Optimization of a 100% Product Utilization Process for LPG Separation Based on Distillation-Membrane Technology

Zhou, Peigen; Jing, Tong; Dai, Jianlong; Li, Jinzhi; Yi, Zhuan; Yan, Wentao; Zhou, Yong

doi:10.3390/membranes16010040

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Optimization of a 100% Product Utilization Process for LPG Separation Based on Distillation-Membrane Technology

by

Peigen Zhou

¹,

Tong Jing

¹,

Jianlong Dai

¹,

Jinzhi Li

^2,*,

Zhuan Yi

¹,

Wentao Yan

¹ and

Yong Zhou

^1,*

¹

College of Chemical Engineering, Zhejiang University of Technology, Hangzhou 310014, China

²

Sinopec Research Institute of Petroleum Processing Co., SINOPEC, Beijing 100083, China

^*

Authors to whom correspondence should be addressed.

Membranes 2026, 16(1), 40; https://doi.org/10.3390/membranes16010040 (registering DOI)

Submission received: 4 December 2025 / Revised: 2 January 2026 / Accepted: 9 January 2026 / Published: 10 January 2026

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Abstract

This study presents the techno-economic optimization of a hybrid distillation-membrane process for the complete fractionation of liquefied petroleum gas (LPG), targeting high-purity propane, n-butane, and isobutane recovery. The process employs an initial distillation column to separate propane (99% purity) from a propane-enriched stream, which is subsequently fed to a two-stage membrane system using an MFI zeolite hollow-fiber membrane for n-butane/isobutane separation. Through systematic simulation and sensitivity analysis, different membrane configurations were evaluated. The two-stage process with a partial residue-side reflux configuration demonstrated superior economic performance, achieving a total operating cost of 31.58 USD/h. Key membrane parameters—area, permeance, and separation factor—were optimized to balance separation efficiency with energy consumption and cost. The analysis identified an optimal configuration: a membrane area of 800 m², an n-butane permeance of 0.9 kg·m⁻²·h⁻¹, and a separation factor of 40. This setup ensured high n-alkane recovery while effectively minimizing energy use and capital investment. The study concludes that the optimized distillation-membrane hybrid process offers a highly efficient and economically viable strategy for the full utilization of LPG components.

Keywords: full utilization; process design; distillation—membrane separation process design; systematic simulation

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MDPI and ACS Style

Zhou, P.; Jing, T.; Dai, J.; Li, J.; Yi, Z.; Yan, W.; Zhou, Y. Optimization of a 100% Product Utilization Process for LPG Separation Based on Distillation-Membrane Technology. Membranes 2026, 16, 40. https://doi.org/10.3390/membranes16010040

AMA Style

Zhou P, Jing T, Dai J, Li J, Yi Z, Yan W, Zhou Y. Optimization of a 100% Product Utilization Process for LPG Separation Based on Distillation-Membrane Technology. Membranes. 2026; 16(1):40. https://doi.org/10.3390/membranes16010040

Chicago/Turabian Style

Zhou, Peigen, Tong Jing, Jianlong Dai, Jinzhi Li, Zhuan Yi, Wentao Yan, and Yong Zhou. 2026. "Optimization of a 100% Product Utilization Process for LPG Separation Based on Distillation-Membrane Technology" Membranes 16, no. 1: 40. https://doi.org/10.3390/membranes16010040

APA Style

Zhou, P., Jing, T., Dai, J., Li, J., Yi, Z., Yan, W., & Zhou, Y. (2026). Optimization of a 100% Product Utilization Process for LPG Separation Based on Distillation-Membrane Technology. Membranes, 16(1), 40. https://doi.org/10.3390/membranes16010040

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Optimization of a 100% Product Utilization Process for LPG Separation Based on Distillation-Membrane Technology

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