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Crude Oil Separates Without Boiling: KAIST and Georgia Tech Develop Energy-Saving Membrane Technology
An international research team led by KAIST has developed a membrane technology that could significantly reduce the energy required for crude oil refining by replacing part of the century-old distillation process.
KAIST(President Kwang Hyung Lee) announced that a team led by Professor Dong-Yeun Koh of KAIST, in collaboration with Professor Ryan Lively's group at Georgia Tech, demonstrated a simple and inexpensive membrane capable of separating crude oil at room temperature without heating. The research was published in Nature, one of the world's leading scientific journals.
Crude oil underpins modern life by providing not only transportation fuels but also essential feedstocks for plastics, packaging materials, textiles, and countless consumer products. Because the cost of refining directly influences the price of these products, technologies that reduce refining energy consumption can generate substantial economic and environmental benefits.
Traditionally, refineries separate crude oil through distillation, a process that heats crude oil above 350 °C to vaporize it and then cools the vapor to recover different fractions. Globally, crude oil distillation consumes approximately 1,100 terawatt-hours (TWh) of energy each year—equivalent to the annual output of about 130 nuclear power plants, each at gigawatt scale, operating continuously. As a result, distillation remains one of the largest sources of energy consumption and greenhouse gas emissions in the refining industry.
At the same time, increasing cost pressures in global petrochemical markets have intensified the need for more energy-efficient separation technologies.
Membrane-based crude oil fractionations have attracted increasing attention as a potential alternative. However, conventional wisdom has held that molecularly precise separation requires an ultrathin selective layer coated onto the membrane surface. While effective, such coatings increase manufacturing costs and are prone to defects when scaled to large areas, limiting industrial deployment.
To overcome this challenge, the researchers took a radically different approach. Instead of relying on a specialized coating, they passed crude oil directly through a bare porous polyacrylonitrile (PAN) membrane—a chemically stable and inexpensive polymer commonly used as a support material in industrial membranes.
As crude oil permeated through the membrane, heavy hydrocarbons selectively deposited on the pore walls, gradually narrowing the pores and creating self-assembled separation channels smaller than 2 nanometers. Rather than relying on a specially engineered coating, the crude oil itself created the nanoscale pathways needed for precise molecular separation.
Through these self-formed channels, lighter fractions such as naphtha, gasoline, and kerosene permeated rapidly, while heavier components were effectively retained. In a surprising reversal, membrane fouling—normally regarded as a performance-degrading phenomenon—became the very mechanism that enabled highly selective separation.
The bare PAN membrane delivered crude oil permeation rates approximately 23 times higher than those of previously reported state-of-the-art crude oil membranes while maintaining stable performance for 28 consecutive days.
Professor Ryan Lively (Georgia Tech) commented “one of the key challenges facing membrane systems for crude oil separation was the low productivities of the membrane units – the PAN membranes with their surprising separation mechanism – dramatically increase the productivity of the membrane unit, to the point where industry should seriously consider adopting the technology.”
Importantly, the technology can be integrated into existing refinery infrastructure as a modular filtration unit, avoiding major equipment replacement and reducing barriers to industrial adoption.
Process simulations showed that using the membrane as a pretreatment step before conventional distillation could reduce energy consumption by 31.6%, carbon dioxide emissions by 37.6%, cooling water usage by 20.7%, and operating costs by 36%.
If adopted throughout Korea's refining and petrochemical sector, the technology could reduce greenhouse-gas emissions by approximately 10 million tonnes annually—equivalent to the emissions of roughly four million internal combustion vehicles.
Beyond crude oil refining, the membrane platform could be applied to a broad range of chemical separation processes, including the purification of pyrolysis oil derived from waste plastics, the recovery of solvents used in battery manufacturing, pharmaceutical purification, and biofuel production. The researchers believe the technology could serve as a versatile platform for next-generation molecular separations across multiple industries.
Professor Dong-Yeun Koh of KAIST said, “This study reveals a new scientific principle in which a membrane interacts with a complex mixture and spontaneously forms its own separation channels. Working with real crude oil supplied by HD Hyundai Oilbank allowed us to validate the technology under conditions relevant to industrial operation.”
Professor Jae W. Lee of KAIST, a co-corresponding author of the study, added, “By advancing large-area membrane modularization and long-term operational reliability, we hope to broaden the adoption of membrane-based processes throughout the refining and petrochemical industries.”
Dr. Jihoon Choi and Dr. Hyeokjun Seo of KAIST, the study’s co-first authors, said, “Our goal is to precisely control this spontaneous pore-constriction phenomenon and develop it into a membrane platform applicable to the entire refining process. We also aim to expand the technology to plastic recycling, biofuel purification, and other sustainable chemical processes that support carbon neutrality.”
The study was co-first-authored by Dr. Jihoon Choi and Dr. Hyeokjun Seo of KAIST and was published online in Nature on June 24, 2026.
Paper Title: Crude Oil Fractionation by Means of Mesoporous Polyacrylonitrile Membranes
DOI 10.1038/s41586-026-10677-3
https://www.nature.com/articles/s41586-026-10677-3
This research was supported by the Ministry of Science and ICT of Korea through the Basic Research Program for Outstanding Early-Career Researchers and the Engineering Research Center (ERC) Program.
2026.06.25 View 2157 -
KAIST achieves over 95% high-purity CO₂ capture using only smartphone charging power
Direct Air Capture (DAC) is a technology that filters out carbon dioxide present in the atmosphere at extremely low concentrations (below 400 ppm). The KAIST research team has now succeeded in capturing over 95% high-purity carbon dioxide using only low power at the level of smartphone charging voltage (3V), without hot steam or complex facilities. While high energy cost has been the biggest obstacle for conventional DAC technologies, this study is regarded as a breakthrough demonstrating real commercialization potential. Overseas patent applications have already been filed, and because it can be easily linked with renewable energy such as solar and wind power, the technology is being highlighted as a “game changer” for accelerating the transition to carbon-neutral processes.
KAIST (President Kwang Hyung Lee) announced on the 25th of August that Professor Dong-Yeun Koh’s research team from the Department of Chemical and Biomolecular Engineering, in collaboration with Professor T. Alan Hatton’s group at MIT’s Department of Chemical Engineering, has developed the world’s first ultra-efficient e-DAC (Electrified Direct Air Capture) technology based on conductive silver nanofibers.
Conventional DAC processes required high-temperature steam (over 100℃) in the regeneration stage, where absorbed or adsorbed carbon dioxide is separated again. This process consumes about 70% of the total energy, making energy efficiency crucial, and requires complex heat-exchange systems, which makes cost reduction difficult. The joint research team, led by KAIST, solved this problem with “fibers that heat themselves electrically,” adopting Joule heating, a method that generates heat by directly passing electricity through fibers, similar to an electric blanket. By heating only where needed without an external heat source, energy loss was drastically reduced.
This technology can rapidly heat fibers to 110℃ within 80 seconds with only 3V—the energy level of smartphone charging. This shortens adsorption–desorption cycles dramatically even in low-power environments, while reducing unnecessary heat loss by about 20% compared to existing technologies.
The core of this research was not just making conductive fibers, but realizing a “breathable conductive coating” that achieves both “electrical conductivity” and “gas diffusion.”
The team uniformly coated porous fiber surfaces with a composite of silver nanowires and nanoparticles, forming a layer about 3 micrometers (µm) thick—much thinner than a human hair. This “3D continuous porous structure” allowed excellent electrical conductivity while securing pathways for CO₂ molecules to move smoothly into the fibers, enabling uniform, rapid heating and efficient CO₂ capture simultaneously.
Furthermore, when multiple fibers were modularized and connected in parallel, the total resistance dropped below 1 ohm (Ω), proving scalability to large-scale systems. The team succeeded in recovering over 95% high-purity CO₂ under real atmospheric conditions.
This achievement was the result of five years of in-depth research since 2020. Remarkably, in late 2022, long before the paper’s publication, the core technology had already been filed for PCT and domestic/international patents (WO2023068651A1, countries entered: US, EP, JP, AU, CN), securing foundational intellectual property rights. This indicates that the technology is not only highly advanced but also developed with practical commercialization in mind beyond the laboratory level.
The biggest innovation of this technology is that it runs solely on electricity, making it very easy to integrate with renewable energy sources such as solar and wind. It perfectly matches the needs of global companies that have declared RE100 and seek carbon-neutral process transitions.
Professor Dong-Yeun Koh of KAIST said, “Direct Air Capture (DAC) is not just a technology for reducing carbon dioxide emissions, but a key means of achieving ‘negative emissions’ by purifying the air itself. The conductive fiber-based DAC technology we developed can be applied not only to industrial sites but also to urban systems, significantly contributing to Korea’s leap as a leading nation in future DAC technologies.”
This study was led by Young Hun Lee (PhD, 2023 graduate of KAIST; currently at MIT Department of Chemical Engineering) and co-first-authored by Jung Hun Lee and Hwajoo Joo (MIT, Department of Chemical Engineering). The results were published online on August 1, 2025, in Advanced Materials, one of the world’s leading journals in materials science, and in recognition of its excellence, the work was also selected for the Front Inside Cover.
※ Paper title: “Design of Electrified Fiber Sorbents for Direct Air Capture with Electrically-Driven Temperature Vacuum Swing Adsorption”
※ DOI: https://doi.org/10.1002/adma.202504542
This study was supported by the Aramco–KAIST CO₂ Research Center and the National Research Foundation of Korea with funding from the Ministry of Science and ICT (No. RS-2023-00259416, DACU Source Technology Development Project).
2025.08.25 View 6235