Microfabricated Multiphase Reactors for the Selective Direct Fluorination of Aromatics

Flow Chemistry: A Sustainable Voyage Through the Chemical Universe en Route to Smart Manufacturing

Microfluidic devices and systems have entered many areas of chemical engineering, and the rate of their adoption is only increasing. As we approach and adapt to the critical global challenges we face in the near future, it is important to consider the capabilities of flow chemistry and its applications in next-generation technologies for sustainability, energy production, and tailor-made specialty chemicals. We present the introduction of microfluidics into the fundamental unit operations of chemical engineering. We discuss the traits and advantages of microfluidic approaches to different reactive systems, both well-established and emerging, with a focus on the integration of modular microfluidic devices into high-efficiency experimental platforms for accelerated process optimization and intensified continuous manufacturing. Finally, we discuss the current state and new horizons in self-driven experimentation in flow chemistry for both intelligent exploration through the chemical universe and distributed manufacturing. Expected final online publication date for the Annual Review of Chemical and Biomolecular Engineering, Volume 13 is October 2022. Please see http://www.annualreviews.org/page/journal/pubdates for revised estimates.

Towards controlled bubble nucleation in microreactors for enhanced mass transport

The exact location of bubbles with respect to the catalytic layer impacts the microreactor performance. In this work, we propose to control bubble nucleation using micropits to maximize the microreactor efficiency.

Synthesis of pH indicators for Cerenkov imaging by electrophilic substitution of bromine by fluorine in an aromatic system

Direct electrophilic fluorination using molecular fluorine gas is used in organic synthesis to create novel fluorine-containing compounds with potential beneficial activity that could not be obtained by nucleophilic substitution. In this paper, we report a novel electrophilic substitution of bromine by fluorine in an aromatic system. The mechanism of this type of fluorination was explored using the reaction between bromothymolsulfonphthalein (Bromothymol Blue) and dilute fluorine gas under acidic conditions. Substitution occurs in the bromine atoms located in the ortho-position relative to the hydroxyl group. A similar electrophilic fluorination of thymolsulfonphthalein (Thymol Blue) leads to a substitution of hydrogen atoms in the same position (ortho to hydroxyl). NMR spectroscopy was used to confirm the fluorination sites. NMR spectra of thymolsulfonphthalein and its derivatives under basic conditions can be explained by considering the absence of resonance between the two phenolic rings. Both dibromothymol blue and fluorobromothymol blue revealed intermolecular attenuate Cerenkov radiation selectively near their maximum absorbance in a pH dependent manner.

Halogenation of organic compounds using continuous flow and microreactor technology

Halogenation reactions involving highly reactive halogenating agents can be performed safely and with improved efficiency and selectivity under continuous flow conditions.

A flow reactor setup for photochemistry of biphasic gas/liquid reactions

A home-built microreactor system for light-mediated biphasic gas/liquid reactions was assembled from simple commercial components. This paper describes in full detail the nature and function of the required building elements, the assembly of parts, and the tuning and interdependencies of the most important reactor and reaction parameters. Unlike many commercial thin-film and microchannel reactors, the described set-up operates residence times of up to 30 min which cover the typical rates of many organic reactions. The tubular microreactor was successfully applied to the photooxygenation of hydrocarbons (Schenck ene reaction). Major emphasis was laid on the realization of a constant and highly reproducible gas/liquid slug flow and the effective illumination by an appropriate light source. The optimized set of conditions enabled the shortening of reaction times by more than 99% with equal chemoselectivities. The modular home-made flow reactor can serve as a prototype model for the continuous operation of various other reactions at light/liquid/gas interfaces in student, research, and industrial laboratories.

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

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

Microfluidic studies of carbon dioxide

Carbon dioxide (CO2) sequestration, storage and recycling will greatly benefit from comprehensive studies of physical and chemical gas-liquid processes involving CO2. Over the past five years, microfluidics emerged as a valuable tool in CO2-related research, due to superior mass and heat transfer, reduced axial dispersion, well-defined gas-liquid interfacial areas and the ability to vary reagent concentrations in a high-throughput manner. This Minireview highlights recent progress in microfluidic studies of CO2-related processes, including dissolution of CO2 in physical solvents, CO2 reactions, the utilization of CO2 in materials science, and the use of supercritical CO2 as a "green" solvent.

Novel process windows for enabling, accelerating, and uplifting flow chemistry

Novel Process Windows make use of process conditions that are far from conventional practices. This involves the use of high temperatures, high pressures, high concentrations (solvent-free), new chemical transformations, explosive conditions, and process simplification and integration to boost synthetic chemistry on both the laboratory and production scale. Such harsh reaction conditions can be safely reached in microstructured reactors due to their excellent transport intensification properties. This Review discusses the different routes towards Novel Process Windows and provides several examples for each route grouped into different classes of chemical and process-design intensification.

Cruise control for segmented flow

Capitalizing on the benefits of microscale segmented flows, e.g., enhanced mixing and reduced sample dispersion, so far requires specialist training and accommodating a few experimental inconveniences. For instance, microscale gas-liquid flows in many current setups take at least 10 min to stabilize and iterative manual adjustments are needed to achieve or maintain desired mixing or residence times. Here, we report a cruise control strategy that overcomes these limitations and allows microscale gas-liquid (bubble) and liquid-liquid (droplet) flow conditions to be rapidly "adjusted" and maintained. Using this strategy we consistently establish bubble and droplet flows with dispersed phase (plug) velocities of 5-300 mm s(-1), plug lengths of 0.6-5 mm and continuous phase (slug) lengths of 0.5-3 mm. The mixing times (1-5 s), mass transfer times (33-250 ms) and residence times (3-300 s) can therefore be directly imposed by dynamically controlling the supply of the dispersed and the continuous liquids either from external pumps or from local pressurized reservoirs. In the latter case, no chip-external pumps, liquid-perfused tubes or valves are necessary while unwanted dead volumes are significantly reduced.

Rapid microfluidic screening of CO2 solubility and diffusion in pure and mixed solvents

We present a high-throughput method to determine rapidly and simultaneously the solubility and the diffusivity of CO(2) in pure solvents and mixtures using segmented flow in a microchannel. Gas bubbles are injected via a T-junction into the liquid stream and the evolution of the bubbles' lengths are followed visually. We measure both solubility and diffusion coefficient from the shrinkage and expansion of the bubbles. The presented method is used to study the physical absorption of CO(2) in various pure solvents and to screen the complete composition space of binary and ternary mixtures.

Automated microfluidic platform for studies of carbon dioxide dissolution and solubility in physical solvents

We present an automated microfluidic (MF) approach for the systematic and rapid investigation of carbon dioxide (CO(2)) mass transfer and solubility in physical solvents. Uniformly sized bubbles of CO(2) with lengths exceeding the width of the microchannel (plugs) were isothermally generated in a co-flowing physical solvent within a gas-impermeable, silicon-based MF platform that is compatible with a wide range of solvents, temperatures and pressures. We dynamically determined the volume reduction of the plugs from images that were accommodated within a single field of view, six different downstream locations of the microchannel at any given flow condition. Evaluating plug sizes in real time allowed our automated strategy to suitably select inlet pressures and solvent flow rates such that otherwise dynamically self-selecting parameters (e.g., the plug size, the solvent segment size, and the plug velocity) could be either kept constant or systematically altered. Specifically, if a constant slug length was imposed, the volumetric dissolution rate of CO(2) could be deduced from the measured rate of plug shrinkage. The solubility of CO(2) in the physical solvent was obtained from a comparison between the terminal and the initial plug sizes. Solubility data were acquired every 5 min and were within 2-5% accuracy as compared to literature data. A parameter space consisting of the plug length, solvent slug length and plug velocity at the microchannel inlet was established for different CO(2)-solvent pairs with high and low gas solubilities. In a case study, we selected the gas-liquid pair CO(2)-dimethyl carbonate (DMC) and volumetric mass transfer coefficients 4-30 s(-1) (translating into mass transfer times between 0.25 s and 0.03 s), and Henry's constants, within the range of 6-12 MPa.

Micro Reactors, Flow Reactors and Continuous Flow Synthesis

Dr Paul Watts is a reader in organic chemistry at The University of Hull and since graduating from the University of Bristol, where he completed a PhD in bio-organic natural product synthesis, he has led the Micro Reactor Group at Hull. In this role, he has published 90 papers, and he regularly contributes to the field by way of invited book chapters, review articles, and keynote lecturers on the subject of micro reaction technology in organic synthesis.

Dr Charlotte Wiles is the Chief Technology Officer at Chemtrix BV, and has been actively researching within the area of micro reaction technology for 10 years, starting with a PhD entitled Micro reactors in organic chemistry, which she obtained from The University of Hull in 2003. In the past decade, she has authored many scientific papers and review articles, recently co-authoring a book on the subject of micro reaction technology in organic synthesis. More recently, she has tailored her experience to the development and evaluation of commercially available continuous flow reactors, systems and peripheral equipment.

This review article explains the advantages of micro reactors and flow reactors as tools for conducting organic synthesis and describes how the technology may be used in research and development as well as production. A selection of examples is taken from the literature to illustrate how micro reactors enables chemists to perform their reactions more efficiently than when using batch processes.

Microfluidic Droplet Consistency Monitoring and Cell Detection via Laser Excitation

Microfluidic droplets formed in emulsions are used in a variety of analytical techniques and hold great potential for future scientific and commercial applications. Our experiments merge quantitative quality engineering methods into the microdroplet field. We present a unique microdroplet generation and consistency monitoring system with laser optics excitation and detection. Our setup analyzes each droplet with sub-millisecond signal resolution and single photon accuracy, and is compatible with process control methods. To demonstrate the consistency of microdroplet generation over time, we measure and examine the mean frequency of aqueous plug-shaped droplet (microplug) formation in oil phase, as well as the mean length of plugs, and the interval between consecutive droplets. We also demonstrate the detection of cancer cells encapsulated within aqueous microdroplets in continuous oil phase flow. Two-channel optical monitoring allows for the simultaneous and independent inspection of both microdroplet generation and identification of green fluorescent protein-labelled cancer cells within the droplets. Increased accuracy and consistency are central to many established and developing microfluidic technologies. A systematic, quantitative approach as demonstrated with our experiments may be essential in the development of advanced microfluidic concepts that require exacting reproducibility and would greatly benefit from incorporated automated measurement techniques for process control.

Deciding whether to go with the flow: evaluating the merits of flow reactors for synthesis

The fine chemicals and pharmaceutical industries are transforming how their products are manufactured, where economically favorable, from traditional batchwise processes to continuous flow. This evolution is impacting synthetic chemistry on all scales-from the laboratory to full production. This Review discusses the relative merits of batch and micro flow reactors for performing synthetic chemistry in the laboratory.

Taylor Flow in Microchannels: A Review of Experimental and Computational Work

Over the past few decades an enormous interest in two-phase flow in microchannels has developed because of their application in a wide range of new technologies, ranging from lab-on-a-chip devices used in medical and pharmaceutical applications to micro-structured process equipment used in many modern chemical plants. Taylor flow, in which gas bubbles are surrounded by a liquid film and separated by liquid plugs, is the most common flow regime encountered in such applications. This review introduces the important attributes of two phase flow in microchannels and then focuses on the Taylor flow regime. The existing knowledge from both experimental and computational studies is presented. Finally, perspectives for future work are suggested.

Microchemical systems for continuous-flow synthesis

Microchemical systems have evolved rapidly over the last decade with extensive chemistry applications. Such systems enable discovery and development of synthetic routes while simultaneously providing increased understanding of underlying pathways and kinetics. We review basic trends and aspects of microsystems as they relate to continuous-flow microchemical synthesis. Key literature reviews are summarized and principles governing different microchemical operations discussed. Current trends and limitations of microfabrication, micromixing, chemical synthesis in microreactors, continuous-flow separations, multi-step synthesis, and integration of analytics are delineated. We conclude by summarizing the major challenges and outlook related to these topics.

Flash chemistry: fast chemical synthesis by using microreactors

This concept article provides a brief outline of the concept of flash chemistry for carrying out extremely fast reactions in organic synthesis by using microreactors. Generation of highly reactive species is one of the key elements of flash chemistry. Another important element of flash chemistry is the control of extremely fast reactions to obtain the desired products selectively. Fast reactions are usually highly exothermic, and heat removal is an important factor in controlling such reactions. Heat transfer occurs very rapidly in microreactors by virtue of a large surface area per unit volume, making precise temperature control possible. Fast reactions often involve highly unstable intermediates, which decompose very quickly, making reaction control difficult. The residence time can be greatly reduced in microreactors, and this feature is quite effective in controlling such reactions. For extremely fast reactions, kinetics often cannot be used because of the lack of homogeneity of the reaction environment when they are conducted in conventional reactors such as flasks. Fast mixing using micromixers solves such problems. The concept of flash chemistry has been successfully applied to various organic reactions including a) highly exothermic reactions that are difficult to control in conventional reactors, b) reactions in which a reactive intermediate easily decomposes in conventional reactors, c) reactions in which undesired byproducts are produced in the subsequent reactions in conventional reactors, and d) reactions whose products easily decompose in conventional reactors. The concept of flash chemistry can be also applied to polymer synthesis. Cationic polymerization can be conducted with an excellent level of molecular-weight control and molecular-weight distribution control.

Formation of bubbles and droplets in parallel, coupled flow-focusing geometries

This paper describes the mechanism of formation of bubbles of nitrogen in water containing Tween 20 as a surfactant, and of droplets of water in hexadecane containing Span 80 as a surfactant. The study of these microfluidic systems compares two or four flow-focusing generators coupled through shared inlets, supplying the continuous phase, and through a common outlet channel. The processes that form bubbles in neighboring generators interact for a wide range of flow parameters; the formation of bubbles alternates in time and space, and the bubbles assemble into complex patterns in the outlet channel. The dynamics of formation of bubbles in these systems are stable for long time (at least 10 min). For a certain range of flow parameters, the coupled flow-focusing generators exhibit two stable modes of operation for a single set of flow parameters. The dynamics of formation of droplets of water in hexadecane by the coupled flow-focusing generators are simpler--the adjacent generators produce only monodisperse droplets over the entire range of flow parameters that are explored. These observations suggest that the mechanism of interaction between coupled flow-focusing generators relies on the compressibility of the dispersed phase (e.g., the gas or liquid), and on variations in pressure at the flow-focusing orifices induced by the breakup of bubbles or droplets.

Microdroplets: a sea of applications?

The exploitation of microdroplets produced within microfluidic environments has recently emerged as a new and exciting technological platform for applications within the chemical and biological sciences. Interest in microfluidic systems has been stimulated by a range of fundamental features that accompany system miniaturization. Such features include the ability to process and handle small volumes of fluid, improved analytical performance when compared to macroscale analogues, reduced instrumental footprints, low unit cost, facile integration of functional components and the exploitation of atypical fluid dynamics to control molecules in both time and space. Moreover, microfluidic systems that generate and utilize a stream of sub-nanolitre droplets dispersed within an immiscible continuous phase have the added advantage of allowing ultra-high throughput experimentation and being able to mimic conditions similar to that of a single cell (in terms of volume, pH, and salt concentration) thereby compartmentalizing biological and chemical reactions. This review provides an overview of methods for generating, controlling and manipulating droplets. Furthermore, we discuss key fields of use in which such systems may make a significant impact, with particular emphasis on novel applications in the biological and physical sciences.