Oil refining costs could be halved thanks to a new membrane discovery

Crystalline membranes offer a breakthrough in oil processing

According to НВ — Техно: A global research team published findings in the journal Science on July 11 that detail a new type of crystalline membrane for petroleum refining. Made from covalent organic frameworks (COFs), these membranes can separate crude oil fractions without the need for heating, potentially slashing energy use in the refining process. Traditional distillation consumes roughly 11% of all energy derived from extracted crude, making efficiency gains a major target for the industry.

The researchers focused on a specific class of COFs featuring adjustable pore sizes and sub-nanometer channels, which allow them to effectively separate different oil fractions. Tests using undiluted Arabian Light crude oil showed that a two-stage filtration system boosted the concentration of aliphatic compounds from 54.5% to 96.1%.

Scalable and energy-efficient design

The technology has proven scalable: the team established continuous roll-to-roll production of membrane sheets measuring 50 meters in length and 0.3 meters in width. Rolled modules used in a pilot separation system operated for over 250 hours. Energy consumption in the new system was about 20.7 megajoules per barrel of oil-far below the typical 50 to 200 megajoules per barrel required for conventional distillation.

Furthermore, membrane permeability was fully restored after routine cleaning, demonstrating durability and long-term viability. This advancement in oil refining could dramatically lower energy costs and make the process more economical overall.

The study’s results could have a major impact on the petroleum refining industry, as reducing energy consumption is critical for improving economic efficiency and lessening environmental harm. The adoption of these new membranes may represent an important step toward more sustainable and energy-efficient oil processing, meeting modern demands for environmental safety.

Ongoing research and deployment of this technology could transform how oil resources are handled on a global scale.

In light of this breakthrough, it's also worth exploring how the innovative approach of refining oil without heat could further transform the industry. This recent discovery not only highlights advancements in energy efficiency but aligns with other significant developments in the field. For a deeper understanding of these revolutionary methods, you can read more about the potential of heat-free oil refining.