Engineering of ceramic membranes with superhydrophobic pores for different size water droplets removal from water-in-oil emulsions

•The ZnO nanoclusters@SiC membranes with superhydrophobic pores were prepared.•The ceramic membrane with superhydrophobic pores exhibited enhanced separation efficiency for water-in-oil emulsion separation.•The separation mechanism of the superhydrophobic pores for water-in-oil emulsion separation was revealed. Superhydrophobic (SHB) ceramic membrane surfaces have proved their superiority in water-in-oil (W/O) emulsion separation. However, the construction of ceramic membranes with SHB pores remains challenging and the interaction between the SHB pores and water droplets is still unclear. Herein, by growing uniform ZnO nanoclusters (NCs) onto the SiC grains of a symmetric SiC ceramic membrane and then grafting with triethoxy(octyl)silane, a series of ZnO NCs@SiC membranes with SHB pores were prepared. Prior to secondary hydrothermal synthesis ZnO NCs, the small-sized ZnO nanoparticles (NPs) were grown onto the SiC grains via a sol–gel process. All the ZnO NCs@SiC membranes with SHB pores showed improved water removal performance from W/O emulsions compared with that of the pristine membrane. The optimal membrane with SHB pores displayed a pore size of 0.19 μm with a water contact angle of 163.96°. The smaller water droplets in W/O emulsions, the membrane pores are easier to be polluted. When separating a 1000 ppm W/O emulsion with a water droplet size of 500 nm at a transmembrane pressure of 0.5 bar, the water rejection reached 98.90 %, and the steady-state oil flux was 92.99 L·m−2·h−1. Based on the separation experiments, the separation mechanism was revealed. This work provides significant perceptions into constructing SHB pores of ceramic membranes, which might be useful for other possible applications.