3D-Printed Hierarchical Ceramic Architectures for Ultrafast Emulsion Treatment and Simultaneous Oil–Water Filtration

There is a critical need for energy-efficient water treatment processes as the world seeks to limit global warming below 1.5 °C. Gravity-driven mesh filtration presents a sustainable solution to treating oily wastewater and emulsions, which are byproducts of many human activities. The promise of a green alternative is getting closer with the development of 3D printing combined with reusable, recyclable, and ubiquitous materials such as silica to produce durable and recyclable filters with controllable mesh spacing. In this work, several filters were fabricated to separate oily water mixtures with a separation efficiency of 99% at high flow flux by coating 3D porous ceramic architectures with organosilanes. The proposed ceramic filters can also treat oil-in-water and water-in-oil surfactant-stabilized emulsions with high flow flux. This strategy to functionalize the 3D printed silica surface to form either hydrophobic or hydrophilic surfaces can open a new possibility for gravity-driven simultaneous oil–water separation. The first gravity-driven hierarchical auto-oil–water separator (HAOS) was introduced to separate an oily water mixture into two different containers using a combination of 3D printed hierarchical hydrophilic and hydrophobic filters without an additional postseparation step.