Researchers Develop Low-Cost Membrane to Cut Refining Energy

Scientists have developed a low-cost polymer membrane that separates crude oil at room temperature, potentially reducing reliance on energy-intensive refining processes. According to process simulations published in a study this year, the breakthrough could cut refining energy consumption by 31.6%, CO2 emissions by 37.6%, cooling water usage by 20.7%, and operating costs by 36%.

The research was conducted by scientists from the Korea Advanced Institute of Science and Technology (KAIST) and the Georgia Institute of Technology. Instead of relying on an ultra-thin specialized coating like previous membrane attempts, the team passed crude oil directly through a bare porous polyacrylonitrile (PAN) membrane, which is a chemically stable and inexpensive polymer commonly used as an industrial support material.

Membrane Mechanism and Performance

When crude oil passes through the bare PAN membrane at room temperature, heavy hydrocarbons selectively stick to the pore walls, turning the membrane into a clogged filter. This accumulation gradually narrows the pores and creates separation channels smaller than 2 nanometers. The setup delivered crude oil permeation rates approximately 23 times higher than previous state-of-the-art crude oil membranes while maintaining stable performance for 28 consecutive days.

Refineries could adopt the technology through relatively simple retrofits by adding a modular filtration unit without requiring massive investments. The membranes cannot replace distillation entirely but can be used as a pretreatment step at an early stage to separate fractions without heating crude oil above 350 degrees Celsius from the beginning.

Key facts

• The polymer membrane reduces crude oil refining energy consumption by 31.6% according to simulations.
• Carbon dioxide emissions could be cut by 37.6% and operating costs by 36%.
• The bare PAN membrane achieved 23 times higher crude oil permeation rates than previous technologies.
• The filtration unit operates at room temperature, avoiding the need to heat crude oil above 350 degrees Celsius from the start.