of China (Grant Nos. 51002162) and the “Western Action Program”. SUPPORTING INFORMATION AVAILABLE Videos demonstrating the absorption procedures of motor oil (Movie S1) and petroleum (Movie S2) from the corresponding oil/water mixtures have been provided, respectively. This information is available free of charge via the Internet at

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2007, 157, 336. (33) Cassie, A. B. D.; Baxter, S. Wettability of porous surfaces. Trans. Faraday Soc. 1944, 40, 546. (34) Baxter, S.; Cassie, A. B. D. The water repellency of fabrics and a new water repellency test. J. Text. Inst. 1945, 36, 67. (35) Voronov, R. S.; Papavassiliou, D. V. Review of fluid slip over superhydrophobic surfaces and its dependence on the contact angle. Ind. Eng. Chem. Res. 2008, 47, 2455. (36) Zhu, Q.; Tao, F.; Pan, Q. Fast and selective removal of oils from water surface via highly hydrophobic core–shell Fe2O3@C nanoparticles under magnetic field. ACS Appl. Mater. Interfaces 2010, 2, 3141.

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Facile Fabrication of Superhydrophobic Sponge with Selective

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