Pore structure and surface property design of silicon carbide membrane for water-in-oil emulsification

In recent years, ceramic membranes have been applied as emulsification media in preparing emulsified heavy oils for residue fluid catalytic cracking units. In this case, silicon carbide (SiC) material is used for harsh environments due to its excellent chemical and thermal stabilities. Herein, a superhydrophobic SiC emulsified functional membrane was prepared by using an in-situ sintering method and subsequent grafting modification. The open porosity of these prepared membranes can be controlled from 26% to 48%, and the water contact angle of the membranes under oil was approximately 170°. The decrease of open porosity improved the bending strength of the membranes and also affected the emulsification performance. The size of water droplets decreased from 1.16 μm to 0.98 μm as the open porosity decreased from 48% to 26%. Moreover, the SiC membranes exhibited high flux and stability during the preparation of water-in-oil (W/O) emulsions, and the fouled membranes can be conveniently and effectively regenerated by ultrasonic cleaning with ethanol. Hence, the SiC membranes produced W/O emulsions with small droplets in harsh environments, such as the emulsification of heavy oil and high-viscosity oil at high temperature. • Pore structure and surface property of SiC membranes were successfully tailored. • High bending strength and excellent underwater superhydrophobicity were achieved. • Open porosity was revealed to dominate the membrane emulsification performance. • SiC membranes showed high flux and stability in preparing water-in-oil emulsions. • SiC membranes can be effectively regenerated by ultrasonically cleaning in ethanol.