Enabling Continuous-Flow Chemistry in Microstructured Devices for Pharmaceutical and Fine-Chemical Production

Continuous diameter increase reactor – a reactor concept for maximizing productivity by a controlled diameter extension

This paper presents a novel theoretical approach for maximizing productivity in microreactors by a controlled extension of the tube diameter. A one-dimensional numeric model was developed where the tube diameter increases based on the reaction heat to achieve a constant temperature throughout the reactor length. Through this approach, a basic plug flow reactor model for mass and heat transfer was used with an integrated algorithm for a controlled diameter extension. A parametric study was performed to ensure safe operating conditions concerning thermal runaway. The results show an increase in productivity of approximately 42% for the fictional second-order test reaction.

Graphical abstract

Continuous flow technology-a tool for safer oxidation chemistry

The advantages and benefits of continuous flow technology for oxidation chemistry have been illustrated in tube reactors, micro-channel reactors, tube-in-tube reactors and micro-packed bed reactors in the presence of various oxidants.

Investigation of the effect of microflow reactor diameter on condensation reactions in l-proline-immobilized polymer monoliths

Structure of porous monolith in a microflow reactor and the reactor diameter affect the residence time distribution (RTD). The effect of the RTD on the catalytic efficiency of the asymmetric aldol addition reaction was examined.

Reactor Selection for Upgrading Hemicelluloses: Conventional and Miniaturised Reactors for Hydrogenations

This work presents an advanced reactor selection strategy that combines elements of a knowledge-based expert system to reduce the number of feasible reactor configurations with elaborated and automatised process simulations to identify reactor performance parameters. Special focus was given to identify optimal catalyst loadings and favourable conditions for each configuration to enable a fair comparison. The workflow was exemplarily illustrated for the Ru/C-catalysed hydrogenation of arabinose and galactose to the corresponding sugar alcohols. The simulations were performed by using pseudo-2D reactor models implemented in Aspen Custom Modeler® and automatised by using the MS-Excel interface and VBA. The minichannel packings, namely wall-coated minichannel reactor (MCWR), minichannel reactor packed with catalytic particles (MCPR), and minichannel reactor packed with a catalytic open-celled foam (MCFR), outperform the conventional and miniaturised trickle-bed reactors (TBR and MTBR) in terms of space-time yield and catalyst use. However, longer reactor lengths are required to achieve 99% conversion of the sugars in MCWR and MCPR. Considering further technical challenges such as liquid distribution, packing the reactor, as well as the robustness and manufacture of catalysts in a biorefinery environment, miniaturised trickle beds are the most favourable design for a production scenario of 5000 t/a galactitol. However, the minichannel configurations will be more advantageous for reaction systems involving consecutive and parallel reactions and highly exothermic systems.

Simultaneous self-optimisation of yield and purity through successive combination of inline FT-IR spectroscopy and online mass spectrometry in flow reactions

Self-optimisation constitutes a very helpful tool for chemical process development, both in lab and in industrial applications. However, research on the application of model-free autonomous optimisation strategies (based on experimental investigation) for complex reactions of high industrial significance, which involve considerable intermediate and by-product formation, is still in an early stage. This article describes the development of an enhanced autonomous microfluidic reactor platform for organolithium and epoxide reactions that incorporates a successive combination of inline FT-IR spectrometer and online mass spectrometer. Experimental data is collected in real-time and used as feedback for the optimisation algorithms (modified Simplex algorithm and Design of Experiments) without time delay. An efficient approach to handle intricate optimisation problems is presented, where the inline FT-IR measurements are used to monitor the reaction’s main components, whereas the mass spectrometer’s high sensitivity permits insights into the formation of by-products. To demonstrate the platform’s flexibility, optimal reaction conditions of two organic syntheses are identified. Both pose several challenges, as complex reaction mechanisms are involved, leading to a large number of variable parameters, and a considerable amount of by-products is generated under non-ideal process conditions. Through multidimensional real-time optimisation, the platform supersedes labor- and cost-intensive work-up procedures, while diminishing waste generation, too. Thus, it renders production processes more efficient and contributes to their overall sustainability.

Graphical abstract

One-flow upscaling neutralization of an organophosphonate-derived pesticide/nerve agent simulant to value-added chemicals in a novel Teflon microreactor platform

Synthesizing value-added products from chemical warfare agents is a concept well beyond the usual notion of simply neutralizing the agents.

Continuous Flow Upgrading of Selected C2-C6 Platform Chemicals Derived from Biomass

The ever increasing industrial production of commodity and specialty chemicals inexorably depletes the finite primary fossil resources available on Earth. The forecast of population growth over the next 3 decades is a very strong incentive for the identification of alternative primary resources other than petro-based ones. In contrast with fossil resources, renewable biomass is a virtually inexhaustible reservoir of chemical building blocks. Shifting the current industrial paradigm from almost exclusively petro-based resources to alternative bio-based raw materials requires more than vibrant political messages; it requires a profound revision of the concepts and technologies on which industrial chemical processes rely. Only a small fraction of molecules extracted from biomass bears significant chemical and commercial potentials to be considered as ubiquitous chemical platforms upon which a new, bio-based industry can thrive. Owing to its inherent assets in terms of unique process experience, scalability, and reduced environmental footprint, flow chemistry arguably has a major role to play in this context. This review covers a selection of C₂ to C₆ bio-based chemical platforms with existing commercial markets including polyols (ethylene glycol, 1,2-propanediol, 1,3-propanediol, glycerol, 1,4-butanediol, xylitol, and sorbitol), furanoids (furfural and 5-hydroxymethylfurfural) and carboxylic acids (lactic acid, succinic acid, fumaric acid, malic acid, itaconic acid, and levulinic acid). The aim of this review is to illustrate the various aspects of upgrading bio-based platform molecules toward commodity or specialty chemicals using new process concepts that fall under the umbrella of continuous flow technology and that could change the future perspectives of biorefineries.

Self-optimising processes and real-time-optimisation of organic syntheses in a microreactor system using Nelder–Mead and design of experiments

Comparing an enhanced simplex algorithm with model-free design of experiments, this work presents a flexible platform for multi-objective, real-time optimisation.

Microfluidic immobilized enzyme reactors for continuous biocatalysis

This review investigates strategies for employing μ-IMERs for continuous biocatalysis via a top-down approach.

Liver-on-a-Chip‒Magnetic Nanoparticle Bound Synthetic Metalloporphyrin-Catalyzed Biomimetic Oxidation of a Drug in a Magnechip Reactor

Biomimetic oxidation of drugs catalyzed by metalloporphyrins can be a novel and promising way for the effective and sustainable synthesis of drug metabolites. The immobilization of 5,10,15,20-tetrakis(2,3,4,5,6-pentafluorophenyl)iron(II) porphyrin (FeTPFP) and 5,10,15,20-tetrakis-(4-sulfonatophenyl)iron(II) porphyrin (FeTSPP) via stable covalent or rapid ionic binding on aminopropyl-functionalized magnetic nanoparticles (MNPs-NH₂) were developed. These immobilized catalysts could be efficiently applied for the synthesis of new pharmaceutically active derivatives and liver related phase I oxidative major metabolite of an antiarrhythmic drug, amiodarone integrated in a continuous-flow magnetic chip reactor (Magnechip).

On-chip organic synthesis enabled using an engine-and-cargo system in an electrowetting-on-dielectric digital microfluidic device

This paper presents a microfluidic chemical reaction using an electrowetting-on-dielectric (EWOD) digital microfluidic device. Despite a number of chemical/biological applications using EWOD digital microfluidic devices, their applications to organic reactions have been seriously limited because most of the common solvents used in synthetic organic chemistry are not compatible with EWOD devices. To address this unsolved issue, we first introduce a novel technique using an "engine-and-cargo" system that enables the use of non-movable fluids (e.g., organic solvents) on an EWOD device. With esterification as the model reaction, on-chip chemical reactions were successfully demonstrated. Conversion data obtained from on-chip reactions were used to characterize and optimize the reaction with regard to reaction kinetics, solvent screening, and catalyst loading. As the first step toward on-chip combinatorial synthesis, parallel esterification of three different alcohols was demonstrated. Results from this study clearly show that an EWOD digital microfluidic platform is a promising candidate for microscale chemical reactions.

Miniaturized and Automated Synthesis of Biomolecules-Overview and Perspectives

Chemical synthesis is performed by reacting different chemical building blocks with defined stoichiometry, while meeting additional conditions, such as temperature and reaction time. Such a procedure is especially suited for automation and miniaturization. Life sciences lead the way to synthesizing millions of different oligonucleotides in extremely miniaturized reaction sites, e.g., pinpointing active genes in whole genomes, while chemistry advances different types of automation. Recent progress in matrix-assisted laser desorption/ionization mass spectrometry (MALDI-MS) imaging could match miniaturized chemical synthesis with a powerful analytical tool to validate the outcome of many different synthesis pathways beyond applications in the life sciences. Thereby, due to the radical miniaturization of chemical synthesis, thousands of molecules can be synthesized. This in turn should allow ambitious research, e.g., finding novel synthesis routes or directly screening for photocatalysts. Herein, different technologies are discussed that might be involved in this endeavor. A special emphasis is given to the obstacles that need to be tackled when depositing tiny amounts of materials to many different extremely miniaturized reaction sites.

Preparation of highly active phosphated TiO2catalystsviacontinuous sol–gel synthesis in a microreactor

Highly efficient TiO₂based catalysts for biomass conversion were obtained through optimised and well-controlled sol–gel synthesis in a multi-mixer microreactor.

Definitive screening designs for multistep kinetic models in flow

A definitive screening design (DSD) combined with reaction profiling was conducted using a flow reactor, in a short time frame, for the accurate estimation of kinetic parameters.

Continuous nitration of alcohols in a Freon flow

The first ever installation for continuous nitration in a liquefied gas mobile phase was developed.

Thermal Decomposition of Ethyl Diazoacetate in Microtube Reactor: A Kinetics Study

Ethyl diazoacetate (EDA) commonly experiences intensive decomposition as well as complex conversion concerning safety and efficiency. In this work, a careful kinetics study on the thermal decomposition of EDA was isothermally conducted in a microtube reactor to establish a mechanism-based kinetic model. The model parameters were well calibrated with experimental data including the yield of dimmers and the conversion of EDA, confirming the rationality of the proposed three-step reaction route. It allows the model to concisely describe the complex species transformations during EDA decomposition, which is unavailable for an apparent kinetic model. Considering an isothermal reaction system and the tolerance of EDA consumption by thermal decomposition, this work could help reveal the requirement on the kinetic characteristics of the desired catalytic reaction in which EDA is involved, as a reference on reaction process modeling and regulation.

Synergy of Microtechnology and Biotechnology: Microreactors as an Effective Tool for Biotransformation Processes§: §The paper was presented at European Biotechnology Congress, 25-27 May 2017, Dubrovnik, Croatia

Despite the fact that microreactors have been present for more than 40 years now and that their potential has been extensively exploited in chemical synthesis, analytics and screening, to date very few biocatalytic processes have been explored in microreactors. It is claimed that enzymatic microreactor technology is exactly in the same place where chemical microreactors were 15 years ago. However, general opinion is that the efforts devoted to the research of micro-enzymatic reactors will inaugurate a new breakthrough in bio-based processing. The aim of this review is to explore the synergy between microtechnology, mainly microreactors, and biotechnology, and to assess its potential, opportunities, challenges and future application in biotechnology.

Mass spectrometric directed system for the continuous-flow synthesis and purification of diphenhydramine

A highly integrated approach to the development of a process for the continuous synthesis and purification of diphenhydramine is reported. Mass spectrometry (MS) is utilized throughout the system for on-line reaction monitoring, off-line yield quantitation, and as a reaction screening module that exploits reaction acceleration in charged microdroplets for high throughput route screening. This effort has enabled the discovery and optimization of multiple routes to diphenhydramine in glass microreactors using MS as a process analytical tool (PAT). The ability to rapidly screen conditions in charged microdroplets was used to guide optimization of the process in a microfluidic reactor. A quantitative MS method was developed and used to measure the reaction kinetics. Integration of the continuous-flow reactor/on-line MS methodology with a miniaturized crystallization platform for continuous reaction monitoring and controlled crystallization of diphenhydramine was also achieved. Our findings suggest a robust approach for the continuous manufacture of pharmaceutical drug products, exemplified in the particular case of diphenhydramine, and optimized for efficiency and crystal size, and guided by real-time analytics to produce the agent in a form that is readily adapted to continuous synthesis.

Continuous-flow processes for the catalytic partial hydrogenation reaction of alkynes

The catalytic partial hydrogenation of substituted alkynes to alkenes is a process of high importance in the manufacture of several market chemicals. The present paper shortly reviews the heterogeneous catalytic systems engineered for this reaction under continuous flow and in the liquid phase. The main contributions appeared in the literature from 1997 up to August 2016 are discussed in terms of reactor design. A comparison with batch and industrial processes is provided whenever possible.