Synthesis of Water-Sensitive Metal–Organic Frameworks within Fiber Sorbent Modules

Scalable Formation of Diamine-Appended Metal-Organic Framework Hollow Fiber Sorbents for Postcombustion CO2 Capture

We describe a straightforward and scalable fabrication of diamine-appended metal-organic framework (MOF)/polymer composite hollow fiber sorbent modules for CO₂ capture from dilute streams, such as flue gas from natural gas combined cycle (NGCC) power plants. A specific Mg-MOF, Mg₂(dobpdc) (dobpdc^4- = 4,4'-dioxidobiphenyl-3,3'-dicarboxylate), incorporated into poly(ether sulfone) (PES) is directly spun through a conventional "dry-jet, wet-quench" method. After phase separation, a cyclic diamine 2-(aminomethyl)piperidine (2-ampd) is infused into the MOF within the polymer matrix during postspinning solvent exchange. The MOF hollow fibers from direct spinning contain as high as 70% MOF in the total fibers with 98% of the pure MOF uptake. The resulting fibers exhibit a step isotherm and a "shock-wave-shock" breakthrough profile consistent with pure 2-ampd-Mg₂(dobpdc). This work demonstrates a practical method for fabricating 2-ampd-Mg₂(dobpdc) fiber sorbents that display the MOF's high CO₂ adsorption capacity while lowering the pressure drop during operation.

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.

Controlled Synthesis of Metal-Organic Frameworks in Scalable Open-Porous Contactor for Maximizing Carbon Capture Efficiency

Metal-organic frameworks (MOFs) are a class of microporous materials that have been highlighted with fast and selective sorption of gas molecules; however, they are at least partially unstable in the scale-up process. Here, we report a rational shaping of MOFs in a scalable architecture of fiber sorbent. The long-standing stability challenge of MOFs was resolved by using stable metal oxide precursors that are subject to controlled surface oxide dissolution-growth chemistry during the Mg-based MOF synthesis. Highly uniform MOF crystals are synthesized along with the open-porous fiber sorbents networks, showing unprecedented cyclic CO₂ capacities in both flue gas and direct air capture (DAC) conditions. The same chemistry enables an in situ flow synthesis of Mg-MOF fiber sorbents, providing a scalable pathway for MOF synthesis in an inert condition with minimal handling steps. This modular approach can serve both as a reaction stage for enhanced MOF fiber sorbent synthesis and as a "process-ready" separation device.

The Effect of Surface Hydroxylation on MOF Formation on ALD Metal Oxides: MOF-525 on TiO2/Polypropylene for Catalytic Hydrolysis of Chemical Warfare Agent Simulants

Metal-organic framework (MOF) fibrous composites were synthesized in a variety of methods in attempt to incorporate the highly effective reactivity of MOFs into a more facile and applicable format. Recent advances have demonstrated incorporating a metal oxide nucleation surface or reactive layer promotes conformal, well-adhered MOF growth on substrates. These materials have demonstrated promising reactivity in capturing or degrading chemical warfare agents and simulants. Here, we examine the mechanisms for MOF nucleation from metal oxide thin films to explore why some metal oxide sources are better suited for one synthesis mechanism over another. We isolate metal oxide extent of hydroxylation as an indicative factor as to whether the film serves as a nucleation promoter or may be converted directly to the MOF thin films. MOF-525 growth on Al₂O₃, TiO₂, and ZnO coated fibers is demonstrated to corroborate these findings and used to degrade chemical warfare agent simulant dimethyl-4-nitrophenyl phosphate.

Propylene Enrichment via Kinetic Vacuum Pressure Swing Adsorption Using ZIF-8 Fiber Sorbents

This work presents the synthesis, characterization, and implementation of ZIF-8/cellulose acetate fiber sorbents for the cyclic kinetic adsorption separation of an equimolar propane/propylene feed. These fiber sorbents are packed as structured mass-transfer contactors and employed in a two-bed vacuum pressure swing adsorption cycle without propylene product purge. The unoptimized adsorption cycle process produces a high-pressure product of up to 81% propane purity at 31% recovery at 0 °C. The effects of adsorption step time, temperature, and feed rate are investigated and presented as a purity/recovery trade-off. This work represents the first successful demonstration of a metal-organic framework fiber sorbent in a pressure swing adsorption cycle and the first use of metal-organic frameworks in a kinetic separation cycle.

UTSA-16 Growth within 3D-Printed Co-Kaolin Monoliths with High Selectivity for CO2/CH4, CO2/N2, and CO2/H2 Separation

Honeycomb monoliths loaded with metal-organic frameworks (MOFs) are highly desirable adsorption contactors because of their low-pressure drop, rapid mass-transfer kinetics, and high-adsorption capacity. Moreover, three-dimensional (3D)-printing technology renders direct material modification a realistic and economic prospect. In this study, 3D printing was utilized to impregnate kaolin-based monolith with UTSA-16 metal formation precursor (Co), whereupon an internal growth was facilitated via a solvothermal synthesis approach. The cobalt weight loading in the kaolin support was varied systematically to optimize the MOF growth while retaining monolith mechanical integrity. The obtained UTSA-16 monolith with 90 wt % loading exhibited similar textural features and adsorption characteristics to its powder analogue while improving upon structural integrity. In comparison to previously developed 3D-printed UTSA-16 monoliths, the UTSA-16-kaolin monolith not only showed higher MOF loading but also higher compression stress, indicative of its robust structure. Furthermore, the 3D-printed UTSA-16-kaolin monolith displayed a comparable CO₂ adsorption capacity to the UTSA-16 powder (3.1 vs 3.5 mmol/g at 25 °C and 1 bar), which was proportional to its loading. Selectivity values of 49, 238, and 3725 were obtained for CO₂/CH₄, CO₂/N₂, and CO₂/H₂, respectively, demonstrating good separation potential of the 3D-printed MOF monolith for various gas mixtures, as determined by both equilibrium and dynamic adsorption measurements. Overall, this study provides a novel route for the fabrication of UTSA-16-loaded monoliths, which demonstrate both high MOF loading and mechanical integrity that could be readily applied to various CO₂ capture applications.

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.

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.