Gas Separation Membrane Market Size, Growth Report, 2033

Gas Separation Membrane Market Overview

Global gas separation membrane market size is estimated at USD 573.5 million in 2024 and is expected to reach USD 672.57 million by 2033 at a 1.8% CAGR.

The gas separation membrane market is experiencing significant advancements in membrane technology, with more than 80 active commercial gas membrane systems deployed worldwide in sectors including natural gas processing, hydrogen recovery, and carbon dioxide capture. Gas separation membranes are critical for processes such as air separation, CO₂ removal, and biogas purification. Over 60% of industrial gas separation membranes are based on polymeric materials, predominantly polyimide and polysulfone.

The global demand is being driven by the push for cleaner energy and improved process efficiency. In 2023, over 1.2 million standard cubic meters per day of CO₂ were captured using membrane systems in industrial facilities. Hollow fiber configurations account for approximately 70% of membrane installations due to their compactness and high surface area.

Oil and gas applications account for over 40% of the membrane deployment globally, particularly for CO₂ removal from natural gas. Asia-Pacific and North America collectively contributed to over 65% of global membrane utilization in 2023. Market expansion is further fueled by regulatory shifts, with over 25 countries implementing stricter emission control policies, increasing demand for efficient separation technologies. Membrane manufacturers are increasingly investing in multilayer composite membranes to enhance selectivity and permeability for target gases.

Key Findings

Top Driver: Stringent emission regulations in industrial processing.

Top Country/Region: North America dominates the market due to large-scale natural gas processing.

Top Segment: Hollow fiber membranes lead the market in terms of adoption.

Gas Separation Membrane Market Trends

The gas separation membrane market has shown consistent technological progression with a shift toward high-performance membranes. In 2023, over 45% of new installations utilized composite membranes to improve permeability and selectivity, especially in CO₂ and hydrogen separation. Innovations in polymer chemistry have allowed the development of membranes that can handle high-pressure and high-temperature conditions, withstanding over 70 bar of pressure in natural gas treatment plants.

A growing trend is the integration of gas membranes in decentralized biogas upgrading facilities. As of 2024, over 600 small-scale biogas plants across Europe have incorporated membrane separation for methane enrichment, increasing their energy conversion efficiency by up to 35%. In addition, modular skid-based membrane units are gaining traction in portable applications, particularly in remote oil fields and mining operations.

Hydrogen recovery from refinery off-gases and syngas is another expanding segment. Membrane systems accounted for approximately 20% of hydrogen separation setups globally in 2023, up from 14% in 2020. Hydrogen purity levels of over 99.5% were achieved using advanced asymmetric membranes.

Vapor/nitrogen separation systems, particularly in the pharmaceutical and chemical industries, witnessed a growth in installation, contributing over 15% of the total membrane volume sold globally. Nitrogen purity exceeding 98% was reported in operations using spiral wound configurations.

Gas Separation Membrane Market Dynamics

DRIVER

Rising demand for cleaner industrial gas processing

Government regulations and industrial energy efficiency mandates are compelling industries to adopt environmentally friendly gas separation technologies. Over 120 countries have strengthened emissions regulations by 2023, particularly targeting CO₂ and VOC emissions. Gas separation membranes offer a compact and energy-efficient solution. In the oil & gas sector, more than 50% of gas processing units now incorporate membrane modules for CO₂ or H₂S removal. Membranes reduce energy consumption by up to 30% compared to traditional amine-based absorption systems. As global hydrogen demand exceeds 90 million metric tons annually, membrane-based recovery from industrial off-gases is expanding significantly, especially in refineries and chemical plants.

RESTRAINT

Limitations in membrane selectivity and fouling issues

Gas separation membranes face operational challenges related to limited selectivity for similar-sized gas molecules and susceptibility to fouling from contaminants. For instance, polyimide membranes exposed to hydrocarbons often experience up to 25% permeability decline within 18 months. High concentrations of water vapor and oils in industrial gases reduce membrane efficiency. Despite advances, over 15% of membrane systems require chemical cleaning every six months. Such maintenance demands and performance drops restrict the use of membranes in applications requiring ultra-pure gas streams. In high-value processes, such as semiconductor-grade nitrogen or ultrapure hydrogen generation, users prefer cryogenic or PSA systems over membranes due to consistency and reliability.

OPPORTUNITY

Expansion of biogas upgrading and carbon capture projects

The global biogas sector is scaling rapidly, with over 19,000 plants active as of 2023, many of which are integrating membrane systems for CO₂ removal. Membrane-based upgrading units now purify more than 5 billion cubic meters of biogas annually. With over 120 carbon capture pilot projects in place worldwide, many new systems are choosing membranes due to their small footprint and scalability. Membranes capable of selectively separating CO₂ from flue gases with permeance levels exceeding 500 GPU are gaining preference. Governments across Europe and Asia are funding low-carbon technology programs, resulting in more than $1 billion worth of project tenders involving gas separation membranes for CCS applications.

CHALLENGE

High upfront costs for industrial membrane systems

The capital expenditure for industrial membrane systems remains high, with average installation costs ranging from $200,000 to $600,000 per unit depending on capacity and configuration. While operational costs are lower compared to solvent-based systems, the need for frequent membrane replacement and system integration raises total cost of ownership. In CO₂ removal plants handling more than 100 MMSCFD gas volumes, membrane replacements alone account for nearly 12% of annual operating budgets. Furthermore, skilled technicians are required for tuning and optimization of systems, increasing labor dependency and cost.

Gas Separation Membrane Market Segmentation

The gas separation membrane market is segmented based on type and application. Type-wise, the market includes hollow fiber, spiral wound, and others, while by application it comprises isolation of inert nitrogen from air, hydrogen recovery, CO₂ removal from natural gas, vapor/nitrogen separation, and other specialized uses. Hollow fiber membranes dominate the segment with over 65% share, due to high packing density and operational efficiency. CO₂ removal from natural gas remains the top application with more than 40% usage due to high demand in natural gas sweetening facilities across North America, Asia, and the Middle East.

By Type

Hollow Fiber: Hollow fiber membranes represent the most widely used configuration, accounting for approximately 65% of installations. With surface areas exceeding 1,500 m² per module, they offer superior packing efficiency. Their flexibility and cost-effectiveness make them ideal for high-volume gas separations, especially in CO₂ removal from natural gas streams. Plants in Texas and Saudi Arabia report using over 500 such modules per site.
Spiral Wound: Spiral wound membranes are preferred in medium-pressure systems and in applications where compact module design is required. With average surface areas of 300–500 m² per module, spiral wound configurations accounted for about 25% of total membrane use in 2023, particularly in nitrogen separation and air enrichment systems.
Others: This includes plate-and-frame and tubular configurations, accounting for less than 10% of the market. These are used primarily in niche applications such as laboratory gas separation and low-volume specialty separations, such as helium purification or isotope separation.

By Application

Isolation of Inert N₂ from Air: Nitrogen separation using membranes is widespread in food packaging and chemical processing. Membrane systems can deliver nitrogen with purity up to 99.5%. In 2023, over 1,200 nitrogen systems were operational globally, producing more than 300,000 Nm³/h combined.
H₂ Recovery: Hydrogen recovery from petrochemical and refinery off-gases is a fast-growing segment. Membrane systems helped recover over 250 million Nm³ of hydrogen in 2023. Selective membranes with H₂/CH₄ selectivity >100 are increasingly adopted.
CO₂ Removal from Natural Gas: CO₂ removal applications accounted for 40% of total demand, with membrane systems processing over 4 billion cubic meters of natural gas in 2023. Facilities in the U.S. and Middle East report operational gains of 20% after switching from amine units to membranes.
Vapor/Nitrogen Separation: In pharmaceutical plants, nitrogen separation for inerting processes is rising. Membrane systems can reduce oxygen content to less than 1%, enhancing storage safety and extending product shelf life.
Other Applications: These include helium separation, carbon monoxide recovery, and oxygen enrichment for medical use. Though limited in volume, these contribute to high-margin specialty markets and involve around 5% of total membrane production.

Gas Separation Membrane Market Regional Outlook

The gas separation membrane market shows varied growth across global regions. North America and Asia-Pacific dominate usage due to significant deployment in natural gas treatment and hydrogen recovery. Europe is focusing on carbon capture and biogas upgrading with over 600 facilities using membrane technologies. The Middle East is emphasizing natural gas sweetening and nitrogen generation. Africa remains an emerging market with pilot projects underway. Regional performance is shaped by industrial infrastructure, regulatory frameworks, and environmental goals, with developed economies deploying high-capacity units, while developing regions adopt smaller, modular systems.

North America

North America is the largest regional market, driven by extensive oil and gas operations, particularly in the U.S. Over 2,000 membrane units are active in natural gas sweetening and refinery hydrogen recovery. Texas alone houses more than 400 installations. The U.S. DOE invested over $200 million in carbon capture projects between 2022 and 2024, many of which include membrane-based separation. Membrane systems are also used in food-grade nitrogen production and biogas upgrading in over 30 states.

Europe

Europe is a hub for biogas upgrading and industrial decarbonization. Germany, France, and the UK lead in deploying membrane-based CO₂ removal systems, with over 1,000 installations in 2023. More than 35% of Europe's biogas plants use membranes for biomethane production. EU directives encouraging low-emission technologies have pushed industries to retrofit existing setups with membrane modules. The region is also investing in CCS pilot plants using hybrid membrane-PSA systems.

Asia-Pacific

Asia-Pacific is experiencing robust membrane adoption due to rapid industrialization. China and India are major users, especially in hydrogen and nitrogen recovery systems. Over 3,000 membrane modules were installed in China’s petrochemical sector in 2023 alone. Japan is leading in helium recovery and oxygen enrichment membranes. South Korea and Taiwan are investing in compact membrane systems for electronic-grade gas purification. Increasing demand for energy efficiency is expected to boost regional usage further.

Middle East & Africa

The Middle East focuses heavily on natural gas sweetening, with over 500 membrane units operating across UAE, Saudi Arabia, and Qatar. These handle more than 15 billion Nm³/year of sour gas. Africa is emerging, with Nigeria and South Africa exploring CO₂ capture and hydrogen generation projects. Pilot programs launched in 2023 aim to establish membrane-based biogas units in East Africa. Continued investment in energy and environmental tech will shape the region’s growth trajectory.

List of Top Gas Separation Membrane Market Companies

Air Products
Air Liquide
UBE
Grasys
Evonik
Fujifilm
Generon IGS
Honeywell
MTR
Borsig
Parker Hannifin
Tianbang
SSS
Schlumberger

Top 2 Companies with Highest Share

Air Liquide: Air Liquide deployed over 2,500 gas separation membrane units globally by 2023. The company operates in more than 80 countries and supports major hydrogen recovery and nitrogen generation systems worldwide.

Honeywell: Honeywell’s UOP Separex™ membrane systems are installed in more than 300 natural gas processing facilities. The company reports that its membrane units process over 15 billion standard cubic meters of gas per year.

Investment Analysis and Opportunities

The gas separation membrane market is attracting significant investments, particularly in industrial decarbonization, hydrogen economy, and biogas purification. In 2023, more than 120 industrial projects globally integrated gas separation membranes, with capital investments exceeding $3 billion across government and private sectors. These projects span oil and gas processing, power generation, fertilizer production, and waste-to-energy.

Investment in carbon capture and storage (CCS) projects has surged, driven by environmental compliance and sustainability targets. In Europe, more than 30 carbon capture pilot plants initiated between 2022 and 2024 utilize membrane modules, many co-funded through EU Green Deal investments. Governments in countries such as Germany, the Netherlands, and Norway have allocated over $500 million collectively to membrane-enhanced CCS systems.

In Asia-Pacific, private companies and joint ventures are focusing on hydrogen purification. In 2023, Chinese refineries invested over $400 million in membrane-based H₂ recovery systems, replacing traditional PSA units to enhance efficiency and reduce energy use. India and Japan are also focusing on low-emission hydrogen projects, with combined investment commitments exceeding $250 million over two years.

The biogas sector is another key area of investment. More than 1,500 biogas plants were upgraded with membrane units in 2023 alone, with modular membrane systems receiving funding through renewable energy subsidies in over 40 countries. These systems increase methane yield by up to 30% and reduce overall processing costs by 20%.

Startups and technology firms are also entering the market with novel materials such as graphene oxide and mixed matrix membranes (MMMs). Investment in R&D for advanced membranes reached $700 million globally in 2023, led by institutions in the U.S., Germany, and South Korea. Venture capital-backed firms developing membranes for niche gas separations, including helium recovery and oxygen enrichment, are increasingly attracting funding, with at least 50 such ventures globally.

New Product Development

New product development in the gas separation membrane market is focused on enhancing membrane performance, lifespan, and application diversity. In 2023, more than 35 new membrane product lines were launched, targeting higher gas selectivity, reduced fouling, and broader temperature-pressure resistance.

Composite membranes with multilayer asymmetric structures are gaining traction. These membranes combine ultra-thin selective layers with porous support structures, achieving gas permeance of up to 1,000 GPU and selectivity ratios exceeding 100 for H₂/CH₄ and CO₂/CH₄. Companies such as UBE and Evonik introduced advanced polyimide and polysulfone-based membranes with improved tolerance to hydrocarbons and sulfur compounds.

Graphene oxide (GO) membranes entered commercial testing in 2023, offering extreme selectivity and permeability. Early test data shows GO membranes achieving 10x faster gas diffusion rates compared to conventional polymeric types. These are being targeted for compact hydrogen and helium recovery systems. Honeywell and several academic consortia are developing scalable fabrication processes for such nanomaterials.

Anti-fouling coatings are another focus area. New surface-modified membranes using hydrophilic or oleophobic coatings resist contamination from condensable vapors, reducing performance degradation by 40%. These innovations extend membrane operational life from an average of 2.5 years to over 4 years. Fujifilm and Generon have commercialized such coated membranes for high-contaminant gas streams.

Membranes for extreme environments are also under development. Products capable of operating beyond 100°C and 100 bar are now in pilot stages. These membranes enable integration into high-pressure hydrogen separation and deep-gas treatment processes. Custom membranes designed for oxygen enrichment in medical systems and emergency supplies are being prototyped for compact, battery-powered use.

Five Recent Developments

Air Liquide: launched a new high-performance polyimide-based membrane in Q1 2024, increasing H₂ recovery rates by 20% over previous models.
Honeywell UOP: installed its 300th Separex membrane system in a major natural gas processing plant in Texas, processing 1.5 billion cubic meters per year.
Evonik: introduced SEPURAN® Green membranes for biogas upgrading, which now serve over 500 units across Europe, each achieving 98% methane purity.
Generon IGS: developed a skid-mounted nitrogen generation system with integrated membrane and compressor unit, reducing footprint by 30%.
Grasys: completed trials for its hybrid PSA-membrane H₂ separation system in Russia, reporting 25% energy efficiency improvement over standalone PSA.

Report Coverage of Gas Separation Membrane Market

This report provides comprehensive coverage of the global gas separation membrane market across various dimensions—technological, regional, and industry-specific. It assesses the evolution of membrane technologies, including material science advancements, fabrication innovations, and integration into hybrid systems. The analysis includes detailed evaluations of polymeric, composite, and nanomaterial membranes, identifying their application suitability and operational benefits.

The report covers segmentation by membrane type (hollow fiber, spiral wound, and others) and applications such as CO₂ removal from natural gas, nitrogen production, hydrogen recovery, and biogas purification. Each segment is analyzed for its volume demand, technology adoption trends, and material preference across industries such as oil & gas, chemicals, pharmaceuticals, and environmental engineering.

The regional assessment includes North America, Europe, Asia-Pacific, and the Middle East & Africa, with in-depth analysis of industrial activity, infrastructure, regulatory influence, and technology deployment. Over 60 countries are indirectly evaluated through capacity utilization, project announcements, and investment flow.

Competitive analysis identifies the top market participants and their strategic positioning, highlighting Air Liquide and Honeywell as dominant players by deployment count and system capacity. Company profiles include innovation benchmarks, product offerings, and market expansion.