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Abstract
How do you get into flow? We trained in flow chemistry during postdoctoral research and are now applying it in new areas: materials chemistry, crystallization, and supramolecular synthesis. Typically, when researchers think of "flow", they are considering predominantly liquid-based organic synthesis; application to other disciplines comes with its own challenges. In this Perspective, we highlight why we use and champion flow technologies in our fields, summarize some of the questions we encounter when discussing entry into flow research, and suggest steps to make the transition into the field, emphasizing that communication and collaboration between disciplines is key.
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Affiliation(s)
- Andrea Laybourn
- Faculty
of Engineering, University of Nottingham, University Park Campus, Nottingham NG7 2RD, U.K.,
| | - Karen Robertson
- Faculty
of Engineering, University of Nottingham, University Park Campus, Nottingham NG7 2RD, U.K.,
| | - Anna G. Slater
- Department
of Chemistry and Materials Innovation Factory, University of Liverpool, Crown Street, Liverpool L69 7ZD, U.K.,
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2
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Devos C, Brozzi E, Van Gerven T, Kuhn S. Characterization of a Modular Microfluidic Section for Seeded Nucleation in Multiphase Flow. Org Process Res Dev 2023. [DOI: 10.1021/acs.oprd.2c00341] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/11/2023]
Affiliation(s)
- Cedric Devos
- Department of Chemical Engineering, KU Leuven, 3001 Leuven, Belgium
| | - Elena Brozzi
- Department of Chemical Engineering, KU Leuven, 3001 Leuven, Belgium
| | - Tom Van Gerven
- Department of Chemical Engineering, KU Leuven, 3001 Leuven, Belgium
| | - Simon Kuhn
- Department of Chemical Engineering, KU Leuven, 3001 Leuven, Belgium
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3
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Zanuso E, Ruiz HA, Domingues L, Teixeira JA. Oscillatory flow bioreactor operating at high solids loading for enzymatic hydrolysis of lignocellulosic biomass. Biochem Eng J 2022. [DOI: 10.1016/j.bej.2022.108632] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
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4
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Almeida F, Rocha F, Teixeira J, Ferreira A. The influence of electrolytes in aqueous solutions on gas-liquid mass transfer in an oscillatory flow reactor. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2022.118048] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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5
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McGinty J, Svoboda V, MacFhionnghaile P, Wheatcroft H, Price CJ, Sefcik J. Continuous crystallisation of organic salt polymorphs. FRONTIERS IN CHEMICAL ENGINEERING 2022. [DOI: 10.3389/fceng.2022.896329] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022] Open
Abstract
Organic salt crystallisation is of great importance to the pharmaceutical industry as many pharmaceutical products are marketed as salts with salt formation being an essential step in drug development. The model compound used in this work is the polymorphic organic salt ethylenediammonium 3,5-dinitrobenzoate (EDNB) which is the 2:1 salt of 3,5-dinitrobenzoic acid with ethylenediamine. Crystallisation of the two EDNB polymorphs, the stable monoclinic form and the metastable triclinic form, was performed in both semi-batch and continuous processes using continuous mixing approaches. It was demonstrated that continuous mixing approaches, using various types of continuous mixers (co-axial, Ehrfeld, X-mixer) can be used to crystallise the EDNB salt with consistent yield and particle size distribution while achieving control over polymorphic form. The experiments were designed with use of a solution speciation model which provided process understanding and insight to guide development of salt crystallisation processes.
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6
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Fabrication of calcium phosphates with controlled properties using a modular oscillatory flow reactor. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2022.04.036] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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7
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Williams JD, Pöchlauer P, Okumura Y, Inami Y, Kappe CO. Photochemical Deracemization of a Medicinally-Relevant Benzopyran using an Oscillatory Flow Reactor. Chemistry 2022; 28:e202200741. [PMID: 35293645 PMCID: PMC9321886 DOI: 10.1002/chem.202200741] [Citation(s) in RCA: 8] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/08/2022] [Indexed: 12/12/2022]
Abstract
Dynamic deracemization processes, such as crystallization-induced diastereomer transformations (CIDTs), offer the opportunity to combine racemization and resolution processes, to provide high yields of enantiomerically pure compounds. To date, few of these processes have incorporated photochemical racemization. By combining batch crystallization with a flow photoreactor for efficient irradiation, it is possible to perform such deracemization in an effective, scalable and high yielding manner. After applying design of experiment (DoE) principles and mathematical modelling, the most efficient parameter set could be identified, leading to excellent results in just 4 h reaction time: isolated yield of 82 % and assay ee of 96 %. Such photochemical racemization methods can serve to open new avenues for preparation of enantiomerically pure functional molecules on both small and industrially-relevant scales.
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Affiliation(s)
- Jason D Williams
- Center for Continuous Flow Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Inffeldgasse 13, 8010, Graz, Austria.,Institute of Chemistry, University of Graz, NAWI Graz, Heinrichstrasse 28, 8010, Graz, Austria
| | - Peter Pöchlauer
- Thermo Fisher Scientific Linz, St.-Peter-Straße 25, 4020, Linz, Austria
| | - Yoshiyuki Okumura
- R&D and Business Promotion, AskAt Inc. 2F Dai-Tokai Building, 3-22-8 Meieki Nakamura-ku Nagoya, Aichi, 450-0002, Japan
| | - Yukari Inami
- R&D and Business Promotion, AskAt Inc. 2F Dai-Tokai Building, 3-22-8 Meieki Nakamura-ku Nagoya, Aichi, 450-0002, Japan
| | - C Oliver Kappe
- Center for Continuous Flow Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Inffeldgasse 13, 8010, Graz, Austria.,Institute of Chemistry, University of Graz, NAWI Graz, Heinrichstrasse 28, 8010, Graz, Austria
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8
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Effect of oscillatory flow conditions on crystalliser fouling investigated through non-invasive imaging. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2021.117188] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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9
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Schmalenberg M, Mensing L, Lindemann S, Krell T, Kockmann N. Miniaturized draft tube baffle crystallizer for continuous cooling crystallization. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2021.12.024] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/04/2023]
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10
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Fatemi N, Devos C, Van Gerven T, Kuhn S. Continuous crystallization of paracetamol exploiting gas–liquid flow in modular nucleation and growth stages. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2021.117095] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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11
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Sonnenschein J, Wohlgemuth K. Archimedes tube crystallizer: Design and characterization for small-scale continuous crystallization. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2021.12.017] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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12
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Numerically investigating the effects of geometry on hydrodynamics and particle suspension performance in continuous oscillatory baffled crystallizers. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2021.117352] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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13
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Shen L, Dang M. Recent Advance of Melt Crystallization, Towards Process Intensification and Techniques Development. CrystEngComm 2022. [DOI: 10.1039/d2ce00022a] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
Melt crystallization has been considered as a green separation technique and widely applied in industry and manufacture due to several attractive features, including no need for solvent, achieving specific product...
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14
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Sakai Y, Kusaki H, Katayama K. Photocontrollable Crystallization at the Topological Defect of a Liquid Crystalline Droplet. ACS OMEGA 2021; 6:35050-35056. [PMID: 34963986 PMCID: PMC8697613 DOI: 10.1021/acsomega.1c05816] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/17/2021] [Accepted: 11/30/2021] [Indexed: 06/14/2023]
Abstract
Photocontrollable crystallization at topological defects in a liquid crystal (LC) droplet was demonstrated. The molecules dissolved in a surfactant solution outside the LC droplet were moved into the droplet via light absorption. Nuclei emerged tens of seconds after light irradiation and moved toward the topological defect located at the droplet center, thus forming a branch-shaped crystal. This phenomenon was reproduced for multiple different molecules; photoinduced migration, nucleation, and crystal formation were discussed as a plausible mechanism.
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Affiliation(s)
- Yota Sakai
- Department of Applied Chemistry, Chuo University, Tokyo 112-8551, Japan
| | - Hinako Kusaki
- Department of Applied Chemistry, Chuo University, Tokyo 112-8551, Japan
| | - Kenji Katayama
- Department of Applied Chemistry, Chuo University, Tokyo 112-8551, Japan
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15
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Jaiswal P, Kumar Y, Panda D, Guha Biswas K. Vibration in Microchannel Causes Greater Enhancement of Mass Transfer in Toluene–Acetic Acid–Water System. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c04495] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Pooja Jaiswal
- Department of Chemical Engineering and Biochemical Engineering, Rajiv Gandhi Institute of Petroleum Technology, An Institution of National Importance, Jais 229304, Uttar Pradesh, India
| | - Yogendra Kumar
- Department of Chemical Engineering and Biochemical Engineering, Rajiv Gandhi Institute of Petroleum Technology, An Institution of National Importance, Jais 229304, Uttar Pradesh, India
| | - Debashis Panda
- Department of Sciences and Humanities, Rajiv Gandhi Institute of Petroleum Technology, An Institution of National Importance, Jais 229304, Uttar Pradesh, India
| | - Koushik Guha Biswas
- Department of Chemical Engineering and Biochemical Engineering, Rajiv Gandhi Institute of Petroleum Technology, An Institution of National Importance, Jais 229304, Uttar Pradesh, India
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16
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Lian SJ, Hu ZX, Lan Z, Wen RF, Ma XH. Optimal Operation of an Oscillatory Flow Crystallizer: Coupling Disturbance and Stability. ACS OMEGA 2021; 6:28912-28922. [PMID: 34746583 PMCID: PMC8567750 DOI: 10.1021/acsomega.1c03890] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/21/2021] [Accepted: 10/13/2021] [Indexed: 06/13/2023]
Abstract
In the process of industrial crystallization, it is always difficult to balance the secondary nucleation rate and metastable zone width (MSZW). Herein, we report an experimental and numerical study for the cooling crystallization of paracetamol in an oscillatory flow crystallizer (OFC), finding the optimal operating conditions for balancing the secondary nucleation rate and MSZW. The results show that the MSZW decreases with the increase of oscillation Reynolds number (Re o). Compared to the traditional stirring system, the OFC has an MSZW three times larger than that of the stirring system under a similar power density of consumption. With the numerical simulation, the OFC can produce a stable space environment and instantaneous strong disturbance, which is conducive to the crystallization process. Above all, a high Re o is favorable to produce a sufficient nucleation rate, which may inevitably constrict the MSZW to a certain degree. Then, the optimization strategy of the operating parameter (Re o) in the OFC is proposed.
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17
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Cruz P, Alvarez C, Rocha F, Ferreira A. Tailoring the crystal size distribution of an active pharmaceutical ingredient by continuous antisolvent crystallization in a planar oscillatory flow crystallizer. Chem Eng Res Des 2021. [DOI: 10.1016/j.cherd.2021.08.030] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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18
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Yang Y, Ahmed B, Mitchell C, Quon JL, Siddique H, Houson I, Florence AJ, Papageorgiou CD. Investigation of Wet Milling and Indirect Ultrasound as Means for Controlling Nucleation in the Continuous Crystallization of an Active Pharmaceutical Ingredient. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00209] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Yihui Yang
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, Boston, 40 Landsdowne, Cambridge, Massachusetts 02139, United States
| | - Bilal Ahmed
- EPSRC Future CMAC Manufacturing Research Hub, Institute of Pharmacy & Biomedical Sciences, Technology and Innovation Centre, University of Strathclyde, Glasgow G1 1RD, U.K
- EPSRC Future CMAC Manufacturing Research Hub, Department of Chemical and Biological Engineering, University of Sheffield, Sheffield S1 3JD, U.K
| | - Christopher Mitchell
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, Boston, 40 Landsdowne, Cambridge, Massachusetts 02139, United States
| | - Justin L. Quon
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, Boston, 40 Landsdowne, Cambridge, Massachusetts 02139, United States
| | - Humera Siddique
- EPSRC Future CMAC Manufacturing Research Hub, Institute of Pharmacy & Biomedical Sciences, Technology and Innovation Centre, University of Strathclyde, Glasgow G1 1RD, U.K
| | - Ian Houson
- EPSRC Future CMAC Manufacturing Research Hub, Institute of Pharmacy & Biomedical Sciences, Technology and Innovation Centre, University of Strathclyde, Glasgow G1 1RD, U.K
| | - Alastair J. Florence
- EPSRC Future CMAC Manufacturing Research Hub, Institute of Pharmacy & Biomedical Sciences, Technology and Innovation Centre, University of Strathclyde, Glasgow G1 1RD, U.K
| | - Charles D. Papageorgiou
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, Boston, 40 Landsdowne, Cambridge, Massachusetts 02139, United States
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19
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Yu Y, Pandit AV, Robertson P, Ranade VV. Antisolvent Crystallization using a Fluidic Oscillator: Modeling and Validation. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c02368] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Yang Yu
- School of Chemistry and Chemical Engineering, Queen’s University, Belfast BT9 5AG, United Kingdom
| | - Ajinkya V. Pandit
- Bernal Institute, University of Limerick, Limerick V94 T9PX, Ireland
| | - Peter Robertson
- School of Chemistry and Chemical Engineering, Queen’s University, Belfast BT9 5AG, United Kingdom
| | - Vivek V. Ranade
- School of Chemistry and Chemical Engineering, Queen’s University, Belfast BT9 5AG, United Kingdom
- Bernal Institute, University of Limerick, Limerick V94 T9PX, Ireland
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20
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Briggs NB, McGinty J, McCabe C, Raval V, Sefcik J, Florence AJ. Heat Transfer and Residence Time Distribution in Plug Flow Continuous Oscillatory Baffled Crystallizers. ACS OMEGA 2021; 6:18352-18363. [PMID: 34308066 PMCID: PMC8296600 DOI: 10.1021/acsomega.1c02215] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/27/2021] [Accepted: 06/29/2021] [Indexed: 05/12/2023]
Abstract
Heat transfer coefficients in a continuous oscillatory baffled crystallizer (COBC) with a nominal internal diameter of 15 mm have been determined as a function of flow and oscillatory conditions typically used under processing conditions. Residence time distribution measurements show a near-plug flow with high Peclet numbers on the order of 100-1000 s, although there was significant oscillation damping in longer COBC setups. Very rapid heat transfer was found under typical conditions, with overall heat transfer coefficients on the order of 100 s W m-2 K-1. Furthermore, poor mixing in the COBC cooling jacket was observed when lower jacket flow rates were implemented in an attempt to decrease the rate of heat transfer in order to achieve more gradual temperature profile along the crystallizer length. Utilizing the experimentally determined overall heat transfer coefficients, a theoretical case study is presented to investigate the effects of the heat transfer rate on temperature and supersaturation profiles and to highlight potential fouling issues during a continuous plug flow cooling crystallization.
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Affiliation(s)
- Naomi
E. B. Briggs
- EPSRC
Continuous Manufacturing and Advanced Crystallisation Future Manufacturing
Research Hub, Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, 161 Cathedral Street, Glasgow G4 0RE, U.K.
| | - John McGinty
- EPSRC
Continuous Manufacturing and Advanced Crystallisation Future Manufacturing
Research Hub, Department of Chemical and Process Engineering, University of Strathclyde, 75 Montrose Street, Glasgow G1 1XJ, U.K.
| | - Callum McCabe
- EPSRC
Continuous Manufacturing and Advanced Crystallisation Future Manufacturing
Research Hub, Department of Chemical and Process Engineering, University of Strathclyde, 75 Montrose Street, Glasgow G1 1XJ, U.K.
| | - Vishal Raval
- EPSRC
Continuous Manufacturing and Advanced Crystallisation Future Manufacturing
Research Hub, Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, 161 Cathedral Street, Glasgow G4 0RE, U.K.
| | - Jan Sefcik
- EPSRC
Continuous Manufacturing and Advanced Crystallisation Future Manufacturing
Research Hub, Department of Chemical and Process Engineering, University of Strathclyde, 75 Montrose Street, Glasgow G1 1XJ, U.K.
- . Phone: +44 (0)141 548 2410
| | - Alastair J. Florence
- EPSRC
Continuous Manufacturing and Advanced Crystallisation Future Manufacturing
Research Hub, Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, 161 Cathedral Street, Glasgow G4 0RE, U.K.
- . Phone: +44 (0)141 548 4877
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21
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Scale-up of micro- and milli-reactors: An overview of strategies, design principles and applications. CHEMICAL ENGINEERING SCIENCE: X 2021. [DOI: 10.1016/j.cesx.2021.100097] [Citation(s) in RCA: 33] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/29/2022] Open
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22
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Abstract
With an increasing interest in cocrystals due to various advantages, demand for large-scale cocrystallization techniques is rising. Solution cocrystallization is a solvent-based approach that utilizes several single-component crystallization concepts as well as equipment for generating cocrystals. Solution-based techniques can produce cocrystals with reasonable control on purity, size distribution, morphology, and polymorphic form. Many of them also offer a scalable solution for the industrial production of cocrystals. However, the complexity of the thermodynamic landscape and the kinetics of cocrystallization offers fresh challenges which are not encountered in single component crystallization. This review focuses on the recent developments in different solution cocrystallization techniques for the production of pharmaceutically relevant cocrystals. The review consists of two sections. The first section describes the various solution cocrystallization methods, highlighting their benefits and limitations. The second section emphasizes the challenges in developing these techniques to an industrial scale and identifies the major thrust areas where further research is required.
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23
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Domokos A, Nagy B, Szilágyi B, Marosi G, Nagy ZK. Integrated Continuous Pharmaceutical Technologies—A Review. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.0c00504] [Citation(s) in RCA: 26] [Impact Index Per Article: 8.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/20/2022]
Affiliation(s)
- András Domokos
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Brigitta Nagy
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Botond Szilágyi
- Budapest University of Technology and Economics, Faculty of Chemical Technology and Biotechnology, H-1111 Budapest, Hungary
| | - György Marosi
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Zsombor Kristóf Nagy
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
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24
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Cruz PC, Silva CR, Rocha FA, Ferreira AM. Mixing Performance of Planar Oscillatory Flow Reactors with Liquid Solutions and Solid Suspensions. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.0c04991] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Patrícia C. Cruz
- LEPABE—Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
| | - Carolina R. Silva
- LEPABE—Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
| | - Fernando A. Rocha
- LEPABE—Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
| | - António M. Ferreira
- LEPABE—Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
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25
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Tom JK, Achmatowicz MM, Beaver MG, Colyer J, Ericson A, Hwang TL, Jiao N, Langille NF, Liu M, Lovette MA, Sangodkar RP, Sharvan Kumar S, Spada S, Perera D, Sheeran J, Campbell K, Doherty T, Ford DD, Fang YQ, Rossi E, Santoni G, Cui S, Walker SD. Implementing Continuous Manufacturing for the Final Methylation Step in the AMG 397 Process to Deliver Key Quality Attributes. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.0c00440] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/11/2022]
Affiliation(s)
- Janine K. Tom
- Drug Substance Technologies, Process Development, Amgen, Inc., Thousand Oaks, California 91320, United States
| | - Michal M. Achmatowicz
- Drug Substance Technologies, Process Development, Amgen, Inc., Thousand Oaks, California 91320, United States
| | - Matthew G. Beaver
- Drug Substance Technologies, Process Development, Amgen, Inc., Cambridge, Massachusetts 02142, United States
| | - John Colyer
- Drug Substance Technologies, Process Development, Amgen, Inc., Thousand Oaks, California 91320, United States
| | - Ari Ericson
- Drug Substance Technologies, Process Development, Amgen, Inc., Thousand Oaks, California 91320, United States
| | - Tsang-Lin Hwang
- Attribute Sciences, Process Development, Amgen, Inc., Thousand Oaks, California 91320, United States
| | - Nancy Jiao
- Attribute Sciences, Process Development, Amgen, Inc., Thousand Oaks, California 91320, United States
| | - Neil F. Langille
- Drug Substance Technologies, Process Development, Amgen, Inc., Cambridge, Massachusetts 02142, United States
| | - Min Liu
- Attribute Sciences, Process Development, Amgen, Inc., Thousand Oaks, California 91320, United States
| | - Michael A. Lovette
- Drug Substance Technologies, Process Development, Amgen, Inc., Thousand Oaks, California 91320, United States
| | - Rahul P. Sangodkar
- Drug Substance Technologies, Process Development, Amgen, Inc., Cambridge, Massachusetts 02142, United States
| | - Srividya Sharvan Kumar
- Drug Substance Technologies, Process Development, Amgen, Inc., Cambridge, Massachusetts 02142, United States
| | - Simone Spada
- Drug Substance Technologies, Process Development, Amgen, Inc., Cambridge, Massachusetts 02142, United States
| | - Damith Perera
- Snapdragon Chemistry Inc., Waltham, Massachusetts 02451, United States
| | - Jillian Sheeran
- Snapdragon Chemistry Inc., Waltham, Massachusetts 02451, United States
| | - Kiersten Campbell
- Snapdragon Chemistry Inc., Waltham, Massachusetts 02451, United States
| | - Timothy Doherty
- Snapdragon Chemistry Inc., Waltham, Massachusetts 02451, United States
| | - David D. Ford
- Snapdragon Chemistry Inc., Waltham, Massachusetts 02451, United States
| | - Yuan-Qing Fang
- Snapdragon Chemistry Inc., Waltham, Massachusetts 02451, United States
| | - Emiliano Rossi
- F.I.S.-Fabbrica Italiana Sintetici S.p.A., Viale Milano 26, 36075 Montecchio Maggiore, Vincenza
| | - Gabriella Santoni
- F.I.S.-Fabbrica Italiana Sintetici S.p.A., Viale Milano 26, 36075 Montecchio Maggiore, Vincenza
| | - Sheng Cui
- Drug Substance Technologies, Process Development, Amgen, Inc., Cambridge, Massachusetts 02142, United States
| | - Shawn D. Walker
- Drug Substance Technologies, Process Development, Amgen, Inc., Cambridge, Massachusetts 02142, United States
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26
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Cruz P, Rocha F, Ferreira A. Crystallization of paracetamol from aqueous solutions in a planar oscillatory flow crystallizer: effect of the oscillation conditions on the nucleation kinetics. CrystEngComm 2021. [DOI: 10.1039/d1ce00922b] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
Nucleation kinetic data is reported for a planar oscillatory flow crystallizer.
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Affiliation(s)
- Patrícia Cruz
- LEPABE – Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
| | - Fernando Rocha
- LEPABE – Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
| | - António Ferreira
- LEPABE – Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
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27
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Orehek J, Teslić D, Likozar B. Continuous Crystallization Processes in Pharmaceutical Manufacturing: A Review. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.0c00398] [Citation(s) in RCA: 36] [Impact Index Per Article: 9.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/04/2023]
Affiliation(s)
- Jaka Orehek
- National Institute of Chemistry, Hajdrihova 19, 1001 Ljubljana, Slovenia
- Lek d. d., Sandoz, a Novartis division, Verovškova 57, 1526 Ljubljana, Slovenia
| | - Dušan Teslić
- Lek d. d., Sandoz, a Novartis division, Verovškova 57, 1526 Ljubljana, Slovenia
| | - Blaž Likozar
- National Institute of Chemistry, Hajdrihova 19, 1001 Ljubljana, Slovenia
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28
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Empirical Modelling of Hydrodynamic Effects on Starch Nanoparticles Precipitation in a Spinning Disc Reactor. NANOMATERIALS 2020; 10:nano10112202. [PMID: 33158219 PMCID: PMC7694281 DOI: 10.3390/nano10112202] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/30/2020] [Revised: 10/26/2020] [Accepted: 10/30/2020] [Indexed: 11/16/2022]
Abstract
Empirical correlations have been developed to relate experimentally determined starch nanoparticle size obtained in a solvent–antisolvent precipitation process with key hydrodynamic parameters of a spinning disc reactor (SDR). Three different combinations of dimensionless groups including a conventional Reynolds number (Re), rotational Reynolds number (Reω) and Rossby number (Ro) have been applied in individual models for two disc surfaces (smooth and grooved) to represent operating variables affecting film flow such as liquid flowrate and disc rotational speed, whilst initial supersaturation (S) has been included to represent varying antisolvent concentrations. Model 1 featuring a combination of Re, Reω and S shows good agreement with the experimental data for both the grooved and smooth discs. For the grooved disc, Re has a greater impact on particle size, whereas Reω is more influential on the smooth disc surface, the difference likely being due to the passive mixing induced by the grooves irrespective of the magnitude of the disc speed. Supersaturation has little impact on particle size within the limited initial supersaturation range studied. Model 2 which characterises both flow rate and disc rotational speed through Ro alone and combined with Re was less accurate in predicting particle size due to several inherent limitations.
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29
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Hart T, Schultz VL, Thomas D, Kulesza T, Jensen KF. Development of a Versatile Modular Flow Chemistry Benchtop System. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.0c00160] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Travis Hart
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
| | - Victor L. Schultz
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
| | - Dale Thomas
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
| | - Tim Kulesza
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
| | - Klavs F. Jensen
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
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30
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Boffito DC, Fernandez Rivas D. Process intensification connects scales and disciplines towards sustainability. CAN J CHEM ENG 2020. [DOI: 10.1002/cjce.23871] [Citation(s) in RCA: 20] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
Affiliation(s)
- Daria C. Boffito
- Chemical Engineering Department Canada Research Chair in Intensified Mechano‐Chemical Processes for Sustainable Biomass Conversion, Polytechnique Montréal Montréal Québec Canada
| | - David Fernandez Rivas
- Mesoscale Chemical Systems Group, MESA+ Institute and Faculty of Science and Technology University of Twente Enschede The Netherlands
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31
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The Hydrodynamics and Mixing Performance in a Moving Baffle Oscillatory Baffled Reactor through Computational Fluid Dynamics (CFD). Processes (Basel) 2020. [DOI: 10.3390/pr8101236] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
Oscillatory baffled reactors (OBRs) have attracted much attention from researchers and industries alike due to their proven advantages in mixing, scale-up, and cost-effectiveness over conventional stirred tank reactors (STRs). This study quantitatively investigated how different mixing indices describe the mixing performance of a moving baffle OBR using computational fluid dynamics (CFD). In addition, the hydrodynamic behavior of the reactor was studied, considering parameters such as the Q-criterion, shear strain rate, and velocity vector. A modification of the Q-criterion showed advantages over the original Q-criterion in determination of the vortices’ locations. The dynamic mesh tool was utilized to simulate the moving baffles through ANSYS/Fluent. The mixing indices studied were the velocity ratio, turbulent length scale, turbulent time scale, mixing time, and axial dispersion coefficient. We found that the oscillation amplitude had the most significant impact on these indices. In contrast, the oscillatory Reynolds number did not necessarily describe the mixing intensity of a system. Of the tested indices, the axial dispersion coefficient showed advantages over the other indices for quantifying the mixing performance of a moving baffle OBR.
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32
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Veiga A, Castro F, Rocha F, Oliveira A. Silk-based microcarriers: current developments and future perspectives. IET Nanobiotechnol 2020; 14:645-653. [PMID: 33108319 PMCID: PMC8676661 DOI: 10.1049/iet-nbt.2020.0058] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2020] [Revised: 08/04/2020] [Accepted: 08/07/2020] [Indexed: 12/22/2022] Open
Abstract
Cell-seeded microcarriers (MCs) are currently one of the most promising topics in biotechnology. These systems are supportive structures for cell growth and expansion that allow efficient nutrient and gas transfer between the media and the attached cells. Silk proteins have been increasingly used for this purpose in the past few years due to their biocompatibility, biodegradability and non-toxicity. To date, several silk fibroin spherical MCs in combination with alginate, gelatin and calcium phosphates have been reported with very interesting outcomes. In addition, other silk-based three-dimensional structures such as microparticles with chitosan and collagen, as well as organoids, have been increasingly studied. In this study, the physicochemical and biological properties of these biomaterials, as well as the recent methodologies for their processing and for cell culture, are discussed. The potential biomedical applications are also addressed. In addition, an analysis of the future perspectives is presented, where the potential of innovative silk-based MCs processing technologies is highlighted.
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Affiliation(s)
- Anabela Veiga
- LEPABE - Laboratory for Process Engineering, Environment, Biotechnology & Energy, Faculty of Engineering of Porto, Department of Chemical Engineering, University of Porto, Porto, Portugal
| | - Filipa Castro
- LEPABE - Laboratory for Process Engineering, Environment, Biotechnology & Energy, Faculty of Engineering of Porto, Department of Chemical Engineering, University of Porto, Porto, Portugal.
| | - Fernando Rocha
- LEPABE - Laboratory for Process Engineering, Environment, Biotechnology & Energy, Faculty of Engineering of Porto, Department of Chemical Engineering, University of Porto, Porto, Portugal
| | - Ana Oliveira
- Universidade Católica Portuguesa, CBQF - Centro de Biotecnologia e Química Fina - Laboratório Associado, Escola Superior de Biotecnologia, Rua Diogo Botelho 1327, 4169-005 Porto, Portugal
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33
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Doyle BJ, Elsner P, Gutmann B, Hannaerts O, Aellig C, Macchi A, Roberge DM. Mini-Monoplant Technology for Pharmaceutical Manufacturing. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.0c00207] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/18/2022]
Affiliation(s)
- Brendon J. Doyle
- Centre for Catalysis Research and Innovation, Department of Chemical and Biological Engineering, University of Ottawa, Ottawa, Ontario K1N 6N5, Canada
| | - Petteri Elsner
- API Development Services, Lonza AG, CH-3930 Visp, Switzerland
| | | | | | - Christof Aellig
- API Development Services, Lonza AG, CH-3930 Visp, Switzerland
| | - Arturo Macchi
- Centre for Catalysis Research and Innovation, Department of Chemical and Biological Engineering, University of Ottawa, Ottawa, Ontario K1N 6N5, Canada
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34
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Levenstein MA, Kim YY, Hunter L, Anduix-Canto C, González Niño C, Day SJ, Li S, Marchant WJ, Lee PA, Tang CC, Burghammer M, Meldrum FC, Kapur N. Evaluation of microflow configurations for scale inhibition and serial X-ray diffraction analysis of crystallization processes. LAB ON A CHIP 2020; 20:2954-2964. [PMID: 32666988 DOI: 10.1039/d0lc00239a] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/11/2023]
Abstract
The clean and reproducible conditions provided by microfluidic devices are ideal sample environments for in situ analyses of chemical and biochemical reactions and assembly processes. However, the small size of microchannels makes investigating the crystallization of poorly soluble materials on-chip challenging due to crystal nucleation and growth that result in channel fouling and blockage. Here, we demonstrate a reusable insert-based microfluidic platform for serial X-ray diffraction analysis and examine scale formation in response to continuous and segmented flow configurations across a range of temperatures. Under continuous flow, scale formation on the reactor walls begins almost immediately on mixing of the crystallizing species, which over time results in occlusion of the channel. Depletion of ions at the start of the channel results in reduced crystallization towards the end of the channel. Conversely, segmented flow can control crystallization, so it occurs entirely within the droplet. Consequently, the spatial location within the channel represents a temporal point in the crystallization process. Whilst each method can provide useful crystallographic information, time-resolved information is lost when reactor fouling occurs and changes the solution conditions with time. The flow within a single device can be manipulated to give a broad range of information addressing surface interaction or solution crystallization.
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Affiliation(s)
- Mark A Levenstein
- School of Mechanical Engineering, University of Leeds, Woodhouse Lane, Leeds LS2 9JT, UK.
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35
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Pu S, Hadinoto K. Continuous crystallization as a downstream processing step of pharmaceutical proteins: A review. Chem Eng Res Des 2020. [DOI: 10.1016/j.cherd.2020.05.004] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/27/2022]
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36
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Abstract
AbstractOscillatory flow reactors (OFRs) superimpose an oscillatory flow to the net movement through a flow reactor. OFRs have been engineered to enable improved mixing, excellent heat- and mass transfer and good plug flow character under a broad range of operating conditions. Such features render these reactors appealing, since they are suitable for reactions that require long residence times, improved mass transfer (such as in biphasic liquid-liquid systems) or to homogeneously suspend solid particles. Various OFR configurations, offering specific features, have been developed over the past two decades, with significant progress still being made. This review outlines the principles and recent advances in OFR technology and overviews the synthetic applications of OFRs for liquid-liquid and solid-liquid biphasic systems.
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37
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Levenstein MA, Wayment L, Scott CD, Lunt R, Flandrin PB, Day SJ, Tang CC, Wilson CC, Meldrum FC, Kapur N, Robertson K. Dynamic Crystallization Pathways of Polymorphic Pharmaceuticals Revealed in Segmented Flow with Inline Powder X-ray Diffraction. Anal Chem 2020; 92:7754-7761. [PMID: 32365293 DOI: 10.1021/acs.analchem.0c00860] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Abstract
Understanding the transitions between polymorphs is essential in the development of strategies for manufacturing and maximizing the efficiency of pharmaceuticals. However, this can be extremely challenging: crystallization can be influenced by subtle changes in environment, such as temperature and mixing intensity or even imperfections in the crystallizer walls. Here, we highlight the importance of in situ measurements in understanding crystallization mechanisms, where a segmented flow crystallizer was used to study the crystallization of the pharmaceuticals urea: barbituric acid (UBA) and carbamazepine (CBZ). The reactor provides highly reproducible reaction conditions, while in situ synchrotron powder X-ray diffraction (PXRD) enables us to monitor the evolution of this system. UBA has two polymorphs of almost equivalent free-energy and so is typically obtained as a polymorphic mixture. In situ PXRD analysis uncovered a progression of polymorphs from UBA III to the thermodynamic polymorph UBA I, where different positions along the length of the tubular flow crystallizer correspond to different reaction times. Addition of UBA I seed crystals modified this pathway such that only UBA I was observed throughout, while transformation from UBA III into UBA I still occurred in the presence of UBA III seeds. Information regarding the mixing-dependent kinetics of the CBZ form II to III transformation was also uncovered in a series of seeded and unseeded flow crystallization runs, despite atypical habit expression. These results illustrate the importance of coupling controlled reaction environments with in situ XRD to study the phase relationships in polymorphic materials.
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Affiliation(s)
- Mark A Levenstein
- School of Mechanical Engineering, University of Leeds, Woodhouse Lane, Leeds LS2 9JT, U.K.,School of Chemistry, University of Leeds, Woodhouse Lane, Leeds LS2 9JT, U.K
| | - Lois Wayment
- Department of Chemistry, University of Bath, Claverton Down, Bath BA2 7AY, U.K.,CMAC Future Manufacturing Hub, University of Bath, Claverton Down, Bath BA2 7AY, U.K.,Diamond Light Source, Harwell Campus, Didcot, Oxfordshire OX11 0DE, U.K
| | - C Daniel Scott
- Department of Chemistry, University of Bath, Claverton Down, Bath BA2 7AY, U.K.,Centre for Sustainable Chemical Technologies, University of Bath, Claverton Down, Bath BA2 7AY, U.K
| | - Ruth Lunt
- Department of Chemistry, University of Bath, Claverton Down, Bath BA2 7AY, U.K.,CMAC Future Manufacturing Hub, University of Bath, Claverton Down, Bath BA2 7AY, U.K
| | | | - Sarah J Day
- Diamond Light Source, Harwell Campus, Didcot, Oxfordshire OX11 0DE, U.K
| | - Chiu C Tang
- Diamond Light Source, Harwell Campus, Didcot, Oxfordshire OX11 0DE, U.K
| | - Chick C Wilson
- Department of Chemistry, University of Bath, Claverton Down, Bath BA2 7AY, U.K
| | - Fiona C Meldrum
- School of Chemistry, University of Leeds, Woodhouse Lane, Leeds LS2 9JT, U.K
| | - Nikil Kapur
- School of Mechanical Engineering, University of Leeds, Woodhouse Lane, Leeds LS2 9JT, U.K
| | - Karen Robertson
- Department of Chemistry, University of Bath, Claverton Down, Bath BA2 7AY, U.K
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38
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Li J, Sheng L, Tuo L, Xiao W, Ruan X, Yan X, He G, Jiang X. Membrane-Assisted Antisolvent Crystallization: Interfacial Mass-Transfer Simulation and Multistage Process Control. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c01645] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Jin Li
- State Key Laboratory of Fine Chemicals, School of Chemical Engineering, Engineering Laboratory for Petrochemical Energy-efficient Separation Technology of Liaoning Province, Dalian University of Technology, Dalian 116024, China
| | - Lei Sheng
- State Key Laboratory of Fine Chemicals, School of Chemical Engineering, Engineering Laboratory for Petrochemical Energy-efficient Separation Technology of Liaoning Province, Dalian University of Technology, Dalian 116024, China
| | - Linghan Tuo
- State Key Laboratory of Fine Chemicals, School of Chemical Engineering, Engineering Laboratory for Petrochemical Energy-efficient Separation Technology of Liaoning Province, Dalian University of Technology, Dalian 116024, China
| | - Wu Xiao
- State Key Laboratory of Fine Chemicals, School of Chemical Engineering, Engineering Laboratory for Petrochemical Energy-efficient Separation Technology of Liaoning Province, Dalian University of Technology, Dalian 116024, China
| | - Xuehua Ruan
- State Key Laboratory of Fine Chemicals, School of Chemical Engineering, Engineering Laboratory for Petrochemical Energy-efficient Separation Technology of Liaoning Province, Dalian University of Technology, Dalian 116024, China
| | - Xiaoming Yan
- State Key Laboratory of Fine Chemicals, School of Chemical Engineering, Engineering Laboratory for Petrochemical Energy-efficient Separation Technology of Liaoning Province, Dalian University of Technology, Dalian 116024, China
| | - Gaohong He
- State Key Laboratory of Fine Chemicals, School of Chemical Engineering, Engineering Laboratory for Petrochemical Energy-efficient Separation Technology of Liaoning Province, Dalian University of Technology, Dalian 116024, China
| | - Xiaobin Jiang
- State Key Laboratory of Fine Chemicals, School of Chemical Engineering, Engineering Laboratory for Petrochemical Energy-efficient Separation Technology of Liaoning Province, Dalian University of Technology, Dalian 116024, China
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39
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Diab S, Gerogiorgis DI. Design Space Identification and Visualization for Continuous Pharmaceutical Manufacturing. Pharmaceutics 2020; 12:E235. [PMID: 32151096 PMCID: PMC7150984 DOI: 10.3390/pharmaceutics12030235] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/31/2020] [Revised: 03/02/2020] [Accepted: 03/03/2020] [Indexed: 11/16/2022] Open
Abstract
Progress in continuous flow chemistry over the past two decades has facilitated significant developments in the flow synthesis of a wide variety of Active Pharmaceutical Ingredients (APIs), the foundation of Continuous Pharmaceutical Manufacturing (CPM), which has gained interest for its potential to reduce material usage, energy and costs and the ability to access novel processing windows that would be otherwise hazardous if operated via traditional batch techniques. Design space investigation of manufacturing processes is a useful task in elucidating attainable regions of process performance and product quality attributes that can allow insight into process design and optimization prior to costly experimental campaigns and pilot plant studies. This study discusses recent demonstrations from the literature on design space investigation and visualization for continuous API production and highlights attainable regions of recoveries, material efficiencies, flowsheet complexity and cost components for upstream (reaction + separation) via modeling, simulation and nonlinear optimization, providing insight into optimal CPM operation.
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Affiliation(s)
| | - Dimitrios I. Gerogiorgis
- School of Engineering, Institute for Materials and Processes (IMP), University of Edinburgh, The King’s Buildings, Edinburgh EH9 3FB, Scotland, UK;
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40
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Cameli F, Xiouras C, Stefanidis GD. High-throughput on demand access of single enantiomers by a continuous flow crystallization process. CrystEngComm 2020. [DOI: 10.1039/d0ce00366b] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
Abstract
A novel continuous flow reactive crystallization process for the in situ on-demand access of single enantiomer crystals is reported and exemplified for a chiral pharmaceutical intermediate that crystallizes as a racemic conglomerate.
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Affiliation(s)
- Fabio Cameli
- Process Engineering for Sustainable Systems (ProcESS)
- Department of Chemical Engineering
- KU Leuven
- 3001 Leuven
- Belgium
| | - Christos Xiouras
- Crystallization Technology Unit (CTU)
- Janssen Research & Development
- Janssen Pharmaceutical Companies of Johnson & Johnson
- Beerse
- Belgium
| | - Georgios D. Stefanidis
- Process Engineering for Sustainable Systems (ProcESS)
- Department of Chemical Engineering
- KU Leuven
- 3001 Leuven
- Belgium
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41
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Raval V, Siddique H, Brown CJ, Florence AJ. Development and characterisation of a cascade of moving baffle oscillatory crystallisers (CMBOC). CrystEngComm 2020. [DOI: 10.1039/d0ce00069h] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/05/2023]
Abstract
A novel four stage Cascade of Moving Baffle Oscillatory Crystallisers (CMBOC) is developed, characterised and implemented for continuous crystallisation of pharmaceuticals.
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Affiliation(s)
- Vishal Raval
- Strathclyde Institute of Pharmacy & Biomedical Sciences
- University of Strathclyde
- Technology and Innovation centre
- Glasgow
- UK
| | - Humera Siddique
- Strathclyde Institute of Pharmacy & Biomedical Sciences
- University of Strathclyde
- Technology and Innovation centre
- Glasgow
- UK
| | - Cameron J. Brown
- Strathclyde Institute of Pharmacy & Biomedical Sciences
- University of Strathclyde
- Technology and Innovation centre
- Glasgow
- UK
| | - Alastair J. Florence
- Strathclyde Institute of Pharmacy & Biomedical Sciences
- University of Strathclyde
- Technology and Innovation centre
- Glasgow
- UK
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42
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Rosso C, Gisbertz S, Williams JD, Gemoets HPL, Debrouwer W, Pieber B, Kappe CO. An oscillatory plug flow photoreactor facilitates semi-heterogeneous dual nickel/carbon nitride photocatalytic C–N couplings. REACT CHEM ENG 2020. [DOI: 10.1039/d0re00036a] [Citation(s) in RCA: 47] [Impact Index Per Article: 11.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/18/2022]
Abstract
Dual nickel/photocatalytic C–N couplings are performed with an organic heterogeneous photocatalyst, in an oscillatory plug flow reactor. Reaction was complete in 20 min residence time, enabling 2.7 g h−1 throughput and 10-fold catalyst recycling.
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Affiliation(s)
- Cristian Rosso
- Institute of Chemistry
- University of Graz
- 8010 Graz
- Austria
| | - Sebastian Gisbertz
- Department of Biomolecular Systems
- Max-Planck-Institute of Colloids and Interfaces
- 14476 Potsdam
- Germany
- Department of Chemistry and Biochemistry
| | - Jason D. Williams
- Institute of Chemistry
- University of Graz
- 8010 Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CCFLOW)
| | | | | | - Bartholomäus Pieber
- Department of Biomolecular Systems
- Max-Planck-Institute of Colloids and Interfaces
- 14476 Potsdam
- Germany
| | - C. Oliver Kappe
- Institute of Chemistry
- University of Graz
- 8010 Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CCFLOW)
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43
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Doyle BJ, Gutmann B, Bittel M, Hubler T, Macchi A, Roberge DM. Handling of Solids and Flow Characterization in a Baffleless Oscillatory Flow Coil Reactor. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b04496] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Brendon J. Doyle
- Centre for Catalysis Research and Innovation, Department of Chemical and Biological Engineering, University of Ottawa, K1N 6N5 Ottawa, Canada
| | - Bernhard Gutmann
- Chemical Manufacturing Technologies, Lonza AG, CH-3930 Visp, Switzerland
| | - Michael Bittel
- Chemical Manufacturing Technologies, Lonza AG, CH-3930 Visp, Switzerland
| | - Thierry Hubler
- Chemical Manufacturing Technologies, Lonza AG, CH-3930 Visp, Switzerland
| | - Arturo Macchi
- Centre for Catalysis Research and Innovation, Department of Chemical and Biological Engineering, University of Ottawa, K1N 6N5 Ottawa, Canada
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44
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McDonough JR, Armett J, Law R, Harvey AP. Coil-in-Coil Reactor: Augmenting Plug Flow Performance by Combining Different Geometric Features Using 3D Printing. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b04239] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
Affiliation(s)
- Jonathan R. McDonough
- School of Engineering, Merz Court, Newcastle University, Newcastle upon Tyne NE1 7RU, U.K
| | - Jessica Armett
- School of Engineering, Merz Court, Newcastle University, Newcastle upon Tyne NE1 7RU, U.K
| | - Richard Law
- School of Engineering, Merz Court, Newcastle University, Newcastle upon Tyne NE1 7RU, U.K
| | - Adam P. Harvey
- School of Engineering, Merz Court, Newcastle University, Newcastle upon Tyne NE1 7RU, U.K
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45
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McLaughlin AM, Robertson J, Ni XW. Investigation of dissolution rate kinetics of bulk pharmaceutical feed streams within a stirred tank vessel and a twin screw extruder. Pharm Dev Technol 2019; 25:219-226. [PMID: 31651201 DOI: 10.1080/10837450.2019.1685543] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
Abstract
The introduction of continuous manufacturing of pharmaceuticals has highlighted the challenging area of continuous dissolution of solids for work ups to flow chemistry systems. In this study, the use of a 16 mm twin screw extruder (TSE) as a platform technology for solid feeds is investigated using four solid pharmaceutical ingredients (PI) in a mixture of water and IPA. In order for comparison, the same experiments were also carried out in a batch traditional stirred tank vessel (STV). The objectives of this work are to gain further scientific understanding on dissolution kinetics and to compare kinetics in both a batch and continuous system. The concentration of each PI during dissolution is monitored using an in-line UV-ATR probe, allowing the extraction of dissolution kinetics. Faster dissolution rates are achieved in the TSE than in the STV due to higher power dissipation generated by the aggressive shear mixing and thermal energy within the TSE. Complete dissolution of paracetamol is obtained within the residence time of the TSE; complete dissolution of benzoic acid and acetylsalicylic acid are achieved at higher barrel temperatures; however full dissolution of nicotinic acid is not achievable in the TSE under the experimental conditions.
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Affiliation(s)
- Arabella M McLaughlin
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh, UK
| | - John Robertson
- EPSRC Future Continuous Manufacturing and Advanced Crystallisation Research Hub, University of Strathclyde, Glasgow, UK
| | - Xiong-Wei Ni
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh, UK
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46
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Benitez-Chapa AG, Nigam KDP, Alvarez AJ. Process Intensification of Continuous Antisolvent Crystallization Using a Coiled Flow Inverter. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b04160] [Citation(s) in RCA: 17] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Andrea G. Benitez-Chapa
- Tecnologico de Monterrey, School of Engineering and Sciences, Av. Eugenio Garza Sada 2501, Monterrey, N. L. 64849, México
| | - Krishna D. P. Nigam
- Tecnologico de Monterrey, School of Engineering and Sciences, Av. Eugenio Garza Sada 2501, Monterrey, N. L. 64849, México
- Indian Institute of Technology Delhi, Department of Chemical Engineering, Hauz Khas, New Delhi 110016, India
| | - Alejandro J. Alvarez
- Tecnologico de Monterrey, School of Engineering and Sciences, Av. Eugenio Garza Sada 2501, Monterrey, N. L. 64849, México
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47
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Macchi A, Plouffe P, Patience GS, Roberge DM. Experimental methods in chemical engineering: Micro‐reactors. CAN J CHEM ENG 2019. [DOI: 10.1002/cjce.23525] [Citation(s) in RCA: 20] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
Affiliation(s)
- Arturo Macchi
- Centre for Catalysis Research and Innovation, Department of Chemical and Biological EngineeringUniversity of OttawaOttawa ON K1N 6N5 Canada
| | - Patrick Plouffe
- Centre for Catalysis Research and Innovation, Department of Chemical and Biological EngineeringUniversity of OttawaOttawa ON K1N 6N5 Canada
| | - Gregory S. Patience
- Department of Chemical EngineeringÉcole Polytechnique de Montréal Montréal QC H3C 3A7 Canada
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Cruz P, Silva C, Rocha F, Ferreira A. The axial dispersion of liquid solutions and solid suspensions in planar oscillatory flow crystallizers. AIChE J 2019. [DOI: 10.1002/aic.16683] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Affiliation(s)
- Patrícia Cruz
- LEPABE – Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, Department of Chemical EngineeringUniversity of Porto Porto Portugal
| | - Carolina Silva
- LEPABE – Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, Department of Chemical EngineeringUniversity of Porto Porto Portugal
| | - Fernando Rocha
- LEPABE – Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, Department of Chemical EngineeringUniversity of Porto Porto Portugal
| | - António Ferreira
- LEPABE – Laboratory for Process Engineering, Environment, Biotechnology and Energy, Faculty of Engineering, Department of Chemical EngineeringUniversity of Porto Porto Portugal
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Abstract
The last decade has witnessed extensive growth in the field of co-crystallization for mitigating the solubility and dissolution-related issues of poorly soluble drugs. This is largely because co-crystals can modify the physicochemical properties of drugs without any covalent modification in the drug molecules. The US Food and Drug Administration (FDA) now considers drug products that are designed to contain a new co-crystal, analogous to new polymorph of the active pharmaceutical ingredient (API). This positive change in regulatory perspective coupled with successful commercialization of valsartan-sacubitril co-crystal (Entresto, Novartis) has now brought co-crystals into focus, in both industries as well as academia. Co-crystal prediction, screening, and synthesis have been reported in literature; however, co-crystal production at a larger scale needs further investigations. With this aim, the article describes various continuous methods for co-crystal production, along with in-line monitoring during co-crystal production, emphasizing on process analytical technology (PAT). In addition, the scale-up issues of continuous and batch co-crystallization and other suitable techniques for pharmaceutical scale up are detailed. Quality control aspects and regulatory viewpoint crucial for commercial success are elaborated in the future perspective.
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Stankiewicz AI, Yan P. 110th Anniversary: The Missing Link Unearthed: Materials and Process Intensification. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b01479] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/26/2022]
Affiliation(s)
- Andrzej I. Stankiewicz
- Intensified Reaction and Separation Systems, Process & Energy Department, Delft University of Technology, Leeghwaterstraat 39, 2628 CB Delft, The Netherlands
| | - Peng Yan
- School of Chemical Engineering and Technology, National Engineering Research Center of Distillation Technology, Collaborative Innovation Center of Chemical Science and Engineering (Tianjin), Tianjin University, Tianjin 300072, China
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