Trevor D. Hadley

Scalability of Continuous Flow Production of Metal–Organic Frameworks

Achieving the large-scale production of metal-organic frameworks (MOFs) is crucial for their utilization in applied settings. For many MOFs, quality suffers from large-scale, batch reaction systems. We have developed continuous processes for their production which showed promise owing to their versatility and the high quality of the products. Here, we report the successful upscaling of this concept by more than two orders of magnitude to deliver unprecedented production rates and space-time-yields (STYs) while maintaining the product quality. Encouragingly, no change in the reaction parameters, obtained at small scale, was required. The production of aluminium fumarate was achieved at an STY of 97 159 kg m(-3)  day(-1) and a rate of 5.6 kg h(-1) .

Scalable simultaneous activation and separation of metal–organic frameworks

Despite the many promising applications of Metal–Organic Frameworks (MOFs) the key advances to boost production to industrial scale still remain elusive. Recently, it has been shown that continuous flow chemistry is capable of handling the production of a large variety of MOFs, while also being scalable. However commonly used laboratory methods for postproduction processing, i.e. separation and activation are ineffective and costly at scale. Here we present the use of megasonics, a novel and scalable methodology based on sonication with high frequency sound waves, which performs separation and activation simultaneously, yielding high surface areas that previously were only obtainable with laboratory-scale methods like solvent exchange, supercritrics and calcination.

Small Scale Hydrogen Production from Metal-Metal Oxide Redox Cycles

The industrial production of hydrogen by reforming natural gas is well established. However, this process is energy intensive and process economics are adversely affected as scale is decreased. There are many situations where a smaller supply of hydrogen, sometimes in remote locations, is required. To this end, the steam-iron process, an originally coal-based process, has been re-considered as an alternative. Many recent investigations have shown that hydrogen (H2) can be produced when methane (CH4) is used as the feedstock under carefully controlled process conditions. The chemistry driving this chemical looping (CL) process involves the reduction of metal oxides by methane and the oxidation of lower oxidation state metal oxides with steam. This process utilises oxygen from oxide materials that are able to transfer oxygen and eliminates the need of purified oxygen for combustion. Such a system has the potential advantage of being less energy intensive than reforming processes and of being flexible enough for decentralised hydrogen production from stranded reserves of natural gas. This chapter first reviews the existing hydrogen production technologies then highlights the recent progress made on hydrogen production from small scale CL processes. The development of oxygen carrier materials will also be discussed. Finally, a preliminary economic appraisal of the CL process will be presented.