New Membrane Technology Could Transform Hydrocarbon Processing by Slashing Energy Use

A team of international researchers have developed a new class of ultrathin polymer membranes that can rapidly and selectively separate complex hydrocarbon mixtures, potentially transforming how crude oil is refined and refinery streams are processed, significantly reducing the energy required for one of the world’s most energy‑intensive industrial processes.

The study, Ultrathin polymer membranes with locked intrinsic microporosity for hydrocarbon fractionation, has created a new way to form the separating layers in polymer membranes for molecular separations. The breakthrough derives from the way that the crosslinking agent for the polymer film is added to the polymer during membrane fabrication. It results in a scalable membrane technology capable of separating complex organic mixtures into valuable fractions with unprecedented efficiency. The membranes combine extremely high molecular selectivity with fast liquid transport — a combination that has long eluded scientists and engineers working in this field.

 

Re‑thinking a century‑old process

Conventional crude oil refining relies on thermal distillation, a process that consumes vast amounts of energy and accounts for around one percent of global energy use. Although membrane technologies have long promised a far more energy efficient alternative, their industrial uptake has been limited by fundamental materials challenges.

“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 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.”

 

Locking pores at the nanoscale

The breakthrough reported in this study lies in a new way of manufacturing polymer membranes so that their nanoscale pores are “locked” in place during formation.

The researchers focused on polymers of intrinsic microporosity, materials known for their sponge‑like structure containing sub‑nanometre pores. While these pores are ideal for separating molecules by size and type, 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 crosslinking approach that stabilises 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 stabilising 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.”

To probe the molecular origins of locking, the UCL team, led by Dr Foglia, used quasi-elastic neutron scattering at the ISIS Neutron and Muon Source, the UK's national pulsed neutron facility and an unrivalled tool for studying polymer chain dynamics. 

 

Exceptional performance in crude oil and refinery streams

When tested with synthetic crude oil, PLIM membranes showed up to ten‑fold higher permeance than existing state‑of‑the‑art membranes while maintaining high selectivity. The membranes were able to discriminate effectively between hydrocarbon molecules that differ only slightly in size.

In tests using real Arabian Extra Light crude oil, the membranes:

• Removed 99.8% of hydrocarbons heavier than 15 carbon atoms
• Reduced sulphur‑containing compounds by 93%, a critical step in protecting downstream catalysts and equipment

The membranes also performed particularly well with refinery streams such as virgin naphtha. In these tests, they efficiently separated light hydrocarbons (C4–C6), suitable for fuel upgrading, from heavier naphtha fractions used to produce plastics and chemicals — all at permeances comparable to commercial desalination membranes.

 

Designed for scale‑up

Crucially, the researchers demonstrated that the membranes can be manufactured at scale. Using roll‑to‑roll processing, they produced sheets over a metre wide and integrated them into standard spiral‑wound membrane modules commonly used in industry.

“These membranes aren’t just laboratory curiosities,” said Dr Adam Oxley, first author of the research paper and now Deputy Vice President 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.”

Long‑term testing showed stable performance over 30 days of continuous operation, indicating strong potential for real industrial deployment.

 

A more sustainable pathway for refining

While the global energy system is transitioning towards lower‑carbon alternatives, demand remains for fuels, chemicals, solvents, and materials derived from hydrocarbons. Improving the efficiency of existing separation processes is therefore essential in reducing emissions during the transition period.

By enabling membrane‑based separations that are both fast and selective, the PLIM technology could allow industries from oil refining to pharmaceuticals to:

• Cut energy consumption dramatically
• Reduce carbon emissions
• Operate with smaller, more flexible processing units
• Integrate selective desulphurisation earlier in the refining process

The researchers note that the same pore‑locking concept could be extended to other liquid separation challenges, including chemical manufacturing, solvent recovery, and emerging bio‑based feedstocks.

 

Looking ahead

The team is now exploring greener solvents for membrane manufacture and investigating how PLIM membranes could be deployed in targeted hybrid processes alongside existing refinery infrastructure and the manufacture of high value pharmaceuticals in organic solvents.

“This work shows that membrane‑based molecular separation in organic liquids is no longer just a theoretical possibility,” said Professor Livingston. “With the right materials design, it can be fast, selective, scalable — and ready for industry.”

 

 

The Team

This project was led by Exactmer where Drs Jiang and Oxley develop cutting edge new membrane technology, in collaboration with Queen Mary University of London, the University of Edinburgh, KAUST, UCL, and international collaborators including SINOPEC, with support from UKRI, EPSRC, and KAUST. Prof Livingston comments that “it is great to see research at a high level being led by a UK based deep tech spinout – Exactmer – and we are grateful for the UKRI Future Fellowship programme which allows Fellows to be working in industry”.

 

Funders

Zhiwei Jiang and Adam Oxley at Exactmer were funded by a UKRI Future Leadership Fellowship grant (MR/W009382/1) awarded to Exactmer by UK Research and Innovation, with additional funding from SynHiSel.

SynHiSel is a £9M EPSRC-funded programme grant (EP/V047078/1) bringing together leading UK researchers from six UK institutions, the University of Bath, Imperial College London, The University of Edinburgh, The University of Manchester, Newcastle University and Queen Mary University of London, and twelve industrial partners to create high-selectivity membranes for sustainable chemical separations.

 

DOI: science.org/doi/10.1126/science.aed1111