(188c) Continuous Manufacturing of MOFs

Metal-organic frameworks (MOFs) are a class of polymeric materials that exhibit high internal surface areas, making them ideal for applications in gas storage and separation. Adsorbent-based separations using MOFs offer a cost effective and energy-efficient solution compared to the current state-of-the-art. To date, MOFs are predominantly produced batch-wise on a laboratory scale via solvothermal synthesis methods, requiring days or weeks to synthesize. Novel, highly efficient and scalable processes are required to manufacture MOFs at an expedited rate for utilization as sorbents for by-product recovery and separations. This class of sorbent material also necessitates an industrially processible form factor that maintains its base powder adsorption properties and eliminates pressure drop. Under a Department of Energy sponsored program, Physical Sciences Inc. (PSI) has developed and demonstrated an innovative approach for a continuous MOF manufacturing process with substantial reductions in synthesis time to produce materials with adsorption capabilities that meet or exceed current state-of-the-art. The key innovation is replacing conventional small batch solvothermal methods with continuous, energy efficient process enabled by emergent reaction technologies. The process can generate MOF within hours compared to days using conventional batch solvothermal synthesis. The technology was validated via the production of over one kilogram of MOF that showed BET surface areas and pore sizes that are comparable to those produced via solvothermal syntheses. The MOF materials were shape-engineered into form factors that are suitable for packed columns used in standard gas separation and storage applications. This presentation will provide a comprehensive overview of the continuous MOF manufacturing approach, in addition to providing key results, conclusions, and the next steps in the technology development.

Acknowledgement of Support and Disclaimer: This material is based upon work supported by U.S. Department of Energy Organization under Contract Number DE-SC0022591. Any opinions, findings and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of U.S. Department of Energy Organization.