Coupling magnetic particles with flocculants to enhance demulsification and separation of waste cutting emulsion for engineering applications.

Magnetic particles were coupled with a flocculant to enhance the demulsification and separation of waste cutting emulsions. The optimal magnetic particle size and critical magnetic field conditions were investigated to achieve large-scale engineering application of magnetic demulsification separation for waste cutting emulsion treatment. The micro-scale magnetic particles were found to show comparable effects to nano-scale magnetic particles on enhancing the demulsification and separation of cutting emulsions, which are beneficial for broadening the selectivity of low-cost magnetic particles. The critical magnetic separation region was determined to be an area 40 mm from the magnetic field source. Compared to the flocculant demulsification, the magnetic demulsification separation exhibited a significant advantage in accelerating flocs-water separation by decreasing the separation time of flocs from 180-240 min to less than 15 min, compressing the flocs by reducing the floc volume ratio from 60%-90% to lower than 20%, and showing excellent adaptability to the variable properties of waste cutting emulsions. Coupled with the design of the magnetic disk separator, continuous demulsification separation of the waste cutting emulsion was achieved at 1.0 t/hr for at least 10 hr to obtain clear effluent with 81% chemical oxygen demand removal and 89% turbidity reduction. This study demonstrates the feasibility of applying magnetic demulsification separation to large-scale continuous treatment of waste emulsion. Moreover, it addresses the flocs-water separation problems that occur in practical flocculant demulsification engineering applications.

3D Printing of an Oil/Water Mixture Separator with In Situ Demulsification and Separation.

Currently, many meshes, membranes, and fabrics with extreme wettability of superhydrophobicity/superoleophilicity, or superhydrophilicity and underwater superoleophobicity are promising candidates for oil/water mixture separation. Nevertheless, a facile yet effective way to design and fabricate porous mesh still remains challenging. In this work, fused deposition modeling (FDM) 3D printing of Fe/polylactic acid (PLA) composites was employed to fabricate superhydrophilic and underwater superoleophobic mesh (S-USM) with hydrogel coatings via the surface polymerization of Fe(II)-mediated redox reaction. In addition, salt of aluminum chloride was incorporated within the hydrogel coating, which was attributed to strengthening the demulsification of oil-in-water emulsions, resulting in efficient separation of oil-in-water mixtures. The S-USM was efficient for a wide range of oil-in-water mixtures, such as dodecane, diesel, vegetable oil, and even crude oil, with a separation efficiency of up to 85%. In this study, the flexible design and fabrication of 3D printing were used for the facile creation of spherical oil skimmers with hydrogel coatings that were capable of removing the floating oil. Most importantly, this work is expected to promote post-treatment processes using 3D printing as a new manufacturing technology and, in this way, a series of devices of specific shape and function will be expanded to satisfy desired requirements and bring great convenience to personal life.