Techno-Economic Analysis of a Carbon Molecular Sieve-Based Xylene Isomer Purification Process

The separation and purification of xylene isomers is critical to the production of polyethylene terephthalate (PET). These separations are complex to operate and demand tremendous amounts of energy and thus are an opportunity for reducing industrial energy consumption. Membranes provide a low-energy footprint technology with simpler operation, and recently, membrane materials have been developed that are capable of separating xylene isomers. While these materials have demonstrated the ability to separate xylenes, they have yet to be commercially deployed. This work conducts a techno-economic analysis (TEA) to provide insight on the commercial attractiveness of a <i>p</i>-xylene selective carbon molecular sieve (CMS) membrane from both a cost and energy standpoint. This TEA was conducted through the pairing of a Maxwell-Stefan transport framework for rigid microporous materials with process modeling. Single-stage organic solvent reverse osmosis (OSRO) and pervaporation processes were used to evaluate the effects of recovery, selectivity, and diffusivity on the energy intensity and cost of the xylene separation. The final analysis used two systems, a single pervaporation stage followed by two OSRO stages, which was compared against a three-stage OSRO cascade. These were benchmarked against the commercial Parex process. We estimate that the membrane processes have the potential to enable impressive cost savings compared to the Parex process. While both systems outperformed the Parex process in terms of cost, the pervaporation/OSRO hybrid process was able to achieve the lowest cost of all due to its reduced membrane surface area compared to standalone OSRO. These findings demonstrate the potential of membrane systems in the field of difficult small molecule solvent separations.