Green fabrication of durable foam composites with asymmetric wettability by an emulsion spray-coating method for photothermally induced crude oil cleanup.

[Display omitted] • A green and scalable emulsion spray-coating technique is developed to prepare foam composites. • The foam composite possesses exterior superhydrophobicity and interior hydrophilicity. • ACNTs are decorated onto the skeleton of the foam with strong interfacial adhesion. • The foam composite possesses excellent corrosion resistance and durability. • Photothermally induced crude oil cleanup with a high efficiency is achieved. Chemical spills, especially oil spills, are becoming an increasingly serious environmental issue. It remains a challenge to develop green techniques to prepare mechanically robust oil–water separation materials, especially those capable of separating high-viscosity crude oils. Herein, we propose an environmentally friendly emulsion spray-coating method to fabricate durable foam composites with asymmetric wettability for oil–water separation. After the emulsion, composed of acidified carbon nanotubes (ACNTs), polydimethylsiloxane (PDMS) and its curing agent, is sprayed onto melamine foam (MF), water in the emulsion is first evaporated, while PDMS and ACNTs are finally deposited on the foam skeleton. The foam composite exhibits gradient wettability and turns from superhydrophobicity of the top surface (the water contact angle reaches as high as 155.2°) to hydrophilicity of the interior region. The foam composite can be used for the separation of oils with different densities and has a 97% separation efficiency for chloroform. In particular, the photothermal conversion-induced temperature rise can reduce the oil viscosity and complete the high-efficiency cleanup of crude oil. This emulsion spray-coating technique and asymmetric wettability show promise for the green and low-cost fabrication of high-performance oil/water separation materials. [ABSTRACT FROM AUTHOR]