Figure
1.
Water contact angle of the as-prepared pressed graphitic carbon sphere.
Saisai Li, Haijun Zhang, Longhao Dong, Haipeng Liu, and Quanli Jia, Three-dimensional graphitic carbon sphere foams as sorbents for cleaning oil spills, Int. J. Miner. Metall. Mater., 29(2022), No. 3, pp.513-520. https://dx.doi.org/10.1007/s12613-020-2180-3
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海上溢油事故频发，工业含油污水、城市含油废水的随意排放对人类生活环境和健康造成了严重的影响。传统的水油分离方法不仅容易引起二次环境污染而且也会造成资源浪费。因此，在本工作中，以多孔石墨微球为原料，采用凝胶注膜法制备了具有三维网络结构的多孔石墨微球泡沫，并将其应用在油类污染物的吸附中。研究结果表明，所制备的石墨微球泡沫的孔隙率高达62%，其孔径范围约为25–200 μm，且所制备的泡沫表现出良好的亲油疏水性，其水接触角（WCA）随温度的升高而增大，最大约为130°。此外，泡沫中石墨微球的含量对所制备产物的疏水性、接触角及显微微观结构的影响较大。所制备的泡沫具有优异的油吸附能力，对石蜡油、植物油和真空泵油的吸附能力约为12–15 g/g，约为石墨微球泡沫的10倍左右，在石油泄漏事故中具有较大的应用潜力。
Frequent offshore oil spill accidents, industrial oily sewage, and the indiscriminate disposal of urban oily sewage have caused serious impacts on the human living environment and health. The traditional oil–water separation methods not only cause easily environmental secondary pollution but also a waste of limited resources. Therefore, in this work, three-dimensional (3D) graphitic carbon sphere (GCS) foams (collectively referred hereafter as 3D foams) with a 3D porous structure, pore size distribution of 25–200 μm, and high porosity of 62vol% were prepared for oil adsorption via gel casting using GCS as the starting materials. The results indicate that the water contact angle (WCA) of the as-prepared 3D foams is 130°. The contents of GCS greatly influenced the hydrophobicity, WCA, and microstructure of the as-prepared samples. The adsorption capacities of the as-prepared 3D foams for paraffin oil, vegetable oil, and vacuum pump oil were approximately 12–15 g/g, which were 10 times that of GCS powder. The as-prepared foams are desirable characteristics of a good sorbent and could be widely used in oil spill accidents.
In recent years, oil spill accidents have frequently happened during extraction, transportation, transfer, and storage processes, leading to high risks and frequencies of oil leakages, which seriously polluted the marine environment [1–2]. Oil leakages in the natural environment not only cause a great loss of energy but also have catastrophic effects on the environment and ecosystem [3]. Several techniques have been developed to solve the oil leakage problem, such as mechanical extraction [4], in situ burning [5], chemical modification [6], biological oxidation [7], and physical adsorption methods [8]. The first four methods have limitations, such as secondary pollution, high cost, and complex operation [9]. The last one, i.e., physical adsorption methods, is considered the most efficient technique for the treatment of oil spills because of its easy operation, friendly environment, and low energy consumption [10]. Zeolites [11], kaolinite [12], goethite [13], and Si-MCM-41 [14] are commonly used as adsorbents, but these adsorbents have shortcomings, such as low adsorption capacity and tedious recovery process [15]. Therefore, the development of highly effective adsorbent materials is of primary importance for the removal of oil spillage and chemical leakage in the environment [16].
Currently, three-dimensional (3D) porous materials with hydrophobic and oleophilic properties are becoming the most popular materials that can be used for oil adsorption because of their high porosity and high adsorption capacities [16–18]. Up to now, most published studies have been focused on polyurethane foam [19], wax modified plants [20], and melamine sponge-based 3D porous materials [21], which suffer from complex preparation processes and large waste volumes. Moreover, the template method is most commonly used for many 3D porous materials, but it also has a relatively complex template removal process and wastes template materials, such as SiO2 and zeolite. In comparison, the gel casting foaming technique combined with freeze drying has easy operation and is environment friendly.
Recently, carbon materials, such as graphene, activated carbon, carbon nanotube, and graphitic carbon spheres (GCS) [22–33], have attracted much attention. Among which, GCS are becoming a more valuable alternative for preparing 3D porous foams applied in oil leakages owing to their high specific surface area, good dispersion, great liquidity, and hydrophobicity. Hence, in this work, 3D GCS foams (collectively referred hereafter as 3D foams) were synthesized via gel casting combined with freeze drying using GCS as carbon sources, sodium lauryl sulfate (SDS) as the foaming agent, gelatin as the crosslinking agent, and stearic acid and epoxy resin as the foam stabilizer and binder agents. The effects of the amounts of GCS, gelatin, and resin on the preparation of 3D foams were studied. Moreover, the adsorption capacities of as-prepared 3D foams for different kinds of oils were examined.
The main materials used in this study are SDS, gelatin, stearic acid, epoxy resin, and deionized (DI) water. The SDS, gelatin, and stearic acid were obtained from Sinopharm Chemical Reagent Co., Ltd. (Shanghai, China), and the epoxy resin was obtained from Kunshan lvdun Chemical Co., Ltd. (Jiangsu, China). All chemicals used were of analytical grade and were used as received without any further purification.
The GCS were first prepared according to the method introduced in our previous article [33]. Then, the SDS, gelatin, stearic acid, epoxy resin, and GCS were mixed in DI water at a fixed mass ratio with strong stirring to produce a foam slurry, and the mixture was directly subjected to freezing to form foam monoliths. Finally, the 3D foams were prepared after heat treatment at 110°C for 24 h.
A powder X-ray diffraction (XRD) analysis using a Philips X’Pert PRO diffractometer (X’Pert PRO, Philips, Hillsboro, The Netherlands) equipped with a Cu Kα radiation (λ = 0.1542 nm) was employed to examine the as-prepared sample at 40 mA and 40 kV. The microstructures and morphologies of the final products were observed using a field-emission scanning electron microscope (FE-SEM, Nova 400 nanoSEM, FEI, USA). Water wettability of the samples was evaluated by measuring the water contact angle (WCA) using an optical contact angle measuring system with a high-speed USB camera angle (WCA) and a video-bra (Dataphysics OCA15Pro). Then, the pore size distribution was measured using mercury intrusion porosimetry (Quantachrome PM60GT-18, Quantachrome Instruments Ltd., USA). Nitrogen adsorption/desorption measurements were performed using a gas sorption analyzer (Autosorb-1-MP/LP, Quantachrome, USA). The samples were out-gassed at 150°C for 3 h under vacuum in the degas port, and the specific surface area was calculated using the Brunauer–Emmett–Teller model.
The absorption capacities of the as-prepared GCS and 3D foams were determined by a weight measurement with three different kinds of oils. For the GCS powder, the measured procedure was as follows: the mass of the GCS was first determined, and the adsorbed oil on the GCS was dropped. The GCS reached their maximum adsorption capacity after they were completely wetted by oil, and then the added mass was regarded as the weight of the adsorbed oil. For the as-prepared 3D foams, the foam was taken in and weighed first, recording it as W0, and then immersed in the oil liquid for 10 min. Then, the foam was taken out, and the sample filled with oil liquid was weighed, recording it as W1. Each sample was performed thrice, and the average values were taken as the adsorption capacity (Q) of the sample. Q is calculated according to the following formula:
| Q=(W1W0−1) | (1) |
The GCS possess a high specific surface area of approximately 564 m2/g, good dispersion, great liquidity, and hydrophobicity properties. They were prepared via hydrothermal carbonization combined with the catalytic graphitization method using glucose as carbon sources; these methods have low cost of raw materials and a simple preparation process [33]. To investigate the hydrophobicity and lipophilicity of the prepared GCS, the wetting property of pressed GCS with a dimension of 20 mm (diameter) × 5 mm (height) was tested by the WCA. Fig. 1 shows that the GCS have a hydrophobic surface with a WCA of approximately 133°, which might be attributed to the high graphitization degree of the CGS (Fig. 2(a)). As shown in Fig. 2(a), the GCS exhibited an evident peak at 26.3°, which was assigned to the characteristic {002} plane of graphite (ICDD 01-075-1621), indicating the presence of graphitic carbon in the GCS. Moreover, the GCS adsorption capacities were approximately 1.0–1.5 times of their own weights and increased with the increase in oil densities for paraffin oil, vegetable oil, and vacuum pump oil (Fig. 2(b)).
Fig. 2(b) shows that the adsorption capacity of GCS to oil pollutants is limited. To further enhance the adsorption capacity, the 3D foams were prepared using GCS as the carbon source. As shown in Fig. 3, the water droplets with a spherical shape can be stable for a long time on the foam, indicating the hydrophobicity nature of the as-prepared foam. The WCAs of the foams with different amounts of GCS are shown in Fig. 4 (fixed SDS content = 1.7wt%, gelatin content = 4.2wt%, and resin content = 8.3wt%). The WCA was approximately 130° for the sample without any GCS. With the GCS amount increased to 0.42wt%, the WCA decreased to approximately 120°, and the water droplets gradually immersed in the foam. The phenomenon might be attributed to the change in the morphology and pore structure of the as-prepared foams after adding the GCS. By further increasing the GCS by 0.83wt%–1.65wt%, the WCAs increased to approximately 130° again because of the hydrophobicity property of the GCS. XRD was investigated to confirm the structure of the as-prepared 3D foam prepared with 0.83wt% GCS (fixed SDS content = 1.7wt%, gelatin content = 4.2wt%, and resin content = 8.3wt%). The peak corresponded to the {002} plane of the graphite still existing in the sample (Fig. 5). However, its crystallinity was lower than that of GCS (Fig. 2(a)), which might be attributed to the amorphous carbon brought about by the added organic materials (gelatin and resin) during the foaming process. The XRD results again confirmed that adding GCS during the foaming process increased the hydrophobicity property of the foams (Fig. 5).
Fig. 6 shows the SEM images of the specimens whose WACs are shown in Fig. 4, clearly demonstrating the effects of GCS amounts on the morphology of the 3D foams. Without GCS, the foams were mainly composed of window pores with a pore size distribution of approximately 50–100 μm (Fig. 6(a)). When GCS was added into the foams, the morphology of the as-prepared sample exhibited a 3D irregular network structure (Fig. 6(b–e)), which may be attributed to the defoaming phenomenon resulting from the addition of GCS during the preparation process.
The porosity and pore size distributions of the 3D foams were characterized by mercury intrusion porosimetry and shown in Fig. 7. With the increasing contents of GCS, the porosity of the foam gradually increased first and then decreased (Fig. 7(a)), and the pore size distributions also became wider and concentrated in the range of 25–200 μm with the added GCS amounting to 0.42wt%–1.65wt%. This result indicates that the addition of GCS destroyed the pore structure and widened the pore size distributions of the samples (Fig. 7(b)), which agrees well with the SEM results presented in Fig. 6.
Finally, the adsorption properties of the as-prepared 3D foams were examined. As shown in Fig. 8, the adsorption capacities for the oil of the foams was much higher than that of the original GCS. With the increase in GCS dosages, the adsorption capacities of the 3D foams initially increased and then decreased again, and the optimal GCS content was 0.83wt%, which were consistent with the porosity and pore size distributions of the samples (Fig. 7). To investigate the effect of the specific surface area of the as-prepared 3D foams on the oil adsorption, the specific surface areas of the 3D foams without GCS and with 0.83wt% GCS (fixed SDS content = 1.7wt%, gelatin content = 4.2wt%, and resin content = 8.3wt%) were evaluated using N2 adsorption and desorption (Fig. 9), which were 0.24 m2/g and 0.33 m2/g, respectively. Both of them were much lower than that of GCS (564 m2/g) [33]. The higher oil adsorption capacity of the as-prepared foams, compared with that of GCS, indicated that the oil adsorption performance mainly depended on macropores in the as-prepared samples.
Gelatin as a crosslinking agent has a great influence on the pore size distributions and mechanical strengths of the foams. The addition of gelatin on the preparation of 3D foams was examined, and the findings are shown in Figs. 10–11. The findings demonstrated that the WCAs presented an increasing trend with increasing gelatin amounts, which might be attributed to the increase in the viscosity of the solution and the decrease in the total porosity and pore size distribution of the foam (Fig. 11). The WCAs of the as-prepared 3D foams accordingly increased with the decrease in the pore size of the foams, which might be attributed to the increase in the water contacted areas, defects, and roughness, and finally, the WCAs were enhanced [34]. Moreover, the morphologies of the samples were similar with the SEM results presented above (Fig. 6(b–e)).
The porosity and pore size distributions of the as-prepared 3D foams were characterized by mercury intrusion porosimetry, as shown in Fig. 11. The porosity of the foams decreased with the increase in the gelatin content (Fig. 11(a)), and the pore size distributions gradually narrowed (Fig. 11(b)), which might be ascribed to the increase in the viscosity of the initial gel solution as the gelatin amounts increased, leading to decreased porosity.
The oil adsorption capacities of the as-prepared 3D foams with different gelatin contents showed that when the gelatin amounts increased from 2.6wt% to 4.2wt%, the adsorption capacities were quite similar. However, when the gelatin content was further increased to (5.0–5.8)wt%, the adsorption capacities of the samples decreased (Fig. 12). The main reason can be attributed to the decrease in the foam porosities (Fig. 11(a)). In a word, the optimal addition of gelatin was 4.2wt%.
In addition, by fixing the GCS, gelatin, and foaming agent amounts to 0.83wt%, 4.2wt%, and 1.7wt%, respectively, the effect of resin addition on the adsorption capacities of the 3D foams was also studied. The WCAs of the foams with different resin amounts were approximately 130° (Fig. 13), and the morphologies of the samples were all 3D network structures with the interconnected pores ranging from tens to hundreds of micrometers, as shown in the above results. However, the porosities of the foams gradually decreased with the increasing resin amounts (Fig. 14(a)), and the pore size distributions first increased and then decreased (Fig. 14(b)). Based on the above-mentioned results, the optimal resin amount is 8.3wt%. A proper amount of resin was in favor of the foaming process, and the viscosity of the gel solution will increase due to the introduction of high amounts of resin and weaken the foaming process. These effects may result in the initial increase in the pore size distributions of the samples and then decrease with the increasing resin amounts.
Fig. 15 shows the adsorption capacities of as-prepared 3D foams by adding different amounts of resin. The total adsorption capacities of the samples first increased and then slightly decreased, which were consistent with the porosity results shown in Fig. 14. Thus, under the experimental conditions, the optimal preparation conditions for the 3D foams are 0.83wt% for GCS, 4.2wt% for gelatin, and 8.3wt% for resin.
In view of the present oil spill accidents, materials with high porosity and hydrophobicity properties are becoming important materials that can be used in oil adsorption. In this work, a simple and feasible foam gel casting method was successfully developed to prepare 3D GCS foams for oil adsorption. The as-prepared 3D foams possessed a high porosity of 62vol% with a pore size distribution of 25–200 μm, and a 3D porous structure. Moreover, the amounts of GCS had a great influence on the hydrophobicity, WCAs, and microstructure of the as-prepared 3D foams. The WCA of the as-prepared foam was approximately 130°, and the adsorption capacities for oil were approximately 12–15 g/g, which were 10 times those of starting GCS powders, indicating that the as-prepared 3D foams have a potential application prospect in oil spill pollution. The present work also provides a new type of 3D porous materials for oil/water separation.
This work was financially supported by the National Natural Science Foundation of China (Nos. 51872210 and 51672194), the Program for Innovative Teams of Outstanding Young and Middle-aged Researchers in the Higher Education Institutions of Hubei Province, China (No. T201602), and the Key Program of Natural Science Foundation of Hubei Province, China (No. 2017CFA004).
The authors declare no potential conflict of interest.
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