A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808
Metal–organic frameworks (MOFs) are promising materials for a wide range of applications given their chemical stability and structural tunability. Most traditional MOF synthesis methods use batch reactors with intrinsic inefficiencies during scale-up that negatively impact process productivity. Here...
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| Format: | Article |
| Language: | English |
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Royal Society of Chemistry (RSC)
2022
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| Online Access: | https://hdl.handle.net/1721.1/139658 |
| _version_ | 1826217324717277184 |
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| author | Bagi, Sujay Yuan, Shuai Rojas-Buzo, Sergio Shao-Horn, Yang Román-Leshkov, Yuriy |
| author2 | Massachusetts Institute of Technology. Department of Mechanical Engineering |
| author_facet | Massachusetts Institute of Technology. Department of Mechanical Engineering Bagi, Sujay Yuan, Shuai Rojas-Buzo, Sergio Shao-Horn, Yang Román-Leshkov, Yuriy |
| author_sort | Bagi, Sujay |
| collection | MIT |
| description | Metal–organic frameworks (MOFs) are promising materials for a wide range of applications given their chemical stability and structural tunability. Most traditional MOF synthesis methods use batch reactors with intrinsic inefficiencies during scale-up that negatively impact process productivity. Here, we report a low-cost and energy-efficient continuous manufacturing process for MOF-808—a Zr-MOF widely studied as a catalyst and adsorbent in industrially important processes—using flow-through reactors that increase process yields and minimize solvent use compared to batch processes. The flow platform allowed us to investigate the influence of several synthesis parameters, including residence time, linker concentration, and volumetric ratio of modulator and solvent on the crystallization process. Under optimal conditions, the N,N-dimethylformamide solvent and formic acid modulator volumetric amounts were decreased by 84% and 67%, respectively, and resulted in an increase in productivity (defined in units of kgMOF m−3 day−1) by two orders of magnitude with similar yields, compared to established batch synthesis methods. A process engineering assessment based on laboratory-scale synthesis routes was performed to compare energy and cost savings for flow and batch workflows, indicating that solvent use was the largest contributor to the overall cost. The methodology presented in this work opens new pathways for critical assessment and optimization of continuous manufacturing routes on a lab-scale environment, which serve as a preliminary step for the transition to more efficient MOF synthesis routes at the industrial scale. |
| first_indexed | 2024-09-23T17:01:50Z |
| format | Article |
| id | mit-1721.1/139658 |
| institution | Massachusetts Institute of Technology |
| language | English |
| last_indexed | 2024-09-23T17:01:50Z |
| publishDate | 2022 |
| publisher | Royal Society of Chemistry (RSC) |
| record_format | dspace |
| spelling | mit-1721.1/1396582023-02-13T21:01:22Z A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808 Bagi, Sujay Yuan, Shuai Rojas-Buzo, Sergio Shao-Horn, Yang Román-Leshkov, Yuriy Massachusetts Institute of Technology. Department of Mechanical Engineering Massachusetts Institute of Technology. Department of Chemical Engineering Massachusetts Institute of Technology. Department of Materials Science and Engineering Metal–organic frameworks (MOFs) are promising materials for a wide range of applications given their chemical stability and structural tunability. Most traditional MOF synthesis methods use batch reactors with intrinsic inefficiencies during scale-up that negatively impact process productivity. Here, we report a low-cost and energy-efficient continuous manufacturing process for MOF-808—a Zr-MOF widely studied as a catalyst and adsorbent in industrially important processes—using flow-through reactors that increase process yields and minimize solvent use compared to batch processes. The flow platform allowed us to investigate the influence of several synthesis parameters, including residence time, linker concentration, and volumetric ratio of modulator and solvent on the crystallization process. Under optimal conditions, the N,N-dimethylformamide solvent and formic acid modulator volumetric amounts were decreased by 84% and 67%, respectively, and resulted in an increase in productivity (defined in units of kgMOF m−3 day−1) by two orders of magnitude with similar yields, compared to established batch synthesis methods. A process engineering assessment based on laboratory-scale synthesis routes was performed to compare energy and cost savings for flow and batch workflows, indicating that solvent use was the largest contributor to the overall cost. The methodology presented in this work opens new pathways for critical assessment and optimization of continuous manufacturing routes on a lab-scale environment, which serve as a preliminary step for the transition to more efficient MOF synthesis routes at the industrial scale. 2022-01-24T13:49:24Z 2022-01-24T13:49:24Z 2021-12-13 2022-01-24T13:41:34Z Article http://purl.org/eprint/type/JournalArticle https://hdl.handle.net/1721.1/139658 Bagi, Sujay, Yuan, Shuai, Rojas-Buzo, Sergio, Shao-Horn, Yang and Román-Leshkov, Yuriy. 2021. "A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808." Green Chemistry, 23 (24). en 10.1039/d1gc02824c Green Chemistry Creative Commons Attribution NonCommercial License 4.0 https://creativecommons.org/licenses/by-nc/4.0/ application/pdf Royal Society of Chemistry (RSC) Royal Society of Chemistry (RSC) |
| spellingShingle | Bagi, Sujay Yuan, Shuai Rojas-Buzo, Sergio Shao-Horn, Yang Román-Leshkov, Yuriy A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808 |
| title | A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808 |
| title_full | A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808 |
| title_fullStr | A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808 |
| title_full_unstemmed | A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808 |
| title_short | A continuous flow chemistry approach for the ultrafast and low-cost synthesis of MOF-808 |
| title_sort | continuous flow chemistry approach for the ultrafast and low cost synthesis of mof 808 |
| url | https://hdl.handle.net/1721.1/139658 |
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