Assessment of CO2/CH4 Separation Performance of 3D-Printed Carbon Monoliths in Pressure Swing Adsorption

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.

Popping and Locking: Balanced Rigidity and Porosity of Zeolitic Imidazolate Frameworks for High-Productivity Methane Purification

Zeolitic imidazolate frameworks (ZIFs) hold great promise in carbon capture, owing to their structural designability and functional porosity. However, intrinsic linker dynamics limit their pressure-swing adsorption application to biogas upgrading and methane purification. Recently, a functionality-locking strategy has shown feasibility in suppressing such dynamics. Still, a trade-off between structural rigidity and uptake capacity remains a key challenge for optimizing their high-pressure CO2/CH4 separation performance. Here, we report a sequential structural locking (SSL) strategy for enhancing the CO2 capture capacity and CH4 purification productivity in dynamic ZIFs (dynaZIFs). Specifically, we isolated multiple functionality-locked phases, ZIF-78-lt, -ht1, and -ht2, by activation at 50, 160, and 210 °C, respectively. We observed multiple-level locking through gas adsorption and powder X-ray diffraction. We uncovered an SSL mechanism dominated by linker-linker π-π interactions that transit to C-H···O hydrogen bonds with binding energies increasing from -0.64 to -2.77 and -5.72 kcal mol-1, respectively, as evidenced by single-crystal X-ray diffraction and density functional theory calculations. Among them, ZIF-78-ht1 exhibits the highest CO2 capture capacity (up to 18.6 mmol g-1) and CH4 purification productivity (up to 7.6 mmol g-1) at 298 K and 30 bar. These findings provide molecular and energetic insights into leveraging framework flexibility through the SSL mechanism to optimize porous materials' separation performance.

Cold Temperature Direct Air CO2 Capture with Amine-Loaded Metal-Organic Framework Monoliths

Zeolites, silica-supported amines, and metal-organic frameworks (MOFs) have been demonstrated as promising adsorbents for direct air CO2 capture (DAC), but the shaping and structuring of these materials into sorbent modules for practical processes have been inadequately investigated compared to the extensive research on powder materials. Furthermore, there have been relatively few studies reporting the DAC performance of sorbent contactors under cold, subambient conditions (temperatures below 20 °C). In this work, we demonstrate the successful fabrication of adsorbent monoliths composed of cellulose acetate (CA) and adsorbent particles such as zeolite 13X and MOF MIL-101(Cr) by a 3D printing technique: solution-based additive manufacturing (SBAM). These monoliths feature interpenetrated macroporous polymeric frameworks in which microcrystals of zeolite 13X or MIL-101(Cr) are evenly distributed, highlighting the versatility of SBAM in fabricating monoliths containing sorbents with different particle sizes and density. Branched poly(ethylenimine) (PEI) is successfully loaded into the CA/MIL-101(Cr) monoliths to impart CO2 uptakes of 1.05 mmol gmonolith-1 at -20 °C and 400 ppm of CO2. Kinetic analysis shows that the CO2 sorption kinetics of PEI-loaded MIL-101(Cr) sorbents are not compromised in the monoliths compared to the powder sorbents. Importantly, these monoliths exhibit promising working capacities (0.95 mmol gmonolith-1) over 14 temperature swing cycles with a moderate regeneration temperature of 60 °C. Dynamic breakthrough experiments at 25 °C under dry conditions reveal a CO2 uptake capacity of 0.60 mmol gmonolith-1, which further increases to 1.05 and 1.43 mmol gmonolith-1 at -20 °C under dry and humid (70% relative humidity) conditions, respectively. Our work showcases the successful implementation of SBAM in making DAC sorbent monoliths with notable CO2 capture performance over a wide range of sorption temperatures, suggesting that SBAM can enable the preparation of efficient sorbent contactors in various form factors for other important chemical separations.

Potassium Silicate as Low-Temperature Binder in 3D-Printed Porous Structures for CO2 Separation

Activated carbon sorbents were directly 3D-printed into highly adaptable monolithic/multi-channel systems by using potassium silicate as a low-temperature binder. By employing emerging 3D-printing technologies, monolithic structured sorbents were printed and fully characterized using N₂, Ar, and CO₂-sorption and Hg-intrusion porosimetry. The CO₂-capture performance and the required temperature for active-site regeneration were evaluated by thermogravimetric analysis-looping experiments. A mechanically stable activated carbon sorbent was developed with an increased carbon capture performance, even when a room-temperature regeneration by N₂ purging was applied. Although the CO₂ uptake slightly dropped after several cycles due to incomplete recovery at room temperature, a capacity increase of 25% was observed in comparison with the original activated carbon powder. To improve the recovery of the active sorbent, an optimization of the desorption step was performed by increasing the regeneration temperature up to 150 °C. This resulted in a CO₂ uptake of the composite material of 0.76 mmol/g, almost tripling the working capacity of the original activated carbon powder (0.28 mmol/g). An in situ X-ray diffraction study was carried out to confirm the proposed sorption mechanism, indicating the presence of potassium bicarbonates and confirming the combination of physisorption and chemisorption in our composites. Finally, the structured adsorbent was heated homogeneously by applying a current through the monolith. These results describe the development of a new type of 3D-printed regenerable CO₂ sorbents by using potassium silicate as a low-temperature binder, providing high mechanical strength, good chemical and thermal stability, and improving the total CO₂ capacity. Moreover, the developed monolith is showing a homogeneous resistivity, leading to uniform Joule heating of the CO₂ adsorbent.

Rational Design of Carbon-Based Porous Aerogels with Nitrogen Defects and Dedicated Interfacial Structures toward Highly Efficient CO2 Greenhouse Gas Capture and Separation

CO₂ capture from flowing flue gases through adsorption technology is essential to reduce the emission of CO₂ to the atmosphere. The rational design of highly efficient carbon-based absorbents with interfacial structures containing interconnected porous structures and abundant adsorption sites might be one of the promising strategies. Here, we report the synthesis of nitrogen-doped carbon aerogels (NCAs) via prepolymerized phenol-melamine-formaldehyde organic aerogels (PMF) by controlling the addition amount of ZnCl₂ and the precursor M/P ratio. It has been revealed that NCAs with a higher specific surface area and interconnected porous structures contain a large amount of pyridinic nitrogen and pyrrolic nitrogen. These would act as the intrinsic adsorption sites for highly effective CO₂ capture and further improve the CO₂/N₂ separation efficiencies. Among the prepared samples, NCA-1-2 with a high micropore surface area and high nitrogen content exhibits a high CO₂ adsorption capacity (4.30 mmol g^-1 at 0 °C and 1 bar) and CO₂/N₂ selectivity (36.5 at 25 °C, IAST). Under typical flue gas conditions (25 °C and 1.01 bar), equilibrium gas adsorption analysis and dynamic breakthrough measurement associated with a high adsorption capacity of 2.65 mmol g^-1 at 25 °C and 1.01 bar and 0.81 mmol g^-1 at 25 °C and 0.15 bar. This rationally designed N-doped carbon aerogel with specific interfacial structures and high CO₂ adsorption capacity, high selectivity, and adsorption performance remained pretty stable after multiple uses.

Screening of Adsorbent/Catalyst Composite Monoliths for Carbon Capture-Utilization and Ethylene Production

Combining CO₂ adsorption and utilization in oxidative dehydrogenation of ethane (ODHE) into a single bed is an exciting way of converting a harmful greenhouse gas into marketable commodity chemicals while reducing energy requirements from two-bed processes. However, novel materials should be developed for this purpose because most adsorbents are incapable of capturing CO₂ at the temperatures required for ODHE reactions. Some progress has been made in this area; however, previously reported dual-functional materials (DFMs) have always been powdered-state composites and no efforts have been made toward forming these materials into practical contactors. In this study, we report the first-generation of structured DFM adsorbent/catalyst monoliths for combined CO₂ capture and ODHE utilization. Specifically, we formulated M-CaO/ZSM-5 monoliths (M = In, Ce, Cr, or Mo oxides) by 3D-printing inks with CaCO₃ (CaO precursor), insoluble metal oxides, and ZSM-5. The physiochemical properties of the monoliths were vigorously characterized using X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), N₂ physisorption, elemental mapping, pyridine Fourier transform infrared spectroscopy (Py-FTIR), H₂-temperature-programmed reduction (H₂-TPR), and NH₃-temperature-programmed desorption (NH₃-TPD). Their performances for combined CO₂ adsorption at 600 °C and ODHE reaction at 700 °C under 25 mL/min of 7% C₂H₆ were then investigated. The combined adsorption/catalysis experiments revealed the best performance in Cr-CaO/ZSM-5, which achieved 56% CO₂ conversion, 91.2% C₂H₄ selectivity, and 33.8% C₂H₄ yield. This exceptional performance, which was improved from powdered-state DFMs, was attributed to the high acidity and numerous oxidation states of the Cr₂O₃ dopant which were verified by NH₃-TPD and H₂-TPR. Overall, this study reports the first-ever proof-of-concept for 3D-printed DFM adsorbent/catalyst materials and furthers the area of CO₂ capture and ODHE utilization by providing a simple pathway to structure these composites.