KAUST develops advanced membranes to cut energy use in industrial gas separation

King Abdullah University of Science and Technology (KAUST) has announced the development of a new membrane technology that reduces energy consumption in industrial gas separation processes, which account for around 15% of global energy use. The breakthrough was achieved in collaboration with academic partners from China and France, according to the university.

KAUST stated that the study, published in the journal Nature, focused on metal-organic frameworks (MOFs)—highly porous materials that enable efficient molecular separation. The research team succeeded in developing membrane structures containing over 90% MOFs, while maintaining flexibility, durability, and compatibility with industrial manufacturing techniques.

The researchers also overcame a major technical challenge by using a small molecular anchor to link MOF sheets with polymer chains, ensuring high performance and enabling large-scale membrane production. The team demonstrated the ability to produce 20-meter-long membrane rolls using continuous roll-to-roll manufacturing, confirming the potential for integration into existing industrial production lines.

High efficiency and diverse applications

Professor Mohamed Al-Daoudi, professor of chemical sciences at KAUST and a corresponding author of the study, explained that this innovation provides a practical pathway for manufacturing advanced membranes at the industrial scale, bringing the technology closer to real-world application. He added that industrial separation processes consume significant amounts of energy daily.

Experiments showed the technology delivered high efficiency in applications such as carbon capture, hydrogen purification, and propylene purification for the petrochemical industry. The membrane successfully produced polymer-grade propylene in a single separation step, maintaining its performance over 150 days of continuous operation.

Modeling results indicated that the technology could reduce purification costs by up to 80% compared to traditional distillation, with potential uses in natural gas purification, hydrogen recovery, and direct air capture of carbon dioxide.

The study involved researchers from KAUST, Hong Kong University of Science and Technology (Guangzhou), Guangzhou University, Tsinghua University, University of Montpellier, and the French National Centre for Scientific Research (CNRS), and was led by Professor Xing Zhu, a former KAUST doctoral graduate.