Stainless Steel Screen Modified with Renatured Xerogel for Efficient and Highly Stable Oil/Water Separation via Gravity

The application of hydrogel coatings to surface-modified metallic materials has gained considerable attention in engineering practice such as water–oil separation. However, the low coating adhesion and poor coating stability restrict its application. In this study, to obtain special wettability and durable filter materials, polyacrylamide (PAM)/sodium alginate (SA) xerogel particles were first prepared and adhered to a stainless steel screen by using an epoxy resin as a linker. Subsequently, the xerogel particles of the screen rehydrates in water to form a PAM–SA double-network hydrogel. The results show that the screen modified by PAM–SA xerogel of 20–30 μm particle size and a linker concentration of 0.1 g/mL resulted in a chimeric structure and subsequently transformed a uniform double-network hydrogel coating in water. According to the experimental results, the rough hydrogel coating exhibits superhydrophilicity and superoleophobicity under water; in particular, it has excellent wear resistance as well as physical and chemical stability. Under gravity-driven action, the PAM–SA-modified screen demonstrates high separation efficiency values of up to 99% in separating a wide range of oil/water mixtures and maintaining a water flux of (2–6) × 104 L·m–2·h–1. There was no significant reduction in efficiency of separation and water flux after 10 cycles, indicating that the PAM–SA-modified screen is capable of offering outstanding separation performance and durability. Moreover, the hydrogel-modified screen demonstrated corrosion and swelling resistance in some extreme environments, paving a way for practical applications in water treatment. The novel hydrogel-coating-modified screen with ease of preparation holds great promise for oil/water separation and other engineering applications.