Superhydrophobic magnetic Fe3O4 polyurethane sponges for oil–water separation and oil-spill recovery

The effective and affordable separation of oil and water, a crucial process in the safe handling of environmental disasters such as crude oil spills and recovery of valuable resources, is a highly sought-after yet challenging task. Herein, superhydrophobic PU sponge was fabricated for the fast and cost-effective adsorptive separation of oil and different organic solvents from water. Octadecyltrichlorosilane (OTS)-functionalized Fe3O4@SiO2 core-shell microspheres were dip-coated on the surface of porous materials via a dip-coating process, thereby endowing them with superhydrophobicity. Owing to the hydrophobic interaction between OTS molecules and oil and increased capillary force in the micropores, the resulting superhydrophobic sponge served as a selective oil-sorbent scaffold for absorbing oil from oil-water mixtures, including oil-water suspensions and emulsions. Remarkably, after the recovery of the adsorbed oil via mechanical extrusion, these superhydrophobic materials could be reused multiple times and maintain their oil-water separation efficacy even after 10 oil-water separation cycles.