Developing materials with high efficiency for recovering oil to mitigate the environmental impact of oil spills has always been a challenging task. A commercial melamine formaldehyde sponge was coated with an optimised superhydrophobic/superoleophilic hyper-crosslinked polymer and applied to the removal of crude oil from oil-in-water emulsions for the improvement of oil spill clean-up processes. The high surface area, porosity, hydrophobicity, and selectivity of oil over water made the hyper-crosslinked polymer coated sponge (HPCS) an ideal sorbent for efficient oil/water separation. The system was able to strip crude oil from water emulsions of 1000 ppm to a negligible level of 2 ppm oil with minimal amounts of the HPCS material. More importantly, the HPCS material could be reused via a simple mechanical compression process, and the uptake capacity was retained over ten cycles. For five cycles of oil adsorption/mechanical compression the HPCS was able to provide water filtrate with oil concentrations of under 15 ppm. This is an effective and economical recovery system, removing the need for consistent solvent washing and drying processes. These results suggest that the HPCS is a promising material for oil/water separation and recovery under challenging conditions.
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