Optimum structured adsorbents for gas separation processes

3D-Printed MOF Monoliths: Fabrication Strategies and Environmental Applications

Metal-organic frameworks (MOFs) have been extensively considered as one of the most promising types of porous and crystalline organic-inorganic materials, thanks to their large specific surface area, high porosity, tailorable structures and compositions, diverse functionalities, and well-controlled pore/size distribution. However, most developed MOFs are in powder forms, which still have some technical challenges, including abrasion, dustiness, low packing densities, clogging, mass/heat transfer limitation, environmental pollution, and mechanical instability during the packing process, that restrict their applicability in industrial applications. Therefore, in recent years, attention has focused on techniques to convert MOF powders into macroscopic materials like beads, membranes, monoliths, gel/sponges, and nanofibers to overcome these challenges.Three-dimensional (3D) printing technology has achieved much interest because it can produce many high-resolution macroscopic frameworks with complex shapes and geometries from digital models. Therefore, this review summarizes the combination of different 3D printing strategies with MOFs and MOF-based materials for fabricating 3D-printed MOF monoliths and their environmental applications, emphasizing water treatment and gas adsorption/separation applications. Herein, the various strategies for the fabrication of 3D-printed MOF monoliths, such as direct ink writing, seed-assisted in-situ growth, coordination replication from solid precursors, matrix incorporation, selective laser sintering, and digital light processing, are described with the relevant examples. Finally, future directions and challenges of 3D-printed MOF monoliths are also presented to better plan future trajectories in the shaping of MOF materials with improved control over the structure, composition, and textural properties of 3D-printed MOF monoliths.

On Comparing Packed Beds and Monoliths for CO2 Capture from Air Through Experiments, Theory, and Modeling

This study compares the performance of amine-functionalized γ-alumina sorbents in the form of 3 mm γ-alumina pellets and of a γ-alumina wash-coated monolith for CO2 capture for direct air capture (DAC). Breakthrough experiments were conducted on the two contactors to analyze the adsorption kinetics and performance for different gas feeds. A constant pattern analysis revealed dominant mass transfer resistances in the gas film and in the pores, with axial dispersion also observed, particularly at higher concentrations. A 1D, physical model was used to fit the experiments and thus to estimate mass transfer and axial dispersion coefficients, which appear to be consistent with the hypotheses derived from constant pattern analysis. A dual kinetic model to describe mass transfer was found to better describe the tail behavior in the monolith, whereas a pseudo-first-order model was sufficient to describe breakthroughs on packed beds. A substantial two-order magnitude decrease in mass transfer coefficients was noted when reducing the feed concentration from 5.6% to 400 ppm CO2, thus underscoring the significant mass transfer limitations observed in DAC. Comparison between the contactors revealed notably higher mass transfer coefficients in the monolith compared to the packed beds, which are attributed to shorter diffusion lengths and lower equilibrium capacity. While the faster mass transfer coefficients observed in the monolith experiments led to reduced specific energy consumption and increased adsorption productivity compared to the packed bed at 400 ppm, no significant improvement was observed for the same process at the higher concentration of 5.6% CO2 in the feed. This finding highlights the need to tailor the contactor design to the specific gas separation requirements. This research contributes to the understanding and quantification of mass transfer kinetics at DAC concentrations in both packed bed and monolith contactors. It demonstrates the crucial role of the contactor in DAC systems and the importance of optimizing the adsorption step to enhance productivity and DAC performance.

Development, characterization and application of 3D printed adsorbents for in situ recovery of taxadiene from microbial cultivations

Microbial cell factories are an attractive alternative to produce high-value natural products using sustainable processes. However, product recovery is one of the main challenges to reduce production cost and make these technologies economically interesting. In this work, new resins were formulated to 3D print hydrophobic adsorbents for the recovery of biologics from microbial cultivations. Benzyl methacrylate (BEMA) and butyl methacrylate (BUMA) were selected as functional monomers suitable for the adsorption of hydrophobic compounds. Pore morphology was tailored through the inclusion of pore forming agents (porogens) in the resin. Different porogens and porogen concentrations were evaluated resulting in materials with different porous networks. Sudan 1 and the anticancer drug paclitaxel were employed as model compounds to test the adsorption performance of hydrophobic and terpene molecules onto the developed 3D printed materials. The material with greatest adsorption capacity was obtained using BEMA monomer with 40 % (v/v) porogen (BEMA40). The performance of BEMA40 to recover taxadiene from small-scale (5 mL) Saccharomyces cerevisiae cultivations was tested and compared with commercial Diaion HP-20 beads. Taxadiene titres on BEMA40 (46 ± 2 mg/L) and Diaion HP-20 (54 ± 4 mg/L) were comparable, with no taxadiene detected in the cells and cell-free media, suggesting near 100 % taxadiene partition on the adsorbents. Compared to commercial beads, 3D printed adsorbents can be customized with adjustments in the resin formulation, are well adaptable to diverse bioreactor types, do not clog sampling ports and columns and are easier to handle during post processing. The results of this work demonstrate the potential of 3D printing to fabricate hydrophobic interaction adsorbent materials and their application in the recovery of biological products.

Alumina Incorporation in Self-Supported Poly(ethylenimine) Sorbents for Direct Air Capture

Self-supported branched poly(ethylenimine) scaffolds with ordered macropores are synthesized with and without Al2O3 powder additive by cross-linking poly(ethylenimine) (PEI) with poly(ethylene glycol) diglycidyl ether (PEGDGE) at -196 °C. The scaffolds' CO2 uptake performance is compared with a conventional sorbent, i.e., PEI impregnated on an Al2O3 support. PEI scaffolds with Al2O3 additive show narrow pore size distribution and thinner pore walls than alumina-free materials, facilitating higher CO2 uptake at conditions relevant to direct air capture. The PEI scaffold containing 6.5 wt % Al2O3 had the highest CO2 uptake of 1.23 mmol/g of sorbent under 50% RH 400 ppm of CO2 conditions. In situ DRIFT spectroscopy and temperature-programmed desorption experiments show a significant CO2 uptake contribution via physisorption as well as carbamic acid formation, with lower CO2 binding energies in PEI scaffolds relative to conventional PEI sorbents, likely a result of a lower population of primary amines due to the amine cross-linking reactions during scaffold synthesis. The PEI scaffold containing 6.5 wt % Al2O3 is estimated to have the lowest desorption energy penalty under humid conditions, 4.6 GJ/tCO2, among the sorbents studied.

Carbon dioxide separation and capture by adsorption: a review

Rising adverse impact of climate change caused by anthropogenic activities is calling for advanced methods to reduce carbon dioxide emissions. Here, we review adsorption technologies for carbon dioxide capture with focus on materials, techniques, and processes, additive manufacturing, direct air capture, machine learning, life cycle assessment, commercialization and scale-up.

Green synthesis of a hydrophobic metal-organic gel for the capture of trace odorous hexanal from humid air

The development of superhydrophobic adsorbents for the capture of trace volatile organic compounds (VOCs) from humid indoor air is still a challenge. Herein, we reported the formation of a granular zinc-based metal-organic gel, i.e., ZIF-412(gel) by optimizing the synthesis conditions. The thermally stable xerogel exhibited high surface area (1008 m²/g), hydrophobicity, and viscosity for self-depositing on the substrate such as non-woven fibers. Dynamic adsorption experiments under various humidity conditions demonstrated as-synthesized ZIF-412(gel) owned excellent VOC (hexanal) adsorption performance with adsorption capacity higher than commercial activated carbon and some water-stable MOFs including ZIF-8, ZIF-67, MIL-101(Cr) and ZIF-414. ZIF-412(gel) could be regenerated at temperature as low as 358 K without obvious loss in adsorption capacity. The adsorption mechanism of hexanal over ZIF-412(gel) is also simulated by Grand canonical Monte Carlo (GCMC).

Direct Ink 3D Printing of Porous Carbon Monoliths for Gas Separations

Additive manufacturing or 3D printing is the advanced method of manufacturing monolithic adsorbent materials. Unlike beads or pellets, 3D monolithic adsorbents possess the advantages of widespread structural varieties, low heat and mass transfer resistance, and low channeling of fluids. Despite a large volume of research on 3D printing of adsorbents having been reported, such studies on porous carbons are highly limited. In this work, we have reported direct ink 3D printing of porous carbon; the ink consisted of commercial activated carbon, a gel of poly(4-vinylphenol) and Pluronic F127 as plasticizer, and bentonite as the binder. The 3D printing was performed in a commercial 3D printer that has been extensively modified in the lab. Upon 3D printing and carbonization, the resultant 3D printed porous carbon demonstrated a stable structure with a BET area of 400 m²/g and a total pore volume of 0.27 cm³/g. The isotherms of six pure-component gases, CO₂, CH₄, C₂H₆, N₂, CO, and H₂, were measured on this carbon monolith at 298 K and pressure up to 1 bar. The selectivity of four gas pairs, C₂H₆/CH₄, CH₄/N₂, CO/H₂, and CO₂/N₂, was calculated by Ideally Adsorbed Solution Theory (IAST) and reported. Ten continuous cycles of adsorption and desorption of CO₂ on this carbon confirmed no loss of working capacity of the adsorbent.

Adsorption of Carbon Dioxide with Ni-MOF-74 and MWCNT Incorporated Poly Acrylonitrile Nanofibers

Among the new adsorbent forms, nanofiber structures have attracted extra attention because of features such as high surface area, controllable properties, and fast kinetics. The objective of this study is to produce the polyacrylonitrile (PAN) electrospun nanofibers loaded with Ni-MOF-74/MWCNT to obtain maximum CO₂ adsorption. The prepared PAN/MWCNT/MOF nanofiber based on the Box–Behnken design (BBD) model suggests the CO₂ adsorption of about 1.68 mmol/g (at 25 °C and 7 bar) includes 14.61 w/v%, 1.43 w/w%, and 11.9 w/w% for PAN, MWCNT, and MOF, respectively. The results showed the effective CO₂ adsorption of about 1.65 ± 0.03 mmol/g (BET = 65 m²/g, pore volume = 0.08 cm³/g), which proves the logical outcomes of the chosen model. The prepared PAN/MWCNT/MOF nanofiber was characterized using different analyzes such as SEM, TEM, TG, XRD, FTIR, and N₂ adsorption–desorption isotherms. More MOF mass loading on the nanofiber surface via secondary growth method resulted in 2.83 mmol/g (BET = 353 m²/g, pore volume = 0.22 cm³/g, 43% MOF mass loading) and 4.35 mmol/g (BET = 493 m²/g, pore volume = 0.27 cm³/g, 65% MOF mass loading) CO₂ adsorption at 7 bar for the first and second growth cycles, respectively. This indicates that secondary growth is more effective in the MOF loading amount and, consequently, adsorption capacity compared to the MOF loading during electrospinning.

Polymeric Fiber Sorbents Embedded with Porous Organic Cages

The synthesis and functionalization of porous organic cages (POCs) for separation have attracted growing interest over the past decade. However, the potential of solid-phase POCs for practical, large-scale separations will require incorporation into appropriate gas-solid or liquid-solid contactors. Contactors with more effective mass transfer properties and lower pressure drops than pelletized systems are preferred. Here, we prepared and characterized fiber sorbents with POCs throughout a cellulose acetate (CA) polymer matrix, which were then deployed in model separations. The POC CC3 was shown to be stable after exposure to spinning solvents, as confirmed by NMR, powder X-ray diffraction, and gas sorption experiments. CC3-CA fibers were spun using the dry-jet wet-quench spinning method. Spun fibers retained the adsorptive properties of CC3 powders, as confirmed by CO₂ and N₂ physisorption and TGA, reaching upward of 60 wt % adsorbent loading, whereas the pelletized CC3 counterparts suffered significant losses in textural properties. The separation capabilities of the CC3-CA fibers are tested with both simulated postcombustion flue gas and with Xe/Kr mixtures. Fixed bed breakthrough experiments performed on fibers samples show that CC3 embedded in polymeric fibers can effectively perform these proof-of-concept gas separations. The development of fiber sorbents embedded with POCs provides an alternative to traditional pelletization for the incorporation of these materials into adsorptive separation systems.

Recent Advances in 3D Printing of Structured Materials for Adsorption and Catalysis Applications

Porous solids in the form of adsorbents and catalysts play a crucial role in various industrially important chemical, energy, and environmental processes. Formulating them into structured configurations is a key step toward their scale up and successful implementation at the industrial level. Additive manufacturing, also known as 3D printing, has emerged as an invaluable platform for shape engineering porous solids and fabricating scalable configurations for use in a wide variety of separation and reaction applications. However, formulating porous materials into self-standing configurations can dramatically affect their performance and consequently the efficiency of the process wherein they operate. Toward this end, various research groups around the world have investigated the formulation of porous adsorbents and catalysts into structured scaffolds with complex geometries that not only exhibit comparable or improved performance to that of their powder parents but also address the pressure drop and attrition issues of traditional configurations. In this comprehensive review, we summarize the recent advances and current challenges in the field of adsorption and catalysis to better guide the future directions in shape engineering solid materials with a better control on composition, structure, and properties of 3D-printed adsorbents and catalysts.

Porous Clay Heterostructure with Alginate Encapsulation for Toluene Removal

A volatile organic compound adsorbent based on a porous clay heterostructure (PCH) with alginate biopolymer was successfully prepared. From N₂ adsorption-desorption analysis, the specific surface area, pore volume, and pore size of bentonite were dramatically increased after introducing the porous structure. Following complexation with alginate (Alg-PCH), the pore volume and pore size were not significantly affected by pore structure. The thermal stability of Alg-PCH shows enhanced thermal stability compared to alginate and alginate beads. The morphology layered structure of Alg-PCH was carried out by transmission electron microscopy (TEM), suggesting the disorder and re-order of the c-axis layer stacking by porous structure and complexation with alginate, respectively, which was well-matched with X-ray diffraction results. To optimize the preparation of Alg-PCH, various reaction conditions (alginate, CaCl₂ concentration, bead size, and weight ratio between alginate and PCH) were utilized. According to the toluene adsorption-desorption experiments, the preparation conditions for Alg-PCH were selected as a 2 mm extrusion tip, 0.5% of alginate, and 2% of CaCl₂ solution with a 1:50 alginate:PCH weight ratio. Additionally, it shows 61.63 mg/g adsorption capacity with around 49% desorption efficacy under atmospheric temperature and pressure.

Guidelines for Techno-Economic Analysis of Adsorption Processes

Techno-economic analyses (TEAs) of CO2 capture technologies have risen in popularity, due to growing interest in meeting CO2 emissions reduction targets. Adsorption processes are one of the technologies proposed for CO2 capture, and although difficult, standardization of TEAs for adsorption should be attempted. The reason is that TEAs are often referred to as input data to other forms of modeling, to guide policy, and to act as summaries for those unfamiliar with adsorption processes. Herein, we discuss the aspects that should be considered when conducting TEAs for CO2 adsorption processes, and we present the implications of choices made at the TEA stage and offer guidance on best practice. our aim is to make TEAs of adsorption processes widely accessible to the adsorption community, and more generally to communities engaged in the evaluation of CCS technologies.

Gel-Print-Grow: A New Way of 3D Printing Metal-Organic Frameworks

3D printing offers an attractive means of forming structured metal-organic frameworks (MOFs), as this technique imparts digital geometric tuning to fit any process column. However, 3D-printed MOF structures are usually formed by suspending presynthesized particles into an ink for further processing. This leads to poor rheological properties as MOFs do not bind with inert binders. Herein, we address this problem by coordinating the MOF secondarily by 3D printing its gelated precursors. Specifically, we produced a printable sol-gel containing ∼70 wt % of HKUST-1 precursors and optimized the in situ growth conditions by varying the desolvation temperature and activation solvent. Analysis of the so-called gel-print-grow monoliths' properties as a function of the coordination variables revealed that desolvating at 120 °C produced fully formed MOF particles with comparable diffractive indices to the parent powder regardless of the activation solvent used. Assessment of the samples' textural properties revealed that washing in acetone or methanol produced the highest surface areas, pore volumes, and CO₂ adsorption capacities, however, washing with methanol produced binder swelling and collapse of the printed structure, thereby indicating that washing with acetone was more effective overall. This study represents a promising way of 3D printing MOFs and a breakthrough in additive manufacturing, since the simple, high-throughput, framework detailed herein-whereby the synthesis temperature and washing solvent are varied to optimize MOF coordination-could easily be applied to other crystallites. As such, it is anticipated that this new and exciting method will provide new paths to shape engineer MOFs for applications in energy-intensive fields and beyond.

Three-Dimensional-Printed Core-Shell Structured MFI-Type Zeolite Monoliths for Volatile Organic Compound Capture under Humid Conditions

Crystalline aluminosilicate zeolites with high sorption capacity and low production cost have been recognized as a promising adsorbent for volatile organic compound (VOC) capture. However, the ubiquitous water vapor in the VOC streams may compete with VOCs during the practical separation process because of the hydrophilic property of aluminosilicate zeolites. Herein, a self-supporting core-shell structured MFI-type zeolite monolith was fabricated by 3D-printing aluminosilicate ZSM-5 zeolites as the core, followed by coating silicalite-1 zeolites as a hydrophobic shell via post-hydrothermal crystallization. Natural sepiolite nanofibers (SNFs) were employed as printing ink additives for reinforcing the mechanical stability of 3D-printed ZSM-5 monoliths. Colloidal silica was also introduced into the printing inks, affording continuous growth of silicalite-1 layers (with a thickness of ∼200 nm) over ZSM-5 crystals. Such core-shell structured MFI-type zeolite monoliths exhibited superior dynamic adsorption performance for toluene at 298 K under humid conditions (relative humidity: 50%), with a saturated adsorption capacity of 44.3 mg/g. This work provides a facile strategy for designing self-supporting zeolite monoliths with core-shell architectures for adsorption/separation and other advanced applications.

Fabricating Mechanically Robust Binder-Free Structured Zeolites by 3D Printing Coupled with Zeolite Soldering: A Superior Configuration for CO2 Capture

3D-printing technology is a promising approach for rapidly and precisely manufacturing zeolite adsorbents with desirable configurations. However, the trade-off among mechanical stability, adsorption capacity, and diffusion kinetics remains an elusive challenge for the practical application of 3D-printed zeolites. Herein, a facile "3D printing and zeolite soldering" strategy is developed to construct mechanically robust binder-free zeolite monoliths (ZM-BF) with hierarchical structures, which can act as a superior configuration for CO2 capture. Halloysite nanotubes are employed as printing ink additives, which serve as both reinforcing materials and precursor materials for integrating ZM-BF by ultrastrong interfacial "zeolite-bonds" subjected to hydrothermal treatment. ZM-BF exhibits outstanding mechanical properties with robust compressive strength up to 5.24 MPa, higher than most of the reported structured zeolites with binders. The equilibrium CO2 uptake of ZM-BF reaches up to 5.58 mmol g-1 (298 K, 1 bar), which is the highest among all reported 3D-printed CO2 adsorbents. Strikingly, the dynamic adsorption breakthrough tests demonstrate the superiority of ZM-BF over commercial benchmark zeolites for flue gas purification and natural gas and biogas upgrading. This work introduces a facile strategy for designing and fabricating high-performance hierarchically structured zeolite adsorbents and even catalysts for practical applications.

Challenges and opportunities for adsorption-based CO2 capture from natural gas combined cycle emissions

In recent years, the power sector has shown a growing reliance on natural gas, a cleaner-burning fuel than coal that emits approximately half as much CO2 per kWh of energy produced. This rapid growth in the consumption of natural gas has led to increased CO2 emissions from gas-fired power plants. To limit the contribution of fossil fuel combustion to atmospheric CO2 levels, carbon capture and sequestration has been proposed as a potential emission mitigation strategy. However, despite extensive exploration of solid adsorbents for CO2 capture, few studies have examined the performance of adsorbents in post-combustion capture processes specific to natural gas flue emissions. In this perspective, we emphasize the importance of considering gas-fired power plants alongside coal-fired plants in future analyses of carbon capture materials. We address specific challenges and opportunities related to adsorptive carbon capture from the emissions of gas-fired plants and discuss several promising candidate materials. Finally, we suggest experiments to determine the viability of new CO2 capture materials for this separation. This broadening in the scope of current carbon capture research is urgently needed to accelerate the deployment of transformational carbon capture technologies.

Highly Robust MOF Polymeric Beads with a Controllable Size for Molecular Separations

Shaping metal-organic frameworks (MOFs) into robust particles with a controllable size is of large interest to the field of adsorption. Therefore, a method is presented here to produce robust MOF beads of different sizes, ranging from 250 μm to several millimeters, which, moreover, preserve the adsorption properties of the unformulated MOF. A simple, mild, and flexible method is demonstrated with the zeolitic imidazolate framework-8 (ZIF-8)/polyvinyl formal composite material. The properties of the composite material are determined via optical imaging, scanning electron microscopy, energy-dispersive X-ray spectroscopy, inductively coupled plasma mass spectrometry, X-ray diffraction, mercury intrusion, argon porosimetry and pycnometry as well as thermogravimetric analysis/differential scanning calorimetry, crush strength tests, and immersion experiments. The proposed method allows the production of resistant particles with a high MOF loading (up to 85 wt %) and remarkable structural and textural properties required for adsorptive separation processes, including a preserved ZIF-8 crystalline structure, microporosity, and a narrow macropore size distribution (1.27 μm average). The particles show a spherical shape with an average aspect ratio of 0.85. The stability tests demonstrated that the composite MOF material exhibits a high mechanical strength (3.09 N/Pc crushing strength) almost equivalent to that of a widely used commercial zeolite material. Furthermore, the material remains stable up to 200 °C and in most solvents. The adsorption properties are explored via static and dynamic experiments in the vapor and liquid phases. The results show that the adsorption capacities are only reduced in proportion to the binder content compared with the pristine material, indicating no binder intrusion in the ZIF-8 pores. Fixed-bed experiments demonstrate the remarkable separation performance in the vapor phase, whereas mass transfer limitations arise in the liquid phase with increasing flow rate. The mass transfer limitations are attributed to the diffusion in the macropores or through the ZIF-8 crystal outer layer.

Critical Comparison of Structured Contactors for Adsorption-Based Gas Separations

Recent advances in adsorptive gas separations have focused on the development of porous materials with high operating capacity and selectivity, useful parameters that provide early guidance during the development of new materials. Although this material-focused work is necessary to advance the state of the art in adsorption science and engineering, a substantial problem remains: how to integrate these materials into a fixed bed to efficiently utilize the separation. Structured sorbent contactors can help manage kinetic and engineering factors associated with the separation, including pressure drop, sorption enthalpy effects, and external heat integration (for temperature swing adsorption, or TSA). In this review, we discuss monoliths and fiber sorbents as the two main classes of structured sorbent contactors; recent developments in their manufacture; advantages and disadvantages of each structure relative to each other and to pellet packed beds; recent developments in system modeling; and finally, critical needs in this area of research.

Controlled Gas Uptake in Metal-Organic Frameworks with Record Ammonia Sorption

Ammonia is a vital commodity in our food supply chain, but its toxicity and corrosiveness require advanced protection and mitigation. These needs are not met efficiently by current materials, which suffer from either low capacity or low affinity for NH₃. Here, we report that a series of microporous triazolate metal-organic frameworks containing open metal sites exhibit record static and dynamic ammonia capacities. Under equilibrium conditions at 1 bar, the materials adsorb up to 19.79 mmol NH₃ g^-1, more than twice the capacity of activated carbon, the industry standard. Under conditions relevant to personal protection equipment, capacities reach 8.56 mmol g^-1, 27% greater than the previous best material. Structure-function relationships and kinetic analyses of NH₃ uptake in isostructural micro- and mesoporous materials made from Co, Ni, and Cu reveal stability trends that are in line with the water substitution rates in simple metal-aquo complexes. Altogether, these results provide clear, intuitive descriptors that govern the static and dynamic uptake, kinetics, and stability of MOF sorbents for strongly interacting gases.

Optimized cesium and potassium ion-exchanged zeolites A and X granules for biogas upgrading

Ion exchange of binderless zeolite A and X granules leads to high CO₂/CH₄ selectivity and CO₂ uptake capacity.

Straightforward Processing Route for the Fabrication of Robust Hierarchical Zeolite Structures

Strong hierarchical porous zeolite structures are prepared by a sol-gel method using freeze gelation. Instead of conventional binders in powder form, such as bentonite or kaolin, it has been proven that using a freeze gelation method based on a colloidal silica sol is a more straightforward and easier-to-use-approach in fabricating highly mechanically stable zeolite monoliths. The resulting zeolite slurries possess superior rheological properties (not being pseudoplastic) and show low viscosities. This low viscosity of the slurry enables an increase in the solid content without compromising the extraordinary good flow behavior for casting applications. Additionally, in comparison to conventional powdery binders, zeolite samples prepared by using a colloidal silica sol exhibit a significantly higher mechanical strength. This mechanical strength can be further improved by either increasing the zeolite content or increasing the silica to zeolite ratio. Increasing the zeolite content leads to an increased volumetric adsorption capacity for CO₂ as the test gas, resulting from the increased amount of zeolite particles per unit volume. In addition, a higher solid content of the zeolite monoliths leads to higher compression strengths, while showing the same elastic deformation and brittle failure characteristics. In turn, increasing the silica to zeolite ratio does not affect the volumetric adsorption capacity for CO₂. Nevertheless, higher silica contents lead to a significant increase in the elastic deformation and absorbed work until failure. Therefore, the proposed processing route based on freeze gelation presents an easy and unique tool to tune the mechanical and gas adsorptive properties of hierarchically structured zeolite monoliths, according to the application requirements.

3D-Printed Metal-Organic Framework Monoliths for Gas Adsorption Processes

Metal-organic frameworks (MOFs) have shown promising performance in separation, adsorption, reaction, and storage of various industrial gases; however, their large-scale applications have been hampered by the lack of a proper strategy to formulate them into scalable gas-solid contactors. Herein, we report the fabrication of MOF monoliths using the 3D printing technique and evaluation of their adsorptive performance in CO₂ removal from air. The 3D-printed MOF-74(Ni) and UTSA-16(Co) monoliths with MOF loadings as high as 80 and 85 wt %, respectively, were developed, and their physical and structural properties were characterized and compared with those of MOF powders. Our adsorption experiments showed that, upon exposure to 5000 ppm (0.5%) CO₂ at 25 °C, the MOF-74(Ni) and UTSA-16(Co) monoliths can adsorb CO₂ with uptake capacities of 1.35 and 1.31 mmol/g, respectively, which are 79% and 87% of the capacities of their MOF analogues under the same conditions. Furthermore, a stable performance was obtained for self-standing 3D-printed monolithic structures with relatively good adsorption kinetics. The preliminary findings reported in this investigation highlight the advantage of the robocasting (3D printing) technique for shaping MOF materials into practical configurations that are suitable for various gas separation applications.

Monolith-Supported Amine-Functionalized Mg2(dobpdc) Adsorbents for CO2 Capture

The potential of using an amine-functionalized metal organic framework (MOF), mmen-M₂(dobpdc) (M = Mg and Mn), supported on a structured monolith contactor for CO₂ capture from simulated flue gas is explored. The stability of the unsupported MOF powders under humid conditions is explored using nitrogen physisorption and X-ray diffraction analysis before and after exposure to humidity. Based on its superior stability to humidity, mmen-Mg₂(dobpdc) is selected for further growth on a honeycomb cordierite monolith that is wash-coated with α-alumina. A simple approach for the synthesis of an Mg₂(dobpdc) MOF film using MgO nanoparticles as the metal precursor is used. Rapid drying of MgO on the monolith surface followed by a hydrothermal treatment is demonstrated to allow for the synthesis of a MOF film with good crystallite density and favorable orientation of the MOF crystals. The CO₂ adsorption behavior of the monolith-supported mmen-Mg₂(dobpdc) material is assessed using 10% CO₂ in helium and 100% CO₂, demonstrating a CO₂ uptake of 2.37 and 2.88 mmol/g, respectively. Excellent cyclic adsorption/desorption performance over multiple cycles is also observed. This is one of the first examples of the deployment of an advanced MOF adsorbent in a scalable, low-pressure drop gas-solid contactor. Such demonstrations are critical to the practical application of MOF materials in adsorptive gas separations, as structured contactors have many practical advantages over packed or fluidized beds.