Towards MOFs' mass market adoption: MOF Technologies' efficient and versatile one-step extrusion of shaped MOFs directly from raw materials.

Metal Organic Frameworks (MOFs) offer unparalleled physical and sorption properties due to their chemical tunability and unmatched porosity. MOFs are consequently envisaged to play a key role in commercial gas storage and separation applications. However, it is essential to tackle their current market entry barriers, if mainstream adoption is to be realised. MOF Technologies is a pioneer in MOF commercialisation and has developed innovative solutions with unprecedented efficiency to bring these materials to market. A continuous, versatile and sustainable one-step production method of MOFs in shaped form is demonstrated for the first time. Its advantages for large-scale production and mass customisation are exemplified and validated with performance evaluation under realistic operating conditions.

Adsorber heat exchanger using Al-fumarate beads for heat-pump applications - a transport study.

Metal-Organic Frameworks (MOFs), thanks to their type V water adsorption isotherms ("S-Shape") and large water capacities, are considered as potential breakthrough adsorbents for heat-pump applications. In particular, Al(OH)-fumarate could enable efficient regeneration at a lower temperature than silica-gel which would allow us to address the conversion of waste heat at low temperature such as found in data centers. Despite its greater adsorption capacity features, heat and mass transport limitations could jeopardize the potential performance of Al(OH)-fumarate. Heat and mass transport depend on the size of the bodies (mm range), their packing and on the pore structures, i.e. macro-mesopore volumes and sizes. This paper describes the cost-efficient and scalable synthesis and shaping processes of Al(OH)-fumarate beads of various sizes appropriate for use in water Adsorption Heat-Pumps (AHPs). The objective was to study transport limitations (i.e. mass and heat) in practical e beads which meet mechanical stability requirements. Dynamic data at the grain scale was obtained by the Large Temperature Jump method while dynamic data at the adsorber scale was obtained on a heat exchanger filled with more than 1 kg of Al(OH)-fumarate beads. Whereas the binder content had little impact on mass and heat transfer in this study, we found that Knudsen diffusion in mesopores of the grain may be the main limiting factor at the grain scale. At the adsorber scale, heat-transfer within the bed packing as well as to the heat exchanger is likely responsible for the slow adsorption and desorption kinetics which have been observed for very low desorption temperature. Finally, the dynamic aspects of the observed water adsorption isotherm shift with temperature are discussed in light of reported reversible structure modification upon temperature triggered water adsorption-desorption.

In Situ Monitoring and Mechanism of the Mechanochemical Formation of a Microporous MOF-74 Framework.

Mechanochemistry provides a rapid, efficient route to metal-organic framework Zn-MOF-74 directly from a metal oxide and without bulk solvent. In situ synchrotron X-ray diffraction monitoring of the reaction course reveals two new phases and an unusual stepwise process in which a close-packed intermediate reacts to form the open framework. The reaction can be performed on a gram scale to yield a highly porous material after activation.

ZIF-8 Pellets as a Robust Material for Hydrogen Cryo-Adsorption Tanks.

Cryoadsorption on the inner surface of porous materials is a promising solution for safe, fast, and reversible hydrogen storage. Within the class of highly porous metal-organic frameworks, zeolitic imidazolate frameworks (ZIFs) show high thermal, chemical, and mechanical stability. In this study, we selected ZIF-8 synthesized mechanochemically by twin-screw extrusion as powder and pellets. The hydrogen storage capacity at 77 K and up to 100 bar has been analyzed in two laboratories applying three different measurement setups showing a high reproducibility. Pelletizing ZIF-8 increases the packing density close to the corresponding value for a single crystal without loss of porosity, resulting in an improved volumetric hydrogen storage capacity close to the upper limit for a single crystal. The high volumetric uptake combined with a low and constant heat of adsorption provides ca. 31 g of usable hydrogen per liter of pellet assuming a temperature-pressure swing adsorption process between 77 K - 100 bar and 117 K - 5 bar. Cycling experiments do not indicate any degradation in storage capacity. The excellent stability during preparation, handling, and operation of ZIF-8 pellets demonstrates its potential as a robust adsorbent material for technical application in pilot- and full-scale adsorption vessel prototypes.

Manometric real-time studies of the mechanochemical synthesis of zeolitic imidazolate frameworks.

We demonstrate a simple method for real-time monitoring of mechanochemical synthesis of metal-organic frameworks, by measuring changes in pressure of gas produced in the reaction. Using this manometric method to monitor the mechanosynthesis of the zeolitic imidazolate framework ZIF-8 from basic zinc carbonate reveals an intriguing feedback mechanism in which the initially formed ZIF-8 reacts with the CO2 byproduct to produce a complex metal carbonate phase, the structure of which is determined directly from powder X-ray diffraction data. We also show that the formation of the carbonate phase may be prevented by addition of excess ligand. The excess ligand can subsequently be removed by sublimation, and reused. This enables not only the synthesis but also the purification, as well as the activation of the MOF to be performed entirely without solvent.

Recent Developments in Mechanochemical Materials Synthesis by Extrusion.

Mechanochemical synthesis, i.e., reactions conducted by grinding solid reactants together with no or minimal solvent, has been demonstrated as an excellent technique for the formation of both organic and inorganic compounds. Mechanochemistry is viewed as an alternative approach to chemical synthesis and is not always considered when developing manufacturing processes of fine chemicals. Here, recent advances are highlighted regarding mechanochemical synthesis, by utilizing a well-developed continuous technique - extrusion, and the advantages it offers to further support its use in the manufacturing of these chemicals. To put this work into context, it is shown how extrusion plays a vital role for manufacturing in the food, polymer, and pharmaceutical industries, and how the research carried out by these respective industrialists provides great insight and understanding of the technique, with the results being applicable in the chemical industry. The synthesis of metal-organic frameworks (MOFs) is highlighted herein as an excellent example showcasing the advantages that extrusion provides to the manufacture of these materials, one advantage being the exceptional space time yields (STYs) reported for these processes, at three orders of magnitude greater than conventional (solvothermal) synthesis.

Synthesis by extrusion: continuous, large-scale preparation of MOFs using little or no solvent.

Grinding solid reagents under solvent-free or low-solvent conditions (mechanochemistry) is emerging as a general synthetic technique which is an alternative to conventional solvent-intensive methods. However, it is essential to find ways to scale-up this type of synthesis if its promise of cleaner manufacturing is to be realised. Here, we demonstrate the use of twin screw and single screw extruders for the continuous synthesis of various metal complexes, including Ni(salen), Ni(NCS)2(PPh3)2 as well as the commercially important metal organic frameworks (MOFs) Cu3(BTC)2 (HKUST-1), Zn(2-methylimidazolate)2 (ZIF-8, MAF-4) and Al(fumarate)(OH). Notably, Al(fumarate)(OH) has not previously been synthesised mechanochemically. Quantitative conversions occur to give products at kg h-1 rates which, after activation, exhibit surface areas and pore volumes equivalent to those of materials produced by conventional solvent-based methods. Some reactions can be performed either under completely solvent-free conditions whereas others require the addition of small amounts of solvent (typically 3-4 mol equivalents). Continuous neat melt phase synthesis is also successfully demonstrated by both twin screw and single screw extrusion for ZIF-8. The latter technique provided ZIF-8 at 4 kg h-1. The space time yields (STYs) for these methods of up to 144 × 103 kg per m3 per day are orders of magnitude greater than STYs for other methods of making MOFs. Extrusion methods clearly enable scaling of mechanochemical and melt phase synthesis under solvent-free or low-solvent conditions, and may also be applied in synthesis more generally.