Advancing Solvent Dehydration with Innovative HybSi® AR Membranes: Economic and Environmental Benefits of Pervaporation

A techno-economic and environmental evaluation of dehydrating five industrially relevant solvents (isopropanol, acetonitrile, tetrahydrofuran, acetic acid, and n-methyl-2-pyrrolidone) using pervaporation-based processes was performed and compared to their respective traditional distillation processes. A standalone pervaporation and two hybrid processes (i.e., distillation-pervaporation and distillation-pervaporation-distillation) employing HybSi^® AR membranes were simulated in Aspen Plus, where the pervaporation module was modeled as a separator block that followed the experimental data. The experiments were performed at a vacuum pressure of 20 mbar and a temperature of 130 °C. The performance was compared based on several technical, economic, and environmental measures, of which key metrics are the levelized cost of separation (LCOS) and CO₂ footprint reduction. From the economic perspective, the pervaporation-based processes are much more economical than the distillation processes for isopropanol (up to 42% reduction in LCOS) and acetonitrile (up to 39% reduction in LCOS), while their economic performance is similar to the benchmark process in the case of tetrahydrofuran (only up to 4% reduction in LCOS). For acetic acid (9% higher LCOS) and n-methyl-2-pyrrolidone (124% higher LCOS), the pervaporation-based processes do not perform better than the distillation processes under the current technical and economic considerations. However, a sensitivity analysis showed the potential to make the pervaporation-based processes more economical by improving the permeate flux and membrane module cost. On the other hand, the pervaporation-based processes are much more environmentally friendly for all the solvents studied compared to their respective benchmark processes. The reduction in CO₂ footprint is in the order of 86%, 82%, 73%, 82%, and 65%, respectively, for the aforementioned solvents.