A Highly Hydrophobic and Flame-Retardant Melamine Sponge for Emergency Oil Spill Response

Frequent crude oil spills during offshore oil and gas production and transportation have inflicted irreversible detrimental effects on both human activities and marine ecosystems; with particular risks of secondary disasters such as combustion and explosions. To address these challenges; advanced oil sorption technologies have been developed to overcome the inherent limitations of conventional remediation methods. In this study, a flame-retardant protective coating was fabricated on melamine sponge (MS) through precipitation polymerization of octa-aminopropyl polyhedral oligomeric silsesquioxane (POSS) and hexachlorocyclotriphosphazene (HCCP), endowing the MS@PPOS-PDMS-Si composite with exceptional char-forming capability. Secondary functional layer: By coupling the complementary physicochemical properties of polydimethylsiloxane (PDMS) and SiO2 nanofibers, we enabled them to function jointly, achieving superior performance in the material systems; this conferred enhanced hydrophobicity and structural stability to the MS matrix. Characterization results demonstrated a progressive reduction in peak heat release rate (PHRR) from 137.66 kW/m2 to118.35 kW/m2, 91.92 kW/m2, and ultimately 46.23 kW/m2, accompanied by a decrease in total smoke production (TSP) from 1.62 m2 to 0.76 m2, indicating significant smoke suppression. Furthermore, the water contact angle (WCA) exhibited substantial improvement from 0° (superhydrophilic) to 140.7° (highly hydrophobic). Cyclic sorption–desorption testing revealed maintained oil–water separation efficiency exceeding 95% after 10 operational cycles. These findings position the MS@PPOS-PDMS-Si composite as a promising candidate for emergency oil spill response and marine pollution remediation applications, demonstrating superior performance in fire safety, environmental durability, and operational reusability.