Flow Chemistry: Recent Developments in the Synthesis of Pharmaceutical Products

Advanced Real-Time Process Analytics for Multistep Synthesis in Continuous Flow*

In multistep continuous flow chemistry, studying complex reaction mixtures in real time is a significant challenge, but provides an opportunity to enhance reaction understanding and control. We report the integration of four complementary process analytical technology tools (NMR, UV/Vis, IR and UHPLC) in the multistep synthesis of an active pharmaceutical ingredient, mesalazine. This synthetic route exploits flow processing for nitration, high temperature hydrolysis and hydrogenation reactions, as well as three inline separations. Advanced data analysis models were developed (indirect hard modeling, deep learning and partial least squares regression), to quantify the desired products, intermediates and impurities in real time, at multiple points along the synthetic pathway. The capabilities of the system have been demonstrated by operating both steady state and dynamic experiments and represents a significant step forward in data-driven continuous flow synthesis.

A continuous flow synthesis of [1.1.1]propellane and bicyclo[1.1.1]pentane derivatives

A continuous flow process to generate [1.1.1]propellane on demand is presented rendering solutions of [1.1.1]propellane that can directly be derivatised into various bicyclo[1.1.1]pentane (BCP) species. This was realised in throughputs up to 8.5 mmol h-1 providing an attractive and straightforward access to gram quantities of selected BCP building blocks. Lastly, a continuous photochemical transformation of [1.1.1]propellane into valuable BCPs bearing mixed ester/acyl chloride moieties was developed.

Visible-Light Photocatalytic Tri- and Difluoroalkylation Cyclizations: Access to a Series of Indole[2,1-a]isoquinoline Derivatives in Continuous Flow

A process for achieving photocatalyzed tri- and difluoromethylation/cyclizations for constructing a series of tri- or difluoromethylated indole[2,1-a]isoquinoline derivatives is described. This protocol utilized an inexpensive organic photoredox catalyst and provided good yields. Moreover, the combination of continuous flow and photochemistry, designed to provide researchers with a unique green process, was also shown to be key to allowing the reaction to proceed (product yield of 83% in flow vs 0% in batch).

Stereoselective organocatalysis and flow chemistry

Organic synthesis has traditionally been performed in batch. Continuous-flow chemistry was recently rediscovered as an enabling technology to be applied to the synthesis of organic molecules. Organocatalysis is a well-established methodology, especially for the preparation of enantioenriched compounds. In this chapter we discuss the use of chiral organocatalysts in continuous flow. After the classification of the different types of catalytic reactors, in Section 2, each class will be discussed with the most recent and significant examples reported in the literature. In Section 3 we discuss homogeneous stereoselective reactions in flow, with a look at the stereoselective organophotoredox transformations in flow. This research topic is emerging as one of the most powerful method to prepare enantioenriched products with structures that would otherwise be challenging to make. Section 4 describes the use of supported organocatalysts in flow chemistry. Part of the discussion will be devoted to the choice of the support. Examples of packed-bed, monolithic and inner-wall functionalized reactors will be introduced and discussed. We hope to give an overview of the potentialities of the combination of (supported) chiral organocatalysts and flow chemistry.

A sustainable strategy for the straightforward preparation of 2H-azirines and highly functionalized NH-aziridines from vinyl azides using a single solvent flow-batch approach

The reported flow-batch approach enables the easy preparation of 2H-azirines and their stereoselective transformation into highly functionalized NH-aziridines, starting from vinyl azides and organolithium compounds. The protocol has been developed using cyclopentyl methyl ether (CPME) as an environmentally benign solvent, resulting into a sustainable, safe and potentially automatable method for the synthesis of interesting strained compounds.

Mechanochemistry for sustainable and efficient dehydrogenation/hydrogenation

Hydrogenation and dehydrogenation reactions are one of the pillars of the chemical industry, with applications from bulk chemicals to pharmaceuticals manufacturing. The ability to selectively add hydrogen across double and (or) triple bonds is key in the chemist’s toolbox and the enabling component in the development of sustainable processes. Traditional solution-based approaches to these reactions are tainted by significant consumption of energy and production of solvent waste. This review highlights the development and applications of recently emerged solvent-free approaches to conduct the hydrogenation of organic molecules using mechanochemistry, i.e., chemical transformations induced or sustained by mechanical force. In particular, we will show mechanochemical techniques such as ball-milling enabled catalytic or stoichiometric metal-mediated hydrogenation and dehydrogenation reactions that are simple, fast, and conducted under significantly milder conditions compared with traditional solution routes. Importantly, we highlight the current challenges and opportunities in this field, while also identifying exciting cases in which mechanochemical hydrogenation strategies lead to new, unique targets and reactivity.

Flow Biocatalysis: A Challenging Alternative for the Synthesis of APIs and Natural Compounds

Biocatalysts represent an efficient, highly selective and greener alternative to metal catalysts in both industry and academia. In the last two decades, the interest in biocatalytic transformations has increased due to an urgent need for more sustainable industrial processes that comply with the principles of green chemistry. Thanks to the recent advances in biotechnologies, protein engineering and the Nobel prize awarded concept of direct enzymatic evolution, the synthetic enzymatic toolbox has expanded significantly. In particular, the implementation of biocatalysts in continuous flow systems has attracted much attention, especially from industry. The advantages of flow chemistry enable biosynthesis to overcome well-known limitations of “classic” enzymatic catalysis, such as time-consuming work-ups and enzyme inhibition, as well as difficult scale-up and process intensifications. Moreover, continuous flow biocatalysis provides access to practical, economical and more sustainable synthetic pathways, an important aspect for the future of pharmaceutical companies if they want to compete in the market while complying with European Medicines Agency (EMA), Food and Drug Administration (FDA) and green chemistry requirements. This review focuses on the most recent advances in the use of flow biocatalysis for the synthesis of active pharmaceutical ingredients (APIs), pharmaceuticals and natural products, and the advantages and limitations are discussed.

Continuous-Flow Synthesis of Thioureas, Enabled by Aqueous Polysulfide Solution

We have developed the continuous-flow synthesis of thioureas in a multicomponent reaction starting from isocyanides, amidines, or amines and sulfur. The aqueous polysulfide solution enabled the application of sulfur under homogeneous and mild conditions. The crystallized products were isolated by simple filtration after the removal of the co-solvent, and the sulfur retained in the mother liquid. Presenting a wide range of thioureas synthesized by this procedure confirms the utility of the convenient continuous-flow application of sulfur.

A Review of Reactor Designs for Hydrogen Storage in Clathrate Hydrates

Clathrate hydrates are ice-like, crystalline solids, composed of a three-dimensional network of hydrogen bonded water molecules that confines gas molecules in well-defined cavities that can store gases as a solid solution. Ideally, hydrogen hydrates can store hydrogen with a maximum theoretical capacity of about 5.4 wt%. However, the pressures necessary for the formation of such a hydrogen hydrate are 180–220 MPa and therefore too high for large-scale plants and industrial use. Thus, since the early 1990s, there have been numerous studies to optimize pressure and temperature conditions for hydrogen formation and storage and to develop a proper reactor type via optimisation of the heat and mass transfer to maximise hydrate storage capacity in the resulting hydrate phase. So far, the construction of the reactor has been developed for small, sub-litre scale; and indeed, many attempts were reported for pilot-scale reactor design, on the multiple-litre scale and larger. The purpose of this review article is to compile and summarise this knowledge in a single article and to highlight hydrogen-storage prospects and future challenges.

Rh(i)- and Rh(ii)-catalyzed C-H alkylation of benzylamines with alkenes and its application in flow chemistry

The Rh-catalyzed C–H alkylation of benzylamines with alkenes using a picolinamide derivative as a directing group is reported. Both Rh(i) and Rh(ii) complexes can be used as active catalysts for this transformation. In addition, a flow set up was designed to successfully mimic this process under flow conditions. Several examples are presented under flow conditions and it was confirmed that a flow process is advantageous over a batch process. Deuterium labelling experiments were performed to elucidate the mechanism of the reaction, and the results indicated a possible carbene mechanism for this C–H alkylation process.

Rh(i)- and Rh(ii)-catalyzed C–H alkylation of benzylamines with alkenes using a picolinamide derivative as a directing group is reported under both batch and flow.

Selective separation of amines from continuous processes using automated pH controlled extraction

An automated separation system is described for identifying the optimal conditions for purifying an amine from a mixture.

A high-temperature continuous stirred-tank reactor cascade for the multistep synthesis of InP/ZnS quantum dots

Multistep and continuous production of core–shell InP/ZnS semiconductor nanocrystals in a high-temperature and miniature continuous stirred-tank reactor cascade.

Magnetic nanocatalysts utilized in the synthesis of aromatic pharmaceutical ingredients

This review covers recent developments in nanoscale magnetic catalytic systems and their applications in facilitating organic synthetic reactions of aromatic pharmaceutical ingredients.

Design of a novel dual function membrane microreactor for liquid–liquid–liquid phase transfer catalysed reaction: selective synthesis of 1-naphthyl glycidyl ether

Where, Ar-aryl group, Q⁺X⁻-phase transfer catalyst, Ar–O⁻Q⁺-catalyst complex with Ar–O⁻, R⁺–X⁻-haloalkane, Ar–O–R-product.

In situ sensors for flow reactors – a review

A comprehensive review on integrating microfluidic reactors with in situ sensors for reaction probing of chemical transformation.

Exploiting a silver–bismuth hybrid material as heterogeneous noble metal catalyst for decarboxylations and decarboxylative deuterations of carboxylic acids under batch and continuous flow conditions

A silver-containing hybrid material is reported as a heterogeneous noble metal catalyst for protodecarboxylations and decarboxylative deuterations of carboxylic acids.

NMR spectroscopy goes mobile: Using NMR as process analytical technology at the fume hood

Nuclear magnetic resonance (NMR) is potentially a very powerful process analytical technology (PAT) tool as it gives an atomic resolution picture of the reaction mixture without the need for chromatography. NMR is well suited for interrogating transient intermediates, providing kinetic information via NMR active nuclei, and most importantly provides universally quantitative information for all species in solution. This contrasts with commonly used PAT instruments, such as Raman or Flow-infrared (IR), which requires a separate calibration curve for every component of the reaction mixture. To date, the large footprint of high-field (≥400 MHz) NMR spectrometers and the immobility of superconducting magnets, coupled with strict requirements for the architecture for the room it is to be installed, have been a major obstacle to using this technology right next to fume hoods where chemists perform synthetic work. Here, we describe the use of a small, lightweight 60 MHz Benchtop NMR system (Nanalysis Pro-60) located on a mobile platform, that was used to monitor both small and intermediate scale Grignard formation and coupling reactions. We also show how low field NMR can provide a deceptively simple yes/no answer (for a system that would otherwise require laborious off-line testing) in the enrichment of one component versus another in a kilogram scale distillation. Benchtop NMR was also used to derive molecule specific information from Flow-IR, a technology found in most manufacturing sites, and compare the ease at which the concentrations of the reaction mixtures can be derived by NMR versus IR.

Enabling intensification of multiphase chemical processes with additive manufacturing

Fixed bed supports of various materials (metal, ceramic, polymer) and geometries are used to enhance the performance of many unit operations in chemical processes. Consider first metal and ceramic monolith support structures, which are typically extruded. Extruded monoliths contain regular, parallel channels enabling high throughput because of the low pressure drop accompanying high flow rate. However, extruded channels have a low surface-area-to-volume ratio resulting in low contact between the fluid phase and the support. Additive manufacturing, also referred to as three dimensional printing (3DP), can be used to overcome these disadvantages by offering precise control over key design parameters of the fixed bed including material-of-construction and total bed surface area, as well as accommodating system integration features compatible with continuous flow chemistry. These design parameters together with optimized extrinsic process conditions can be tuned to prepare customizable separation and reaction systems based on objectives for chemical process and/or the desired product. We discuss key elements of leveraging the flexibility of additive manufacturing to intensification with a focus on applications in continuous flow processes and disperse, multiphase systems enabling a range of scalable chemistry spanning discovery to manufacturing operations.

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.

Catalytic Reductive Alkylation of Amines in Batch and Microflow Conditions Using a Silicon-Wafer-Based Palladium Nanocatalyst

We describe the development of the catalytic reductive alkylation of amines with aldehydes under the atmospheric pressure of H2 using a brush-like silicon-nanostructure-supported palladium nanoparticle composite (SiNS-Pd) as a silicon-wafer-based reusable heterogeneous catalyst. The present reaction of primary and secondary amines with various aliphatic and aromatic aldehydes in the presence of the catalyst (0.02-0.05 mol % Pd) gave the corresponding secondary and tertiary amines including Lomerizine and Aticaprant in a 68% quantitative yield without overalkylation. We also designed and fabricated a flow device equipped with SiNS-Pd for microflow reactions, which was applied to the gas-liquid-solid triphasic reaction system (i.e., H2 gas, a substrate solution, and a solid catalyst). A multigram-scale reaction of aniline and benzaldehyde was demonstrated to obtain N-benzylaniline (ca. 4 g/day), in which the internal volume of the flow channel was 43 μL, the residence time was approximately 1 s, and the turnover number (TON) reached 4.0 × 104 in a continuous 24 h run (1.7 × 103 h-1; 0.50 s-1).

Telescoped Continuous Flow Synthesis of Optically Active γ-Nitrobutyric Acids as Key Intermediates of Baclofen, Phenibut, and Fluorophenibut

The two-step flow asymmetric synthesis of chiral γ-nitrobutyric acids as key intermediates of the GABA analogues baclofen, phenibut, and fluorophenibut is reported on a multigram scale. The telescoped process comprises an enantioselective Michael-type addition facilitated by a polystyrene-supported heterogeneous organocatalyst under neat conditions followed by in situ-generated performic acid-mediated aldehyde oxidation. Simple access to valuable optically active substances is provided with key advances in terms of productivity and sustainability compared to those of previous batch approaches.

A Visible-Light-Powered Polymerization Method for the Immobilization of Enantioselective Organocatalysts into Microreactors

A versatile one‐step photopolymerization approach for the immobilization of enantioselective organocatalysts is presented. Chiral organocatalyst‐containing monoliths based on polystyrene divinylbenzene copolymer were generated inside channels of microfluidic chips. Exemplary performance tests were performed for the monolithic Hayashi–Jørgensen catalyst in continuous flow, which showed good results for the Michael addition of aldehydes to nitroalkenes in terms of stereoselectivity and catalyst stability with minimal consumption of reagents and solvents.

Flow Chemistry for Cycloaddition Reactions

Continuous flow reactors form part of a rapidly growing research area that has changed the way synthetic chemistry is performed not only in academia but also at the industrial level. This Review highlights the most recent advances in cycloaddition reactions performed in flow systems. Cycloadditions are atom-efficient transformations for the synthesis of carbo- and heterocycles, involved in the construction of challenging skeletons of complex molecules. The main advantages of translating these processes into flow include using intensified conditions, safer handling of hazardous reagents and gases, easy tuning of reaction conditions, and straightforward scaling up. These benefits are especially important in cycloadditions such as the copper(I)-catalyzed azide alkyne cycloaddition (CuAAC), Diels-Alder reaction, ozonolysis and [2+2] photocycloadditions. Some of these transformations are key reactions in the industrial synthesis of pharmaceuticals.

The evolution of Tamiflu synthesis, 20 years on: Advent of enabling technologies the last piece of the puzzle?

Influenza is a serious respiratory disease responsible for significant morbidity and mortality due to both annual epidemics and pandemics; its treatment involves the use of neuraminidase inhibitors. (-)-Oseltamivir phosphate (Tamiflu) approved in 1999, is one of the most potent oral anti-influenza neuraminidase inhibitors. Consequently, more than 70 Tamiflu synthetic procedures have been developed to date. Herein, we highlight the evolution of Tamiflu synthesis since its discovery over 20 years ago in the quest for a truly efficient, safe, cost-effective and environmentally benign synthetic procedure. We have selected a few representative routes to give a clear account of the past, present and the future with the advent of enabling technologies.

Flow chemistry as a tool to access novel chemical space for drug discovery

This perspective scrutinizes flow chemistry as a useful tool for medicinal chemists to expand the current chemical capabilities in drug discovery. This technology has demonstrated his value not only for the traditional reactions used in Pharma for the last 20 years, but also for bringing back to the lab underused chemistries to access novel chemical space. The combination with other technologies, such as photochemistry and electrochemistry, is opening new avenues for reactivity that will smoothen the access to complex molecules. The introduction of all these technologies in automated platforms will improve the productivity of medicinal chemistry labs reducing the cycle times to get novel and differentiated bioactive molecules, accelerating discovery cycle times.