The Structural Evolution of Recrystallized Asymmetric SiC Membranes for High-Performance Oily Wastewater Treatment

Asymmetric SiC membranes with surface pore sizes ranging from 0.12 to 0.31 μm at a constant open porosity of approximately 42% were fabricated by dip-coating SiC support followed by sintering from 1700 to 2000 °C. The effect of membrane structural constants (hydraulic resistance (k1), pore size exponent (k2), and shape factor (k3)) on PWP were evaluated by comparing the symmetric and asymmetric structures. In addition, the experimentally determined values of PWP were quantitatively analyzed by comparing with theoretically predicted values obtained using the Kozeny–Carman (K–C) and Hagen–Poiseuille (H–P) models. Despite having a smaller pore size, the asymmetric membranes exhibited high PWP (1257-3883 LMH) due to decreased flow resistance (low k1), enhanced pore size effect (high k2), and improved flow network (high k3) as compared to symmetric membranes. The hydrophilicity of the prepared membranes improved remarkably, with increasing average surface roughness (102.3 nm to 161.0 nm) due to an increase in pore size, which also caused a decrease in water contact angle (WCA) from approximately 27.44° to 21.67° with increasing sintering temperature (1700–2000 °C). Furthermore, the prepared membrane separation performance was found to be affected by its pore size, and the 1900 °C sintered SiC membrane showed optimal gradient profile and pore structure, demonstrating its practical reusability and scalability for O/W wastewater treatment.