Researchers at King Abdullah University of Science and Technology (KAUST), together with collaborators in China and France, have developed a new membrane technology that could significantly reduce the energy required for industrial gas separation.
Published in Nature, the study focuses on metal-organic frameworks (MOFs), highly porous materials capable of separating molecules with exceptional precision. Although MOFs have shown strong potential as alternatives to energy-intensive separation methods, their use has been limited by difficulties in producing durable membranes at industrial scale.
The researchers developed a membrane architecture containing more than 90 percent MOF material while maintaining flexibility, durability and compatibility with existing manufacturing processes. A molecular anchor connects MOF nanosheets with polymer chains, creating an integrated structure that overcomes limitations associated with conventional polymer-based membranes.
The team demonstrated the technology using roll-to-roll manufacturing, successfully producing continuous membrane rolls measuring 20 metres. Tests showed strong performance in carbon capture, hydrogen purification and propylene purification. The membrane produced polymer-grade propylene in a single stage and maintained performance during 150 days of continuous operation.
Modeling suggests the technology could reduce purification costs by up to 80 percent compared with conventional distillation. The researchers believe the scalable membrane design could support applications including carbon capture, natural gas purification, hydrogen recovery and direct air capture.
