Flow Chemistry in Contemporary Chemical Sciences: A Real Variety of Its Applications

Synthesis of 3,5-disubstituted isoxazoles by domino reductive Nef reaction/cyclization of β-nitroenones

β-Nitroenones can be efficiently converted into 3,5-disubstituted isoxazoles by using tin(II)chloride dihydrate and ethyl acetate as a reducing agent and solvent, respectively. Products are obtained in good yields and several functional groups are tolerated thanks to the mild reaction conditions.

Towards Industrially Important Applications of Enhanced Organic Reactions by Microfluidic Systems

This review presents a comprehensive evaluation for the manufacture of organic molecules via efficient microfluidic synthesis. Microfluidic systems provide considerably higher control over the growth, nucleation, and reaction conditions compared with traditional large-scale synthetic methods. Microfluidic synthesis has become a crucial technique for the quick, affordable, and efficient manufacture of organic and organometallic compounds with complicated characteristics and functions. Therefore, a unique, straightforward flow synthetic methodology can be developed to conduct organic syntheses and improve their efficiency.

Automated silylation of flavonoids using 3D printed microfluidics prior to chromatographic analysis: system development

Flavonoids are a class of secondary plant metabolites with low molecular weights. Most flavonoids are highly polar and unsuitable for gas chromatographic analyses. Derivatization is commonly used to make them amenable to gas chromatography by altering their physicochemical properties. Although highly effective, derivatization techniques introduce extra preparation steps and often use hazardous chemicals. The aim of this study was to automate derivatization (specifically, silylation) by developing 3D printed microfluidic devices in which derivatization of flavonoids can occur. A microfluidic device was designed and 3D printed using clear polypropylene. Quercetin and other flavonoids (TED 13 and ZTF 1016) isolated from plant extracts were silylated with N-tert-butyldimethylsilyl-N-methyltrifluoroacetamide (MTBSTFA) at room temperature both in batch and in continuous flow. All the samples were analyzed using Fourier transform infrared (FTIR) spectroscopy, gas chromatography combined with mass spectrometry (GC-MS), and high-resolution accurate mass spectrometry (HR-MS). Interestingly, the HR-MS results showed that the flow method was about 25 times more efficient than the batch method for quercetin samples. The TED 13 flavonoid was completely derivatized in the flow method compared to the batch method where the reaction was incomplete. Similar results were observed for ZTF 1016, where the flow method resulted in a four times derivatized compound, while the compound was only derivatized once in batch. In conclusion, 3D printed microfluidic devices have been developed and used to demonstrate a semi-automated, inexpensive, and more efficient natural product derivatization method based on continuous flow chemistry as an alternative to the traditional batch method.

Impact of nanotechnology on progress of flow methods in chemical analysis: A review

In evolution of instrumentation for analytical chemistry as crucial technological breakthroughs should be considered a common introduction of electronics with all its progress in integration, and then microprocessors which was followed by a widespread computerization. It is seems that a similar role can be attributed to the introduction of various elements of modern nanotechnology, observed with a fast progress since beginning of this century. It concerns all areas of the applications of analytical chemistry, including also progress in flow analysis, which are being developed since the middle of 20th century. Obviously, it should not be omitted the developed earlier and analytically applied planar structures like lipid membranes or self-assembled monolayers They had essential impact prior to discoveries of numerous extraordinary nanoparticles such as fullerenes, carbon nanotubes and graphene, or nanocrystalline semiconductors (quantum dots). Mostly, due to catalytic effects, significantly developed surface and the possibility of easy functionalization, their application in various stages of flow analytical procedures can significantly improve them. The application of new nanomaterials may be used for the development of new detection methods for flow analytical systems in macro-flow setups as well as in microfluidics and lateral flow immunoassay tests. It is also advantageous that quick flow conditions of measurements may be helpful in preventing unfavorable agglomeration of nanoparticles. A vast literature published already on this subject (e.g. almost 1000 papers about carbon nanotubes and flow-injection analytical systems) implies that for this reviews it was necessary to make an arbitrary selection of reported examples of this trend, focused mainly on achievements reported in the recent decade.

Synthesis of cyclic carbonates from CO2 cycloaddition to bio-based epoxides and glycerol: an overview of recent development

Anthropogenic carbon dioxide (CO₂) emissions contribute significantly to global warming and deplete fossil carbon resources, prompting a shift to bio-based raw materials. The two main technologies for reducing CO₂ emissions are capturing and either storing or utilizing it. However, while capture and storage have high reduction potential, they lack economic feasibility. Conversely, by utilizing the CO₂ captured from streams and air to produce valuable products, it can become an asset and curb greenhouse gas effects. CO₂ is a challenging C1-building block due to its high kinetic inertness and thermodynamic stability, requiring high temperature and pressure conditions and a reactive catalytic system. Nonetheless, cyclic carbonate production by reacting epoxides and CO₂ is a promising green and sustainable chemistry reaction, with enormous potential applications as an electrolyte in lithium-ion batteries, a green solvent, and a monomer in polycarbonate production. This review focuses on the most recent developments in the synthesis of cyclic carbonates from glycerol and bio-based epoxides, as well as efficient methods for chemically transforming CO₂ using flow chemistry and novel reactor designs.

Design, Heat Transfer, and Visualization of the Milli-Reactor by CFD and ANN

This paper proposes a milli-reactor design method incorporating reactor runaway criteria. Based on Computational Fluid Dynamic (CFD) simulation, neural networks are applied to obtain the optimal reactor structure according to the target reaction requirements. Varma’s theory, the critical Nusselt number for stable operation of the flow reactor, is derived. Inserts of the multi-blade structure are designed and investigated to enhance mixing and heat transfer performance. The flow field and heat transfer capacities are obtained by CFD calculations in the range of Re 50–1800. The internal components increase the heat transfer performance up to 21 times, and the pressure drop up to 16 times. The inclined angle of the blade is recommended to be 45°, which can effectively improve heat transfer without generating excessive pressure drop. By partial least squares regression (PLS) analysis, Re and the number of blades are the most critical factors affecting heat transfer, and the five blades and smaller tilt angles are recommended. The CFD calculation results are in good agreement with the Particle Image Velocimetry (PIV) experimental results.

Development of a Fully Continuous-Flow Approach Towards Asymmetric Total Synthesis of Tetrahydroprotoberberine Natural Alkaloids

Continuous flow synthetic technologies had been widely applied in the total synthesis in the past few decades. Fully continuous flow synthesis is still extremely focused on multi-step synthesis of complex natural pharmaceutical molecules. Thus, the development of fully continuous flow total synthesis of natural products is in demand but challenging. Herein, we demonstrated the first fully continuous flow approach towards asymmetric total synthesis of natural tetrahydroprotoberberine alkaloids, (-)-isocanadine, (-)-tetrahydropseudocoptisine, (-)-stylopine and (-)-nandinine. This method features a concise linear sequence involving four chemical transformations and three on-line work-up processing in an integrated flow platform, without any intermediate purification. The overall yield and enantioselectivity of this four-step continuous flow chemistry were up to 50 % and 92 %ee, respectively, in a total residence time of 32.5 min, corresponding to a throughput of 145 mg/h.

Fundamentals and utilization of solid/ liquid phase boundary interactions on functional surfaces

The affinity of macroscopic solid surfaces or dispersed nano- and bioparticles towards liquids plays a key role in many areas from fluid transport to interactions of the cells with phase boundaries. Forces between solid interfaces in water become especially important when the surface texture or particles are in the colloidal size range. Although, solid-liquid interactions are still prioritized subjects of materials science and therefore are extensively studied, the related literature still lacks in conclusive approaches, which involve as much information on fundamental aspects as on recent experimental findings related to influencing the wetting and other wetting-related properties and applications of different surfaces. The aim of this review is to fill this gap by shedding light on the mechanism-of-action and design principles of different, state-of-the-art functional macroscopic surfaces, ranging from self-cleaning, photoreactive or antimicrobial coatings to emulsion separation membranes, as these surfaces are gaining distinguished attention during the ongoing global environmental and epidemic crises. As there are increasing numbers of examples for stimulus-responsive surfaces and their interactions with liquids in the literature, as well, this overview also covers different external stimulus-responsive systems, regarding their mechanistic principles and application possibilities.

Amide Bonds Meet Flow Chemistry: A Journey into Methodologies and Sustainable Evolution

Formation of amide bonds is of immanent importance in organic and synthetic medicinal chemistry. Its presence in "traditional" small-molecule active pharmaceutical ingredients, in linear or cyclic oligo- and polypeptidic actives, including pseudopeptides, has led to the development of dedicated synthetic approaches for the formation of amide bonds starting from, if necessary, suitably protected amino acids. While the use of solid supported reagents is common in traditional peptide synthesis, similar approaches targeting amide bond formation in continuous-flow mode took off more significantly, after a first publication in 2006, only a couple of years ago. Most efforts rely upon the transition of traditional approaches in flow mode, or the combination of solid-phase peptide synthesis principles with flow chemistry, and advantages are mainly seen in improving space-time yields. This Review summarizes and compares the various approaches in terms of basic amide formation, peptide synthesis, and pseudopeptide generation, describing the technological approaches and the advantages that were generated by the specific flow approaches. A final discussion highlights potential future needs and perspectives in terms of greener and more sustainable syntheses.

Continuous Flow Bioconjugations of NIR‐AZA Fluorophores via Strained Alkyne Cycloadditions with Intra‐Chip Fluorogenic Monitoring**

The importance of bioconjugation reactions continues to grow for cell specific targeting and dual therapeutic plus diagnostic medical applications. This necessitates the development of new bioconjugation chemistries, in‐flow synthetic and analytical methods. With this goal, continuous flow bioconjugations were readily achieved with short residence times for strained alkyne substituted carbohydrate and therapeutic peptide biomolecules in reaction with azide and tetrazine substituted fluorophores. The strained alkyne substrates included substituted 2‐amino‐2‐deoxy‐α‐D‐glucopyranose, and the linear and cyclic peptide sequences QIRQQPRDPPTETLELEVSPDPAS‐OH and c(RGDfK) respectively. The catalyst and reagent‐free inverse electron demand tetrazine cycloadditions proved more favourable than the azide 1,3‐dipolar cycloadditions. Reaction completion was achieved with residence times of 5 min at 40 °C for tetrazine versus 10 min at 80 °C for azide cycloadditions. The use of a fluorogenic tetrazine fluorophore, in a glass channelled reactor chip, allowed for intra‐chip reaction monitoring by recording fluorescence intensities at various positions throughout the chip. As the Diels‐Alder reactions proceeded through the chip, the fluorescence intensity increased accordingly in real‐time. The application of continuous flow fluorogenic bioconjugations could offer an efficient translational access to theranostic agents.

Flow-Injection Methods in Water Analysis-Recent Developments

Widespread demand for the analysis and control of water quality and supply for human activity and ecosystem sustainability has necessitated the continuous improvement of water analysis methods in terms of their reliability, efficiency, and costs. To satisfy these requirements, flow-injection analysis using different detection methods has successfully been developed in recent decades. This review, based on about 100 original research papers, presents the achievements in this field over the past ten years. Various methodologies for establishing flow-injection measurements are reviewed, together with microfluidics and portable systems. The developed applications mostly concern not only the determination of inorganic analytes but also the speciation analysis of different elements, and the determination of several total indices of water quality. Examples of the determination of organic residues (e.g., pesticides, phenolic compounds, and surfactants) in natural surface waters, seawater, groundwater, and drinking water have also been identified. Usually, changes in the format of manual procedures for flow-injection determination results in the improvement of various operational parameters, such as the limits of detection, the sampling rate, or selectivity in different matrices.

Characterization of axial dispersion in vertical helical coil for gas-liquid-liquid flow at low Reynolds numbers

Gas-Liquid-Liquid (GLL) slug flow reactors offer several advantages like higher interfacial area, excellent mass transfer, and lower backmixing. The mesoscale (diameter ~ few mm) helical coiled reactors operating in slug...

Modern advancements in continuous-flow aided kinetic analysis

Although kinetic analysis has traditionally been conducted in a batch vessel, continuous-flow aided kinetic analysis continues to swell in popularity.

Towards 4th industrial revolution efficient and sustainable continuous flow manufacturing of active pharmaceutical ingredients

The convergence of end-to-end continuous flow synthesis with downstream processing, process analytical technology (PAT), artificial intelligence (AI), machine learning and automation in ensuring improved accessibility of quality medicines on demand.

Catalytic hydrogenation of nitrocyclohexane as an alternative pathway for the synthesis of value-added products

Catalytic hydrogenation of nitrocyclohexane could be an alternative source of various useful chemicals: cyclohexanone oxime, cyclohexanone, cyclohexanol, cyclohexylamine and dicyclohexylamine. Each one of these compounds found application in the modern...

Total Synthesis of Glipizide and Glibenclamide in Continuous Flow

Glipizide and glibenclamide remain some of the widely prescribed antidiabetic sulfonylurea drugs for the treatment of type 2 diabetes mellitus. Herein the authors report on an isocyanate-free synthetic procedure towards the preparation of these on demand drugs at multigram scale using continuous flow technology. The safety concern over the use of isocyanates in most of the existing synthetic routes was dealt with in this present work by using N-carbamates synthesised in situ from activation of amines with chloroformates as safer alternatives. An overall yield of 80-85 % was obtained for the semi-telescoped steps within 10 min total residence time.

Multistep Continuous Flow Synthesis of Stavudine

Herein, we demonstrate an elegant multistep continuous flow synthesis for stavudine (d4T), a potent nucleoside chemotherapeutic agent for human immunodeficiency virus, acquired immunodeficiency syndrome (AIDS) and AIDS-related conditions. This was accomplished via six chemical transformations in five sequential continuous flow reactors from an affordable starting material, 5-methyluridine. In the first instance, single step continuous flow synthesis was demonstrated with an average of 97% yield, 21.4 g/h throughput per step, and a total of 15.5 min residence time. Finally, multistep continuous flow synthesis of d4T in 87% total yield with a total residence time of 19.9 min and 117 mg/h throughput without intermediate purification was demonstrated.

A comprehensive review of flow chemistry techniques tailored to the flavours and fragrances industries

Due to their intrinsic physical properties, which includes being able to perform as volatile liquids at room and biological temperatures, fragrance ingredients/intermediates make ideal candidates for continuous-flow manufacturing. This review highlights the potential crossover between a multibillion dollar industry and the flourishing sub-field of flow chemistry evolving within the discipline of organic synthesis. This is illustrated through selected examples of industrially important transformations specific to the fragrances and flavours industry and by highlighting the advantages of conducting these transformations by using a flow approach. This review is designed to be a compendium of techniques and apparatus already published in the chemical and engineering literature which would constitute a known solution or inspiration for commonly encountered procedures in the manufacture of fragrance and flavour chemicals.

Self-Organized Implanting of Micro/Nanofiltration Membranes in Advanced Flow μ-Reactors

A low-cost, simple, and one-step synthesis of cellulose acetate nanoparticles (CANPs) has been invented using a continuous-flow advanced microfluidic reactor. For this purpose, the CANPs are self-organized inside a cross-junction microchannel by flowing cellulose acetate (CA) dissolved in N,N-dimethylformamide (DMF) through the axial inlet and the antisolvent water through the pair of side inlets. The preferential solubility (insolubility) of DMF (CA) to antisolvent water stimulates the in situ synthesis of CANPs at the DMF/water miscible interface following a phase-inversion process. Subsequently, nanofiltration, ultrafiltration, and microfiltration membranes of different porosities and permeabilities have been prepared from freshly synthesized CANPs. The porosity, thickness, transparency, and wettability of the membranes are tuned by varying the thickness of the membranes, size of the nanoparticles, and the porosity of the membranes. The as-synthesized CANPs show enhanced bactericidal properties with and without loading an external drug, curcumin, which has been validated against the Gram-negative Pseudomonas aeruginosa species. Importantly, enabling a pulsatile flow during the synthesis, the CANPs are embedded as nanofiltration membranes inside the microfluidic channel. Such microfluidic devices have been used to separate a corrosive dye from water. Concisely, the proposed in situ synthesis of CANPs in the continuous-flow microfluidic reactors, their usage for fabricating membranes with tunable wettability and transparency, and their subsequent integration into the microfluidic channel show the potential of the invention for a host of applications related to health care and environmental remediation.

Flow-Through PolyHIPE Silver-Based Catalytic Reactor

Catalytic reactors performing continuously are an important step towards more efficient and controllable processes compared to the batch operation mode. For this purpose, homogenous high internal phase emulsion polymer materials with an immobilized silver catalyst were prepared and used as a continuous plug flow reactor. Porous material with epoxide groups was functionalized to bear aldehyde groups which were used to reduce silver ions using Tollens reagent. Investigation of various parameters revealed that the mass of deposited silver depends on the aldehyde concentration as well as the composition of Tollens reagent. Nanoparticles formed on the pore surface showed high crystallinity with a cuboctahedra crystal shape and highly uniform surface coverage. The example of the 4-nitrophenol catalytic reduction in a continuous process was studied and demonstrated to be dependent on the mass of deposited silver. Furthermore, productivity increased with the volumetric silver density and flow rate, and it was preserved during prolonged usage and storage.

Kinetic Modeling of Advanced Oxidation Processes Using Microreactors: Challenges and Opportunities for Scale-Up

With the increasing number of recalcitrant pollutants in wastewater treatment plants, there will be a stringent need for rapid and convenient development of tertiary treatment processes such as advanced oxidation processes (AOPs). Microreactors offer a great opportunity for ultrafast and safe intrinsic kinetic parameters determination, by-products identification, and ecotoxicity assessment. Despite the considerable potential of these devices, they have been mostly used for catalyst screening or pseudo-first order kinetics determination, not allowing for knowledge transfer across scales. This work offers an overview of the adoption of micro- and photo-microreactors for intrinsic kinetics investigations in the field of AOPs to guide future research efforts.

From circular synthesis to material manufacturing: advances, challenges, and future steps for using flow chemistry in novel application area

We review the emerging use of flow technologies for circular chemistry and material manufacturing, highlighting advances, challenges, and future directions.

Dual-Channel Stopped-Flow Apparatus for Simultaneous Fluorescence, Anisotropy, and FRET Kinetic Data Acquisition for Binary and Ternary Biological Complexes

The Stopped-Flow apparatus (SF) tracks molecular events by mixing the reactants in sub-millisecond regimes. The reaction of intrinsically or extrinsically labeled biomolecules can be monitored by recording the fluorescence, F(t), anisotropy, r(t), polarization, p(t), or FRET, F(t)_FRET, traces at nanomolar concentrations. These kinetic measurements are critical to elucidate reaction mechanisms, structural information, and even thermodynamics. In a single detector SF, or L-configuration, the r(t), p(t), and F(t) traces are acquired by switching the orientation of the emission polarizer to collect the I_VV and I_VH signals however it requires two-shot experiments. In a two-detector SF, or T-configuration, these traces are collected in a single-shot experiment, but it increases the apparatus’ complexity and price. Herein, we present a single-detector dual-channel SF to obtain the F(t) and r(t) traces simultaneously, in which a photo-elastic modulator oscillates by 90° the excitation light plane at a 50 kHz frequency, and the emission signal is processed by a set of electronic filters that split it into the r(t) and F(t) analog signals that are digitized and stored into separated spreadsheets by a custom-tailored instrument control software. We evaluated the association kinetics of binary and ternary biological complexes acquired with our dual-channel SF and the traditional methods; such as a single polarizer at the magic angle to acquire F(t), a set of polarizers to track F(t), and r(t), and by energy transfer quenching, F(t)_FRET. Our dual-channel SF economized labeled material and yielded rate constants in excellent agreement with the traditional methods.

3D printing and continuous flow chemistry technology to advance pharmaceutical manufacturing in developing countries

The realization of a downward spiralling of diseases in developing countries requires them to become self-sufficient in pharmaceutical products. One of the ways to meet this need is by boosting the local production of active pharmaceutical ingredients and embracing enabling technologies. Both 3D printing and continuous flow chemistry are being exploited rapidly and they are opening huge avenues of possibilities in the chemical and pharmaceutical industries due to their well-documented benefits. The main barrier to entry for the continuous flow chemistry technique in low-income settings is the cost of set-up and maintenance through purchasing of spare flow reactors. This review article discusses the technical considerations for the convergence of state-of-the-art technologies, 3D printing and continuous flow chemistry for pharmaceutical manufacturing applications in developing countries. An overview of the 3D printing technique and its application in fabrication of continuous flow components and systems is provided. Finally, quality considerations for satisfying regulatory requirements for the approval of 3D printed equipment are underscored. An in-depth understanding of the interrelated aspects in the implementation of these technologies is crucial for the realization of sustainable, good quality chemical reactionware.

Oscillatory flow reactors for synthetic chemistry applications

Oscillatory 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.

Modern Flow Analysis

A brief overview of articles published in this Special Issue of Molecules titled “Modern Flow Analysis” is provided. In addition to cross-sectional and methodological works, there are some reports on new technical and instrumental achievements. It has been shown that all these papers create a good picture of contemporary flow analysis, revealing the most current trends and problems in this branch of flow chemistry.

Development of a Simple Reversible-Flow Method for Preparation of Micron-Size Chitosan-Cu(II) Catalyst Particles and Their Testing of Activity

A simple flow system employing a reversible-flow syringe pump was employed to synthesize uniform micron-size particles of chitosan-Cu(II) (CS-Cu(II)) catalyst. A solution of chitosan and Cu(II) salt was drawn into a holding coil via a 3-way switching valve and then slowly pumped to drip into an alkaline solution to form of hydrogel droplets. The droplets were washed and dried to obtain the catalyst particles. Manual addition into the alkaline solution or employment of flow system with a vibrating rod, through which the end of the flow line is inserted, was investigated for comparison. A sampling method was selected to obtain representative samples of the population of the synthesized particles for size measurement using optical microscopy. The mean sizes of the particles were 880 ± 70 µm, 780 ± 20 µm, and 180 ± 30 µm for the manual and flow methods, without and with the vibrating rod, respectively. Performance of the flow methods, in terms of rate of droplet production and particle size distribution, are discussed. Samples of 180 µm size CS-Cu(II) particles were tested for catalytic reduction of 0.5 mM p-nitrophenol to p-aminophenol by 100-fold excess borohydride. The conversion was 98% after 20 min, whereas without the catalyst there was only 14% conversion.