Scalable and sustainable manufacturing of ultrathin metal–organic framework nanosheets (MONs) for solar cell applications

Metal-organic framework nanosheets (MONs) are an emerging class of 2D materials whose tunable chemistry make them ideal for a wide range of sensing, catalytic, electronics and separation applications. However, creating scalable routes to the synthesis of high quality, ultrathin nanosheets remains challenging and little consideration has been given to the economics of making these materials. Here, we demonstrate a scalable synthesis of zinc-porphyrin based nanosheets, Zn2(H2TCPP), for use in organic solar cells and conduct a techno-economic analysis of their pilot-plant scale manufacture. A thorough investigation of the process chemistry of the solvothermal synthesis enabled reduction of reaction time, increased solid content and scale-up of the reaction in batch. Significantly, the addition of triethylamine accelerated the reaction kinetics, which enabled the synthesis temperature to be dropped from > 80 °C to room temperature. Application of these new reaction conditions in a continuous stirred-tank reactor directly formed monolayer MONs at 99 % yield with a space–time yield of 16 kg m−3 day−1, an approximately 20-fold increase in yield compared to adapting the literature procedure. Techno-economic analysis showed a 94 % reduction in the production costs compared to the literature reaction conditions and indicated that the production cost was dominated by ligand price. The general applicability of the method was demonstrated through synthesis of related Cu2(H2TCPP) MONs and tunability through metalation of the porphyrin units with six different metal ions. Finally, the value of the nanosheets was demonstrated through a near doubling in the power conversion efficiency of organic photovoltaic devices when the MONs were incorporated into the active layer. Overall, this work demonstrates the first scalable and sustainable route to producing monolayer nanosheets for high value applications.