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<p>In this study, rigid polyurethane (PU) foam was modified by incorporating nanoclay to enhance its oil adsorption performance. Morphological analyses using Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD) revealed that nanoclay addition altered the PU foam structure, resulting in larger and more irregular cells. A continuous pilot-scale adsorption system was designed and operated to evaluate the oil removal efficiency of pure and nanoclay-modified PU foams. Performance was assessed through turbidity, chemical oxygen demand (COD), total organic carbon (TOC), total petroleum hydrocarbons (TPH), total oil and grease (TOG), and laser particle size analysis (LPSA). The nanoclay-modified PU foam achieved superior oil removal efficiencies, with TPH and TOG reductions exceeding 99%, and COD and turbidity removals around 94%. Moreover, continuous operation over 65&#xa0;min with 700&#xa0;mg/L oily water feed maintained oil removal above 94%. This study demonstrates, for the first time, the practical application of commercially available polyurethane (PU) foam functionalized with nanoclay in a pilot-scale continuous adsorption process, effectively preventing breakthrough and saturation. The results highlight the potential for scalable, sustainable, and cost-effective technologies for oily water treatment and advanced wastewater management.</p>

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Nanoclay-modified polyurethane foams for adsorption of oil from water using a pilot-scale continuous process

  • 期刊论文

  • 发表日期：

    2026年2月2日

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  • M. Khorsi,
  • S. Bazgir,
  • M. Barani

摘要

In this study, rigid polyurethane (PU) foam was modified by incorporating nanoclay to enhance its oil adsorption performance. Morphological analyses using Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD) revealed that nanoclay addition altered the PU foam structure, resulting in larger and more irregular cells. A continuous pilot-scale adsorption system was designed and operated to evaluate the oil removal efficiency of pure and nanoclay-modified PU foams. Performance was assessed through turbidity, chemical oxygen demand (COD), total organic carbon (TOC), total petroleum hydrocarbons (TPH), total oil and grease (TOG), and laser particle size analysis (LPSA). The nanoclay-modified PU foam achieved superior oil removal efficiencies, with TPH and TOG reductions exceeding 99%, and COD and turbidity removals around 94%. Moreover, continuous operation over 65 min with 700 mg/L oily water feed maintained oil removal above 94%. This study demonstrates, for the first time, the practical application of commercially available polyurethane (PU) foam functionalized with nanoclay in a pilot-scale continuous adsorption process, effectively preventing breakthrough and saturation. The results highlight the potential for scalable, sustainable, and cost-effective technologies for oily water treatment and advanced wastewater management.