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 kg_MOF 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.

While biodiesel is one of many necessary steps forward in a cleaner transportation future, alkali metal residuals, including Na and K (in the form of oxides, sulfates, hydroxides, and carbonates) originating from fuel production catalysts were found to be detrimental to emissions control components. Na + K and Ca + Mg (also biodiesel production byproducts) are regulated by ASTM-D6751 standards (American Society for Testing and Materials) to be less than 5 ppm for B100; however, the literature gives examples of physical and chemical degradation of automotive emissions catalysts and their substrates with these Na and K residuals. The purpose of this study is to investigate the impacts of ash from Na-doped biodiesel fuel (B20) on a diesel particulate filter (DPF). Investigations found that the Na-ash accumulated in the DPF has several unique properties which help to fundamentally explain some of the interactions and impacts of biodiesel on the particle filter. The biodiesel-related Na-ash was found to (1) have a significantly lower melting temperature than typical ash from inorganic lubricant additives and Ultra Low Sulfur Diesel (ULSD) fuel resulting in ash particles sintered to the DPF catalyst/substrate, (2) have a primary particle size which is about an order of magnitude larger than typical ash, (3) produce a larger amount of ash resulting in significantly thick wall ash layers and (4) penetrate the DPF substrate about 3× deeper than typical ULSD and lubricant-related ash. This study utilizes numerous characterization techniques to investigate the interactions between biodiesel-related ash and a DPF, ranging from visualization to composition to thermal analysis methods. The findings suggest the need for tighter control of the thermal environment in the DPF when using biodiesel, additional/improved DPF cleaning efforts, and avoidance of unregulated biodiesel with high Na/K levels.

An important focus of grease development is to minimize friction and wear while improving load bearing capacity. ASTM D2266 test method is commonly used to evaluate performance of grease at 75°C, 40 kg and 1200 rpm for 1 hour. However, actual applications may require bearings to be subjected to cyclic loading and variable frequency conditions wherein rotations per minute (rpm), load and duration of test are variables. Five different blends of greases were formulated using ZDDP (3 wt.%), PTFE (2 wt.%), MoDTC (2 wt.%), combination of ZDDP/PTFE in a weight ratio of 3:2 and a combination of ZDDP/PTFE/MoDTC in 3:2:2 weight ratios. They were tested under ASTM D2266 test method as well as under cyclic loading and variable frequency conditions where loads, frequency and duration of the tests were treated as variables. It was found that the combination of ZDDP/PTFE/MoDTC results in significant improvement in the wear and friction under cyclic loading as well as ASTM D2266 test conditions. It was also demonstrated that MoDTC accelerated the tribochemical degradation of ZDDP that resulted in the formation of a protective tribofilm layer on the interacting surfaces. The analysis of the tribofilm formed indicated that when MoDTC was used together with ZDDP and PTFE, a combination of MoS₂, phosphates and sulfates of Zn and Fe are formed whereas when only ZDDP and PTFE was used the tribofilms were largely composed of phosphates and sulfates of Zn and Fe.