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Gnädinger U, Poier D, Trombini C, Dabros M, Marti R. Development of Lab-Scale Continuous Stirred-Tank Reactor as Flow Process Tool for Oxidation Reactions Using Molecular Oxygen. Org Process Res Dev 2024; 28:1860-1868. [PMID: 38783850 PMCID: PMC11110044 DOI: 10.1021/acs.oprd.3c00424] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/03/2023] [Revised: 03/30/2024] [Accepted: 04/03/2024] [Indexed: 05/25/2024]
Abstract
The use of sustainable oxidants is of great interest to the chemical industry, considering the importance of oxidation reactions for the manufacturing of chemicals and society's growing awareness of its environmental impact. Molecular oxygen (O2), with an almost optimal atom efficiency in oxidation reactions, presents one of the most attractive alternatives to common reagents that are not only toxic in most cases but produce stoichiometric amounts of waste that must be treated. However, fire and explosion safety concerns, especially when used in combination with organic solvents, restrict its easy use. Here, we use state-of-the-art 3D printing and experimental feedback to develop a miniature continuous stirred-tank reactor (mini-CSTR) that enables efficient use of O2 as an oxidant in organic chemistry. Outstanding heat dissipation properties, achieved through integrated jacket cooling and a high surface-to-volume ratio, allow for a safe operation of the exothermic oxidation of 2-ethylhexanal, surpassing previously reported product selectivity. Moving well beyond the proof-of-concept stage, we characterize and illustrate the reactor's potential in the gas-liquid-solid triphasic synthesis of an endoperoxide precursor of antileishmanial agents. The custom-designed magnetic overhead stirring unit provides improved stirring efficiency, facilitating the handling of suspensions and, in combination with the borosilicate gas dispersion plate, leading to an optimized gas-liquid interface. These results underscore the immense potential that lies within the use of mini-CSTR in sustainable chemistry.
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Affiliation(s)
- Ursina Gnädinger
- Institute
of Chemical Technology, Haute École d’Ingénierie
et d’Architecture Fribourg, HES-SO
University of Applied Sciences and Arts Western Switzerland, 1700 Fribourg, Switzerland
| | - Dario Poier
- Institute
of Chemical Technology, Haute École d’Ingénierie
et d’Architecture Fribourg, HES-SO
University of Applied Sciences and Arts Western Switzerland, 1700 Fribourg, Switzerland
| | - Claudio Trombini
- Department
of Chemistry “G. Ciamician”, Alma Mater Studiorum, University of Bologna, Via Selmi 2, 40126 Bologna, Italy
| | - Michal Dabros
- Institute
of Chemical Technology, Haute École d’Ingénierie
et d’Architecture Fribourg, HES-SO
University of Applied Sciences and Arts Western Switzerland, 1700 Fribourg, Switzerland
| | - Roger Marti
- Institute
of Chemical Technology, Haute École d’Ingénierie
et d’Architecture Fribourg, HES-SO
University of Applied Sciences and Arts Western Switzerland, 1700 Fribourg, Switzerland
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2
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Mc Veigh M, Bellan LM. Microfluidic synthesis of radiotracers: recent developments and commercialization prospects. LAB ON A CHIP 2024; 24:1226-1243. [PMID: 38165824 DOI: 10.1039/d3lc00779k] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/04/2024]
Abstract
Positron emission tomography (PET) is a powerful diagnostic tool that holds incredible potential for clinicians to track a wide variety of biological processes using specialized radiotracers. Currently, however, a single radiotracer accounts for over 95% of procedures, largely due to the cost of radiotracer synthesis. Microfluidic platforms provide a solution to this problem by enabling a dose-on-demand pipeline in which a single benchtop platform would synthesize a wide array of radiotracers. In this review, we will explore the field of microfluidic production of radiotracers from early research to current development. Furthermore, the benefits and drawbacks of different microfluidic reactor designs will be analyzed. Lastly, we will discuss the various engineering considerations that must be addressed to create a fully developed, commercially effective platform that can usher the field from research and development to commercialization.
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Affiliation(s)
- Mark Mc Veigh
- Interdisciplinary Materials Science Program, Vanderbilt University, Nashville, TN, 37235, USA
| | - Leon M Bellan
- Department of Mechanical Engineering, Vanderbilt University, Nashville, TN, 37235, USA.
- Department of Biomedical Engineering, Vanderbilt University, Nashville, TN 37235, USA
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3
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Ncongwane TB, Ndinteh DT, Smit E. Automated silylation of flavonoids using 3D printed microfluidics prior to chromatographic analysis: system development. Anal Bioanal Chem 2023; 415:7151-7160. [PMID: 37804326 PMCID: PMC10684624 DOI: 10.1007/s00216-023-04981-4] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/19/2023] [Revised: 08/30/2023] [Accepted: 09/22/2023] [Indexed: 10/09/2023]
Abstract
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.
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Affiliation(s)
- Thabang Bernette Ncongwane
- Center for Natural Products Research, Department of Chemical Sciences, University of Johannesburg, Auckland Park, PO Box 524, Johannesburg, South Africa
| | - Derek Tantoh Ndinteh
- Center for Natural Products Research, Department of Chemical Sciences, University of Johannesburg, Auckland Park, PO Box 524, Johannesburg, South Africa
| | - Elize Smit
- Center for Natural Products Research, Department of Chemical Sciences, University of Johannesburg, Auckland Park, PO Box 524, Johannesburg, South Africa.
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4
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Lisboa TP, de Faria LV, de Oliveira WBV, Oliveira RS, Matos MAC, Dornellas RM, Matos RC. Cost-effective protocol to produce 3D-printed electrochemical devices using a 3D pen and lab-made filaments to ciprofloxacin sensing. Mikrochim Acta 2023; 190:310. [PMID: 37466780 DOI: 10.1007/s00604-023-05892-y] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/14/2023] [Accepted: 06/29/2023] [Indexed: 07/20/2023]
Abstract
A novel conductive filament based on graphite (Gr) dispersed in polylactic acid polymer matrix (PLA) is described to produce 3D-electrochemical devices (Gr/PLA). This conductive filament was used to additively manufacture electrochemical sensors using the 3D pen. Thermogravimetric analysis confirmed that Gr was successfully incorporated into PLA, achieving a composite material (40:60% w/w, Gr and PLA, respectively), while Raman and scanning electron microscopy revealed the presence of defects and a high porosity on the electrode surface, which contributes to improved electrochemical performance. The 3D-printed Gr/PLA electrode provided a more favorable charge transfer (335 Ω) than the conventional glassy carbon (1277 Ω) and 3D-printed Proto-pasta® (3750 Ω) electrodes. As a proof of concept, the ciprofloxacin antibiotic, a species of multiple interest, was selected as a model molecule. Thus, a square wave voltammetry (SWV) method was proposed in the potential range + 0.9 to + 1.3 V (vs Ag|AgCl|KCl(sat)), which provided a wide linear working range (2 to 32 µmol L-1), 1.79 µmol L-1 limit of detection (LOD), suitable precision (RSD < 7.9%), and recovery values from 94 to 109% when applied to pharmaceutical and milk samples. Additionally, the sensor is free from the interference of other antibiotics routinely employed in veterinary practices. This device is disposable, cost-effective, feasibly produced in financially limited laboratories, and consequently promising for evaluation of other antibiotic species in routine applications.
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Affiliation(s)
- Thalles Pedrosa Lisboa
- Chemistry Department, Federal University of Juiz de Fora, Juiz de Fora, 36036-900, Brazil.
- College of Exact Sciences and Technology, Federal University of Grande Dourados, Dourados, 79804-970, Brazil.
| | | | | | - Raylla Santos Oliveira
- Chemistry Department, Federal University of Juiz de Fora, Juiz de Fora, 36036-900, Brazil
| | | | | | - Renato Camargo Matos
- Chemistry Department, Federal University of Juiz de Fora, Juiz de Fora, 36036-900, Brazil.
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Menzel F, Cotton J, Klein T, Maurer A, Ziegler T, Neumaier JM. FOMSy: 3D-printed flexible open-source microfluidic system and flow synthesis of PET-tracer. J Flow Chem 2023. [DOI: 10.1007/s41981-023-00267-z] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/29/2023]
Abstract
AbstractIn this work, we introduce a low-cost open-source flow system that includes a dual syringe pump with implemented pressure sensor and back pressure regulator. The entire system can be built for around 500 €. Commercially available flow systems can be very expensive with equipment starting at, but often greatly exceeding, 10,000 €. This high price of entry makes such technology prohibitively expensive for many research groups. Such systems stand to benefit the emerging academic pharmaceutical field by providing the experience and availability of reliable and affordable solutions. To implement accessible flow chemistry at research facilities, the systems must be made affordable. In addition, space in research laboratories is usually limited and commercially available flow systems can be very bulky. Having a compact and individually adjustable system is thus beneficial, with 3D printing technology offering the solution. Our compact 3D-printed system meets the needs of many applications in flow chemistry research as well as educational requirements for universities. As a proof of concept, we conceptualized, developed, and tested a custom flow system that can be used to synthesize [18F]2-fluoro-2-desoxy-d-glucose ([18F]FDG), the most commonly used PET-tracer. This system was designed to perform the typical functions and operations required in radiotracer production i.e. radiofluorination, dilution, SPE-trapping, deprotection, and SPE-elution. With this proof-of-concept in hand, the system can be easily customized to produce other radiopharmaceuticals.
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6
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The synthesis of Aspirin and Acetobromo-α-D-glucose using 3D printed flow reactors: an undergraduate demonstration. J Flow Chem 2022. [DOI: 10.1007/s41981-022-00236-y] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/16/2022]
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7
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3D-printing design for continuous flow catalysis. TRENDS IN CHEMISTRY 2022. [DOI: 10.1016/j.trechm.2022.05.005] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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8
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du Preez A, Meijboom R, Smit E. Low-Cost 3D-Printed Reactionware for the Determination of Fatty Acid Content in Edible Oils using a Base-Catalyzed Transesterification Method in Continuous Flow. FOOD ANAL METHOD 2022. [DOI: 10.1007/s12161-022-02233-2] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Abstract
AbstractA low-cost flow system was designed, manufactured, and tested to perform automated base-catalyzed transesterification of triacylglycerols to determine the fatty acid content in edible oils. In combination with traditional gas chromatographic analysis (GC-FID), this approach provides a semi-automated process that requires minimal manual intervention. The main flow system components, namely syringe pumps, connectors (i.e., flangeless fittings), and reactors, were manufactured using 3D-printing technology, specifically fused deposition modeling (FDM). By fine-tuning 3D-printer settings, high-quality leak-tight fittings with standard threading were manufactured in polypropylene (PP), which reduced the overall cost of the flow system significantly. Due to the enhanced reactivity in flow, lower catalyst concentrations (≤ 1.5 wt.%) were needed compared to traditional batch reactions (5 wt.%). The suitability of the automated flow method was determined by comparing results with the certified fatty acid content in sunflower seed oil from Helianthus annuus. Acceptable levels of accuracy (relative errors < 5%) and precision (RSD values ≤ 0.02%) were achieved. The mostly 3D-printed flow system was successfully used to determine the fatty acid content of sunflower and other commercial edible oils, namely avocado oil, canola oil, extra virgin olive oil, and a canola and olive oil blend. Linoleic acid (C18:2) was the major component in sunflower oil, whereas all other oils consisted mainly of oleic acid (C18:1). The fatty acid content of the edible oils was comparable to certified and literature values.
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9
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Buglioni L, Raymenants F, Slattery A, Zondag SDA, Noël T. Technological Innovations in Photochemistry for Organic Synthesis: Flow Chemistry, High-Throughput Experimentation, Scale-up, and Photoelectrochemistry. Chem Rev 2022; 122:2752-2906. [PMID: 34375082 PMCID: PMC8796205 DOI: 10.1021/acs.chemrev.1c00332] [Citation(s) in RCA: 201] [Impact Index Per Article: 100.5] [Reference Citation Analysis] [Abstract] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/21/2021] [Indexed: 02/08/2023]
Abstract
Photoinduced chemical transformations have received in recent years a tremendous amount of attention, providing a plethora of opportunities to synthetic organic chemists. However, performing a photochemical transformation can be quite a challenge because of various issues related to the delivery of photons. These challenges have barred the widespread adoption of photochemical steps in the chemical industry. However, in the past decade, several technological innovations have led to more reproducible, selective, and scalable photoinduced reactions. Herein, we provide a comprehensive overview of these exciting technological advances, including flow chemistry, high-throughput experimentation, reactor design and scale-up, and the combination of photo- and electro-chemistry.
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Affiliation(s)
- Laura Buglioni
- Micro
Flow Chemistry and Synthetic Methodology, Department of Chemical Engineering
and Chemistry, Eindhoven University of Technology, Het Kranenveld, Bldg 14—Helix, 5600 MB, Eindhoven, The Netherlands
- Flow
Chemistry Group, van ’t Hoff Institute for Molecular Sciences
(HIMS), Universiteit van Amsterdam (UvA), Science Park 904, 1098 XH, Amsterdam, The Netherlands
| | - Fabian Raymenants
- Flow
Chemistry Group, van ’t Hoff Institute for Molecular Sciences
(HIMS), Universiteit van Amsterdam (UvA), Science Park 904, 1098 XH, Amsterdam, The Netherlands
| | - Aidan Slattery
- Flow
Chemistry Group, van ’t Hoff Institute for Molecular Sciences
(HIMS), Universiteit van Amsterdam (UvA), Science Park 904, 1098 XH, Amsterdam, The Netherlands
| | - Stefan D. A. Zondag
- Flow
Chemistry Group, van ’t Hoff Institute for Molecular Sciences
(HIMS), Universiteit van Amsterdam (UvA), Science Park 904, 1098 XH, Amsterdam, The Netherlands
| | - Timothy Noël
- Flow
Chemistry Group, van ’t Hoff Institute for Molecular Sciences
(HIMS), Universiteit van Amsterdam (UvA), Science Park 904, 1098 XH, Amsterdam, The Netherlands
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10
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Concilia G, Lai A, Thurgood P, Pirogova E, Baratchi S, Khoshmanesh K. Investigating the mechanotransduction of transient shear stress mediated by Piezo1 ion channel using a 3D printed dynamic gravity pump. LAB ON A CHIP 2022; 22:262-271. [PMID: 34931212 DOI: 10.1039/d1lc00927c] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/14/2023]
Abstract
Microfluidic systems are widely used for studying the mechanotransduction of flow-induced shear stress in mechanosensitive cells. However, these studies are generally performed under constant flow rates, mainly, due to the deficiency of existing pumps for generating transient flows. To address this limitation, we have developed a unique dynamic gravity pump to generate transient flows in microfluidics. The pump utilises a motorised 3D-printed cam-lever mechanism to change the inlet pressure of the system in repeated cycles. 3D printing technology facilitates the rapid and low-cost prototyping of the pump. Customised transient flow patterns can be generated by modulating the profile, size, and rotational speed of the cam, location of the hinge along the lever, and the height of the syringe. Using this unique dynamic gravity pump, we investigated the mechanotransduction of shear stress in HEK293 cells stably expressing Piezo1 mechanosensitive ion channel under transient flows. The controllable, simple, low-cost, compact, and modular design of the pump makes it suitable for studying the mechanobiology of shear sensitive cells under transient flows.
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Affiliation(s)
| | - Austin Lai
- School of Health & Biomedical Sciences, RMIT University, Bundoora, Victoria, Australia.
| | - Peter Thurgood
- School of Engineering, RMIT University, Melbourne, Victoria, Australia.
| | - Elena Pirogova
- School of Engineering, RMIT University, Melbourne, Victoria, Australia.
| | - Sara Baratchi
- School of Health & Biomedical Sciences, RMIT University, Bundoora, Victoria, Australia.
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11
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Alimi OA, Meijboom R. Current and future trends of additive manufacturing for chemistry applications: a review. JOURNAL OF MATERIALS SCIENCE 2021; 56:16824-16850. [PMID: 34413542 PMCID: PMC8363067 DOI: 10.1007/s10853-021-06362-7] [Citation(s) in RCA: 11] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Accepted: 07/17/2021] [Indexed: 06/13/2023]
Abstract
Three-dimensional (3-D) printing, also known as additive manufacturing, refers to a method used to generate a physical object by joining materials in a layer-by-layer process from a three-dimensional virtual model. 3-D printing technology has been traditionally employed in rapid prototyping, engineering, and industrial design. More recently, new applications continue to emerge; this is because of its exceptional advantage and flexibility over the traditional manufacturing process. Unlike other conventional manufacturing methods, which are fundamentally subtractive, 3-D printing is additive and, therefore, produces less waste. This review comprehensively summarises the application of additive manufacturing technologies in chemistry, chemical synthesis, and catalysis with particular attention to the production of general laboratory hardware, analytical facilities, reaction devices, and catalytically active substances. It also focuses on new and upcoming applications such as digital chemical synthesis, automation, and robotics in a synthetic environment. While discussing the contribution of this research area in the last decade, the current, future, and economic opportunities of additive manufacturing in chemical research and material development were fully covered.
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Affiliation(s)
- Oyekunle Azeez Alimi
- Research Centre for Synthesis and Catalysis, Department of Chemical Sciences, University of Johannesburg, Auckland Park, P.O. Box 524, Johannesburg, 2006 South Africa
| | - Reinout Meijboom
- Research Centre for Synthesis and Catalysis, Department of Chemical Sciences, University of Johannesburg, Auckland Park, P.O. Box 524, Johannesburg, 2006 South Africa
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12
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Iffelsberger C, Wert S, Matysik FM, Pumera M. Catalyst Formation and In Operando Monitoring of the Electrocatalytic Activity in Flow Reactors. ACS APPLIED MATERIALS & INTERFACES 2021; 13:35777-35784. [PMID: 34283572 DOI: 10.1021/acsami.1c09127] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/13/2023]
Abstract
Flow reactors are of increasing importance and have become crucial devices due to their wide application in chemical synthesis, electrochemical hydrogen evolution reaction (HER), or electrochemical waste water treatment. In many of these applications, catalyst materials such as transition-metal chalcogenides (TMCs) for the HER, provide the desired electrochemical reactivity for the HER. Generally, the flow electrolyzers' performance is evaluated as the overall output, but the decrease in activity of the electrolyzer is due to localized failure of the catalyst. Herein, we present a method for the spatially resolved (tens of micrometers) In Operando analysis of the catalytic activity under real operation conditions as well as the localized deposition of the catalyst in an operating model flow reactor. For these purposes, scanning electrochemical microscopy was applied for MoSx catalyst deposition and for localized tracking of the TMC activity with a resolution of 25 μm. This approach offers detailed information about the catalytic performance and should find broad application for the characterization and optimization of flow reactor catalysis under real operational conditions.
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Affiliation(s)
- Christian Iffelsberger
- Future Energy and Innovation Laboratory, Central European Institute of Technology, Brno University of Technology, Purkyňova 123, 61200 Brno, Czech Republic
| | - Stefan Wert
- Institute of Analytical Chemistry, Chemo- and Biosensors, University of Regensburg, 93053 Regensburg, Germany
| | - Frank-Michael Matysik
- Institute of Analytical Chemistry, Chemo- and Biosensors, University of Regensburg, 93053 Regensburg, Germany
| | - Martin Pumera
- Future Energy and Innovation Laboratory, Central European Institute of Technology, Brno University of Technology, Purkyňova 123, 61200 Brno, Czech Republic
- Department of Food Technology, Mendel University in Brno, Zemedelska 1, CZ-613 00 Brno, Czech Republic
- Department of Chemical and Biomolecular Engineering, Yonsei University, 50 Yonsei-ro, Seodaemun-gu, Seoul 03722, Korea
- Department of Medical Research, China Medical University Hospital, China Medical University, No. 91 Hsueh-Shih Road, Taichung 40402, Taiwan
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13
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Gambacorta G, Sharley JS, Baxendale IR. A comprehensive review of flow chemistry techniques tailored to the flavours and fragrances industries. Beilstein J Org Chem 2021; 17:1181-1312. [PMID: 34136010 PMCID: PMC8182698 DOI: 10.3762/bjoc.17.90] [Citation(s) in RCA: 18] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/29/2021] [Accepted: 04/22/2021] [Indexed: 12/28/2022] Open
Abstract
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.
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Affiliation(s)
- Guido Gambacorta
- Department of Chemistry, University of Durham, Stockton Road, Durham, DH1 3LE, United Kingdom
| | - James S Sharley
- Department of Chemistry, University of Durham, Stockton Road, Durham, DH1 3LE, United Kingdom
| | - Ian R Baxendale
- Department of Chemistry, University of Durham, Stockton Road, Durham, DH1 3LE, United Kingdom
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14
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Manufacturing and Application of 3D Printed Photo Fenton Reactors for Wastewater Treatment. INTERNATIONAL JOURNAL OF ENVIRONMENTAL RESEARCH AND PUBLIC HEALTH 2021; 18:ijerph18094885. [PMID: 34064341 PMCID: PMC8125145 DOI: 10.3390/ijerph18094885] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/29/2021] [Revised: 04/28/2021] [Accepted: 05/02/2021] [Indexed: 11/17/2022]
Abstract
Additive manufacturing (AM) or 3D printing offers a new paradigm for designing and developing chemical reactors, in particular, prototypes. The use of 3D printers has been increasing, their performance has been improving, and their price has been reducing. While the general trend is clear, particular applications need to be assessed for their practicality. This study develops and follows a systematic approach to the prototyping of Advanced Oxidation Processes (AOP) reactors. Specifically, this work evaluates and discusses different printable materials in terms of mechanical and chemical resistance to photo-Fenton reactants. Metallic and ceramic materials are shown to be impracticable due to their high printing cost. Polymeric and composite materials are sieved according to criteria such as biodegradability, chemical, thermal, and mechanical resistance. Finally, 3D-printed prototypes are produced and tested in terms of leakage and resistance to the photo-Fenton reacting environment. Polylactic acid (PLA) and wood-PLA composite (Timberfill®) were selected, and lab-scale raceway pond reactors (RPR) were printed accordingly. They were next exposed to H2O2/Fe(II) solutions at pH = 3 ± 0.2 and UV radiation. After 48 h reaction tests, results revealed that the Timberfill® reactor produced higher Total Organic Carbon (TOC) concentrations (9.6 mg·L-1) than that obtained for the PLA reactor (5.5 mg·L-1) and Pyrex® reactor (5.2 mg·L-1), which suggests the interference of Timberfill® with the reaction. The work also considers and discusses further chemical and mechanical criteria that also favor PLA for 3D-printing Fenton and photo-Fenton reactors. Finally, the work also provides a detailed explanation of the printing parameters used and guidelines for preparing prototypes.
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15
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Hapke S, Luinstra GA, Zentel KM. Optimization of a 3D-printed tubular reactor for free radical polymerization by CFD. J Flow Chem 2021. [DOI: 10.1007/s41981-021-00154-5] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/23/2023]
Abstract
AbstractA flow reactor for the complex reaction network of the free radical solution polymerization of n-butyl acrylate was optimized by a combination of kinetic modeling, computational fluid dynamics (CFD) and additive manufacturing. CFD was used to model a flow reactor with SMX mixing elements. An optimized geometry was 3D-printed from polypropylene. The modeled residence time behavior was compared to relevant experiments, giving a validation for the flow behavior of the reactor. A kinetic model for the free radical solution polymerization of n-butyl acrylate (BA) was in addition implemented into the CFD model. It was used to predict the polymerization behavior in the flow reactor and the resulting product properties. The experimental and computational results were in acceptable agreement.
Graphical abstract
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16
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Kleoff M, Schwan J, Christmann M, Heretsch P. A Modular, Argon-Driven Flow Platform for Natural Product Synthesis and Late-Stage Transformations. Org Lett 2021; 23:2370-2374. [PMID: 33689372 DOI: 10.1021/acs.orglett.1c00661] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/14/2023]
Abstract
A modular flow platform for natural product synthesis was designed. To access different reaction setups with a maximum of flexibility, interchangeable 3D-printed components serve as backbone. By switching from liquid- to gas-driven flow, reagent and solvent waste is minimized, which translates into an advantageous sustainability profile. To enable inert conditions, "Schlenk-in-flow" techniques for the safe handling of oxygen- and moisture sensitive reagents were developed. Adopting these techniques, reproducible transformations in natural product synthesis were achieved.
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Affiliation(s)
- Merlin Kleoff
- Institut für Chemie und Biochemie, Organische Chemie, Freie Universität Berlin, Takustraße 3, 14195 Berlin, Germany
| | - Johannes Schwan
- Institut für Chemie und Biochemie, Organische Chemie, Freie Universität Berlin, Takustraße 3, 14195 Berlin, Germany
| | - Mathias Christmann
- Institut für Chemie und Biochemie, Organische Chemie, Freie Universität Berlin, Takustraße 3, 14195 Berlin, Germany
| | - Philipp Heretsch
- Institut für Chemie und Biochemie, Organische Chemie, Freie Universität Berlin, Takustraße 3, 14195 Berlin, Germany
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17
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Sivo A, Galaverna RDS, Gomes GR, Pastre JC, Vilé G. From circular synthesis to material manufacturing: advances, challenges, and future steps for using flow chemistry in novel application area. REACT CHEM ENG 2021. [DOI: 10.1039/d0re00411a] [Citation(s) in RCA: 22] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/17/2022]
Abstract
We review the emerging use of flow technologies for circular chemistry and material manufacturing, highlighting advances, challenges, and future directions.
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Affiliation(s)
- Alessandra Sivo
- Department of Chemistry
- Materials and Chemical Engineering “Giulio Natta”
- Politecnico di Milano
- IT-20131 Milano
- Italy
| | | | | | | | - Gianvito Vilé
- Department of Chemistry
- Materials and Chemical Engineering “Giulio Natta”
- Politecnico di Milano
- IT-20131 Milano
- Italy
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18
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Benítez-Mateos AI, Contente ML, Roura Padrosa D, Paradisi F. Flow biocatalysis 101: design, development and applications. REACT CHEM ENG 2021. [DOI: 10.1039/d0re00483a] [Citation(s) in RCA: 30] [Impact Index Per Article: 10.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/06/2023]
Abstract
Flow biocatalysis: where to start? This tutorial review aims to guide and inspire new-comers to the field to boost the potential of flow biocatalysis.
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Affiliation(s)
| | | | | | - Francesca Paradisi
- Department of Chemistry and Biochemistry
- University of Bern
- Bern
- Switzerland
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19
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Gordeev EG, Ananikov VP. Widely accessible 3D printing technologies in chemistry, biochemistry and pharmaceutics: applications, materials and prospects. RUSSIAN CHEMICAL REVIEWS 2020. [DOI: 10.1070/rcr4980] [Citation(s) in RCA: 22] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
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20
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Penny MR, Tsui N, Hilton ST. Extending practical flow chemistry into the undergraduate curriculum via the use of a portable low-cost 3D printed continuous flow system. J Flow Chem 2020. [DOI: 10.1007/s41981-020-00122-5] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/06/2023]
Abstract
AbstractContinuous flow chemistry is undergoing rapid growth and adoption within the pharmaceutical industry due to its ability to rapidly translate chemical discoveries from medicinal chemistry laboratories into process laboratories. Its growing significance means that it is imperative that flow chemistry is taught and experienced by both undergraduate and postgraduate synthetic chemists. However, whilst flow chemistry has been incorporated by industry, there remains a distinct lack of practical training and knowledge at both undergraduate and postgraduate levels. A key challenge associated with its implementation is the high cost (>$25,000) of the system’s themselves, which is far beyond the financial reach of most universities and research groups, meaning that this key technology remains open to only a few groups and that its associated training remains a theoretical rather than a practical subject. In order to increase access to flow chemistry, we sought to design and develop a small-footprint, low-cost and portable continuous flow system that could be used to teach flow chemistry, but that could also be used by research groups looking to transition to continuous flow chemistry. A key element of its utility focusses on its 3D printed nature, as low-cost reactors could be readily incorporated and modified to suit differing needs and educational requirements. In this paper, we demonstrate the system’s flexibility using reactors and mixing chips designed and 3D printed by an undergraduate project student (N.T.) and show how the flexibility of the system allows the investigation of differing flow paths on the same continuous flow system in parallel.
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21
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Sagandira CR, Siyawamwaya M, Watts P. 3D printing and continuous flow chemistry technology to advance pharmaceutical manufacturing in developing countries. ARAB J CHEM 2020; 13:7886-7908. [PMID: 34909056 PMCID: PMC7511217 DOI: 10.1016/j.arabjc.2020.09.020] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/16/2020] [Revised: 09/12/2020] [Accepted: 09/13/2020] [Indexed: 12/18/2022] Open
Abstract
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.
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Affiliation(s)
| | | | - Paul Watts
- Nelson Mandela University, University Way, Port Elizabeth 6031, South Africa,Corresponding author
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22
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Guo Y, Rosa LF, Müller S, Harnisch F. Monitoring stratification of anode biofilms in bioelectrochemical laminar flow reactors using flow cytometry. ENVIRONMENTAL SCIENCE AND ECOTECHNOLOGY 2020; 4:100062. [PMID: 36157706 PMCID: PMC9488081 DOI: 10.1016/j.ese.2020.100062] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/22/2020] [Revised: 09/25/2020] [Accepted: 09/26/2020] [Indexed: 06/16/2023]
Abstract
A laminar flow bioelectrochemical systems (BES) was designed and benchmarked using microbial anodes dominated with Geobacter spp. The reactor architecture was based on modeled flow fields, the resulting structure was 3D printed and used for BES manufacturing. Stratification of the substrate availability within the reactor channels led to heterogeneous biomass distribution, with the maximum biomass found mainly in the initial/middle channels. The anode performance was assessed for different hydraulic retention times while coulombic efficiencies of up to 100% (including also hydrogen recycling from the cathode) and current densities of up to 75 μA cm-2 at an anode surface to volume ratio of 1770 cm2 L-1 after 35 days were achieved. This low current density can be clearly attributed to the heterogeneous distributions of biomass and the stratification of the microbial community structure. Further, it was shown that time and space resolved analysis of the reactor microbiomes per channel is feasible using flow cytometry.
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23
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Alimi OA, Ncongwane TB, Meijboom R. Design and fabrication of a monolith catalyst for continuous flow epoxidation of styrene in polypropylene printed flow reactor. Chem Eng Res Des 2020. [DOI: 10.1016/j.cherd.2020.04.025] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/27/2022]
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24
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Menzel F, Klein T, Ziegler T, Neumaier JM. 3D-printed PEEK reactors and development of a complete continuous flow system for chemical synthesis. REACT CHEM ENG 2020. [DOI: 10.1039/d0re00206b] [Citation(s) in RCA: 14] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Abstract
This paper presents the development of milli- and microfluidic reactors made of polyether ether ketone (PEEK) and 3D-printed equipment for a complete continuous flow system.
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Affiliation(s)
- Florian Menzel
- Institute of Organic Chemistry
- University of Tübingen
- 72076 Tübingen
- Germany
| | - Thomas Klein
- Institute of Organic Chemistry
- University of Tübingen
- 72076 Tübingen
- Germany
| | - Thomas Ziegler
- Institute of Organic Chemistry
- University of Tübingen
- 72076 Tübingen
- Germany
| | - Jochen M. Neumaier
- Institute of Organic Chemistry
- University of Tübingen
- 72076 Tübingen
- Germany
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25
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Sharma MK, Raval J, Ahn GN, Kim DP, Kulkarni AA. Assessing the impact of deviations in optimized multistep flow synthesis on the scale-up. REACT CHEM ENG 2020. [DOI: 10.1039/d0re00025f] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
This manuscript highlights the unavoidable connection between manual and self-optimized flow synthesis protocols for multistep flow synthesis and its scale-up.
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Affiliation(s)
- M. K. Sharma
- Chemical Engineering and Process Development Division
- CSIR-National Chemical Laboratory
- Pune – 411008
- India
- AcSIR
| | - J. Raval
- Chemical Engineering and Process Development Division
- CSIR-National Chemical Laboratory
- Pune – 411008
- India
- AcSIR
| | - Gwang-Noh Ahn
- Center for Intelligent Microprocess of Pharmaceutical Synthesis
- Department of Chemical Engineering
- Pohang University of Science and Technology (POSTECH)
- Pohang 37673
- Korea
| | - Dong-Pyo Kim
- Center for Intelligent Microprocess of Pharmaceutical Synthesis
- Department of Chemical Engineering
- Pohang University of Science and Technology (POSTECH)
- Pohang 37673
- Korea
| | - A. A. Kulkarni
- Chemical Engineering and Process Development Division
- CSIR-National Chemical Laboratory
- Pune – 411008
- India
- AcSIR
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26
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Barthels F, Barthels U, Schwickert M, Schirmeister T. FINDUS: An Open-Source 3D Printable Liquid-Handling Workstation for Laboratory Automation in Life Sciences. SLAS Technol 2019; 25:190-199. [PMID: 31540570 DOI: 10.1177/2472630319877374] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
3D-printed laboratory devices can enable ambitious research purposes even at a low-budget level. To follow this trend, here we describe the construction, calibration, and usage of the FINDUS (Fully Integrable Noncommercial Dispensing Utility System). We report the successful 3D printing and assembly of a liquid-handling workstation for less than $400. Using this setup, we achieve reliable and flexible liquid-dispensing automation with relative pipetting errors of less than 0.3%. We show our system is well suited for several showcase applications from both the biology and chemistry fields. In support of the open-source spirit, we make all 3D models, assembly instructions, and source code available for free download, rebuild, and modification.
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Affiliation(s)
- Fabian Barthels
- Institute of Pharmacy and Biochemistry, Johannes Gutenberg University Mainz, Mainz, Germany
| | - Ulrich Barthels
- Institute of Pharmacy and Biochemistry, Johannes Gutenberg University Mainz, Mainz, Germany
| | - Marvin Schwickert
- Institute of Pharmacy and Biochemistry, Johannes Gutenberg University Mainz, Mainz, Germany
| | - Tanja Schirmeister
- Institute of Pharmacy and Biochemistry, Johannes Gutenberg University Mainz, Mainz, Germany
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