The Use of Molecular Oxygen for Liquid Phase Aerobic Oxidations in Continuous Flow

Light-Driven Photobiocatalytic Oxyfunctionalization in a Continuous Reactor System without External Oxygen Supply

Oxygenases catalyze C-H oxyfunctionalization under mild reaction conditions and often display outstanding selectivity. However, their utilization is hampered by the difficulty of transporting oxygen across the gas-liquid interface, which is particularly problematic for continuous reactor systems and can only be alleviated by high pressure or the use of complex oxygen-permeable materials. Herein, oxygen is directly released into the medium by the phototrophic cyanobacterium Synechocystis sp. PCC 6803 expressing the genes of a Baeyer-Villiger Monooxygenase from Burkholderia xenovorans to drive the oxidation of cyclohexanone for the production of the polymer precursor, ε-caprolactone. The rates at which photosynthetic oxygen can solely drive the oxidation were determined by performing the reaction in a continuous coil reactor with a very limited external oxygen supply. In heterotrophic nonoxygen-producing Escherichia coli expressing the same gene, a 10-fold lower specific activity was observed when the oxidation was performed in the coil reactor compared with batch mode underlining the impact of oxygen-limitation on the volumetric productivity. In contrast, cyanobacterial whole cells showed activities of 16.7 and 13.5 U gDCW -1 in nonoxygen-limited batch and oxygen-limited continuous flow, respectively. Net oxygen production of the whole-cell biocatalyst during the reaction led to a steady-state oxygen concentration allowing volumetric productivities as high as 3 mmol L-1 h-1 highlighting the advantages of photoautotrophic production systems for oxyfunctionalization under oxygen-limiting conditions. Moreover, the space-time yield of the reaction was improved 7-fold (2.8 vs 0.4 g L-1 h-1) by utilizing the continuous coil reactor compared to the batch mode. The combination of flow catalysis and photosynthetic oxygen production can overcome current limitations in photo(bio)oxidation and achieve significant improvements in terms of volumetric productivity enabling more sustainable chemical synthesis. This approach using whole-cells of cyanobacteria achieves a notably lower ratio of waste to product (E-factor) and higher atom economy compared with oxidation mediated by Escherichia coli .

Activation of Molecular Oxygen and Selective Oxidation with Metal Complexes

ConspectusSelective oxidation with molecular oxygen is one of the most appealing approaches to functionalization of organic molecules and, yet at the same time, one of the most challenging reactions facing organic synthesis due to poor selectivity control. Molecular oxygen is a green and inexpensive oxidant, producing water as the only byproduct in oxidation. Not surprisingly, it has been used in the manufacturing of many commodity chemicals in the industry. It is also nature's choice of oxidant and drives a variety of oxidation reactions critical to life and various other biologic processes. While the past decades have witnessed great progress in understanding, both structurally and mechanistically, how nature exploits metalloenzymes, i.e., monooxygenases and dioxygenases, to tackle some of the most challenging oxidation reactions, e.g., methane oxidation to methanol, there are only a small number of well-defined, man-made metal complexes that have been reported to enable selective oxidation with molecular oxygen of compounds more relevant to fine chemical and pharmaceutical synthesis.In the past 10 years or so, our laboratories have developed several transition metal complexes and shown that they are capable of catalyzing selective oxidation under 1 atm of O2. Thus, we have shown that an Fe(II)-bisimidazolidinyl-pyridine complex catalyzes selective oxygenation of C-H bonds in ethers with concomitant release of hydrogen gas instead of water, and when the iron center is replaced with Fe(III), selective oxidative cleavage of C═C bonds of olefins becomes feasible. To address the low activity of the iron complex in oxidizing less active olefins, we have developed a Mn(II)-bipyridine complex, which catalyzes oxidative cleavage of C═C bonds in aliphatic olefins, C-C bonds in diols, and carboxyl units in carboxylic acids under visible light irradiation. Light is necessary in the oxidation to cleave an off-cycle, inactive manganese dimer into a catalytically active Mn═O oxo species. Furthermore, we have found that a binuclear salicylate-bridged Cu(II) complex enables the C-H oxidation of tetrahydroisoquinolines as well as C═C bond cleavage, and when a catalytic vitamin B1 analogue is brought in, oxygenation of tetrahydroisoquinolines to lactams takes place via carbene catalysis. Still further, we have found that a readily accessible binuclear Rh(II)-terpyridine complex catalyzes the oxidation of alcohols, and being water-soluble, the catalyst can be easily separated and reused multiple times. In addition, we recently unearthed a simple protocol that allows waste polystyrene to be depolymerized to isolable, valuable chemicals. A cheap Brønsted acid acts as the catalyst, activating molecular oxygen to a singlet state through complexation with the polymer under light irradiation, thereby depolymerizing the polymer.

Selective oxidation of glycerol mediated by surface plasmon of gold nanoparticles deposited on titanium dioxide nanowires

This paper describes an alternative method for the in situ synthesis of gold nanoparticles (AuNPs) with a particle size of less than 3 nm, using nanoreactors formed by reverse micelles of 1,4-bis-(2-ethylhexyl) sulfosuccinate sodium (AOT) and nanoparticle stabilization with l-cysteine, which favor the preparation of nanoparticles with size and shape control, which are homogeneously dispersed (1% by weight) on the support of titanium dioxide nanowires (TNWs). To study the activity and selectivity of the prepared catalyst (AuNPs@TNWs), an aqueous solution of 40 mM glycerol was irradiated with a green laser (λ = 530 nm, power = 100 mW) in the presence of the catalyst and O2 as an oxidant at 22 °C for 6 h, obtaining a glycerol conversion of 86% with a selectivity towards hydroxypyruvic acid (HA) of more than 90%. From the control and reactions, we concluded that the Ti-OH groups promote the glycerol adsorption on the nanowires surface and the surface plasmon of the gold nanoparticles favors the selectivity of the reaction towards the hydroxypyruvic acid.

Preparation of Sulfonyl Chlorides by Oxidative Chlorination of Thiols and Disulfides using HNO3/HCl/O2 in a Flow Reactor

A continuous flow metal-free protocol for the synthesis of sulfonyl chlorides from thiols and disulfides in the presence of nitric acid, hydrochloric acid and oxygen was developed. The influence of the reaction parameters was investigated under batch and flow conditions. Online 19F NMR was successfully implemented to investigate different reaction conditions within a single experiment. The sulfonyl chlorides were isolated (mostly in 70-81 % yield) after performing a simple aqueous washing procedure. In particular, the protocol was successfully operated for >6 hours to convert diphenyl disulfide to its corresponding sulfonyl chloride, achieving a throughput of 3.7 g h-1. The environmental impact of the protocol was assessed and compared to an existing continuous flow protocol using 1,3-dichloro-5,5-dimethylhydantoin (DCH) as reagent. The process mass intensity (PMI) for the newly-developed flow protocol (15) compared favorably to the DCH flow process (20).

Diversification of Pharmaceutical Manufacturing Processes: Taking the Plunge into the Non-PGM Catalyst Pool

Recent global events have led to the cost of platinum group metals (PGMs) reaching unprecedented heights. Many chemical companies are therefore starting to seriously consider and evaluate if and where they can substitute PGMs for non-PGMs in their catalytic processes. This review covers recent highly relevant applications of non-PGM catalysts in the modern pharmaceutical industry. By highlighting these selected successful examples of non-PGM-catalyzed processes from the literature, we hope to emphasize the enormous potential of non-PGM catalysis and inspire further development within this field to enable this technology to progress toward manufacturing processes. We also present some historical contexts and review the perceived advantages and challenges of implementing non-PGM catalysts in the pharmaceutical manufacturing environment.

Continuous Flow Oxidation of Alcohols Using TEMPO/NaOCl for the Selective and Scalable Synthesis of Aldehydes

A simple and benign continuous flow oxidation protocol for the selective conversion of primary and secondary alcohols into their respective aldehyde and ketone products is reported. This approach makes use of catalytic amounts of TEMPO in combination with sodium bromide and sodium hypochlorite in a biphasic solvent system. A variety of substrates are tolerated including those containing heterocycles based on potentially sensitive nitrogen and sulfur moieties. The flow approach can be coupled with inline reactive extraction by formation of the carbonyl-bisulfite adduct which aids in separation of remaining substrate or other impurities. Process robustness is evaluated for the preparation of phenylpropanal at decagram scale, a trifluoromethylated oxazole building block as well as a late-stage intermediate for the anti-HIV drug maraviroc which demonstrates the potential value of this continuous oxidation method.

Development of Lab-Scale Continuous Stirred-Tank Reactor as Flow Process Tool for Oxidation Reactions Using Molecular Oxygen

The use of sustainable oxidants is of great interest to the chemical industry, considering the importance of oxidation reactions for the manufacturing of chemicals and society's growing awareness of its environmental impact. Molecular oxygen (O2), with an almost optimal atom efficiency in oxidation reactions, presents one of the most attractive alternatives to common reagents that are not only toxic in most cases but produce stoichiometric amounts of waste that must be treated. However, fire and explosion safety concerns, especially when used in combination with organic solvents, restrict its easy use. Here, we use state-of-the-art 3D printing and experimental feedback to develop a miniature continuous stirred-tank reactor (mini-CSTR) that enables efficient use of O2 as an oxidant in organic chemistry. Outstanding heat dissipation properties, achieved through integrated jacket cooling and a high surface-to-volume ratio, allow for a safe operation of the exothermic oxidation of 2-ethylhexanal, surpassing previously reported product selectivity. Moving well beyond the proof-of-concept stage, we characterize and illustrate the reactor's potential in the gas-liquid-solid triphasic synthesis of an endoperoxide precursor of antileishmanial agents. The custom-designed magnetic overhead stirring unit provides improved stirring efficiency, facilitating the handling of suspensions and, in combination with the borosilicate gas dispersion plate, leading to an optimized gas-liquid interface. These results underscore the immense potential that lies within the use of mini-CSTR in sustainable chemistry.

Modular synthesis of congested β2,2-amino acids via the merger of photocatalysis and oxidative functionalisations

A two-step protocol for the modular synthesis of β2- and α-quaternary β2,2-amino acid derivatives is reported. The key steps are a photocatalytic hydroalkylation reaction, followed by an oxidative functionalisation to access N-protected β-amino acids, esters, and amides. This strategy can be effectively scaled up via continuous-flow technology.

Base-Promoted Tandem Pathway for Keto-Amides: Visible Light-Mediated Room-Temperature Amidation Using Molecular Oxygen as an Oxidant

Herein, we report metal- and photocatalyst-free room-temperature amidation for α-ketoamide synthesis from feedstock phenacyl bromides and amines using molecular oxygen as an oxidant as well as a source of oxygen in the amide segment. Visible light-mediated base-promoted one-pot sequential C-N/C═N/C═O bond formation takes place in a tandem manner to afford the desired product. Functional group tolerance (benzylic alcohol, keto, cyano, nitro, halo, etc.), a broad substrate scope, and gram-scale synthesis make this synthetic methodology more attractive. We have observed that electron-rich aromatic amines, aliphatic amines, and phenacyl bromide derivatives proceeded the present transformation with marginally superior reactivity in comparison to electron-deficient aromatic amines and phenacyl bromide derivatives. Moreover, several control experiments, in situ isolation of secondary amine and imine as key intermediates, and 18O-labeling experiments provide complete insight into the mechanism of the tandem pathway.

Honeycomb reactor: a promising device for streamlining aerobic oxidation under continuous-flow conditions

We report on the high potential of a honeycomb reactor for the use in aerobic oxidation under continuous-flow conditions. The honeycomb reactor is made of porous material with narrow channels separated by porous walls allowing for high density accumulation in the reactor. This structure raised the mixing efficiency of a gas-liquid reaction system, and it effectively accelerated the aerobic oxidation of benzyl alcohols to benzaldehydes under continuous-flow conditions. This reactor is a promising device for streamlining aerobic oxidation with high process safety because it is a closed system.

Electrocatalytic activity of electrodeposited CoOx thin film on low-carbon unalloyed steel substrate toward electrochemical oxygen evolution reaction (OER)

In this study, we report elaboration of a thin film of CoOx on a low carbon unalloyed steel substrate by electrochemical route and the study of its electrocatalytic performances with respect to the evolution reaction of oxygen (OER) in NaOH medium. The elaborated deposits were well-characterized using X-ray diffraction. Kinetic and thermodynamic parameters such as exchange current density, Tafel slope, reaction order with respect to OH- ions and apparent activation energy were studied. The CoOx displays satisfactory OER performance in an alkaline medium, with a low overvoltage of 362 mV at 10 mA/cm2 and a Tafel slope of 81 mV/dec at 293 K. The apparent kinetic activation energy (= 29.79 kJ/mol) was similar to those obtained for the reported catalytic electrode materials. The O2 gas obtained on the cobalt oxide electrode was 2.865 mmol/s.cm2, which is 28 times higher than that obtained for the platinum electrode (0.102 mmol/s.cm2). Chronoamperometry demonstrates a better electrochemical stability under a polarization potential of 2 V in 1 M NaOH for nearly 25 h. The low cost, the high OER performance, as well as the good stability of the CoOx electrode make it a promising candidate for the industrial-scale water electrolysis.

The Diverse Modes of Oxygen Reactivity in Life & Chemistry

Oxygen is a molecule of utmost importance in our lives. Beside its vital role for the respiration and sustaining of organisms, oxygen is involved in numerous chemical and physical processes. Upon combination of the different forms of molecular oxygen species with various activation modes, substrates, and reaction conditions an extremely wide chemical space can be covered that enables rich applications of diverse oxygenation processes. This Review provides an instructive overview of the individual properties and reactivities of oxygen species and illustrates their importance in nature, everyday life, and in the context of chemical synthesis.

Solvent-Free Hydrogenation of Squalene Using Parts per Million Levels of Palladium Supported on Carbon Nanotubes: Shift from Batch Reactor to Continuous-Flow System

The transition from batch catalytic processes to continuous flow processes requires highly active and stable catalysts that still need to be developed. The preparation and characterization of catalysts where palladium single atoms and nanoparticles are simultaneously present on carbon nanotubes were recently reported by us. These catalysts are considerably more active than commercial or previously described catalysts for the liquid phase hydrogenation of terpenes. Herein is shown that under solvent-free conditions, squalene (SQE) could be converted into squalane (SQA,>98 %) using only 300 ppm of Pd in less than 1.4 h at 20 bar H₂ and 120 °C. Catalyst stability was assessed in a lab-scale flow reactor, and long-term experiments led to turnover number (TON) higher than 300000 without any detectable loss in the activity. Then, the implementation of this catalyst in a commercial intensified continuous-flow milli-reactor pilot was achieved. High purity SQA (>98 %) could be obtained by continuous hydrogenation of solvent-free SQE at 180 °C and 30 bar H₂ with a contact time below 15 min. A production capacity of 3.6 kg per day of SQA could be obtained with an effective reactor volume (V_R ) of 43.2 mL for this complex 3 phase reaction. Large-scale production can now be foreseen thanks to seamless scale-up provided by the continuous flow pilot supplier.

Tunable Multi-Phase System for Highly Chemo-Selective Oxidation of Hydroxymethyl-Furfural

Three different multiphase systems (MP 1-3) comprised of two immiscible liquids, with or without an ionic liquid (IL: methyltrioctyl ammonium chloride), were investigated for the oxidation of 5-hydroxymethyl-furfural (HMF) over 5 % Ru/C as a catalyst and air (8 bar) as an oxidant. These conditions proved versatile for an excellent control of the reaction selectivity to 4 distinct products derived from full or partial oxidation of the carbonyl and alcohol functions of HMF, and each one achieved in 87-96 % isolated yield at complete conversion. MP1 based on water and isooctane, yielded 2,5-furandicarboxylic acid (FDCA, 91 % yield). In MP2, obtained by adding the IL to MP1, the oxidation proceeded towards the formation of 5-formyl-2-furancarboxylic acid (FFCA, 87-89 % yield). MP2 also proved successful in the design of a one pot-two step oxidation/reduction sequence to prepare 5-hydroxymethyl-2-furancarboxylic acid (HMFCA, 85 % yield). In MP3, the use of an acetonitrile/cyclooctane biphase yielded 2,5-diformylfuran (DFF, 96 % yield). All the multiphase systems MP 1-3 allowed a perfect segregation of the catalyst in a single phase (either the hydrocarbon or the IL) distinct from the one containing HMF and its oxidation products. This was crucial not only for the catalyst/product separation but also for the recycle of Ru/C that was possible under all the tested conditions. Accordingly, MP-reaction were run in a semicontinuous mode without removing the catalyst from the reactor nor resorting to conventional separation and activation techniques. Negligible Ru leaching, less than 0.96 ppb, was measured in all cases.

Liquid Phase Oxidation of Hydrocarbons to High-Value Chemicals in Microfluidic Reactors - Prospects and Challenges

Liquid phase oxidation (LPO) of hydrocarbon is an industrially important process to produce petrochemicals and pharmaceuticals. It follows a free radical path having initiation, propagation and termination. The initiation step is slow while the propagation and termination steps are fast. The main challenge of such process is to control product selectivity at an appreciable conversion level. With the advancement of microfluidic reactor technology, it is possible to control the free radical steps. The present contribution critically reviewed the reaction engineering aspects of LPO of hydrocarbon, the influence of microfluidic reactor design and operation on reaction mechanism, conversion and product selectivity. It also outlines the challenges associated with microfluidic reactor operation, and prospects to apply the understanding from microfluidic reactors in few sectors. The understanding from the free radical oxidation process can also be applied to any other free radical processes.

Technological Innovations in Photochemistry for Organic Synthesis: Flow Chemistry, High-Throughput Experimentation, Scale-up, and Photoelectrochemistry

Photoinduced chemical transformations have received in recent years a tremendous amount of attention, providing a plethora of opportunities to synthetic organic chemists. However, performing a photochemical transformation can be quite a challenge because of various issues related to the delivery of photons. These challenges have barred the widespread adoption of photochemical steps in the chemical industry. However, in the past decade, several technological innovations have led to more reproducible, selective, and scalable photoinduced reactions. Herein, we provide a comprehensive overview of these exciting technological advances, including flow chemistry, high-throughput experimentation, reactor design and scale-up, and the combination of photo- and electro-chemistry.

Copper/TEMPO-catalyzed continuous aerobic alcohol oxidation in a micro-packed bed reactor

A micro-packed bed reactor has been developed to demonstrate aerobic oxidation of alcohols to aldehydes, utilizing green oxidant O2 and effective Cu/TEMPO-catalyzed system.

A computational study of the reaction mechanism of 2,2-azobis(isobutyronitrile)-initiated oxidative cleavage of geminal alkenes

A computational study of 2,2-azobis(isobutyronitrile) (AIBN)-initiated aerobic oxidative cleavage of alkenes is carried out employing density functional theory (DFT) and high-level coupled-cluster methods, such as coupled-cluster singles and doubles with perturbative triples [CCSD(T)]. Our computations show that the barriers for the formation of dioxetane derivatives suggested by Xu and co-workers (J. Org. Chem., 2014, 79, 7220-7225) for the reaction mechanism of aerobic oxidative cleavage of alkenes are computed to be higher than 65 kcal mol^-1. This barrier is relatively high under the reaction conditions. Our results for the Xu mechanism indicate that the reaction does not proceed via the formation of a dioxetane ring under the reaction conditions. Our results demonstrate that the reaction of aerobic oxidative cleavage of geminal alkenes in the presence of AIBN is initiated by the peroxyl radical 9, contrary to the isobutyronitrile radical 2. Our results show that the 2-(2-hydroxyl-1,1-diarylethoxy)-2-methylpropanenitrile radical (15) does not appear throughout the reaction scheme and the reaction progresses over the 2-(2-hydroxyl-2,2-diarylethoxy)-2-methylpropanenitrile radical (13) rather than the 2-(2-hydroxyl-1,1-diarylethoxy)-2-methylpropanenitrile radical (15). Our results are in agreement with the experimental results for the aerobic oxidative cleavage of the geminal disubstituted alkenes. Our results also demonstrate that the epoxide derivatives can be formed as an intermediate under the reaction conditions. This reaction is not applicable for pyridine derivatives due to the conversion of vinylpyridine derivatives to N-oxide derivatives.

Using High-Power UV-LED to Accelerate a Decatungstate-Anion-Catalyzed Reaction: A Model Study for the Quick Oxidation of Benzyl Alcohol to Benzoic Acid Using Molecular Oxygen

High-power UV-LED irradiation (365 nm) effectively accelerated the decatungstate-anion-catalyzed oxidation of benzyl alcohol 1 to benzoic acid 3 via benzaldehyde 2. As the power of the UV-LED light increased, both the selectivity and yield of benzoic acid also increased. The reaction was finished within 1 h to give 3 in a 93% yield using 2 mol% of decatungstate anion catalyst. The combination of a flow photoreactor and high-power irradiation accelerated the oxidation reaction to an interval of only a few minutes.

Heteroarylation of Ethers, Amides, and Alcohols with Light and O2

An efficient protocol for the C_α-H heteroarylation of ethers, amides, and alcohols using air and light under mild conditions is described. The reaction is applicable to a wide spectrum of functional groups. The generation of C-radicals via photoinduced aerobic oxidation of ethers, amides, and alcohols is the key feature of the process. Control experiments suggest a radical pathway for the reaction.

Continuous flow asymmetric synthesis of chiral active pharmaceutical ingredients and their advanced intermediates

Catalytic enantioselective transformations provide well-established and direct access to stereogenic synthons that are broadly distributed among active pharmaceutical ingredients (APIs). These reactions have been demonstrated to benefit considerably from the merits of continuous processing and microreactor technology. Over the past few years, continuous flow enantioselective catalysis has grown into a mature field and has found diverse applications in asymmetric synthesis of pharmaceutically active substances. The present review therefore surveys flow chemistry-based approaches for the synthesis of chiral APIs and their advanced stereogenic intermediates, covering the utilization of biocatalysis, organometallic catalysis and metal-free organocatalysis to introduce asymmetry in continuously operated systems. Single-step processes, interrupted multistep flow syntheses, combined batch/flow processes and uninterrupted one-flow syntheses are discussed herein.

Expanding the Tool Kit of Automated Flow Synthesis: Development of In-line Flash Chromatography Purification

Recent advancements in in-line extraction and purification technology have enabled complex multistep synthesis in continuous flow reactor systems. However, for the large scope of chemical reactions that yield mixtures of products or residual starting materials, off-line purification is still required to isolate the desired compound. We present the in-line integration of a commercial automated flash chromatography system with a flow reactor for the continuous synthesis and isolation of product(s). A proof-of-principle study was performed to validate the system and test the durability of the column cartridges, performing an automated sequence of 100 runs over 2 days. Three diverse reaction systems that highlight the advantages of flow synthesis were successfully applied with in-line normal- or reversed-phase flash chromatography, continuously isolating products with 97-99% purity. Productivity of up to 9.9 mmol/h was achieved, isolating gram quantities of pure product from a feed of crude reaction mixture. Herein, we describe the development and optimization of the systems and suggest guidelines for selecting reactions well suited to in-line flash chromatography.

Organophotocatalytic Aerobic Oxygenation of Phenols in a Visible-Light Continuous-Flow Photoreactor

A mild photocatalytic phenol oxygenation enabled by a continuous-flow photoreactor using visible light and pressurized air is described herein. Products for wide-ranging applications, including the synthesis of vitamins, were obtained in high yields by precisely controlling principal process parameters. The reactor design permits low organophotocatalyst loadings to generate singlet oxygen. It is anticipated that the efficient aerobic phenol oxygenation to benzoquinones and p-quinols contributes to sustainable synthesis.

Continuous flow strategies for using fluorinated greenhouse gases in fluoroalkylations

Large quantities of fluorinated gases are generated as intermediates or byproducts from fluorinated polymer production annually, and they are effective ozone depleting substances or greenhouse gases. On the other hand, the incorporation of fluoroalkyl groups into drug molecules or bioactive compounds has been shown to enhance biological properties such as the bioavailability, binding selectivity, and metabolic stability. Extraction of fluoroalkyl sources, including trifluoromethyl and difluoromethyl groups, from the fluorinated gases is highly desirable, yet challenging under regular batch reaction conditions. Flow chemistry is an emerging and promising technique to address long-standing challenges in gas-liquid batch reactions such as insufficient interfacial contact and scalability issues. In this review, we highlight recent advances in continuous flow strategies toward enabling the use of fluorinated greenhouse gases in organic synthesis.

Challenges in transfer of gas-liquid reactions from batch to continuous operation: dimensional analysis and simulations for aerobic oxidation

The transfer of gas-liquid reactions from conventional batch processes into continuous operation using milli and micro reactors is claimed as an important step towards process intensification. Importantly, this transfer step should be realized in an early phase of process development, already, in order to minimize research efforts towards the undesired operation strategy. The main challenge of this approach, therefore, arises from lack of knowledge in the early stage of process development and the resulting system with high degrees of freedom. This contribution presents an approach to tackle this challenge by means of mathematical modelling and simulation for the aerobic oxidation of 9,10-dihydroanthracene (DHA) catalyzed by polyoxometalates (POMs) being used as example for gas-liquid reactions. The reaction was chosen as it provides sufficient complexity, since it consists of three consecutive oxidation steps of DHA and a parallel catalytic redox-cycle according to a Mars-van-Krevelen mechanism. It also provides the challenge of unknown reaction kinetics, which have been estimated in this contribution. The dimensionless balance equations for reactor modeling are derived and parametrized based on early stage experimental results obtained in batch operation mode. The discrimination between batch and continuous operation was performed by means of characteristic dimensionless numbers using the identical mathematical model for comparability reasons. The model was used to perform sensitivity studies with emphasis on the interplay between mass transfer characteristics and reaction kinetics for both the batch and continuous operation mode. The simulation results show that the performance of both operation modes mainly depend on the oxidation state of the POM catalyst, which is caused by the differences in oxygen availability. Therefore, results obtained in batch operation mode are prone to be masked by mass transfer issues, which affects catalyst and reactor development at the same time and may thus cause maldevelopments. With respect to process development it can thus be concluded that the transfer from batch to continuous operation together with mathematical modeling is important in an early phase, already, in order to detect limitations misleading the development. Finally, even simple models with roughly estimated parameters from preliminary experiments are shown to be sufficient in the early phase and can systematically be improved, in the subsequent phases.

Graphical abstract

Aerobic Oxidations in Asymmetric Synthesis: Catalytic Strategies and Recent Developments

Despite the remarkable advances in the area of asymmetric catalytic oxidations over the past decades, the development of sustainable and environmentally benign enantioselective oxidation techniques, especially with the efficiency level similar to natural enzymes, still represents a challenge. The growing demand for enantiopure compounds and high interest to industry-relevant green technological advances continue to encourage the research pursuits in this field. Among various oxidants, molecular oxygen is ubiquitous, being available at low cost, environmentally benign and easy-to-handle material. This review highlights recent achievements in catalytic enantioselective oxidations utilizing molecular oxygen as the sole oxidant, with focus on the mechanisms of dioxygen activation and chirogenesis in these transformations.

Fe-Catalyzed Anaerobic Mukaiyama-Type Hydration of Alkenes using Nitroarenes

Hydration of alkenes using first row transition metals (Fe, Co, Mn) under oxygen atmosphere (Mukaiyama-type hydration) is highly practical for alkene functionalization in complex synthesis. Different hydration protocols have been developed, however, control of the stereoselectivity remains a challenge. Herein, highly diastereoselective Fe-catalyzed anaerobic Markovnikov-selective hydration of alkenes using nitroarenes as oxygenation reagents is reported. The nitro moiety is not well explored in radical chemistry and nitroarenes are known to suppress free radical processes. Our findings show the potential of cheap nitroarenes as oxygen donors in radical transformations. Secondary and tertiary alcohols were prepared with excellent Markovnikov-selectivity. The method features large functional group tolerance and is also applicable for late-stage chemical functionalization. The anaerobic protocol outperforms existing hydration methodology in terms of reaction efficiency and selectivity.

Application of reactor engineering concepts in continuous flow chemistry: a review

The adoption of flow technology for the manufacture of chemical entities, and in particular pharmaceuticals, has seen rapid growth over the past two decades with the technology now blurring the lines between chemistry and chemical engineering.

Fluorinated solvent-assisted photocatalytic aerobic oxidative amidation of alcohols via visible-light-mediated HKUST-1/Cs-POMoW catalysis

Successful synthesis and characterization of HKUST-1/Cs-POMoW binary composite, and application in the photocatalytic aerobic oxidative amidation reaction of alcohols under light illuminating in the visible region.

Repurposing Inflatable Packaging Pillows as Bioreactors: a Convenient Synthesis of Glucosone by Whole-Cell Catalysis Under Oxygen

Biocatalysis using molecular oxygen as the electron acceptor has significant potential for selective oxidations at low cost. However, oxygen is poorly soluble in water, and its slow rate of mass transfer in the aqueous phase is a major obstacle, even for laboratory-scale syntheses. Oxygen transfer can be accelerated by vigorous mechanical methods, but these are often incompatible with biological catalysts. Gentler conditions can be achieved with shallow, high surface area bag reactors that are designed for single use and generally for specialized cell culture applications. As a less-expensive alternative to these high-end bioreactors, we describe repurposing inflatable shipping pillows with resealable valves to provide high surface area mixing under oxygen for preparative synthesis of glucosone (D-arabino-hexos-2-ulose) from D-glucose using non-growing Escherichia coli whole cells containing recombinant pyranose 2-oxidase (POX) as catalyst. Parallel reactions permitted systematic study of the effects of headspace composition (i.e., air vs 100% oxygen), cell density, exogenous catalase, and reaction volume in the oxidation of 10% glucose. Importantly, only a single charge of 100% oxygen is required for stoichiometric conversion on a multi-gram scale in 18 h with resting cells, and the conversion was successfully repeated with recycled cells.

How to approach flow chemistry

Flow chemistry is a widely explored technology whose intrinsic features both facilitate and provide reproducible access to a broad range of chemical processes that are otherwise inefficient or problematic. At its core, a flow chemistry module is a stable set of conditions - traditionally thought of as an externally applied means of activation/control (e.g. heat or light) - through which reagents are passed. In an attempt to simplify the teaching and dissemination of this field, we envisioned that the key advantages of the technique, such as reproducibility and the correlation between reaction time and position within the reactor, allow for the redefinition of a flow module to a more synthetically relevant one based on the overall induced effect. We suggest a rethinking of the approach to flow modules, distributing them in two subclasses: transformers and generators, which can be described respectively as a set of conditions for either performing a specific transformation or for generating a reactive intermediate. The chemistry achieved by transformers and generators is (ideally) independent of the substrate introduced, meaning that they must be robust to small adjustments necessary for the adaptation to different starting materials and reagents while ensuring the same chemical outcome. These redefined modules can be used for single-step reactions or in multistep processes, where modules can be connected to each other in reconfigurable combinations to create chemical assembly systems (CAS) targeting compounds and libraries sharing structural cores. With this tutorial review, we provide a guide to the overall approach to flow chemistry, discussing the key parameters for the design of transformers and generators as well as the development of chemical assembly systems.

Telescoped Continuous Flow Synthesis of Optically Active γ-Nitrobutyric Acids as Key Intermediates of Baclofen, Phenibut, and Fluorophenibut

The two-step flow asymmetric synthesis of chiral γ-nitrobutyric acids as key intermediates of the GABA analogues baclofen, phenibut, and fluorophenibut is reported on a multigram scale. The telescoped process comprises an enantioselective Michael-type addition facilitated by a polystyrene-supported heterogeneous organocatalyst under neat conditions followed by in situ-generated performic acid-mediated aldehyde oxidation. Simple access to valuable optically active substances is provided with key advances in terms of productivity and sustainability compared to those of previous batch approaches.