KAIST membrane filters crude oil at room temperature, cuts refining energy 31% and CO2 37%

KAIST researchers have developed a polymer membrane that separates light components like gasoline and naphtha from crude oil without heating it above 350 degrees Celsius. The innovation uses a polyacrylonitrile membrane that self-adjusts its pore size as heavy oil components coat the inner surface, creating channels under 2 nanometers wide. This approach eliminates the need for a costly selective layer that has blocked previous membrane attempts. When added to existing distillation processes, simulations show the technology can cut energy use by 31.6%, cooling water by 20.7%, and CO2 emissions by 37.6%. Operating costs could drop by 36%. The team reports separation speeds 23 times faster than earlier crude oil membranes with no performance decline after a month of continuous operation. Commercialization is expected within 3 to 5 years if scalability tests succeed.