The Flow’s the Thing…︁Or Is It? Assessing the Merits of Homogeneous Reactions in Flask and Flow

A field guide to flow chemistry for synthetic organic chemists

Flow chemistry has unlocked a world of possibilities for the synthetic community, but the idea that it is a mysterious "black box" needs to go. In this review, we show that several of the benefits of microreactor technology can be exploited to push the boundaries in organic synthesis and to unleash unique reactivity and selectivity. By "lifting the veil" on some of the governing principles behind the observed trends, we hope that this review will serve as a useful field guide for those interested in diving into flow chemistry.

Microliter-scale reaction arrays for economical high-throughput experimentation in radiochemistry

The increasing number of positron-emission tomography (PET) tracers being developed to aid drug development and create new diagnostics has led to an increased need for radiosynthesis development and optimization. Current radiosynthesis instruments are designed to produce large-scale clinical batches and are often limited to performing a single synthesis before they must be decontaminated by waiting for radionuclide decay, followed by thorough cleaning or disposal of synthesizer components. Though with some radiosynthesizers it is possible to perform a few sequential radiosyntheses in a day, none allow for parallel radiosyntheses. Throughput of one or a few experiments per day is not well suited for rapid optimization experiments. To combat these limitations, we leverage the advantages of droplet-radiochemistry to create a new platform for high-throughput experimentation in radiochemistry. This system contains an array of 4 heaters, each used to heat a set of 16 reactions on a small chip, enabling 64 parallel reactions for the rapid optimization of conditions in any stage of a multi-step radiosynthesis process. As examples, we study the syntheses of several ¹⁸F-labeled radiopharmaceuticals ([¹⁸F]Flumazenil, [¹⁸F]PBR06, [¹⁸F]Fallypride, and [¹⁸F]FEPPA), performing > 800 experiments to explore the influence of parameters including base type, base amount, precursor amount, solvent, reaction temperature, and reaction time. The experiments were carried out within only 15 experiment days, and the small volume (~ 10 μL compared to the ~ 1 mL scale of conventional instruments) consumed ~ 100 × less precursor per datapoint. This new method paves the way for more comprehensive optimization studies in radiochemistry and substantially shortening PET tracer development timelines.

Continuous flow technology-a tool for safer oxidation chemistry

The advantages and benefits of continuous flow technology for oxidation chemistry have been illustrated in tube reactors, micro-channel reactors, tube-in-tube reactors and micro-packed bed reactors in the presence of various oxidants.

Modern advancements in continuous-flow aided kinetic analysis

Although kinetic analysis has traditionally been conducted in a batch vessel, continuous-flow aided kinetic analysis continues to swell in popularity.

Discovery of unexpectedly complex reaction pathways for the Knorr pyrazole synthesis via transient flow

Kinetic data for the Knorr pyrazole synthesis were acquired using transient flow methods, including a novel reactant stoichiometry ramping method, providing new insights into the mechanism, including autocatalysis and an unexpected intermediate.

Enabling intensification of multiphase chemical processes with additive manufacturing

Fixed bed supports of various materials (metal, ceramic, polymer) and geometries are used to enhance the performance of many unit operations in chemical processes. Consider first metal and ceramic monolith support structures, which are typically extruded. Extruded monoliths contain regular, parallel channels enabling high throughput because of the low pressure drop accompanying high flow rate. However, extruded channels have a low surface-area-to-volume ratio resulting in low contact between the fluid phase and the support. Additive manufacturing, also referred to as three dimensional printing (3DP), can be used to overcome these disadvantages by offering precise control over key design parameters of the fixed bed including material-of-construction and total bed surface area, as well as accommodating system integration features compatible with continuous flow chemistry. These design parameters together with optimized extrinsic process conditions can be tuned to prepare customizable separation and reaction systems based on objectives for chemical process and/or the desired product. We discuss key elements of leveraging the flexibility of additive manufacturing to intensification with a focus on applications in continuous flow processes and disperse, multiphase systems enabling a range of scalable chemistry spanning discovery to manufacturing operations.

Flow Chemistry for Cycloaddition Reactions

Continuous flow reactors form part of a rapidly growing research area that has changed the way synthetic chemistry is performed not only in academia but also at the industrial level. This Review highlights the most recent advances in cycloaddition reactions performed in flow systems. Cycloadditions are atom-efficient transformations for the synthesis of carbo- and heterocycles, involved in the construction of challenging skeletons of complex molecules. The main advantages of translating these processes into flow include using intensified conditions, safer handling of hazardous reagents and gases, easy tuning of reaction conditions, and straightforward scaling up. These benefits are especially important in cycloadditions such as the copper(I)-catalyzed azide alkyne cycloaddition (CuAAC), Diels-Alder reaction, ozonolysis and [2+2] photocycloadditions. Some of these transformations are key reactions in the industrial synthesis of pharmaceuticals.

A practical experiment to teach students continuous flow and physico-chemical methods: acetylation of ethylene diamine in liquid bi-phase

Despite growing applications being reported both in academia and industry, continuous flow chemistry remains a relatively untaught field across most chemistry undergraduate courses. This is particularly true in laboratory practical classes, where it is often deemed simpler to carry out synthetic reactions in traditional batch mode using round-bottomed flasks. Herein, we report the development of an undergraduate project that utilises cheap and readily available materials to construct continuous flow reactors. The students compare the performance of different types of reactors and conditions in a biphasic selective acetylation of a symmetrical diamine. Throughout the investigation, the students can vary multiple parameters as they optimise the reaction, thus actively learning and readjusting them based on their improved understanding. The experiments give the students an appreciation of continuous flow techniques in comparison to batch.

Two-Phase Dibromocyclopropanation of Unsaturated Alcohols Using Flow Chemistry

Dibromocyclopropanations are conventionally done by addition of dibromocarbene to alkenes under phase-transfer conditions in batch reactions using a strong base (50% NaOH (aq)), vigorous stirring and long reaction times. We have shown that cyclopropanation of unsaturated alcohols can be done under ambient conditions using continuous flow chemistry with 40% (w/w) NaOH (aq) as the base. The reactions were generally rapid; the yields were comparable to yields reported in the literature for the conventional batch reaction

Reaction Cycling for Kinetic Analysis in Flow

A reactor capable of efficiently collecting kinetic data in flow is presented. Conversion over time data is obtained by cycling a discrete reaction slug back and forth between two residence coils, with analysis performed each time the solution is passed between the two. In contrast to a traditional steady-state continuous flow system, which requires upward of 5× the total reaction time to obtain reaction progress data, this design achieves much higher efficiency by collecting all data during a single reaction. In combination with minimal material consumption (reactions performed in 300 μL slugs), this represents an improvement in efficiency for typical kinetic experimentation in batch as well. Application to kinetic analysis of a wide variety of transformations (acylation, S_NAr, silylation, solvolysis, Pd catalyzed C-S cross-coupling and cycloadditions) is demonstrated, highlighting both the versatility of the reactor and the benefits of performing kinetic analysis as a routine part of reaction optimization/development. Extension to the monitoring of multiple reactions simultaneously is also realized by operating the reactor with multiple reaction slugs at the same time.

Recent advances in continuous-flow organocatalysis for process intensification

The progresses on continuous-flow organocatalysis from 2016 to early 2020 are reviewed with focus on transition from batch to flow.

The rise of continuous flow biocatalysis – fundamentals, very recent developments and future perspectives

Very recent developments in the field of biocatalysis in continuously operated systems. Special attention on the future perspectives in this key emerging technological area ranging from process analytical technologies to digitalization.

An automated flow platform for accurate determination of gas–liquid–solid reaction kinetics

An automated flow platform based on a tube-in-tube contactor and micro-packed bed reactor is developed to measure the kinetics of gas–liquid–solid hydrogenation reactions.

Enhanced Controllability of Fries Rearrangements Using High-Resolution 3D-Printed Metal Microreactor with Circular Channel

High-resolution 3D-printed stainless steel metal microreactors (3D-PMRs) with different cross-sectional geometry are fabricated to control ultrafast intramolecular rearrangement reactions in a comparative manner. The 3D-PMR with circular channel demonstrates the improved controllability in rapid Fries-type rearrangement reactions, because of the superior mixing efficiency to rectangular cross-section channels (250 µm × 125 µm) which is confirmed based on the computational flow dynamics simulation. Even in case of very rapid intramolecular rearrangement of sterically small acetyl group occurring in 333 µs of reaction time, the desired intermolecular reaction can outpace to the undesired intramolecular rearrangement using 3D-PMR to result in high conversion and yield.

Investigation of a Weak Temperature-Rate Relationship in the Carbamoylation of a Barbituric Acid Pharmaceutical Intermediate

The rate of reaction between N, N'-dicyclohexylbarbituric acid 1 and ethyl 2-isocyanatoacetate 2 is invariant with temperature. Positive orders in each reactant and dissociation of triethylammonium salts of 1 and product 3 at elevated temperature indicate that reaction occurs via a catalytic mechanism where changes to the positions of equilibria negate changes in the rate of the turnover-limiting step. A model for the consumption of 1 in a flow reactor accurately predicted the outcome of a laboratory-scale multivariate study.

Reactor Selection for Effective Continuous Biocatalytic Production of Pharmaceuticals

Enzyme catalyzed reactions are rapidly becoming an invaluable tool for the synthesis of many active pharmaceutical ingredients. These reactions are commonly performed in batch, but continuous biocatalysis is gaining interest in industry because it would allow seamless integration of chemical and enzymatic reaction steps. However, because this is an emerging field, little attention has been paid towards the suitability of different reactor types for continuous biocatalytic reactions. Two types of continuous flow reactor are possible: continuous stirred tank and continuous plug-flow. These reactor types differ in a number of ways, but in this contribution, we focus on residence time distribution and how enzyme kinetics are affected by the unique mass balance of each reactor. For the first time, we present a tool to facilitate reactor selection for continuous biocatalytic production of pharmaceuticals. From this analysis, it was found that plug-flow reactors should generally be the system of choice. However, there are particular cases where they may need to be coupled with a continuous stirred tank reactor or replaced entirely by a series of continuous stirred tank reactors, which can approximate plug-flow behavior. This systematic approach should accelerate the implementation of biocatalysis for continuous pharmaceutical production.

Microflow-based dynamic combinatorial chemistry: a microscale synthesis and screening platform for the rapid and accurate identification of bioactive molecules

The first flow-based synthesis and screening platform that integrates both microflow chemistry and protein-directed dynamic combinatorial chemistry into a single modular unit was disclosed and validated by a case study.

Flow-facilitated ring opening metathesis polymerization (ROMP) and post-polymerization modification reactions

Continuous flow facilitates ROMP reactions to prepare homopolymers and block copolymers and allows for in-line post-polymerization click modifications.

Continuous flow synthesis of ordered porous materials: from zeolites to metal–organic frameworks and mesoporous silica

Herein we review the concepts, challenges and recent developments on the continuous flow synthesis of ordered porous materials.

Continuous flow microreactor for protein PEGylation

PEGylation is increasingly being utilized to enhance the therapeutic efficacy of biopharmaceuticals. Various chemistries and reaction conditions have been established to synthesize PEGylated proteins and more are being developed. Both the extent of conversion and selectivity of protein PEGylation are highly sensitive to process variables and parameters. Therefore, microfluidic-based high-throughput screening platforms would be highly suitable for optimization of protein PEGylation. As part of this study, a poly-dimethylsiloxane-based continuous flow microreactor system was designed and its performance was compared head-to-head with a batch reactor. The reactants within the microreactor were contacted by passive micromixing based on chaotic advection generated by staggered herringbone grooves embedded in serpentine microchannels. The microreactor system was provided with means for on-chip reaction quenching. Lysozyme was used as the model protein while methoxy-polyethylene glycol-(CH2)5COO-NHS was used as the PEGylation reagent. Full mixing was achieved close to the microreactor inlet, making the device suitable for protein PEGylation. The effect of mixing type, i.e., simple stirring versus chaotic laminar mixing on PEGylation, was investigated. Higher selectivity (as high as 100% selectivity) was obtained with the microreactor while the conversion was marginally lower.

Why microfluidics? Merits and trends in chemical synthesis

The intrinsic limitations of conventional batch synthesis have hindered its applications in both solving classical problems and exploiting new frontiers. Microfluidic technology offers a new platform for chemical synthesis toward either molecules or materials, which has promoted the progress of diverse fields such as organic chemistry, materials science, and biomedicine. In this review, we focus on the improved performance of microreactors in handling various situations, and outline the trend of microfluidic synthesis (microsynthesis, μSyn) from simple microreactors to integrated microsystems. Examples of synthesizing both chemical compounds and micro/nanomaterials show the flexible applications of this approach. We aim to provide strategic guidance for the rational design, fabrication, and integration of microdevices for synthetic use. We critically evaluate the existing challenges and future opportunities associated with this burgeoning field.

Automated Determination of Oxygen-Dependent Enzyme Kinetics in a Tube-in-Tube Flow Reactor

Enzyme-mediated oxidation is of particular interest to synthetic organic chemists. However, the implementation of such systems demands knowledge of enzyme kinetics. Conventionally collecting kinetic data for biocatalytic oxidations is fraught with difficulties such as low oxygen solubility in water and limited oxygen supply. Here, we present a novel method for the collection of such kinetic data using a pressurized tube-in-tube reactor, operated in the low-dispersed flow regime to generate time-series data, with minimal material consumption. Experimental development and validation of the instrument revealed not only the high degree of accuracy of the kinetic data obtained, but also the necessity of making measurements in this way to enable the accurate evaluation of high KMO enzyme systems. For the first time, this paves the way to integrate kinetic data into the protein engineering cycle.

The Hitchhiker's Guide to Flow Chemistry ∥

Flow chemistry involves the use of channels or tubing to conduct a reaction in a continuous stream rather than in a flask. Flow equipment provides chemists with unique control over reaction parameters enhancing reactivity or in some cases enabling new reactions. This relatively young technology has received a remarkable amount of attention in the past decade with many reports on what can be done in flow. Until recently, however, the question, "Should we do this in flow?" has merely been an afterthought. This review introduces readers to the basic principles and fundamentals of flow chemistry and critically discusses recent flow chemistry accounts.

Rapid contrast matching by microfluidic SANS

We report a microfluidic approach to perform small angle neutron scattering (SANS) measurements of contrast variation and matching, extensively employed in soft and biological matter research. We integrate a low scattering background microfluidic mixer and serpentine channel in a SANS beamline to yield a single phase, continuous flow, reconfigurable liquid cell. By contrast with conventional, sequential measurements of discrete (typically 4-6) solutions of varying isotopic solvent composition, our approach continually varies solution composition during SANS acquisition. We experimentally and computationally determine the effects of flow dispersion and neutron beam overillumination of microchannels in terms of the composition resolution and precision. The approach is demonstrated with model systems: H₂O/D₂O mixtures, a surfactant (sodium dodecyl sulfate, SDS), a triblock copolymer (pluronic F127), and silica nanoparticles (Ludox) in isotopic aqueous mixtures. The system is able to zoom into a composition window to refine contrast matching conditions, and robustly resolve solute structure and form factors by simultaneous fitting of scattering data with continuously varying contrast. We conclude by benchmarking our microflow-SANS with the discrete approach, in terms of volume required, composition resolution and (preparation and measurement) time required, proposing a leap forward in equilibrium, liquid solution phase mapping and contrast variation by SANS.

Rapid multistep kinetic model generation from transient flow data

S_NAr reaction profiles were generated using an automated reactor, collected in less than 3 hours, and allowed accurate estimation of kinetic parameters.

Today, the generation of kinetic models is still seen as a resource intensive and specialised activity. We report an efficient method of generating reaction profiles from transient flows using a state-of-the-art continuous-flow platform. Experimental data for multistep aromatic nucleophilic substitution reactions are collected from an automated linear gradient flow ramp with online HPLC at the reactor outlet. Using this approach, we generated 16 profiles, at 3 different inlet concentrations and 4 temperatures, in less than 3 hours run time. The kinetic parameters, 4 rate constants and 4 activation energies were fitted with less than 4% uncertainty. We derived an expression for the error in the observed rate constants due to dispersion and showed that such error is 5% or lower. The large range of operational conditions prevented the need to isolate individual reaction steps. Our approach enables early identification of the sensitivity of product quality to parameter changes and early use of unit operation models to identify optimal process-equipment combinations in silico, greatly reducing scale up risks.

Alves L, Brocksom TJ, de Oliveira KT. Combining batch and continuous flow setups in the end-to-end synthesis of naturally occurring curcuminoids

A successful end-to-end continuous flow synthesis of pure curcumin (1) and two other natural derivatives present in turmeric is described.