Droplet capture and coalescence are critical processes for enhancing emulsion separation efficiency in oily wastewater treatment. In this paper, four kinds of motion behaviors and secondary droplet formation behaviors of oil droplets on vertically crossed fibers in a water environment were investigated using high-speed camera technology. The research shows that during the droplet capture process, droplets on large-diameter horizontal fiber exhibit greater lateral spreading, and smaller vertical elongation. Increasing the diameter of horizontal fiber significantly shortens droplet capture time. The capture time on lipophilic fiber intersection of 190–420 μm is 14 ms less than that of 190–190 μm. During the droplet coalescence process, the liquid bridge on large-diameter horizontal fiber is wider, and the droplet contraction ratio is smaller. The droplet contraction ratio on fiber intersection of 190–420 μm is 0.3 smaller than that of 190–190 μm. Increasing the diameter of horizontal fiber can promote rapid fusion between droplets, but lipophobic fibers hinder the degree of fusion and deformation. Furthermore, the diameter and wettability of horizontal fibers have significant effects on the volume of secondary droplets. The volume of secondary droplets increases with the diameter of lipophilic horizontal fiber in the capture process. The volume of secondary droplets on lipophilic horizontal fiber is approximately three times larger than that on lipophobic horizontal fiber in the coalescence process. These findings contribute to understanding the details of coalescence separation and optimizing the design of fiber fillers.
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