Solvent Minimized Synthesis of Amides by Reactive Extrusion

Herein, we report on the translation of a small scale ball-milled amidation protocol into a large scale continuous reactive extrusion process. Critical components to the successful translation were: a) understanding how the different operating parameters of a twin-screw extruder should be harnessed to control prolonged continuous operation, and b) consideration of the physical form of the input materials. The amidation reaction is applied to 36 amides spanning a variety of physical form combinations (liquid-liquid, solid-liquid and solid-solid). Following this learning process, we have developed an understanding for the translation of each physical form combination and demonstrated a 7-hour reactive extrusion process for the synthesis of an amide on 500 gram scale (1.3 mols of product).

Tinkering with Mechanochemical Tools for Scale Up

Mechanochemistry provides an environmentally benign platform to develop more sustainable chemical processes by limiting raw materials, energy use, and waste generation while using physically smaller equipment. A continuously growing research community has steadily showcased examples of beneficial mechanochemistry applications at both the laboratory and the preparative scale. In contrast to solution-based chemistry, mechanochemical processes have not yet been standardized, and thus scaling up is still a nascent discipline. The purpose of this Minireview is to highlight similarities, differences and challenges of the various approaches that have been successfully applied for a range of chemical applications at various scales. We hope to provide a discussion starting point for those interested in further developing mechanochemical processes for commercial use and/or industrialisation.

The Mechanochemical Fries Rearrangement: Manipulating Isomer Ratios in the Synthesis of p-Hydroxyacetophenone at Different Scales

Herein, the first mechanochemical Fries rearrangement for the industrially important synthesis of para-hydroxyacetophenone, inside a ball mill and a twin-screw extruder, is presented. Our approach leads to a yield of 62 % in as little as 90 minutes while liquid-assisted grinding can shift the isomer ratio resulting in an excess of the desired para-product. The multigram scale-up by extrusion leads to 61 % yield in only three minutes while completely avoiding solvents. The extrusion temperature can even further be reduced by combining extrusion with a subsequent ageing step.

The "η-sweet-spot" (ηmax) in liquid-assisted mechanochemistry: polymorph control and the role of a liquid additive as either a catalyst or an inhibitor in resonant acoustic mixing (RAM)

Resonant acoustic mixing (RAM) offers a simple, efficient route for mechanochemical synthesis in the absence of milling media or bulk solvents. Here, we show the use of RAM to conduct the copper-catalysed coupling of sulfonamides and carbodiimides. This coupling was previously reported to take place only by mechanochemical ball milling, while in conventional solution environments it is not efficient, or does not take place at all. The results demonstrate RAM as a suitable methodology to conduct reactions previously accessed only by ball milling and provide a detailed, systematic overview of how the amount of liquid additive, measured by the ratio of liquid volume to weight of reactants (η, in μL mg^-1), can affect the course of a mechanochemical reaction and the polymorphic composition of its product. Switching from ball milling to RAM allowed for the discovery of a new polymorph of the model sulfonylguanidine obtained by catalytic coupling of di(cyclohexyl)carbodiimide (DCC) and p-toluenesulfonamide, and the ability to control reaction temperature in RAM enabled in situ control of the polymorphic behaviour of this nascent product. We show that the reaction conversion for a given reaction time does not change monotonically but, instead, achieves a maximum for a well-defined η-value. This "η-sweet-spot" of conversion is herein designated η_max. The herein explored reactions demonstrate sensitivity to η on the order of 0.01 μL mg^-1, which corresponds to an amount of liquid additive below 5 mol% compared to the reactants, and is at least one to two orders of magnitude lower than the η-value typically considered in the design of liquid-assisted ball milling mechanochemical reactions. Such sensitivity suggests that strategies to optimise liquid-assisted mechanochemical reactions should systematically evaluate η-values at increments of 0.01 μL mg^-1, or even finer. At η-values other than η_max the reaction conversion drops off, demonstrating that the same liquid additive can act either as a catalyst or an inhibitor of a mechanochemical reaction, depending on the amount.

Processing Poly (ethylene terephthalate) Waste into Functional Carbon Materials by Mechanochemical Extrusion

With the plastic pollution becoming worse, the upcycling of plastic waste into functional materials is a great challenge. Herein, a mechanochemical extrusion approach was developed for processing poly(ethylene terephthalate) (PET) waste into porous carbon materials. The essence of the cyclic extrusion approach lies in the solvent-free mixing of thermoplastic PET with pore-directing additive (e. g., silica or zinc chloride) at the molecular level. PET waste could be upcycled into functional carbon with high surface area (up to 1001 m²  g^-1 ), specific shapes, and preferred mechanical strength, after cyclic extrusion and carbonization. Moreover, metal species could be well dispersed onto porous carbons through solvent-free extrusion, different from traditional loading methods (impregnation method, deposition-precipitation method). In this manner, mechanochemical extrusion provides an alternative for upcycling plastic waste into value-added materials.

Mechanochemistry: New Tools to Navigate the Uncharted Territory of "Impossible" Reactions

Mechanochemical transformations have made chemists enter unknown territories, forcing a different chemistry perspective. While questioning or revisiting familiar concepts belonging to solution chemistry, mechanochemistry has broken new ground, especially in the panorama of organic synthesis. Not only does it foster new "thinking outside the box", but it also has opened new reaction paths, allowing to overcome the weaknesses of traditional chemistry exactly where the use of well-established solution-based methodologies rules out progress. In this Review, the reader is introduced to an intriguing research subject not yet fully explored and waiting for improved understanding. Indeed, the study is mainly focused on organic transformations that, although impossible in solution, become possible under mechanochemical processing conditions, simultaneously entailing innovation and expanding the chemical space.

Solvent‐Free Synthesis of Core‐Functionalised Naphthalene Diimides by Using a Vibratory Ball Mill: Suzuki, Sonogashira and Buchwald–Hartwig Reactions

Solvent‐free synthesis by using a vibratory ball mill (VBM) offers the chance to access new chemical reactivity, whilst reducing solvent waste and minimising reaction times. Herein, we report the core functionalisation of N,N’‐bis(2‐ethylhexyl)‐2,6‐dibromo‐1,4,5,8‐naphthalenetetracarboxylic acid (Br₂‐NDI) by using Suzuki, Sonogashira and Buchwald–Hartwig coupling reactions. The products of these reactions are important building blocks in many areas of organic electronics including organic light‐emitting diodes (OLEDs), organic field‐effect transistors (OFETs) and organic photovoltaic cells (OPVCs). The reactions proceed in as little as 1 h, use commercially available palladium sources (frequently Pd(OAc)₂) and are tolerant to air and atmospheric moisture. Furthermore, the real‐world potential of this green VBM protocol is demonstrated by the double Suzuki coupling of a monobromo(NDI) residue to a bis(thiophene) pinacol ester. The resulting dimeric NDI species has been demonstrated to behave as an electron acceptor in functioning OPVCs.

Continuous flow mechanochemistry: reactive extrusion as an enabling technology in organic synthesis

Rapid and wide-ranging developments have established mechanochemistry as a powerful avenue in sustainable organic synthesis. This is primarily due to unique opportunities which have been offered in solvent-free - or highly solvent-minimised - reaction systems. Nevertheless, despite elegant advances in ball-milling technology, limitations in scale-up still remain. This tutorial review covers the first reports into the translation from "batch-mode" ball-milling to "flow-mode" reactive extrusion, using twin-screw extrusion.

2,2'-Bipyridine derived doubly B ← N fused bisphosphine-chalcogenides, [C5H3N(BF2){NCH2P(E)Ph2}]2 (E = O, S, Se): tuning of structural features and photophysical studies

2,2'-Bipyridine based bisphosphine [C₅H₃N{N(H)CH₂PPh₂}]₂ (1) and its bischalcogenide derivatives [C₅H₃N{N(H)CH₂P(E)Ph₂}]₂ (2, E = O; 3, E = S; 4, E = Se) were synthesized, and further reacted with BF₃·Et₂O/Et₃N to form doubly B ← N fused compounds [C₅H₃N(BF₂){NCH₂P(E)Ph₂}]₂ (5, E = O; 6, E = S; 7, E = Se) in excellent yields. The influence of the PE bonds on the electronic properties of the doubly B ← N fused systems and their structural features were investigated in detail, supported by extensive experimental and computational studies. Compound 6 exhibited a very high quantum yield of ϕ = 0.56 in CH₂Cl₂, whereas compound 7 showed a least quantum yield of ϕ = 0.003 in acetonitrile. Density functional theory (DFT) calculations demonstrated that the LUMO/HOMO of compounds 5-7 mostly delocalized over the entire π-conjugated frameworks. The involvement of PE bonds in the HOMO energy level of these compounds follows the order: PO < PS < PSe. Time-correlated single photon counting (TCSPC) experiments of compounds 5-7 revealed the singlet lifetime of 4.26 ns for 6, followed by 4.03 ns for 5 and a lowest value of 2.18 ns (τ₁) and 0.47 ns (τ₂) with a double decay profile for 7. Our findings provide important strategies for the design of highly effective B ← N bridged compounds and tuning their photophysical properties by oxidizing phosphorus with different chalcogens. Compounds 5 and 6 have been employed as green emitters (λ_em = 515 nm) in fluorescent organic light-emitting diodes (OLEDs). For compound 5, doped into the poly(9-vinylcarbazole) (PVK) matrix with 5 wt% doping concentration, nearly 90 Cd m^-2 luminance with 0.022% external quantum efficiency (EQE) was achieved. The best performance was observed for compound 6 doped into PVK by 1 wt% having a maximum luminance of 350 Cd m^-2 and a similar EQE value.

Room temperature synthesis of perylene diimides facilitated by high amic acid solubility

A novel protocol for the synthesis of perylene diimides (PDIs), by reacting perylene dianhydride (PDA) with aliphatic amines is reported. Full conversions were obtained at temperatures between 20 and 60 °C, using DBU as the base in DMF or DMSO. A “green” synthesis of PDIs, that runs at higher temperatures, was developed using K₂CO₃ in DMSO. The reaction sequence for the imidization process, via perylene amic acid intermediates (PAAs), has been confirmed experimentally aided by the synthesis and full characterization of stable model amic acid salts and amic esters. Kinetic studies, using absorption spectroscopy, have established that PDI formation proceeds via fast amic acid formation, followed by a slow conversion to imides. Solubility of the intermediate PAA salts is found to be low and rate-limiting. Based on this finding, quantitative PDI synthesis at room temperature was achieved by diluting the reaction mixture with water, the solvent in which PAA salts have better solubility. Thus, the otherwise harsh synthesis of PDIs has been transformed into an extremely convenient functional group tolerant and highly efficient reaction that runs at room temperature.

Perylene diimides (PDIs) are synthesised at room temperature and obtained in quantitative yields after a single filtration. High solubility of the intermediate amic acid salts 5 and 9 is key to the success of this novel synthesis.

Synthesis and Computational Characterization of Organic UV-Dyes for Cosensitization of Transparent Dye-Sensitized Solar Cells

The fabrication of colorless and see-through dye-sensitized solar cells (DSCs) requires the photosensitizers to have little or no absorption in the visible light region of the solar spectrum. However, a trade-off between transparency and power conversion efficiency (PCE) has to be tackled, since most transparent DSCs are showing low PCE when compared to colorful and opaque DSCs. One strategy to increase PCE is applying two cosensitizers with selective conversion of the UV and NIR radiation, therefore, the non-visible part only is absorbed. In this study, we report synthesis of novel five UV-selective absorbers, based on diimide and Schiff bases incorporating carboxyl and pyridyl anchoring groups. A systematic computational investigation using density functional theory (DFT) and time-dependent DFT approaches was employed to evaluate their prospect of application in transparent DSCs. Experimental UV/Vis absorption spectra showed that all dyes exhibit an absorption band covering the mid/near-UV region of solar spectrum, with a bathochromic shift and a hyperchromic shifts for Py-1 dye. Computational results showed that the studied dyes satisfied the basic photophysical and energetics requirements of operating DSC as well as the stability and thermodynamical spontaneity of adsorption onto surface of TiO2. However, results revealed outperformance of the thienothiophene core-containing Py-1 UV-dye, owing to its advantageous structural attributes, improved conjugation, intense emission, large Stokes shift and maximum charge transferred to the anchor. Chemical compatibility of Py-1 dye was then theoretically investigated as a potential cosensitizer of a reference VG20-C2 NIR-dye. By the judicious selection of pyridyl anchor-based UV-absorber (Py-1) and carboxyl anchor-based NIR-absorber (VG20), the advantage of the optical complementarity and selectivity of different TiO2-adsorption-site (Lewis- and Bronsted-acidic) can be achieved. An improved overall PCE is estimated accordingly.

Mechanochemical Synthesis of Organic Dyes and Fluorophores

The syntheses of dyes and fluorophores have significant commercial importance. In recent years, mechanochemistry has emerged as a green and sustainable alternative for the synthesis of conventional dyes, new fluorophores, and also synthetic modification of known dyes for their use as chemosensors. The dyestuffs based on BODIPYs, rhodamine, fluorescein, perylenedimides, coumarins, benzothiazoles, etc. were synthesized or derivatized by grinding or milling. The synopsis aims to pay key attention to their synthesis and the applications as chemosensors will be briefly covered.

Continuous, Large-Scale, and High Proportion of Bioinspired Phosphogypsum Composites via Reactive Extrusion

Biological matter evolution provides an idea for the human design and synthesis of new materials. However, biomimetic materials only stay in laboratory-scale models, and their large-scale industrial applications are yet to be realized. Here, inspired by nacre's architecture, we report a continuous, large-scale method to fabricate phosphogypsum composites by reactive extrusion strategy. After curing for seven days, with more than 50 wt% of beta-hemihydrate phosphogypsum (β-HPG), the compressive strength and softening coefficient were 24.98 MPa and 0.78, increasing by 110.0% and 20.0%, respectively, compared to the pouring method. The results show that the screw extrusion process can improve the mechanical strength and waterproof properties of β-HPG hydration specimens without any special chemical admixtures and cements.

Direct Amidation of Esters by Ball Milling*

The direct mechanochemical amidation of esters by ball milling is described. The operationally simple procedure requires an ester, an amine, and substoichiometric KOtBu and was used to prepare a large and diverse library of 78 amide structures with modest to excellent efficiency. Heteroaromatic and heterocyclic components are specifically shown to be amenable to this mechanochemical protocol. This direct synthesis platform has been applied to the synthesis of active pharmaceutical ingredients (APIs) and agrochemicals as well as the gram-scale synthesis of an active pharmaceutical, all in the absence of a reaction solvent.

Sodium Butylated Hydroxytoluene: A Functional Group Tolerant, Eco-Friendly Base for Solvent-Free, Pd-Catalysed Amination

NaBHT (sodium 2,6-di-tert-butyl-4-methylphenolate), a strong, but hindered and lipophilic base, has been effectively paired with similarly lipophilic, high-reactivity Pd-NHC (N-heterocyclic carbene) catalysts to produce an ideal combination for performing solvent-free (melt) cross-coupling amination. The mild nucleophilicity of NaBHT, coupled with the anti-oxidant properties of its conjugate acid byproduct, BHT means the process seems to have no functional group incompatibilities. Highly effective coupling of base-sensitive and redox-active functional groups was observed in all cases with only 0.1-0.2 mol percent catalyst. Comparisons using the standard base for this reaction, KOtBu, led to poor couplings or complete degradation in most applications - only NaBHT works.

Sustainability Assessment of Mechanochemistry by Using the Twelve Principles of Green Chemistry

In recent years, mechanochemistry has been growing into a widely accepted alternative for chemical synthesis. In addition to their efficiency and practicality, mechanochemical reactions are also recognized for their sustainability. The association between mechanochemistry and Green Chemistry often originates from the solvent-free nature of most mechanochemical protocols, which can reduce waste production. However, mechanochemistry satisfies more than one of the Principles of Green Chemistry. In this Review we will present a series of examples that will clearly illustrate how mechanochemistry can significantly contribute to the fulfillment of Green Chemistry in a more holistic manner.

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.

Practical allylation with unactivated allylic alcohols under mild conditions

A practical palladium/calcium catalytic system was developed for dehydrative allylation with unactivated allylic alcohols.

Mechanochemical methods for the transfer of electrons and exchange of ions: inorganic reactivity from nanoparticles to organometallics

For inorganic metathesis and reduction reactivity, mechanochemistry is demonstrating great promise towards both nanoparticles and organometallics syntheses.