Last year, I
posted about the potential of polymer membrane technology that can fractionate
hydrocarbons via reverse osmosis and its potential to revolutionize refining. Now, a team of
international researchers has developed a new class of ultrathin polymer
membranes that can separate complex hydrocarbon mixtures. This new method, like
the reverse osmosis method, can significantly reduce the energy required to
separate the hydrocarbons, which currently is one of the most energy-intensive
industrial processes. As recounted by Tech Xplore, the researchers discovered:
“…a new way to form the separating layers in polymer
membranes for molecular separations. The breakthrough derives from the way the
cross-linking agent for the polymer film is added to the polymer during
membrane fabrication.”
“The membranes combine extremely high molecular selectivity with fast liquid transport—a combination that has long eluded scientists and engineers working in this field.”
The results of the testing were reported in a paper in Science:
Currently, the thermal
distillation of hydrocarbons uses about 1% of the global energy supply.
Membrane technologies have long been in development, but have been limited by
the materials used.
"Membranes can, in principle, do the same job as
distillation or evaporation, using far less energy," explains lead
researcher Andrew Livingston, professor of chemical engineering and vice
president of research and innovation at Queen Mary University of London, and
CEO of Exactmer.
"The problem has been finding materials that are
both fast and selective when exposed to real hydrocarbon mixtures."
The key to the new method is
manufacturing polymer membranes so that their nanoscale pores are
"locked" in place during formation. Sub-nanometer pores separate
molecules by size and type, but the polymers normally swell when exposed to
hydrocarbons, causing the pores to expand and lose selectivity.
“To overcome this, the team developed an in-situ
cross-linking approach that stabilizes the polymer structure while the membrane
is being formed. This process locks the pores in their optimal configuration,
producing what the researchers call polymers of locked intrinsic microporosity
(PLIMs).”
"The key was stabilizing the structure before the
polymer had a chance to swell," explains Dr. Zhiwei Jiang, who led the
research as head of membrane research at Exactmer and who is now assistant
professor at Nanyang Technological University in Singapore.
"This preserves the tiny pores that make molecular
separation possible, while still allowing hydrocarbons to flow through very
quickly."
Quasi-elastic neutron
scattering at the ISIS Neutron and Muon Source, the U.K.'s national pulsed
neutron facility, was used to develop the process.
As noted below, the method
tested quite successfully with light Arabian oil. It also tested successfully
by separating a mixture of virgin naphtha with C4-C6 hydrocarbons from heavier
naphtha hydrocarbon components.
The researchers also
demonstrated that the membranes can be manufactured at scale. Testing showed
stable performance over 30 days of continuous operation. As noted below, the
membranes can be manufactured as drop-in membranes into existing module
designs.
"These membranes aren't just laboratory
curiosities," said Dr. Adam Oxley, first author of the research paper and
now deputy vice president of membranes at Exactmer. "They can be produced
using established manufacturing techniques and fitted into existing industrial
module designs. At Exactmer, we are building these new techniques into
membranes used for high-value separations in organic solvents."
Below, the researchers note
that the membrane process can be used in petroleum refining, petrochemicals
production, for industrial solvents, in the pharmaceutical industry, and with
biofuel feedstocks.
Future research directions
include deploying the PLIM membrane tech alongside existing refinery processes
and deriving pharmaceuticals in organic solvents.
"This work shows that membrane-based molecular
separation in organic liquids is no longer just a theoretical
possibility," said Livingston. "With the right materials design, it
can be fast, selective, scalable—and ready for industry."
Dr. Zachary P. Smith,
associate professor of chemical engineering, Massachusetts Institute of
Technology (MIT), said,
"As all chemists know, 'like dissolves like.' So how
can you separate hydrocarbon liquids using a hydrocarbon polymer without the
polymer itself dissolving while in use? Livingston and his team have developed
an approach to 'lock' their polymers in place, making them stable under
aggressive conditions.
"More than that, they have shown that this approach
works with some of the newest and most innovative emerging polymers in membrane
science, helping to push the field into untapped areas of application."
Ryan P. Lively, professor in
the School of Chemical & Biomolecular Engineering at the Georgia Institute
of Technology, added,
"One of the key technological barriers facing
membrane deployment in crude oil refining [is/was] the very low productivity of
the membrane units. The membranes from Livingston's research are more than 100
times more productive than the first-generation membrane materials—the fact
that this was achieved along with improved separation efficiency is a
remarkable achievement.
“The composition of the membrane selective layer is
interesting. The polymer backbones used had been considered previously, and
cross-linked polymers had been considered previously, but the special
combination that the team discovered really hit a sweet spot in terms of
membrane performance.”
"Being able to go from a small postage-stamp test
to a full-size membrane module in such a short time indicates that the
prospects for membrane-based oil refining are bright. Indeed, this article and
others in the academic literature continue to indicate that there are real
economic and environmental benefits to moving forward with membranes for oil
refining at larger and larger scales."
Membrane technologies appear
to be the future of oil refining, but will likely take years to further
develop.
References:
Ultrathin
membranes could transform hydrocarbon processing by slashing energy use. Science
X staff. University of London. TechXplore. June 18, 2026. Ultrathin membranes could transform hydrocarbon processing
by slashing energy use
Ultrathin
polymer membranes with locked intrinsic microporosity for hydrocarbon
fractionation. Adam Oxley, Chunchun Ye, Seok Ju Han, Guoke Zhao, Yihao Guo, Xin
Shi, Jie Liu, Keenan Smith, Mona Sarter, and Zhiwei Jiang +13 authors. Science.
18 Jun 2026. Vol 392, Issue 6804. pp. 1268-1273. Ultrathin polymer membranes with locked intrinsic
microporosity for hydrocarbon fractionation | Science
























