1
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Design of a Compact Microreactor/Heat-Exchanger for a Distributed Production of Liquid Hydrocarbons from Methanol. REACTIONS 2021. [DOI: 10.3390/reactions2040027] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
The paper compares conceptual designs of a microstructured reactor/heat-exchanger for the small-scale production of C8+ range hydrocarbons from methanol over H-ZSM-5 catalytic coatings. In these designs, air was used as a cooling fluid in the adjacent cooling channels. The heat transfer characteristics of a single-zone reactor (with channels 500 μm in diameter) and a two-zone reactor (with an additional coolant inlet) have been compared. A single reaction zone was not able to reduce the temperature gradient below 15 K, while a two-zone configuration, with a counter-current fluid flow in the upstream section and co-current flow in the downstream section, demonstrated a near-isothermal behaviour, with a mean temperature of 653 K.
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2
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Scale-up of micro- and milli-reactors: An overview of strategies, design principles and applications. CHEMICAL ENGINEERING SCIENCE: X 2021. [DOI: 10.1016/j.cesx.2021.100097] [Citation(s) in RCA: 33] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/29/2022] Open
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3
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Maity S, Bhuyan T, Bhattacharya R, Bandyopadhyay D. Self-Organized Implanting of Micro/Nanofiltration Membranes in Advanced Flow μ-Reactors. ACS APPLIED MATERIALS & INTERFACES 2021; 13:19430-19442. [PMID: 33851814 DOI: 10.1021/acsami.1c01078] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/12/2023]
Abstract
A low-cost, simple, and one-step synthesis of cellulose acetate nanoparticles (CANPs) has been invented using a continuous-flow advanced microfluidic reactor. For this purpose, the CANPs are self-organized inside a cross-junction microchannel by flowing cellulose acetate (CA) dissolved in N,N-dimethylformamide (DMF) through the axial inlet and the antisolvent water through the pair of side inlets. The preferential solubility (insolubility) of DMF (CA) to antisolvent water stimulates the in situ synthesis of CANPs at the DMF/water miscible interface following a phase-inversion process. Subsequently, nanofiltration, ultrafiltration, and microfiltration membranes of different porosities and permeabilities have been prepared from freshly synthesized CANPs. The porosity, thickness, transparency, and wettability of the membranes are tuned by varying the thickness of the membranes, size of the nanoparticles, and the porosity of the membranes. The as-synthesized CANPs show enhanced bactericidal properties with and without loading an external drug, curcumin, which has been validated against the Gram-negative Pseudomonas aeruginosa species. Importantly, enabling a pulsatile flow during the synthesis, the CANPs are embedded as nanofiltration membranes inside the microfluidic channel. Such microfluidic devices have been used to separate a corrosive dye from water. Concisely, the proposed in situ synthesis of CANPs in the continuous-flow microfluidic reactors, their usage for fabricating membranes with tunable wettability and transparency, and their subsequent integration into the microfluidic channel show the potential of the invention for a host of applications related to health care and environmental remediation.
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Affiliation(s)
- Surjendu Maity
- Centre for Nanotechnology, Indian Institute of Technology Guwahati, Assam 781039, India
| | - Tamanna Bhuyan
- Centre for Nanotechnology, Indian Institute of Technology Guwahati, Assam 781039, India
| | - Rishav Bhattacharya
- Department of Chemical Engineering, Indian Institute of Technology Guwahati, Assam 781039, India
| | - Dipankar Bandyopadhyay
- Centre for Nanotechnology, Indian Institute of Technology Guwahati, Assam 781039, India
- Department of Chemical Engineering, Indian Institute of Technology Guwahati, Assam 781039, India
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4
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Hydrogenation of Aqueous Acetic Acid over Ru-Sn/TiO2 Catalyst in a Flow-Type Reactor, Governed by Reverse Reaction. Catalysts 2020. [DOI: 10.3390/catal10111270] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022] Open
Abstract
Ru-Sn/TiO2 is an effective catalyst for hydrogenation of aqueous acetic acid to ethanol. In this paper, a similar hydrogenation process was investigated in a flow-type rather than a batch-type reactor. The optimum temperature was 170 °C for the batch-type reactor because of gas production at higher temperatures; however, for the flow-type reactor, the ethanol yield increased with reaction temperature up to 280 °C and then decreased sharply above 300 °C, owing to an increase in the acetic acid recovery rate. The selectivity for ethanol formation was improved over the batch process, and an ethanol yield of 98 mol % was achieved for a 6.7 min reaction (cf. 12 h for batch) (liquid hourly space velocity: 1.23 h−1). Oxidation of ethanol to acetic acid (i.e., the reverse reaction) adversely affected the hydrogenation. On the basis of these results, hydrogenation mechanisms that include competing side reactions are discussed in relation to the reactor type. These results will help the development of more efficient catalytic procedures. This method was also effectively applied to hydrogenation of lactic acid to propane-1,2-diol.
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5
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Scaling continuous API synthesis from milligram to kilogram: extending the enabling benefits of micro to the plant. J Flow Chem 2020. [DOI: 10.1007/s41981-019-00060-x] [Citation(s) in RCA: 27] [Impact Index Per Article: 6.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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6
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Rojahn P, Ruß O, Gössl L, Kroschel M, Herbstritt F, Heck J, Schael F. Mixing Performance in a Distributed-Feed Plate-Type Reactor with Multinozzle Injection for Fine Chemical Production Scale. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.9b06407] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/03/2023]
Affiliation(s)
- Patrick Rojahn
- Chemical Reaction Engineering, Department of Chemical Engineering and Biotechnology, Hochschule Darmstadt-University of Applied Sciences, Stephanstraße 7, D-64295 Darmstadt, Germany
| | - Oliver Ruß
- Chemical Reaction Engineering, Department of Chemical Engineering and Biotechnology, Hochschule Darmstadt-University of Applied Sciences, Stephanstraße 7, D-64295 Darmstadt, Germany
| | - Lars Gössl
- Chemical Reaction Engineering, Department of Chemical Engineering and Biotechnology, Hochschule Darmstadt-University of Applied Sciences, Stephanstraße 7, D-64295 Darmstadt, Germany
| | - Matthias Kroschel
- Ehrfeld Mikrotechnik GmbH, Mikroforum Ring 1, D-55234 Wendelsheim, Germany
| | - Frank Herbstritt
- Ehrfeld Mikrotechnik GmbH, Mikroforum Ring 1, D-55234 Wendelsheim, Germany
| | - Joachim Heck
- Ehrfeld Mikrotechnik GmbH, Mikroforum Ring 1, D-55234 Wendelsheim, Germany
| | - Frank Schael
- Chemical Reaction Engineering, Department of Chemical Engineering and Biotechnology, Hochschule Darmstadt-University of Applied Sciences, Stephanstraße 7, D-64295 Darmstadt, Germany
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7
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Shukla CA, Pal S, Kulkarni AA. Hydrodynamics and Selectivity Engineering of a Multipoint Dosing Flow Reactor. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b04431] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Chinmay A. Shukla
- Academy of Scientific and Innovative Research (AcSIR), CSIR-NCL Campus, Pune 411008, India
- Chem. Eng. & Proc. Dev. Div., CSIR-National Chemical Laboratory, Dr. Homi Bhaba Road, Pashan, Pune 411008, India
| | - Sayan Pal
- Academy of Scientific and Innovative Research (AcSIR), CSIR-NCL Campus, Pune 411008, India
- Chem. Eng. & Proc. Dev. Div., CSIR-National Chemical Laboratory, Dr. Homi Bhaba Road, Pashan, Pune 411008, India
| | - Amol A. Kulkarni
- Academy of Scientific and Innovative Research (AcSIR), CSIR-NCL Campus, Pune 411008, India
- Chem. Eng. & Proc. Dev. Div., CSIR-National Chemical Laboratory, Dr. Homi Bhaba Road, Pashan, Pune 411008, India
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8
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A systematic reactor design approach for the synthesis of active pharmaceutical ingredients. Eur J Pharm Biopharm 2018; 126:75-88. [DOI: 10.1016/j.ejpb.2017.05.007] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/02/2016] [Revised: 03/08/2017] [Accepted: 05/15/2017] [Indexed: 11/15/2022]
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9
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Pedersen MJ, Born S, Neuenschwander U, Skovby T, Mealy MJ, Kiil S, Dam-Johansen K, Jensen KF. Optimization of Grignard Addition to Esters: Kinetic and Mechanistic Study of Model Phthalide Using Flow Chemistry. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.8b00564] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Michael J. Pedersen
- H. Lundbeck A/S, Oddenvej 182, 4500 Nykøbing Sjælland, Denmark
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Building 229, 2800 Kongens Lyngby, Denmark
| | - Stephen Born
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
| | - Ulrich Neuenschwander
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
| | - Tommy Skovby
- H. Lundbeck A/S, Oddenvej 182, 4500 Nykøbing Sjælland, Denmark
| | | | - Søren Kiil
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Building 229, 2800 Kongens Lyngby, Denmark
| | - Kim Dam-Johansen
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Building 229, 2800 Kongens Lyngby, Denmark
| | - Klavs F. Jensen
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
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10
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Pedersen MJ, Skovby T, Mealy MJ, Dam-Johansen K, Kiil S. Redesign of a Grignard-Based Active Pharmaceutical Ingredient (API) Batch Synthesis to a Flow Process for the Preparation of Melitracen HCl. Org Process Res Dev 2018. [DOI: 10.1021/acs.oprd.7b00368] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Michael J. Pedersen
- H. Lundbeck A/S, Oddenvej 182, 4500 Nykøbing Sjælland, Denmark
- Department
of Chemical and Biochemical Engineering, Technical University of Denmark, DTU, Building 229, 2800 Kgs. Lyngby, Denmark
| | - Tommy Skovby
- H. Lundbeck A/S, Oddenvej 182, 4500 Nykøbing Sjælland, Denmark
| | | | - Kim Dam-Johansen
- Department
of Chemical and Biochemical Engineering, Technical University of Denmark, DTU, Building 229, 2800 Kgs. Lyngby, Denmark
| | - Søren Kiil
- Department
of Chemical and Biochemical Engineering, Technical University of Denmark, DTU, Building 229, 2800 Kgs. Lyngby, Denmark
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11
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Besenhard MO, Fathollahi S, Siegmann E, Slama E, Faulhammer E, Khinast JG. Micro-feeding and dosing of powders via a small-scale powder pump. Int J Pharm 2017; 519:314-322. [PMID: 27986476 DOI: 10.1016/j.ijpharm.2016.12.029] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/21/2016] [Accepted: 12/12/2016] [Indexed: 12/21/2022]
Affiliation(s)
- M O Besenhard
- Research Center Pharmaceutical Engineering (RCPE), 8010 Graz, Austria
| | - S Fathollahi
- Research Center Pharmaceutical Engineering (RCPE), 8010 Graz, Austria
| | - E Siegmann
- Research Center Pharmaceutical Engineering (RCPE), 8010 Graz, Austria
| | - E Slama
- Research Center Pharmaceutical Engineering (RCPE), 8010 Graz, Austria
| | - E Faulhammer
- Research Center Pharmaceutical Engineering (RCPE), 8010 Graz, Austria
| | - J G Khinast
- Research Center Pharmaceutical Engineering (RCPE), 8010 Graz, Austria; Graz University of Technology, Institute of Process and Particle Engineering, 8010 Graz, Austria.
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12
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Mielke E, Plouffe P, Koushik N, Eyholzer M, Gottsponer M, Kockmann N, Macchi A, Roberge DM. Local and overall heat transfer of exothermic reactions in microreactor systems. REACT CHEM ENG 2017. [DOI: 10.1039/c7re00085e] [Citation(s) in RCA: 25] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
Heat transfer performance of plate-type metallic microreactors.
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Affiliation(s)
- Eric Mielke
- Centre for Catalysis Research and Innovation
- Department of Chemical and Biological Engineering
- University of Ottawa
- K1N 6N5 Ottawa
- Canada
| | - Patrick Plouffe
- Centre for Catalysis Research and Innovation
- Department of Chemical and Biological Engineering
- University of Ottawa
- K1N 6N5 Ottawa
- Canada
| | - Nikhil Koushik
- Centre for Catalysis Research and Innovation
- Department of Chemical and Biological Engineering
- University of Ottawa
- K1N 6N5 Ottawa
- Canada
| | - Markus Eyholzer
- Chemical Manufacturing Technologies
- Lonza AG
- CH-3930 Visp
- Switzerland
| | | | - Norbert Kockmann
- University of Technology Dortmund
- Biochemical and Chemical Engineering
- Equipment Design
- D-44227 Dortmund
- Germany
| | - Arturo Macchi
- Centre for Catalysis Research and Innovation
- Department of Chemical and Biological Engineering
- University of Ottawa
- K1N 6N5 Ottawa
- Canada
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13
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Belimov M, Metzger D, Pfeifer P. On the temperature control in a microstructured packed bed reactor for methanation of CO/CO2mixtures. AIChE J 2016. [DOI: 10.1002/aic.15461] [Citation(s) in RCA: 28] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Michael Belimov
- Karlsruhe Institute of Technology, Institute for Micro Process Engineering; Hermann-von-Helmholtz-Platz 1 Eggenstein-Leopoldshafen 76344 Germany
| | - David Metzger
- Karlsruhe Institute of Technology, Institute for Micro Process Engineering; Hermann-von-Helmholtz-Platz 1 Eggenstein-Leopoldshafen 76344 Germany
| | - Peter Pfeifer
- Karlsruhe Institute of Technology, Institute for Micro Process Engineering; Hermann-von-Helmholtz-Platz 1 Eggenstein-Leopoldshafen 76344 Germany
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14
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Movsisyan M, Delbeke EIP, Berton JKET, Battilocchio C, Ley SV, Stevens CV. Taming hazardous chemistry by continuous flow technology. Chem Soc Rev 2016; 45:4892-928. [PMID: 27453961 DOI: 10.1039/c5cs00902b] [Citation(s) in RCA: 390] [Impact Index Per Article: 48.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/22/2022]
Abstract
Over the last two decades, flow technologies have become increasingly popular in the field of organic chemistry, offering solutions for engineering and/or chemical problems. Flow reactors enhance the mass and heat transfer, resulting in rapid reaction mixing, and enable a precise control over the reaction parameters, increasing the overall process selectivity, efficiency and safety. These features allow chemists to tackle unexploited challenges in their work, with the ultimate objective making chemistry more accessible for laboratory and industrial applications, avoiding the need to store and handle toxic, reactive and explosive reagents. This review covers some of the latest and most relevant developments in the field of continuous flow chemistry with the focus on hazardous reactions.
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Affiliation(s)
- M Movsisyan
- SynBioC, Department of Sustainable Organic Chemistry and Technology, Ghent University, Coupure Links 653, 9000 Ghent, Belgium.
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15
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Pieber B, Cox DP, Kappe CO. Selective Olefin Reduction in Thebaine Using Hydrazine Hydrate and O2 under Intensified Continuous Flow Conditions. Org Process Res Dev 2015. [DOI: 10.1021/acs.oprd.5b00370] [Citation(s) in RCA: 16] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Bartholomäus Pieber
- Institute
of Chemistry, University of Graz, Heinrichstrasse 28, A-8010 Graz, Austria
| | - D. Phillip Cox
- Noramco,
Inc., 503 Carr Road, Suite 200, Wilmington, Delaware 19809, United States
| | - C. Oliver Kappe
- Institute
of Chemistry, University of Graz, Heinrichstrasse 28, A-8010 Graz, Austria
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16
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Westermann T, Mleczko L. Heat Management in Microreactors for Fast Exothermic Organic Syntheses—First Design Principles. Org Process Res Dev 2015. [DOI: 10.1021/acs.oprd.5b00205] [Citation(s) in RCA: 38] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
| | - Leslaw Mleczko
- Bayer
Technology Services GmbH, 51368 Leverkusen, Germany
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17
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Gutmann B, Cantillo D, Kappe CO. Continuous-flow technology—a tool for the safe manufacturing of active pharmaceutical ingredients. Angew Chem Int Ed Engl 2015; 54:6688-728. [PMID: 25989203 DOI: 10.1002/anie.201409318] [Citation(s) in RCA: 870] [Impact Index Per Article: 96.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/21/2014] [Indexed: 12/12/2022]
Abstract
In the past few years, continuous-flow reactors with channel dimensions in the micro- or millimeter region have found widespread application in organic synthesis. The characteristic properties of these reactors are their exceptionally fast heat and mass transfer. In microstructured devices of this type, virtually instantaneous mixing can be achieved for all but the fastest reactions. Similarly, the accumulation of heat, formation of hot spots, and dangers of thermal runaways can be prevented. As a result of the small reactor volumes, the overall safety of the process is significantly improved, even when harsh reaction conditions are used. Thus, microreactor technology offers a unique way to perform ultrafast, exothermic reactions, and allows the execution of reactions which proceed via highly unstable or even explosive intermediates. This Review discusses recent literature examples of continuous-flow organic synthesis where hazardous reactions or extreme process windows have been employed, with a focus on applications of relevance to the preparation of pharmaceuticals.
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Affiliation(s)
- Bernhard Gutmann
- Institute of Chemistry, University Graz, NAWI Graz, Heinrichstrasse 28, A-8010 Graz (Austria) http://www.maos.net
| | - David Cantillo
- Institute of Chemistry, University Graz, NAWI Graz, Heinrichstrasse 28, A-8010 Graz (Austria) http://www.maos.net
| | - C Oliver Kappe
- Institute of Chemistry, University Graz, NAWI Graz, Heinrichstrasse 28, A-8010 Graz (Austria) http://www.maos.net.
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18
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Gutmann B, Cantillo D, Kappe CO. Kontinuierliche Durchflussverfahren: ein Werkzeug für die sichere Synthese von pharmazeutischen Wirkstoffen. Angew Chem Int Ed Engl 2015. [DOI: 10.1002/ange.201409318] [Citation(s) in RCA: 187] [Impact Index Per Article: 20.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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19
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Pieber B, Glasnov T, Kappe CO. Continuous Flow Reduction of Artemisinic Acid Utilizing Multi-Injection Strategies-Closing the Gap Towards a Fully Continuous Synthesis of Antimalarial Drugs. Chemistry 2015; 21:4368-76. [DOI: 10.1002/chem.201406439] [Citation(s) in RCA: 33] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/11/2014] [Indexed: 11/10/2022]
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20
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Nagaki A, Yoshida JI. Preparation and Use of Organolithium and Organomagnesium Species in Flow. TOP ORGANOMETAL CHEM 2015. [DOI: 10.1007/3418_2015_154] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
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21
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Noël T, Su Y, Hessel V. Beyond Organometallic Flow Chemistry: The Principles Behind the Use of Continuous-Flow Reactors for Synthesis. TOP ORGANOMETAL CHEM 2015. [DOI: 10.1007/3418_2015_152] [Citation(s) in RCA: 45] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
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22
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Continuous API-crystal coating via coacervation in a tubular reactor. Int J Pharm 2014; 475:198-207. [DOI: 10.1016/j.ijpharm.2014.08.009] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/06/2014] [Revised: 08/04/2014] [Accepted: 08/05/2014] [Indexed: 11/22/2022]
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23
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Plouffe P, Macchi A, Roberge DM. From Batch to Continuous Chemical Synthesis—A Toolbox Approach. Org Process Res Dev 2014. [DOI: 10.1021/op5001918] [Citation(s) in RCA: 102] [Impact Index Per Article: 10.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Patrick Plouffe
- Centre
for Catalysis Research
and Innovation, Department of Chemical and Biological Engineering, University of Ottawa, K1N6N5, Ottawa, Canada
| | - Arturo Macchi
- Centre
for Catalysis Research
and Innovation, Department of Chemical and Biological Engineering, University of Ottawa, K1N6N5, Ottawa, Canada
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24
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Hamlin TA, Lazarus GML, Kelly CB, Leadbeater NE. A Continuous-Flow Approach to 3,3,3-Trifluoromethylpropenes: Bringing Together Grignard Addition, Peterson Elimination, Inline Extraction, and Solvent Switching. Org Process Res Dev 2014. [DOI: 10.1021/op500190j] [Citation(s) in RCA: 29] [Impact Index Per Article: 2.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
Affiliation(s)
- Trevor A. Hamlin
- Department
of Chemistry, University of Connecticut, 55 North Eagleville Road, Storrs, Connecticut 06269-3060, United States
| | - Gillian M. L. Lazarus
- Department
of Chemistry, University of Connecticut, 55 North Eagleville Road, Storrs, Connecticut 06269-3060, United States
| | - Christopher B. Kelly
- Department
of Chemistry, University of Connecticut, 55 North Eagleville Road, Storrs, Connecticut 06269-3060, United States
| | - Nicholas E. Leadbeater
- Department
of Chemistry, University of Connecticut, 55 North Eagleville Road, Storrs, Connecticut 06269-3060, United States
- Department of Community Medicine & Health Care, University of Connecticut Health Center, The Exchange, 263 Farmington Avenue, Farmington, Connecticut 06030, United States
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25
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Rapid Determination of Optimal Conditions in a Continuous Flow Reactor Using Process Analytical Technology. Processes (Basel) 2013. [DOI: 10.3390/pr2010024] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
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26
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Lawrence J, O'Sullivan B, Lye GJ, Wohlgemuth R, Szita N. Microfluidic multi-input reactor for biocatalytic synthesis using transketolase. JOURNAL OF MOLECULAR CATALYSIS. B, ENZYMATIC 2013; 95:111-117. [PMID: 24187515 PMCID: PMC3724052 DOI: 10.1016/j.molcatb.2013.05.016] [Citation(s) in RCA: 23] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 01/31/2013] [Revised: 05/08/2013] [Accepted: 05/17/2013] [Indexed: 11/14/2022]
Abstract
Biocatalytic synthesis in continuous-flow microreactors is of increasing interest for the production of specialty chemicals. However, the yield of production achievable in these reactors can be limited by the adverse effects of high substrate concentration on the biocatalyst, including inhibition and denaturation. Fed-batch reactors have been developed in order to overcome this problem, but no continuous-flow solution exists. We present the design of a novel multi-input microfluidic reactor, capable of substrate feeding at multiple points, as a first step towards overcoming these problems in a continuous-flow setting. Using the transketolase-(TK) catalysed reaction of lithium hydroxypyruvate (HPA) and glycolaldehyde (GA) to l-erythrulose (ERY), we demonstrate the transposition of a fed-batch substrate feeding strategy to our microfluidic reactor. We obtained a 4.5-fold increase in output concentration and a 5-fold increase in throughput compared with a single input reactor.
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Affiliation(s)
- James Lawrence
- Department of Biochemical Engineering, University College London, Torrington Place, London WC1E 7JE, UK
| | - Brian O'Sullivan
- Department of Biochemical Engineering, University College London, Torrington Place, London WC1E 7JE, UK
| | - Gary J. Lye
- Department of Biochemical Engineering, University College London, Torrington Place, London WC1E 7JE, UK
| | | | - Nicolas Szita
- Department of Biochemical Engineering, University College London, Torrington Place, London WC1E 7JE, UK
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27
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The past, present and potential for microfluidic reactor technology in chemical synthesis. Nat Chem 2013; 5:905-15. [PMID: 24153367 DOI: 10.1038/nchem.1753] [Citation(s) in RCA: 636] [Impact Index Per Article: 57.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/09/2013] [Accepted: 08/08/2013] [Indexed: 12/23/2022]
Abstract
The past two decades have seen far-reaching progress in the development of microfluidic systems for use in the chemical and biological sciences. Here we assess the utility of microfluidic reactor technology as a tool in chemical synthesis in both academic research and industrial applications. We highlight the successes and failures of past research in the field and provide a catalogue of chemistries performed in a microfluidic reactor. We then assess the current roadblocks hindering the widespread use of microfluidic reactors from the perspectives of both synthetic chemistry and industrial application. Finally, we set out seven challenges that we hope will inspire future research in this field.
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28
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Pedersen MJ, Holm TL, Rahbek JP, Skovby T, Mealy MJ, Dam-Johansen K, Kiil S. Full-Scale Continuous Mini-Reactor Setup for Heterogeneous Grignard Alkylation of a Pharmaceutical Intermediate. Org Process Res Dev 2013. [DOI: 10.1021/op400069e] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/25/2023]
Affiliation(s)
- Michael J. Pedersen
- Department
of Chemical and Biochemical
Engineering, Technical University of Denmark, DTU, Building 229, 2800 Kgs. Lyngby, Denmark
- H. Lundbeck A/S, Oddenvej 182, 4500 Nykøbing Sjælland, Denmark
| | - Thomas L. Holm
- H. Lundbeck A/S, Oddenvej 182, 4500 Nykøbing Sjælland, Denmark
| | | | - Tommy Skovby
- H. Lundbeck A/S, Oddenvej 182, 4500 Nykøbing Sjælland, Denmark
| | | | - Kim Dam-Johansen
- Department
of Chemical and Biochemical
Engineering, Technical University of Denmark, DTU, Building 229, 2800 Kgs. Lyngby, Denmark
| | - Søren Kiil
- Department
of Chemical and Biochemical
Engineering, Technical University of Denmark, DTU, Building 229, 2800 Kgs. Lyngby, Denmark
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29
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Cervera-Padrell AE, Skovby T, Kiil S, Gani R, Gernaey KV. Active pharmaceutical ingredient (API) production involving continuous processes – A process system engineering (PSE)-assisted design framework. Eur J Pharm Biopharm 2012; 82:437-56. [DOI: 10.1016/j.ejpb.2012.07.001] [Citation(s) in RCA: 41] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/25/2012] [Accepted: 07/03/2012] [Indexed: 10/28/2022]
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30
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Hessel V, Vural Gürsel I, Wang Q, Noël T, Lang J. Potential Analysis of Smart Flow Processing and Micro Process Technology for Fastening Process Development: Use of Chemistry and Process Design as Intensification Fields. Chem Eng Technol 2012. [DOI: 10.1002/ceat.201200038] [Citation(s) in RCA: 95] [Impact Index Per Article: 7.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/08/2023]
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31
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Marre S, Roig Y, Aymonier C. Supercritical microfluidics: Opportunities in flow-through chemistry and materials science. J Supercrit Fluids 2012. [DOI: 10.1016/j.supflu.2011.11.029] [Citation(s) in RCA: 109] [Impact Index Per Article: 9.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/09/2023]
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32
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Integration of Continuous Flow Reactors and Online Raman Spectroscopy for Process Optimization. J Pharm Innov 2012. [DOI: 10.1007/s12247-012-9128-8] [Citation(s) in RCA: 8] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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33
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Hartman RL. Managing Solids in Microreactors for the Upstream Continuous Processing of Fine Chemicals. Org Process Res Dev 2012. [DOI: 10.1021/op200348t] [Citation(s) in RCA: 201] [Impact Index Per Article: 16.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/17/2022]
Affiliation(s)
- Ryan L. Hartman
- Department of Chemical
and Biological Engineering, The University of Alabama, Box 870203 Tuscaloosa, AL,
United States
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34
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Hessel V, Gürsel I, Wang Q, Noël T, Lang J. Potenzialanalyse von Milli- und Mikroprozesstechniken für die Verkürzung von Prozessentwicklungszeiten - Chemie und Prozessdesign als Intensivierungsfelder. CHEM-ING-TECH 2012. [DOI: 10.1002/cite.201200007] [Citation(s) in RCA: 41] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
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35
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36
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Kockmann N. Sicherheitsaspekte bei der Prozessentwicklung und Kleinmengenproduktion mit Mikroreaktoren. CHEM-ING-TECH 2012. [DOI: 10.1002/cite.201100222] [Citation(s) in RCA: 18] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
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37
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Cervera-Padrell AE, Morthensen ST, Lewandowski DJ, Skovby T, Kiil S, Gernaey KV. Continuous Hydrolysis and Liquid–Liquid Phase Separation of an Active Pharmaceutical Ingredient Intermediate Using a Miniscale Hydrophobic Membrane Separator. Org Process Res Dev 2012. [DOI: 10.1021/op200242s] [Citation(s) in RCA: 50] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Albert E. Cervera-Padrell
- Department of Chemical and Biochemical Engineering, Technical University of Denmark (DTU), Building 229,
DK-2800 Kgs. Lyngby, Denmark
| | - Sofie T. Morthensen
- Department of Chemical and Biochemical Engineering, Technical University of Denmark (DTU), Building 229,
DK-2800 Kgs. Lyngby, Denmark
| | - Daniel J. Lewandowski
- Department of Chemical and Biochemical Engineering, Technical University of Denmark (DTU), Building 229,
DK-2800 Kgs. Lyngby, Denmark
| | - Tommy Skovby
- Chemical Production Development, H. Lundbeck A/S, Oddenvej 182, DK-4500 Nykoebing Sj., Denmark
| | - Søren Kiil
- Department of Chemical and Biochemical Engineering, Technical University of Denmark (DTU), Building 229,
DK-2800 Kgs. Lyngby, Denmark
| | - Krist V. Gernaey
- Department of Chemical and Biochemical Engineering, Technical University of Denmark (DTU), Building 229,
DK-2800 Kgs. Lyngby, Denmark
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38
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Affiliation(s)
- Neal G. Anderson
- Anderson’s Process Solutions, 7400 Griffin Lane, Jacksonville, Oregon 97530, United States
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39
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Cervera-Padrell AE, Nielsen JP, Jønch Pedersen M, Müller Christensen K, Mortensen AR, Skovby T, Dam-Johansen K, Kiil S, Gernaey KV. Monitoring and Control of a Continuous Grignard Reaction for the Synthesis of an Active Pharmaceutical Ingredient Intermediate Using Inline NIR spectroscopy. Org Process Res Dev 2012. [DOI: 10.1021/op2002563] [Citation(s) in RCA: 45] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Albert E. Cervera-Padrell
- Department of Chemical and Biochemical
Engineering, Technical University of Denmark (DTU), Building 229, DK-2800 Kgs. Lyngby, Denmark
| | - Jesper P. Nielsen
- Chemical Production Development, H. Lundbeck A/S, Oddenvej 182, DK-4500 Nykoebing Sj.,
Denmark
| | - Michael Jønch Pedersen
- Department of Chemical and Biochemical
Engineering, Technical University of Denmark (DTU), Building 229, DK-2800 Kgs. Lyngby, Denmark
| | - Kim Müller Christensen
- Department of Chemical and Biochemical
Engineering, Technical University of Denmark (DTU), Building 229, DK-2800 Kgs. Lyngby, Denmark
| | - Asmus R. Mortensen
- Department of Chemical and Biochemical
Engineering, Technical University of Denmark (DTU), Building 229, DK-2800 Kgs. Lyngby, Denmark
| | - Tommy Skovby
- Chemical Production Development, H. Lundbeck A/S, Oddenvej 182, DK-4500 Nykoebing Sj.,
Denmark
| | - Kim Dam-Johansen
- Department of Chemical and Biochemical
Engineering, Technical University of Denmark (DTU), Building 229, DK-2800 Kgs. Lyngby, Denmark
| | - Søren Kiil
- Department of Chemical and Biochemical
Engineering, Technical University of Denmark (DTU), Building 229, DK-2800 Kgs. Lyngby, Denmark
| | - Krist V. Gernaey
- Department of Chemical and Biochemical
Engineering, Technical University of Denmark (DTU), Building 229, DK-2800 Kgs. Lyngby, Denmark
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40
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Haber J, Kashid MN, Renken A, Kiwi-Minsker L. Heat Management in Single and Multi-injection Microstructured Reactors: Scaling Effects, Stability Analysis, and Role of Mixing. Ind Eng Chem Res 2011. [DOI: 10.1021/ie201158a] [Citation(s) in RCA: 38] [Impact Index Per Article: 2.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- J. Haber
- Group of Catalytic Reaction Engineering (GGRC) Ecole Polytechnique Fédérale de Lausanne (EPFL) Station 6, CH-1015 Lausanne, Switzerland
| | - M. N. Kashid
- Group of Catalytic Reaction Engineering (GGRC) Ecole Polytechnique Fédérale de Lausanne (EPFL) Station 6, CH-1015 Lausanne, Switzerland
| | - A. Renken
- Group of Catalytic Reaction Engineering (GGRC) Ecole Polytechnique Fédérale de Lausanne (EPFL) Station 6, CH-1015 Lausanne, Switzerland
| | - L. Kiwi-Minsker
- Group of Catalytic Reaction Engineering (GGRC) Ecole Polytechnique Fédérale de Lausanne (EPFL) Station 6, CH-1015 Lausanne, Switzerland
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41
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Cortese B, de Croon MHJM, Hessel V. High-Temperature Epoxidation of Soybean Oil in Flow—Speeding up Elemental Reactions Wanted and Unwanted. Ind Eng Chem Res 2011. [DOI: 10.1021/ie200868w] [Citation(s) in RCA: 23] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Bruno Cortese
- Eindhoven University of Technology, Eindhoven, The Netherlands
| | | | - Volker Hessel
- Eindhoven University of Technology, Eindhoven, The Netherlands
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42
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Hartman RL, McMullen JP, Jensen KF. Pro und kontra Strömungsreaktoren in der Synthese. Angew Chem Int Ed Engl 2011. [DOI: 10.1002/ange.201004637] [Citation(s) in RCA: 151] [Impact Index Per Article: 11.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
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43
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Hartman RL, McMullen JP, Jensen KF. Deciding whether to go with the flow: evaluating the merits of flow reactors for synthesis. Angew Chem Int Ed Engl 2011; 50:7502-19. [PMID: 21710673 DOI: 10.1002/anie.201004637] [Citation(s) in RCA: 638] [Impact Index Per Article: 49.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/28/2010] [Indexed: 11/06/2022]
Abstract
The fine chemicals and pharmaceutical industries are transforming how their products are manufactured, where economically favorable, from traditional batchwise processes to continuous flow. This evolution is impacting synthetic chemistry on all scales-from the laboratory to full production. This Review discusses the relative merits of batch and micro flow reactors for performing synthetic chemistry in the laboratory.
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Affiliation(s)
- Ryan L Hartman
- Department of Chemical Engineering, Massachusetts Institute of Technology, 77 Massachusetts Ave, 66-350, Cambridge, MA 02139, USA
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44
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45
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Harsh Reaction Conditions in Continuous-Flow Microreactors for Pharmaceutical Production. Chem Eng Technol 2009. [DOI: 10.1002/ceat.200900355] [Citation(s) in RCA: 109] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
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