Fouling-resistant superhydrophobic polyketone membranes modified with fluorine-containing silica for water-in-oil emulsion separation

Membranes for water-in-oil (W/O) emulsion separation require high emulsion permeance, oil purity selectivity, high water-fouling resistance, and reusability. Therefore, a functional membrane structure that satisfies these needs is required. Herein, we describe the effective modification of a membrane surface by forming functional silica particles on a porous polyketone (PK) membrane to form a hierarchical membrane structure with enhanced roughness and superhydrophobicity. We also demonstrate the potential application of the membrane for W/O emulsion separation based on enhanced performance and fouling resistance. Membranes were fabricated by forming silica particles on a porous PK membrane by a sol–gel method using tetraethoxysilane (TEOS). By modifying these silica particles with fluoroalkyl silane (FAS), a superhydrophobic membrane with a high contact angle of up to 162° was fabricated. The resulting FAS-modified membrane had higher permeance with regard to a toluene W/O emulsion than an unmodified PK membrane or a commercially available polyvinylidene fluoride (PVDF) membrane. It was possible to recycle the FAS-modified membrane by simply washing it in toluene to remove external fouling. This effective membrane surface modification helps to enhance both emulsion permeance and fouling resistance during W/O emulsion separation. [Display omitted] •Superhydrophobic PK membrane was prepared for W/O emulsion separation.•Effective surface modification for enhancement of emulsion permeance and fouling resistance.•Superhydrophobic membrane was fabricated by forming silica particles and bonding fluoroalkyl silane.•Membrane had superior W/O emulsion permeance than unmodified membrane.•Membrane was easily recycled by simple solvent washing because external fouling occurred.