High-Shear Enhancement of Biginelli Reactions in Macromolecular Viscous Media

Chemical reactions and transformations in non-traditional vessels have gained significant interest in recent years. Flow chemistry, with its advantages in mixing, mass transfer, scalability, and automation, is a driving force behind this paradigm shift. In particular, the Vortex Fluidic Device (VFD) has emerged as a versatile tool across various applications, from organic synthesis to materials science. In this study, the role of the VFD in performing the Biginelli reaction, a multicomponent reaction widely used in pharmaceutical and polymer science, for a post-polymerization modification is explored. By conducting the Biginelli reaction in the VFD, rapid product formation with low catalyst loading and without the need for high temperatures is achieved. However, the critical need to understand and know solution viscosity, especially within the context of modifying macromolecules is highlighted.

Room temperature esterification of high-free fatty acid feedstock into biodiesel

The esterification of a high-free fatty acid feedstock to biodiesel is often performed in high-temperature conditions using either homogeneous or heterogeneous acid catalysts. Thus, this study attempts to esterify oleic acid to biodiesel in room temperature conditions using sulphuric acid as a catalyst and a homogenizer device. The influences of process parameters including the molar ratio of oleic acid to methanol, catalyst concentration and rotational speed on biodiesel conversion were determined in different reaction times. The maximum conversion of 96.1 ± 0.4% was obtained in the presence of a molar ratio of 1 : 12, catalyst concentration of 0.7 mol L-1, a rotational speed of 4000 rpm and a reaction time of 30 minutes. The catalytic reusability test showed that the addition of fresh methanol is required to maintain the catalytic activity. However, the homogenizer-intensify esterification of oleic acid to biodiesel showed better performance than other methods as the reaction could conducted at room temperature and at a short reaction time. The predicted biodiesel properties meet the international standard except for oxidative stability. However, the flow properties revealed that the biodiesel can be used in winter season.

Hydrogel-Film-Fabricated Fluorescent Biosensors with Aggregation-Induced Emission for Albumin Detection through the Real-Time Modulation of a Vortex Fluidic Device

Hydrogels have various promising prospects as a successful platform for detecting biomarkers, and human serum albumin (HSA) is an important biomarker in the diagnosis of kidney diseases. However, the difficult-to-control passive diffusion kinetics of hydrogels is a major factor affecting detection performance. This study focuses on using hydrogels embedded with aggregation-induced emission (AIE) fluorescent probe TC426 to detect HSA in real time. The vortex fluidic device (VFD) technology is used as a rotation strategy to control the reaction kinetics and micromixing during measurement. The results show that the introduction of VFD could significantly accelerate its fluorescence response and effectively improve the diffusion coefficient, while VFD processing could regulate passive diffusion into active diffusion, offering a new method for future sensing research.

An Overview on the Production of Biodiesel Enabled by Continuous Flow Methodologies

Biodiesel was produced via transesterification reaction catalyzed by acids, bases, enzymes or supercritical fluids. The catalysis was homogeneous or heterogeneous and the process could be carried out in batch or using a continuous flow process. Microreactors allowed us to obtain better control of the experimental variables, such as temperature, pressure and flow rate, carrying out the reactions in safe conditions, avoiding exothermic and dangerous processes. The synthetic methodologies in continuous flow, combined with other technologies as microwave irradiation or ultrasounds, led to complete automation of the process with an increase in efficiency, also applicable on an industrial scale.

Vortex fluidic induced mass transfer across immiscible phases

Mixing immiscible liquids typically requires the use of auxiliary substances including phase transfer catalysts, microgels, surfactants, complex polymers and nano-particles and/or micromixers. Centrifugally separated immiscible liquids of different densities in a 45° tilted rotating tube offer scope for avoiding their use. Micron to submicron size topological flow regimes in the thin films induce high inter-phase mass transfer depending on the nature of the two liquids. A hemispherical base tube creates a Coriolis force as a 'spinning top' (ST) topological fluid flow in the less dense liquid which penetrates the denser layer of liquid, delivering liquid from the upper layer through the lower layer to the surface of the tube with the thickness of the layers determined using neutron imaging. Similarly, double helical (DH) topological flow in the less dense liquid, arising from Faraday wave eddy currents twisted by Coriolis forces, impact through the less dense liquid onto the surface of the tube. The lateral dimensions of these topological flows have been determined using 'molecular drilling' impacting on a thin layer of polysulfone on the surface of the tube and self-assembly of nanoparticles at the interface of the two liquids. At high rotation speeds, DH flow also occurs in the denser layer, with a critical rotational speed reached resulting in rapid phase demixing of preformed emulsions of two immiscible liquids. ST flow is perturbed relative to double helical flow by changing the shape of the base of the tube while maintaining high mass transfer between phases as demonstrated by circumventing the need for phase transfer catalysts. The findings presented here have implications for overcoming mass transfer limitations at interfaces of liquids, and provide new methods for extractions and separation science, and avoiding the formation of emulsions.

Vortex fluidics mediated non-covalent physical entanglement of tannic acid and gelatin for entrapment of nutrients

We have developed a simple process for the entrapment of nutrients in shear stress induced non-covalent physically entangled tannic acid-gelatin gel in a thin film vortex fluidic device (VFD) operating under continuous flow. This allows control of the porosity and surface area of the pores in order to improve the nutrient entrapment capacity. The VFD microfluidic platform simplifies the processing procedure of physically entangled biopolymers, as a time and cost saving one-step process devoid of any organic solvents, in contrast to the conventional homogenization process, which is also inherently complex, involving multiple-step processing. Moreover, the use of homogenization (as a benchmark to entrap nutrients) afforded much larger porosity and surface area of pores, with lower entrapment capacity of nutrients. Overall, the VFD processing provides a new alternative, bottom-up approach for easy, scalable processing for materials with a high nutrient entrapment capacity.

Vortex fluidic mediated encapsulation of functional fish oil featuring in situ probed small angle neutron scattering

Major challenges for optimizing the benefits of fish oil on human health are improved bioavailability while overcoming the strong odor and avoiding significant oxidation of the omega-3 polyunsaturated fatty acids (PUFAs). The scalable continuous flow thin film vortex fluidic device (VFD) improves the Tween 20 encapsulation of fish oil relative to conventional homogenization processing, with the fish oil particles significantly smaller and the content of the valuable omega-3 fatty acids higher. In addition, after 14 days storage the remaining omega-3 fatty acids content was higher, from ca 31.0% for raw fish oil to ca 62.0% of freeze-dried encapsulated fish oil. The VFD mediated encapsulated fish oil was used to enrich the omega-3 fatty acid content of apple juice, as a model water-based food product, without changing its sensory values. The versatility of the VFD was further demonstrated in forming homogenous suspensions of fish oil containing water-insoluble bioactive molecules, curcumin and quercetin. We have also captured, for the first time, real-time structural changes in nanoencapsulation by installing a VFD with in in situ small angle neutron scattering. Real-time measurements afford valuable insights about self-assembly in solution.

Vortex fluidic mediated food processing

The high heat and mass transfer, and controlled mechanoenergy, in angled vortex fluidics has been applied in chemical and material sciences and allied fields, but its utility in food processing remains largely unexplored. Herein we report three models of food processing incorporating such vortex fluidics, including enzymatic hydrolysis, raw milk pasteurization and encapsulation. The processing times of enzymatic hydrolysis was reduced from about 2–3 hours to 20 minutes, with the processing time of raw milk pasteurization reduced from 30 to 10 minutes, and an encapsulated particle size reduced approximately 10-fold, from micro meters to hundreds of nanometers. These findings highlight exciting possibilities, in exploiting the value of vortex fluidic mediated processing in the food industry.

Chemoselective and Continuous Flow Hydrogenations in Thin Films Using a Palladium Nanoparticle Catalyst Embedded in Cellulose Paper

Cellulose immobilized palladium (0) nanoparticles (PdNPs) were prepared for the use in scalable catalytic reactions in flow. Preparation of the catalyst is remarkably simple and fast, where a palladium acetate solution is drop-casted onto cellulose paper and then exposed to 1 atm of hydrogen for a mere 90 s to produce embedded Pd(0) nanoparticles. This catalyst system is efficient in the hydrogenation of alkenes, nitroarenes, ketones, and enamides, with products formed in high yields, under ambient pressure and temperature. The system is also effective for transfer hydrogenation using ammonium formate as an alternative hydrogen source. A high catalyst stability and reusability are demonstrated along with the chemoselective and scalable synthesis of industrially important fine chemicals, including the biobased molecule cyrene.

Direct biodiesel production from wet spent coffee grounds

Utilization of waste spent coffee grounds (SCG) remains limited and requires pre-treatment before being discarded to avoid pollution to the environment. Lipids contained in SCG could be converted to biodiesel through an in situ transesterification method. Current in situ transesterification of wet SCG biomass, conducted at high reaction temperature to reduce the water effect and reduce reaction time, is energy intensive. A new approach, which combines simultaneous extraction-transesterification in a single step using soxhlet apparatus, was developed to produce biodiesel directly from wet SCG biomass. A homogeneous base catalyst at a concentration of 0.75 M showed better catalytic activity than acid, with hexane as a co-solvent on fatty acid (FA) extraction efficiency and FA to fatty acid methyl ester (FAME) conversion efficiency. Studying the factorial effect of ratio of methanol to hexane and reaction time led to the highest FA to FAME conversion efficiency of 97% at a ratio of 1 : 2 and 30 min reaction time. In addition, the catalyst could be used five times without losing its activity. In term of energy consumption, the reactive extraction soxhlet (RES) method could save 38–99% of energy compared to existing methods.

Here, we demonstrate the direct biodiesel production from wet SCG in mild reaction temperature and short reaction time using reactive extraction Soxhlet (RES) method.

Integrating thin film microfluidics in developing a concise synthesis of DGJNAc: A potent inhibitor of α-N-acetylgalctosaminidases

A simple synthesis, which utilizes a thin film microfluidic reactor for a problematic step, of a potent inhibitor of α-N-acetylhexosaminidases, DGJNAc, has been developed.

Vortex fluidic mediated direct transesterification of wet microalgae biomass to biodiesel

A bottleneck in the production of biodiesel from microalgae is the dewatering and lipid extraction process which is the dominant energy penalty and cost. A novel biodiesel production platform based on vortex fluidic device (VFD)-assisted direct transesterification (DT) of wet microalgal biomass of Chloroparva pannonica was developed and evaluated. Fatty acid extraction and fatty acid to FAME conversion efficiencies were used at different parameter settings to evaluate performance of the processing technology in confined and continuous mode. A response surface method based on Box-Behnken experimental design was used to determine the effects of water content, the ratio of biomass to methanol and residence time in the VFD. Average extraction efficiencies were 41% and conversion efficiencies >90% with the processing technology showing a broad tolerance to parameter settings. The findings suggest that VFD-assisted DT is a simple and effective way to produce biodiesel directly from wet microalgae biomass at room temperature.

The assembly and use of continuous flow systems for chemical synthesis

The adoption of and opportunities in continuous flow synthesis ('flow chemistry') have increased significantly over the past several years. Continuous flow systems provide improved reaction safety and accelerated reaction kinetics, and have synthesised several active pharmaceutical ingredients in automated reconfigurable systems. Although continuous flow platforms are commercially available, systems constructed 'in-lab' provide researchers with a flexible, versatile, and cost-effective alternative. Herein, we describe the assembly and use of a modular continuous flow apparatus from readily available and affordable parts in as little as 30 min. Once assembled, the synthesis of a sulfonamide by reacting 4-chlorobenzenesulfonyl chloride with dibenzylamine in a single reactor coil with an in-line quench is presented. This example reaction offers the opportunity to learn several important skills including reactor construction, charging of a back-pressure regulator, assembly of stainless-steel syringes, assembly of a continuous flow system with multiple junctions, and yield determination. From our extensive experience of single-step and multistep continuous flow synthesis, we also describe solutions to commonly encountered technical problems such as precipitation of solids ('clogging') and reactor failure. Following this protocol, a nonspecialist can assemble a continuous flow system from reactor coils, syringes, pumps, in-line liquid-liquid separators, drying columns, back-pressure regulators, static mixers, and packed-bed reactors.

Vortex Fluidic Chemical Transformations

Driving chemical transformations in dynamic thin films represents a rapidly thriving and diversifying research area. Dynamic thin films provide a number of benefits including large surface areas, high shearing rates, rapid heat and mass transfer, micromixing and fluidic pressure waves. Combinations of these effects provide an avant-garde style of conducting chemical reactions with surprising and unusual outcomes. The vortex fluidic device (VFD) has proved its capabilities in accelerating and increasing the efficiencies of numerous organic, materials and biochemical reactions. This Minireview surveys transformations that have benefited from VFD-mediated processing, and identifies concepts driving the effectiveness of vortex-based dynamic thin films.

Vortex fluidics synthesis of polymer coated superparamagnetic magnetite nanoparticles

Polymer coated superparamagnetic magnetite nanoparticles with improved magnetic properties are accessible under continuous flow conditions within a vortex fluidic device.

Accelerating Enzymatic Catalysis Using Vortex Fluidics

Enzymes catalyze chemical transformations with outstanding stereo- and regio-specificities, but many enzymes are limited by their long reaction times. A general method to accelerate enzymes using pressure waves contained within thin films is described. Each enzyme responds best to specific frequencies of pressure waves, and an acceleration landscape for each protein is reported. A vortex fluidic device introduces pressure waves that drive increased rate constants (kcat ) and enzymatic efficiency (kcat /Km ). Four enzymes displayed an average seven-fold acceleration, with deoxyribose-5-phosphate aldolase (DERA) achieving an average 15-fold enhancement using this approach. In solving a common problem in enzyme catalysis, a powerful, generalizable tool for enzyme acceleration has been uncovered. This research provides new insights into previously uncontrolled factors affecting enzyme function.

Harnessing Thin-Film Continuous-Flow Assembly Lines

Inspired by nature's ability to construct complex molecules through sequential synthetic transformations, an assembly line synthesis of α-aminophosphonates has been developed. In this approach, simple starting materials are continuously fed through a thin-film reactor where the intermediates accrue molecular complexity as they progress through the flow system. Flow chemistry allows rapid multistep transformations to occur via reaction compartmentalization, an approach not amenable to using conventional flasks. Thin film processing can also access facile in situ solvent exchange to drive reaction efficiency, and through this method, α-aminophosphonate synthesis requires only 443 s residence time to produce 3.22 g h(-1) . Assembly-line synthesis allows unprecedented reaction flexibility and processing efficiency.

Emerging Technologies for the Production of Renewable Liquid Transport Fuels from Biomass Sources Enriched in Plant Cell Walls

Plant cell walls are composed predominantly of cellulose, a range of non-cellulosic polysaccharides and lignin. The walls account for a large proportion not only of crop residues such as wheat straw and sugarcane bagasse, but also of residues of the timber industry and specialist grasses and other plants being grown specifically for biofuel production. The polysaccharide components of plant cell walls have long been recognized as an extraordinarily large source of fermentable sugars that might be used for the production of bioethanol and other renewable liquid transport fuels. Estimates place annual plant cellulose production from captured light energy in the order of hundreds of billions of tons. Lignin is synthesized in the same order of magnitude and, as a very large polymer of phenylpropanoid residues, lignin is also an abundant, high energy macromolecule. However, one of the major functions of these cell wall constituents in plants is to provide the extreme tensile and compressive strengths that enable plants to resist the forces of gravity and a broad range of other mechanical forces. Over millions of years these wall constituents have evolved under natural selection to generate extremely tough and resilient biomaterials. The rapid degradation of these tough cell wall composites to fermentable sugars is therefore a difficult task and has significantly slowed the development of a viable lignocellulose-based biofuels industry. However, good progress has been made in overcoming this so-called recalcitrance of lignocellulosic feedstocks for the biofuels industry, through modifications to the lignocellulose itself, innovative pre-treatments of the biomass, improved enzymes and the development of superior yeasts and other microorganisms for the fermentation process. Nevertheless, it has been argued that bioethanol might not be the best or only biofuel that can be generated from lignocellulosic biomass sources and that hydrocarbons with intrinsically higher energy densities might be produced using emerging and continuous flow systems that are capable of converting a broad range of plant and other biomasses to bio-oils through so-called 'agnostic' technologies such as hydrothermal liquefaction. Continued attention to regulatory frameworks and ongoing government support will be required for the next phase of development of internationally viable biofuels industries.

Rapid Vortex Fluidics: Continuous Flow Synthesis of Amides and Local Anesthetic Lidocaine

Thin film flow chemistry using a vortex fluidic device (VFD) is effective in the scalable acylation of amines under shear, with the yields of the amides dramatically enhanced relative to traditional batch techniques. The optimized monophasic flow conditions are effective in ≤80 seconds at room temperature, enabling access to structurally diverse amides, functionalized amino acids and substituted ureas on multigram scales. Amide synthesis under flow was also extended to a total synthesis of local anesthetic lidocaine, with sequential reactions carried out in two serially linked VFD units. The synthesis could also be executed in a single VFD, in which the tandem reactions involve reagent delivery at different positions along the rapidly rotating tube with in situ solvent replacement, as a molecular assembly line process. This further highlights the versatility of the VFD in organic synthesis, as does the finding of a remarkably efficient debenzylation of p-methoxybenzyl amines.

Continuous flow Fischer esterifications harnessing vibrational-coupled thin film fluidics

Organic synthesis under shear: high yielding, acid catalysed, continuous flow synthesis of esters involves coupling of vibrations in thin film fluidics, as rapid environmentally friendly organic methodology.

Microencapsulation of bacterial strains in graphene oxide nano-sheets using vortex fluidics

Microencapsulation of bacterial cells with different shapes in graphene oxide (GO) layers is effective using a vortex fluidic device, with the bacterial cells showing restricted cellular growth with their biological activity sustained.

Rapid high conversion of high free fatty acid feedstock into biodiesel using continuous flow vortex fluidics

Rapid reduction of free fatty acids in biodiesel feedstock: the rapid conversion of problematic free fatty acids in bio-oils has been achieved using room temperature, environmentally benign vortex fluidic flow chemistry.