Enhancement of Chemical Selectivity by Microreactors

Co-electrolysis of seawater and carbon dioxide inside a microfluidic reactor to synthesize speciality organics

We report co-electrolysis of seawater and carbon dioxide (CO₂) gas in a solar cell-integrated membraneless microfluidic reactor for continuous synthesis of organic products. The microfluidic reactor was fabricated using polydimethylsiloxane substrate comprising of a central microchannel with a pair of inlets for injection of CO₂ gas and seawater and an outlet for removal of organic products. A pair of copper electrodes were inserted into microchannel to ensure its direct interaction with incoming CO₂ gas and seawater as they pass into the microchannel. The coupling of solar cell panels with electrodes generated a high-intensity electrical field across the electrodes at low voltage, which facilitated the co-electrolysis of CO₂ and seawater. The paired electrolysis of CO₂ gas and seawater produced a range of industrially important organics under influence of solar cell-mediated external electric field. The, as synthesized, organic compounds were collected downstream and identified using characterization techniques. Furthermore, the probable underlying electrochemical reaction mechanisms near the electrodes were proposed for synthesis of organic products. The inclusion of greenhouse CO₂ gas as reactant, seawater as electrolyte, and solar energy as an inexpensive electric source for co-electrolysis initiation makes the microreactor a low-cost and sustainable alternative for CO₂ sequestration and synthesis of organic compounds.

Synthesis of Picramide Using Nitration and Ammonolysis in Continuous Flow

This paper describes a safer, scalable and continuous process for synthesis of picramide. The process consists of two steps: step-1. nitration of p-nitroanisole (PNAN) to 2,4,6-trinitrianisole (TNAN); step-2. ammonolysis of TNAN to picramide. Both the steps were optimized in flow, with yield of 90% and 98% in step-1 and step-2 respectively. Picramide with HPLC purity greater than 99% was obtained. When compared with batch, in step-1, flow process provided significant advantage in selectivity and yield. The optimized flow process was scaled to 25 g/hr production rate in a laboratory flow reactor. The method can be considered fit for the safe production of picramide at commercial scale.

Enhancement of Fluid Mixing with U-Shaped Channels on a Rotating Disc

In this study, centrifugal microfluidics with a simple geometry of U-shaped structure was designed, fabricated and analyzed to attain rapid and efficient fluid mixing. Visualization experiments together with numerical simulations were carried out to investigate the mixing behavior for the microfluidics with single, double and triple U-shaped structures, where each of the U-structures consisted of four consecutive 90° bends. It is found that the U-shaped structure markedly enhances mixing by transverse secondary flow that is originated from the Coriolis-induced vortices and further intensified by the Dean force generated as the stream turns along the 90° bends. The secondary flow becomes stronger with increasing rotational speed and with more U-shaped structures, hence higher mixing performance. The mixing efficiency measured for the three types of mixers shows a sharp increase with increasing rotational speed in the lower range. As the rotational speed further increases, nearly complete mixing can be achieved at 600 rpm for the triple-U mixer and at 720 rpm for the double-U mixer, while a maximum efficiency level of 83-86% is reached for the single-U mixer. The simulation results that reveal detailed characteristics of the flow and concentration fields are in good agreement with the experiments.

Accelerating Biphasic Biocatalysis through New Process Windows

Process intensification through continuous flow reactions has increased the production rates of fine chemicals and pharmaceuticals. Catalytic reactions are accelerated through an unconventional and unprecedented use of a high-performance liquid/liquid counter current chromatography system. Product generation is significantly faster than in traditional batch reactors or in segmented flow systems, which is exemplified through stereoselective phase-transfer catalyzed reactions. This methodology also enables the intensification of biocatalysis as demonstrated in high yield esterifications and in the sesquiterpene cyclase-catalyzed synthesis of sesquiterpenes from farnesyl diphosphate as high-value natural products with applications in medicine, agriculture and the fragrance industry. Product release in sesquiterpene synthases is rate limiting due to the hydrophobic nature of sesquiterpenes, but a biphasic system exposed to centrifugal forces allows for highly efficient reactions.

Design, Fundamental Principles of Fabrication and Applications of Microreactors

This study highlights the development of small-scale reactors, in the form of microstructures with microchannel networking. Microreactors have achieved an impressive reputation, regarding chemical synthesis ability and their applications in the engineering, pharmaceutical, and biological fields. This review elaborates on the fabrication, construction, and schematic fundamentals in the design of the microreactors and microchannels. The materials used in the fabrication or construction of the microreactors include silicon, polymer, and glass. A general review of the application of microreactors in medical, biological, and engineering fields is carried out and significant improvements in these areas are reported. Finally, we highlight the flow patterns, mixing, and scaling-up of multiphase microreactor developments, with emphasis on the more significant industrial applications.

Anionic Polymerization Using Flow Microreactors

Flow microreactors are expected to make a revolutionary change in chemical synthesis involving various fields of polymer synthesis. In fact, extensive flow microreactor studies have opened up new possibilities in polymer chemistry including cationic polymerization, anionic polymerization, radical polymerization, coordination polymerization, polycondensation and ring-opening polymerization. This review provides an overview of flow microreactors in anionic polymerization and their various applications.

Inline Reaction Monitoring of Amine-Catalyzed Acetylation of Benzyl Alcohol Using a Microfluidic Stripline Nuclear Magnetic Resonance Setup

We present an in-depth study of the acetylation of benzyl alcohol in the presence of N, N-diisopropylethylamine (DIPEA) by nuclear magnetic resonance (NMR) monitoring of the reaction from 1.5 s to several minutes. We have adapted the NMR setup to be compatible to microreactor technology, scaling down the typical sample volume of commercial NMR probes (500 μL) to a microfluidic stripline setup with 150 nL detection volume. Inline spectra are obtained to monitor the kinetics and unravel the reaction mechanism of this industrially relevant reaction. The experiments are combined with conventional 2D NMR measurements to identify the reaction products. In addition, we replace DIPEA with triethylamine and pyridine to validate the reaction mechanism for different amine catalysts. In all three acetylation reactions, we find that the acetyl ammonium ion is a key intermediate. The formation of ketene is observed during the first minutes of the reaction when tertiary amines were present. The pyridine-catalyzed reaction proceeds via a different mechanism.

Synthesis of Functionalized Ketones from Acid Chlorides and Organolithiums by Extremely Fast Micromixing

Synthesis of ketones containing various functional groups from acid chlorides bearing electrophilic functional groups and functionalized organolithiums was achieved using a flow microreactor system. Extremely fast mixing is important for high chemoselectivity.

Suzuki–Miyaura Coupling Using Monolithic Pd Reactors and Scaling-Up by Series Connection of the Reactors

The space integration of the lithiation of aryl halides, the borylation of aryllithiums, and Suzuki–Miyaura coupling using a Pd catalyst supported by a polymer monolith flow reactor without using an intentionally added base was achieved. To scale up the process, a series connection of the monolith Pd reactor was examined. To suppress the increase in the pressure drop caused by the series connection, a monolith reactor having larger pore sizes was developed by varying the temperature of the monolith preparation. The monolithic Pd reactor having larger pore sizes enabled Suzuki–Miyaura coupling at a higher flow rate because of a lower pressure drop and, therefore, an increase in productivity. The present study indicates that series connection of the reactors with a higher flow rate serves as a good method for increasing the productivity without decreasing the yields.

Experimental Studies of Ethyl Acetate Saponification Using Different Reactor Systems: The Effect of Volume Flow Rate on Reactor Performance and Pressure Drop

Microreactors intensify chemical processes due to improved flow regimes, mass and heat transfer. In the present study, the effect of the volume flow rate on reactor performance in different reactors (the T-shaped reactor, the interdigital microreactor and the chicane microreactor) was investigated. For this purpose, the saponification reaction in these reactor systems was considered. Experimental results were verified using the obtained kinetic model. The reactor system with a T-shaped reactor shows good performance only at high flow rates, while the experimental setups with the interdigital and the chicane microreactors yield good performance throughout the whole range of volume flow rates. However, microreactors exhibit a higher pressure drop, indicating higher mechanical flow energy consumption than seen using a T-shaped reactor.

Continuous flow chemistry: where are we now? Recent applications, challenges and limitations

A general outlook of the changing face of chemical synthesis is provided in this article through recent applications of continuous flow processing in both industry and academia. The benefits, major challenges and limitations associated with the use of this mode of processing are also given due attention as an attempt to put into perspective the current position of continuous flow processing, either as an alternative or potential combinatory technology for batch processing.

Tuning a Protein-Labeling Reaction to Achieve Highly Site Selective Lysine Conjugation

Activated esters are widely used to label proteins at lysine side chains and N termini. These reagents are useful for labeling virtually any protein, but robust reactivity toward primary amines generally precludes site-selective modification. In a unique case, fluorophenyl esters are shown to preferentially label human kappa antibodies at a single lysine (Lys188) within the light-chain constant domain. Neighboring residues His189 and Asp151 contribute to the accelerated rate of labeling at Lys188 relative to the ≈40 other lysine sites. Enriched Lys188 labeling can be enhanced from 50-70 % to >95 % by any of these approaches: lowering reaction temperature, applying flow chemistry, or mutagenesis of specific residues in the surrounding protein environment. Our results demonstrated that activated esters with fluoro-substituted aromatic leaving groups, including a fluoronaphthyl ester, can be generally useful reagents for site-selective lysine labeling of antibodies and other immunoglobulin-type proteins.

Thermoformed fluoropolymer tubing for in-line mixing

We present a thermoforming method to make in-line micromixer in commercial fluoropolymer tubing.

Visible-Light Photocatalytic Decarboxylation of α,β-Unsaturated Carboxylic Acids: Facile Access to Stereoselective Difluoromethylated Styrenes in Batch and Flow

The development of synthetic methodologies which provide access to both stereoisomers of α,β-disubstituted olefins is a challenging undertaking. Herein, we describe the development of an operationally simple and stereoselective synthesis of difluoromethylated styrenes via a visible-light photocatalytic decarboxylation strategy using fac-Ir(ppy)₃ as the photocatalyst. Meta- and para-substituted cinnamic acids provide the expected E-isomer. In contrast, ortho-substituted cinnamic acids yield selectively the less stable Z-product, whereas the E-isomer can be obtained via continuous-flow processing through accurate control of the reaction time. Furthermore, our protocol is amenable to the decarboxylative difluoromethylation of aryl propiolic acids.

A Modular Flow Design for the meta-Selective C-H Arylation of Anilines

Described herein is an effective and practical modular flow design for the meta-selective C-H arylation of anilines. The design consists of four continuous-flow modules (i.e., diaryliodonium salt synthesis, meta-selective C-H arylation, inline copper extraction, and aniline deprotection) which can be operated either individually or consecutively to provide direct access to meta-arylated anilines. With a total residence time of 1 hour, the desired product could be obtained in high yield and excellent purity without the need for column chromatography, and the residual copper content meets the standards for parenterally administered pharmaceutical substances.

Contribution of microreactor technology and flow chemistry to the development of green and sustainable synthesis

Microreactor technology and flow chemistry could play an important role in the development of green and sustainable synthetic processes. In this review, some recent relevant examples in the field of flash chemistry, catalysis, hazardous chemistry and continuous flow processing are described. Selected examples highlight the role that flow chemistry could play in the near future for a sustainable development.

A Rapid Magnetofluidic Micromixer Using Diluted Ferrofluid

Effective and rapid mixing is essential for various chemical and biological assays. The present work describes a simple and low-cost micromixer based on magnetofluidic actuation. The device takes advantage of magnetoconvective secondary flow, a bulk flow induced by an external magnetic field, for mixing. A superparamagnetic stream of diluted ferrofluid and a non-magnetic stream are introduced to a straight microchannel. A permanent magnet placed next to the microchannel induced a non-uniform magnetic field. The magnetic field gradient and the mismatch in magnetic susceptibility between the two streams create a body force, which leads to rapid and efficient mixing. The micromixer reported here could achieve a high throughput and a high mixing efficiency of 88% in a relatively short microchannel.

Liquid–liquid microflow reaction engineering

Engineering characteristics of liquid–liquid microflow and its advantages in chemical reactions.

Micromixing enables chemoselective reactions of difunctional electrophiles with functional aryllithiums

Generation of highly unstable functional aryllithiums followed by chemoselective reactions with difunctional electrophiles were successfully achieved using flow microreactor systems equipped with micromixers to give highly functionalized compounds without protecting functional groups.

Applications of Continuous-Flow Photochemistry in Organic Synthesis, Material Science, and Water Treatment

Continuous-flow photochemistry in microreactors receives a lot of attention from researchers in academia and industry as this technology provides reduced reaction times, higher selectivities, straightforward scalability, and the possibility to safely use hazardous intermediates and gaseous reactants. In this review, an up-to-date overview is given of photochemical transformations in continuous-flow reactors, including applications in organic synthesis, material science, and water treatment. In addition, the advantages of continuous-flow photochemistry are pointed out and a thorough comparison with batch processing is presented.

Integration of borylation of aryllithiums and Suzuki–Miyaura coupling using monolithic Pd catalyst

Integration of the preparation of arylboronic esters and Suzuki–Miyaura coupling using monolithic Pd catalyst was successfully achieved.

Switching between intermolecular and intramolecular reactions using flow microreactors: lithiation of 2-bromo-2′-silylbiphenyls

Switching between the intermolecular reaction and the intramolecular reaction was achieved at will using flow microreactors.