Continuous-Flow Synthesis of Pigment Red 146 in a Microreactor System

Modular Cascade of Flow Reactors: Continuous Flow Synthesis of Water-Insoluble Diazo Dyes in Aqueous System

Continuous flow synthesis is pivotal in dye production to address batch-to-batch variations. However, synthesizing water-insoluble dyes in an aqueous system poses a challenge that can lead to clogging. This study successfully achieved the safe and efficient synthesis of azo dyes by selecting and optimizing flow reactor modules for different reaction types in the two-step reaction and implementing cascade cooperation. Integrating continuous flow microreactor with continuous stirred tank reactor (CSTR) enabled the continuous flow synthesis of Sudan Yellow 3G without introducing water-soluble functional groups or using organic solvents to enhance solubility. Optimizing conditions (acidity/alkalinity, temperature, residence time) within the initial modular continuous flow reactor resulted in a remarkable 99.5% isolated yield, 98.6 % purity, and a production rate of 2.90 g h-1. Scaling-up based on different reactor module characteristics further increased the production rate to 74.4 g h-1 while maintaining high yield and purity. The construction of this small 3D-printing modular cascaded reactor and process scaling-up provide technical support for continuous flow synthesis of water-insoluble dyes, particularly high-market-share azo dyes. Moreover, this versatile methodology proves applicable to continuous flow processes involving various homogeneous and heterogeneous reaction cascades.

A Novel Bubble-based Microreactor for Enhanced Mass Transfer Dynamics toward Efficient Electrocatalytic Nitrogen Reduction

Electrocatalytic nitrogen reduction reaction (eNRR) is a promising method for sustainable ammonia production. Although the majority of studies on the eNRR are devoted to developing efficient electrocatalysts, it is critical to study the influence of mass transfer because of the poor N2 transfer efficiency. Herein, a novel bubble-based microreactor (BBMR) is proposed that efficiently promotes the mass transfer behavior during the eNRR using microfluidic strategies. The BBMR possesses abundant triphasic interfaces and provides spatial confinement and accurate potential control, ensuring rapid mass transfer dynamics and improved eNRR performance, as confirmed by experimental and simulation studies. The ammonia yield of the reaction over Ag nanoparticles can be enhanced to 31.35 µg h-1 mgcat. -1, which is twice that of the H-cell. Excellent improvements are also achieved using Ru/C and Fe/g-CN catalysts, with 5.0 and 8.5 times increase in ammonia yield, respectively. This work further demonstrates the significant effect of mass transfer on the eNRR performance and provides an effective strategy for process enhancement through electrode design.

Accelerated Diffusion of a Copper(I)-Functionalized COF Packed Bed Reactor for Efficient Continuous Flow Catalysis

Flow chemistry provides a neo-orientation for the research and development of chemical technology, in which heterogeneous continuous catalysis based on packed beds can realize rapid separation and recycling. However, options for heterogeneous catalysts are still limited. In this work, we gradually grow covalent organic frameworks (COFs, TpBpy) on the surface of a silica gel (SiO2)-supported substrate to obtain a stable copper(I)-chelated high-loading heterogeneous catalyst (SiO2@CuI-TpBpy). SiO2@CuI-TpBpy shows high catalytic activity in three-component Huisgen 1,3-dipolar cycloaddition, giving the corresponding triazoles with excellent yields and reposeful recyclability under batch conditions. The structures of the catalysts remain steady, and the copper contents are basically unchanged after five cycles. Then, the catalysts are successfully applied for three-component heterogeneous catalysis in a one-pot continuous flow to prepare rufinamide in 89% yield for 24 h stably and efficiently with mere traces of copper ions remaining. More importantly, the catalytic system reveals a minuscule effect of catalyst particle size on internal diffusion. This COF encapsulation strategy presents a new possibility for the design of industrial heterogeneous catalysts with high metal loading and low internal diffusion resistance.

The continuous flow synthesis of azos

Azo compounds find use in many areas of science, displaying crucial properties for important applications as photoconductive organic pigments, fluorescent quenchers, paints, cosmetics, inks, and in the large and valuable dye industry. Due to the unstable intermediates, and the exothermic and fast reactions used in their synthesis, high value azo compounds are excellent candidates for continuous flow manufacturing. This comprehensive review covers the progress made to date on developing continuous flow systems for azo synthesis and reflects on the main challenges still to be addressed, including scale up, conversion, product purity, and environmental impact. The further development of integrated continuous flow processes has the potential to help tackle these challenges and deliver improved methods for azo compound generation.

Modification of C.I. Pigment Red 146 with surfactants and graphene oxide

Organic pigments are important in a range of fields, from printing ink to industrial coatings. Azo pigments are some of the most common pigments in use today, but they typically have poor solvent solubility and tend to agglomerate. Consequently, the size and crystal structure of the pigment particles has a crucial effect on their optical and physical properties, such as color strength and solvent resistance, respectively. Several technologies, such as microreactors, have been developed to control pigment particle size, but an in-depth study of the effects of modification conditions on pigment properties (color, flowability, and solvent resistance) has not been reported to date. Therefore, in this paper, we report the surface modification of C.I. Pigment Red 146 particles using anionic (Igepon T) and non-ionic surfactants (Peregal O-25) and additives (DB-60 as the second diazo component and graphene oxide) on the pigment properties. In addition, we examined the effect of hydrothermal treatment at different temperatures on the same properties. The various modifications resulted in an increase in the solvent resistance, a reduction in the particle size (from 30.581 to 12.252 μm), a narrowing of the particle size distribution, and an increase in hydrophilicity. In addition, the color brightness and brilliance were significantly improved, and the maximum color strength reached 112.6%. These findings have applications for the development of pigments having enhanced color properties, solvent resistance, and processability.

The color properties and solvent resistance of modified Pigment Red 146 were obviously improved by adding surfactants and graphene oxide.

Revisiting aromatic diazotization and aryl diazonium salts in continuous flow: highlighted research during 2001–2021

Aryl diazonium salts play an important role in chemical transformations; however their explosive nature limits their applications in batch.

Continuous-flow diazotization of red base KD hydrochloride suspensions in a microreaction system

A continuous-flow microreaction system has been developed to perform the diazotization reaction of red base KD suspensions. The yield of the diazotization reaction could reach over 99% in 21.2 s under optimized conditions.