Design and Characterization of a Scaled-up Ultrasonic Flow Reactor

Ultrasound-Assisted Microcontinuous Process Facilitates the Selective Deuteration of Steroid Hormones

Constructing deuterated molecules efficiently and practically has been a long-standing challenge. Deuterated steroid hormones are essential for medical research and drug metabolism studies and are thus in high demand; mild and selective methods for the deuteration of steroid hormones have remained unexplored. Herein, we demonstrate a practical and efficient approach to synthesize 12 deuterated steroid hormones with up to 98% selectivity and 99% d-incorporation under an ultrasound-assisted microcontinuous process. Optical rotation experiments confirm that steroid hormones configurations are preserved during the H/D exchange reaction. Our protocol enables rapid, inexpensive, and sustainable gram-scale synthesis, facilitated by the reuse of deuterated solvents via molecular distillation technology. Applying synthetic deuterated steroid hormones as mass spectrometry standards, six steroid hormones in metabolites are accurately analyzed from Frozen Human Plasma-1950 sample. Overall, this work has successfully demonstrated the application of ultrasound assisted microcontinuous processing in enhancing H/D exchange reactions.

Ultrasound mechanisms and their effect on solid synthesis and processing: a review

Ultrasound proves to be an effective technique for intensifying a wide range of processes involving solids and, as such, is often used to improve control over both solids formation and post-treatment stages. The intensifying capabilities of ultrasonic processing are best interpreted in the context of the chemical, transport, and mechanical effects that occur during sonication. This review presents an overview of how ultrasound influences the processing and synthesis of solids across various material classes, contextualized within an ultrasound effect framework. By describing the mechanisms underlying the different effects of ultrasound on the solid synthesis and processing, this review aims to facilitate a deeper understanding of the current literature in the field and to promote more effective utilization of ultrasound technology in solid synthesis and processing.

A new strategy for modelling sonochemical reactors: Coupling of the non-linear Louisnard model with mass and heat transport equations with applications to cavitating viscous fluids

In this work, novel numerical models were developed and validated to offer new strategies in modelling sonochemical reactors. More specifically, in our original approach the non-linear Louisnard model was coupled with heat and mass transport equations to predict gradients in temperature and species concentration in a sonicated reactor. Additionally, a new operating window was investigated by modelling mixtures of increasing viscosity on both micro- and macroscale sonochemical effects. On the microscale, the effects of increasing viscosity on bubble dynamics were determined by solving the Keller-Miksis equation. Various cavitation threshold definitions were evaluated. The bubble collapse temperature was determined for all investigated mixtures and the energy dissipation of a single bubble was calculated. On the macroscale, different acoustic attenuation models were compared accounting for either linear or non-linear equations. Specifically, viscous losses were implemented in the non-linear Louisnard model, and model predictions were validated against experimental data. The model was able to predict multiple zones of cavitation in the reactor, as observed experimentally, and to estimate the dissipated energy for the different mixtures. Moreover, it was demonstrated that the cavitation-based attenuation dominates the other dissipation phenomena even for the most viscous solutions. The Louisnard model was coupled with heat transport equations, and using this extended version of the model, the temperature profiles were predicted for mixtures of increasing viscosity during sonication. Using a regression formula available in literature, radical production was related to the acoustic pressure field. By including reactions and mass transport in the acoustic model, for the first time in modelling ultrasonic reactors, the full distribution of light in the reactor during sonochemiluminescence (SCL) experiments for water was quantified.

Insights into cavitation enhancement: Numerical simulation and spectrum analysis of a novel dual-frequency octagonal ultrasonic reactor

Ultrasonic reactors, widely applied in process intensification, face limitations in their industrial application due to a lack of theoretical support for their structural design and optimization, particularly concerning the uniformity of the cavitation zone. Addressing this gap, our study introduces a novel approach to design a multi-frequency octagonal ultrasonic reactor of capacity 9.5 L through numerical simulation and spectrum analysis. The effects of reactor shape, transducer position, and multi-frequency ultrasound interaction on the sound pressure distribution in the reactor were simulated, employing a linear wave equation that accounts for the inhomogeneous distribution of bubbles. The accuracy of sound pressure amplitude predictions has been validated through a multi-frequency simulation method, exhibiting good consistency with experimental data. The results revealed that an octagonal structure with transducers positioned at the bottom and sides enhances the uniformity and distribution of the cavitation area compared to traditional rectangular designs. Notably, the combination of 20 and 40 kHz frequencies at a driving pressure of 3 bar significantly enhances cavitation rates to 69.2 %, surpassing the single frequency of 40 kHz by an increase of 16.5 %. The enhanced cavitation rate can be attributed to the dual-frequency operation, which facilitates larger bubble radii, along with higher collapse temperatures and pressures, as determined through bubble dynamics calculations. Moreover, spectrum analysis method enables energy separation, showing that the introduction of a 40 kHz transducer into a 20 kHz field markedly strengthens both steady and transient cavitation intensities. These findings offer practical insights for their structural design and optimization, paving the way for their broader industrial application.

Application and development of ultrasound in industrial crystallization

Crystallization is an important process that affects the properties of final products and is essential in nearly all chemical processing industries. In recent years, ultrasonic technology has received widespread attention due to its ability to enhance crystallization yield, improve crystal morphology and shape, and regulate the particle size and distribution of crystal products. It holds promising prospects for industrial crystallization. In this work, the ultrasonic cavitation effect and ultrasonic crystallization mechanism are described, and the influence of ultrasound on the crystallization effect of products is analysed and discussed. In addition, the application status of ultrasonic reactors and ultrasonic crystallization processes is introduced in detail, and the change trend from laboratory to industrialization is analyzed. Finally, the challenges and opportunities facing the industrialization of ultrasonic crystallization in future developments are discussed. The purpose of this work is to make the selective promotion or inhibition of ultrasound more helpful for industrial crystallization.

Nanogels: Recent Advances in Synthesis and Biomedical Applications

In the context of advanced nanomaterials research, nanogels (NGs) have recently gained broad attention for their versatility and promising biomedical applications. To date, a significant number of NGs have been developed to meet the growing demands in various fields of biomedical research. Summarizing preparation methods, physicochemical and biological properties, and recent applications of NGs may be useful to help explore new directions for their development. This article presents a comprehensive overview of the latest NG synthesis methodologies, highlighting advances in formulation with different types of hydrophilic or amphiphilic polymers. It also underlines recent biomedical applications of NGs in drug delivery and imaging, with a short section dedicated to biosafety considerations of these innovative nanomaterials. In conclusion, this article summarizes recent innovations in NG synthesis and their numerous applications, highlighting their considerable potential in the biomedical field.

Heterogeneous photochemical reaction enabled by an ultrasonic microreactor

The presence of solids as starting reagents/reactants or products in flow photochemical reactions can lead to reactor clogging and yield reduction from side reactions. We address this limitation with a new ultrasonic microreactor for continuous solid-laden photochemical reactions. The ultrasonic photochemical microreactor is characterized by the liquid and solid residence time distribution (RTD) and the absorbed photon flux in the reactor via chemical actinometry. The solid-handling capability of the ultrasonic photochemical microreactor is demonstrated with a silyl radical-mediated metallaphotoredox cross-electrophile coupling with a solid base as a reagent.

Understanding the ultrasound field of high viscosity mixtures: Experimental and numerical investigation of a lab scale batch reactor

In this work, mixtures of increasing viscosity (from 0.9 to ≈720 mPas) are sonicated directly using an ultrasonic horn at 30 kHz to investigate the effect of viscosity on the ultrasound field both from an experimental and numerical point of view. The viscosity of the mixtures is modified by preparing water-polyethylene glycol solutions. The impact of the higher viscosity on the acoustic pressure distribution is studied qualitatively and semi-quantitatively using sonochemiluminescence. The velocity of light scattering particles added in the mixtures is also explored to quantify acoustic streaming effects using Particle Image Velocimetry (PIV). A numerical model is developed that is able to predict cavitationally active zones accounting for both thermoviscous and cavitation based attenuation. The results show that two cavitation zones exist: one directly under the horn tip and one around the part of the horn body that is immersed in the liquid. The erosion patterns on aluminum foil confirm the existence of both zones. The intensity of the cavitationally active zones decreases considerably with increasing viscosity of the solutions. A similar reduction trend is observed for the velocity of the particles contained in the jet directly under the tip of the horn. Less erratic flow patterns relate to the high viscosity mixtures tested. Finally, two numerical models were made combining different boundary conditions related to the ultrasonic horn. Only the model that includes the radial horn movements is able to qualitatively predict well the location of the cavitation zones and the decrease of the zones intensity, for the highest viscosities studied. The current findings should be taken into consideration in the design and modelling phase of horn based sonochemical reactors.

Simulations of a full sonoreactor accounting for cavitation

In spite of the increasing interest in ultrasound processing applications, industrial scale-up remains limited, in particular by the unavailability of predictive computer tools. In this study, using a previously published model of cavitating liquids implementable as a non-linear Helmholtz equation, it is shown that a full sonoreactor can be modelled and simulated. The model includes the full transducer and the vibrations of the vessel walls, using the physics of elastic solids and piezo-electricity. The control-loop used by the generator to set the optimal frequency is also accounted for. Apart from the geometry, the unique input of the model is the current feeding the transducer whereas the dissipated electrical power, transducer complex impedance and working frequency are available as outputs. The model is put to the test against experiments realized in different geometries, varying either the input current or the transducer immersion depth. Despite the overestimation of the power dissipated in the liquid, the evolution of the acoustic load in both cases is reasonably well reproduced by simulation, which partially validates the method used.

Understanding flow chemistry for the production of active pharmaceutical ingredients

Multi-step organic syntheses of various drugs, active pharmaceutical ingredients, and other pharmaceutically and agriculturally important compounds have already been reported using flow synthesis. Compared to batch, hazardous and reactive reagents can be handled safely in flow. This review discusses the pros and cons of flow chemistry in today’s scenario and recent developments in flow devices. The review majorly emphasizes on the recent developments in the flow synthesis of pharmaceutically important products in last five years including flibanserin, imatinib, buclizine, cinnarizine, cyclizine, meclizine, ribociclib, celecoxib, SC-560 and mavacoxib, efavirenz, fluconazole, melitracen HCl, rasagiline, tamsulosin, valsartan, and hydroxychloroquine. Critical steps and new development in the flow synthesis of selected compounds are also discussed.

Research progress of metal organic frameworks and their derivatives for adsorption of anions in water: A review

Anion pollution in water has become a problem that cannot be ignored. The anion concentration should be controlled below the national emission standard to meet the demand for clean water. Among the methods for removing excess anions in water, the adsorption method has a unique removal performance, and the core of the adsorption method is the adsorbent. In recent years, the emerging metal-organic frameworks (MOFs) have the advantages of adjustable porosity, high specific surface area, diverse functions, and easy modification. They are very competitive in the field of adsorption of liquid anions. This article focuses on the adsorption of fluoride, arsenate, chromate, radioactive anions (ReO₄^-, TcO₄^-, SeO₄^2-/SeO₃^2-), phosphate ion, chloride ion, and other anions by MOFs and their derivatives. The preparation methods of MOFs are introduced in turn, the application of different types of metal-based MOFs to adsorb various anions were discussed in categories with their crystal structure and functional groups. The influence on the adsorption of anions is analyzed, including the more common and special adsorption mechanisms, adsorption kinetics and thermodynamics, and regeneration performance are briefly described. Finally, the current situation of MOFs adsorption of anions is summarized, and the outlook for future development is summarized to provide my own opinions for the practical application of MOFs.

Continuous stirred-tank reactor cascade platform for self-optimization of reactions involving solids

Research-scale fully automated flow platform for reaction self-optimization with solids handling facilitates identification of optimal conditions for continuous manufacturing of pharmaceuticals while reducing amounts of raw materials consumed.

Multi-frequency sonoreactor characterisation in the frequency domain using a semi-empirical bubbly liquid model

Recently, multi-frequency systems were reported to improve performance in power ultrasound applications. In line with this, digital prototyping of multi-frequency sonoreactors also started gaining interest. However, the conventional method of simulating multi-frequency acoustic pressure fields in the time-domain led to many challenges and limitations. In this study, a multi-frequency sonoreactor was characterised using frequency domain simulations in 2-D. The studied system consists of a hexagonal sonoreactor capable of operating at 28, 40 and 70 kHz. Four frequency combinations were studied: 28-40, 28-70, 40-70 and 28-40-70 kHz. A semi-empirical, modified Commander and Prosperetti model was used to describe the bubbly-liquid effects in the sonoreactor. The root-mean-squared acoustic pressure was compared against experimental validation results using sonochemiluminescence (SCL) images and was noted to show good qualitative agreement with SCL results in terms of antinode predictions. The empirical phase speed calculated from SCL measurements was found to be important to circumvent uncertainties in bubble parameter specifications which reduces error in the simulations. Additionally, simulation results also highlighted the importance of geometry in the context of optimising the standing wave magnitudes for each working frequency due to the effects of constructive and destructive interference.