Harsh Reaction Conditions in Continuous-Flow Microreactors for Pharmaceutical Production

Gas-liquid mass transfer intensification for bubble generation and breakup in micronozzles

The local gas-liquid mass transfer was characterized during bubble generation in T-contactors and in an adjacent micronozzle. A colorimetric technique with the oxygen sensitive dye resazurin was investigated to visualize gas-liquid mass transfer during slug flow, bubble deformation, as well as laminar and turbulent bubble breakup in the wake of a micronozzle. Two optimized nozzle geometries from previous studies were evaluated concerning volumetric mass transfer coefficients for low pressure loss, narrow residence time distribution, or high dispersion rates. Highest values in kla up to 60 s−1 were found for turbulent bubble breakup and an optimized micronozzle design in respect to pressure drop and dispersion rate. The achieved mass transfer coefficients were correlated with the energy dissipation rate within the micronozzles and with the inverse Kolmogorov time scale in vortex dissipation in good agreement for laminar and turbulent breakup regimes.

Graphical abstract

The Chapman rearrangement in a continuous-flow microreactor

The Chapman rearrangement is of practical significance in pharmaceutical and fine chemical industries. It is a high temperature reaction with an exothermic nature in numerous cases. The conventional batch-wise synthesis is limited by its operational complexities, temperature control difficulties and scale-up hurdles. In this work, a microreactor-based continuous-flow approach was developed to perform the rearrangement in a highly controlled and safer manner. High conversions were obtained within short residence times (≤20 minutes). The detailed kinetics of this reaction, using 2,6-dichloro-phenyl N-phenyl benzimidate and 2-carbomethoxy-phenyl N-phenyl benzimidate as the representative reactants, was explored at varying temperatures to understand the intensified reaction behavior, and was modelled based on the obtained experimental data. The continuous process was scaled up to a 16-fold larger reactor volume by increasing the diameter of the microreactor while maintaining the residence time without further optimization. A very slight variation was observed in the conversion for the larger-sized flow system. Upscaling the batch reaction to a 10 times larger volume, by contrast, resulted in a dramatic decrease in the conversion. The simplicity of scaling up continuous-flow system was clearly demonstrated. A CFD model coupled with the obtained rearrangement kinetics was developed and well validated against the experimental data, which provided a robust platform for guiding the relevant process design and optimization of the continuous-flow processes. The results presented shed new light on the developments and applications of continuous-flow method for the classical Chapman rearrangement that require harsh high temperatures.

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 nitration of alcohols in a Freon flow

The first ever installation for continuous nitration in a liquefied gas mobile phase was developed.

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.

Continuous-flow synthesis of fluorine-containing fine chemicals with integrated benchtop NMR analysis

Fluorine fine chemical synthesis takes a step ahead using integrated NMR online-analysis with a benchtop NMR spectrometer.

Safety assessment in development and operation of modular continuous-flow processes

Improved safety is one of the main drivers for microreactor application in chemical process development and small-scale production.

Feedback in Flow for Accelerated Reaction Development

The pharmaceutical industry is investing in continuous flow and high-throughput experimentation as tools for rapid process development accelerated scale-up. Coupled with automation, these technologies offer the potential for comprehensive reaction characterization and optimization, but with the cost of conducting exhaustive multifactor screens. Automated feedback in flow offers researchers an alternative strategy for efficient characterization of reactions based on the use of continuous technology to control chemical reaction conditions and optimize in lieu of screening. Optimization with feedback allows experiments to be conducted where the most information can be gained from the chemistry, enabling product yields to be maximized and kinetic models to be generated while the total number of experiments is minimized. This Account opens by reviewing select examples of feedback optimization in flow and applications to chemical research. Systems in the literature are classified into (i) deterministic "black box" optimization systems that do not model the reaction system and are therefore limited in the utility of results for scale-up, (ii) deterministic model-based optimization systems from which reaction kinetics and/or mechanisms can be automatically evaluated, and (iii) stochastic systems. Though diverse in application, flow feedback systems have predominantly focused upon the optimization of continuous variables, i.e., variables such as time, temperature, and concentration that can be ramped from one experiment to the next. Unfortunately, this implies that the screening of discrete variables such as catalyst, ligand, or solvent generally does not factor into automated flow optimization, resulting in incomplete process knowledge. Herein, we present a system and strategy developed for optimizing discrete and continuous variables of a chemical reaction simultaneously. The approach couples automated feedback with high-throughput reaction screening in droplet flow microfluidics. This Account details the system configuration for on-demand creation of sub-20 μL droplets with interchangeable reagents and catalysts. These droplets are reacted in a fully automated microfluidic system and analyzed online by LC/MS. Feeding back from the online analytical results, a design of experiments (DoE)-based adaptive response surface algorithm is employed that deductively removes candidate reagents from the optimization as optimal reaction conditions are refined, leading to rapid convergence. Using the automated optimization platform, case studies are presented for solvent selection in a competitive alkylation chemistry and for catalyst-ligand selection in heteroaromatic Suzuki-Miyaura cross-coupling chemistries. For the monoalkylation of trans-1,2-diaminocyclohexane, polar aprotic solvents at moderate temperatures are shown to be favorable, with optimality accurately identified with dimethyl sulfoxide as the solvent in 67 experiments. For Suzuki-Miyaura cross-couplings, the optimality of precatalysts and continuous variable conditions are observed to change in accordance with the coupling reagents, providing insights into catalyst behavior in the context of the reaction mechanism. Future opportunities in automated reaction development include the incorporation of chemoinformatics for faster analysis and machine-learning algorithms to guide and optimize the synthesis. Adoption of this technology stands to reduce graduate student and postdoc time on routine tasks in the laboratory, while feeding back knowledge used to guide new research directions. Moreover, the application of this technology in industry promises to lessen the cost and time associated with advancing pharmaceutical molecules through development and scale-up.

Taming hazardous chemistry by continuous flow technology

Over the last two decades, flow technologies have become increasingly popular in the field of organic chemistry, offering solutions for engineering and/or chemical problems. Flow reactors enhance the mass and heat transfer, resulting in rapid reaction mixing, and enable a precise control over the reaction parameters, increasing the overall process selectivity, efficiency and safety. These features allow chemists to tackle unexploited challenges in their work, with the ultimate objective making chemistry more accessible for laboratory and industrial applications, avoiding the need to store and handle toxic, reactive and explosive reagents. This review covers some of the latest and most relevant developments in the field of continuous flow chemistry with the focus on hazardous reactions.

Epoxidation using molecular oxygen in flow: facts and questions on the mechanism of the Mukaiyama epoxidation

Mukaiyama reaction was performed G/L continuous-flow microreactor. In less than 5 minutes at room temperature, cyclooctene was efficiently transformed to the corresponding epoxide using O₂ as oxidant and aldehyde as co-reductant.

Nanocatalysis in Flow

Nanocatalysis in flow is catalysis by metallic nanoparticles (NPs; 1-50 nm) performed in microstructured reactors. These catalytic processes make use of the enhanced catalytic activity and selectivity of NPs and fulfill the requirements of green chemistry. Anchoring catalytically active metal NPs within a microfluidic reactor enhances the reagent/catalyst interaction, while avoiding diffusion limitations experienced in classical approaches. Different strategies for supporting NPs are reviewed herein, namely, packed-bed reactors, monolithic flow-through reactors, wall catalysts, and a selection of novel approaches (NPs embedded on nanotubes, nanowires, catalytic membranes, and magnetic NPs). Through a number of catalytic reactions, such as hydrogenations, oxidations, and cross-coupling reactions, the advantages and possible drawbacks of each approach are illustrated.

Continuous-flow technology—a tool for the safe manufacturing of active pharmaceutical ingredients

In the past few years, continuous-flow reactors with channel dimensions in the micro- or millimeter region have found widespread application in organic synthesis. The characteristic properties of these reactors are their exceptionally fast heat and mass transfer. In microstructured devices of this type, virtually instantaneous mixing can be achieved for all but the fastest reactions. Similarly, the accumulation of heat, formation of hot spots, and dangers of thermal runaways can be prevented. As a result of the small reactor volumes, the overall safety of the process is significantly improved, even when harsh reaction conditions are used. Thus, microreactor technology offers a unique way to perform ultrafast, exothermic reactions, and allows the execution of reactions which proceed via highly unstable or even explosive intermediates. This Review discusses recent literature examples of continuous-flow organic synthesis where hazardous reactions or extreme process windows have been employed, with a focus on applications of relevance to the preparation of pharmaceuticals.

Continuous flow nitration in miniaturized devices

This review highlights the state of the art in the field of continuous flow nitration with miniaturized devices. Although nitration has been one of the oldest and most important unit reactions, the advent of miniaturized devices has paved the way for new opportunities to reconsider the conventional approach for exothermic and selectivity sensitive nitration reactions. Four different approaches to flow nitration with microreactors are presented herein and discussed in view of their advantages, limitations and applicability of the information towards scale-up. Selected recent patents that disclose scale-up methodologies for continuous flow nitration are also briefly reviewed.