Flow Chemistry Meets Advanced Functional Materials

Continuous Polymer Synthesis and Manufacturing of Polyurethane Elastomers Enabled by Automation

Connecting polymer synthesis and processing is an important challenge for streamlining the manufacturing of polymeric materials. In this work, the automated synthesis of acrylate-capped polyurethane oligomers is integrated with vat photopolymerization 3D printing. This strategy enabled the rapid manufacturing of a library of polyurethane-based elastomeric materials with differentiated thermal and mechanical properties. The automated semicontinuous batch synthesis approach proved enabling for resins with otherwise short shelf lives because of the intimate connection between synthesis, formulation, and processing. Structure-property studies demonstrated the ability to tune properties through systematic alteration of cross-link density and chemical composition.

General Synthesis and Solution Processing of Metal-Organic Framework Nanofibers

By virtue of their extraordinarily high surface areas, ordered pore structures, various compositions, and rich functionality, metal-organic frameworks (MOFs) are of great interest in diverse fields such as gas separation, sensing, catalysis, energy, environment science, and biomedicine. However, the difficulty in processing MOF crystals and controlling the MOF superstructure is emerging as a critical issue in their application. Herein, it is reported that a robust template, i.e., nanofibrillated cellulose (NFC), can be used for the synthesis of MOF materials with 1D nanofiber morphology. NFC@MOF core-shell nanofibers with a uniform network structure and high aspect ratios can be prepared by use of this template. The small crystal size, flexibility, and good dispersity of the NFC@MOF nanofibers make it convenient for the macroscale assembly and solution processing of MOF materials. A proof-of-concept study is demonstrated wherein freestanding MOF nanofiber membranes represent good performance in applications of water treatment and heterogeneous catalysis reaction. This general synthesis and solution-processing strategy may herald a new era in promoting the industrial application of MOFs.

Semiflow Microwave Heating Reactor with Resonator Moving Mechanism Applied to Zeolite Synthesis

A semiflow microwave (MW) heating reactor similar to a flow reactor system was developed. Slurry raw materials in the reaction tube were heated continuously and cooled rapidly by moving a thin MW resonator instead of flowing slurry raw materials. From highly viscous mother slurries, Linde-type A (LTA) and faujasite (FAU)-type zeolite nanoparticles of small crystal grains were synthesized quickly. Results show that this heating system can synthesize hydroxy-sodalite (SOD)-type zeolite from coal fly ash particles including those larger than 50 μm. Numerical calculations using the COMSOL Multiphysics program revealed the thermal distribution of liquids of various viscosities using the semiflow MW heating reactor.

Synthesis of zeolitic imidazolate framework-8 and gold nanoparticles in a sustained out-of-equilibrium state

The design and synthesis of crystalline materials are challenging due to the proper control over the size and polydispersity of the samples, which determine their physical and chemical properties and thus applicability. Metal − organic frameworks (MOFs) are promising materials in many applications due to their unique structure. MOFs have been predominantly synthesized by bulk methods, where the concentration of the reagents gradually decreased, which affected the further nucleation and crystal growth. Here we show an out-of-equilibrium method for the generation of zeolitic imidazolate framework-8 (ZIF-8) crystals, where the non-equilibrium crystal growth is maintained by a continuous two-side feed of the reagents in a hydrogel matrix. The size and the polydispersity of the crystals are controlled by the fixed and antagonistic constant mass fluxes of the reagents and by the reaction time. We also present that our approach can be extended to synthesize gold nanoparticles in a redox process.

Tuning the Stability of Liquids by Controlling the Formation of Interfacial Surfactants

Currently, the stability of liquids by nanoparticle surfactants is widely investigated, while the stability of liquids by supramolecular polymer surfactants is rarely involved. Herein, we combine small organic molecules dissolved...

Comprehensive studies of continuous flow reversible addition–fragmentation chain transfer copolymerization and its application for photoimaging materials

Thorough studies of RAFT copolymerization in a continuous flow to gain deeper insights into kinetics, reactivity, and applicability were conducted with monomers and solvents utilizable for chemically amplified resist systems.

Iron-based metal-organic framework: Synthesis, structure and current technologies for water reclamation with deep insight into framework integrity

Water is a supreme requirement for the existence of life, the contamination from the point and non-point sources are creating a great threat to the water ecosystem. Advance tools and techniques are required to restore the water quality and metal-organic framework (MOFs) with a tunable porous structure, striking physical and chemical properties are an excellent candidate for it. Fe-based MOFs, which developed rapidly in recent years, are foreseen as most promising to overcome the disadvantages of traditional water depolluting practices. Fe-MOFs with low toxicity and preferable stability possess excellent performance potential for almost all water remedying techniques in contrast to other MOF structures, especially visible light photocatalysis, Fenton, and Fenton-like heterogeneous catalysis. Fe-MOFs become essential tool for water treatment due to their high catalytic activity, abundant active site and pollutant-specific adsorption. However, the structural degradation under external chemical, photolytic, mechanical, and thermal stimuli is impeding Fe-MOFs from further improvement in activity and their commercialization. Understanding the shortcomings of structural integrity is crucial for large-scale synthesis and commercial implementation of Fe-MOFs-based water treatment techniques. Herein we summarize the synthesis, structure and recent advancements in water remediation methods using Fe-MOFs in particular more attention is paid for adsorption, heterogeneous catalysis and photocatalysis with clear insight into the mechanisms involved. For ease of analysis, the pollutants have been classified into two major classes; inorganic pollutants and organic pollutants. In this review, we present for the first time a detailed insight into the challenges in employing Fe-MOFs for water remediation due to structural instability.

In Situ Investigation of Multicomponent MOF Crystallization during Rapid Continuous Flow Synthesis

Access to the potential applications of metal-organic frameworks (MOFs) depends on rapid fabrication. While there have been advances in the large-scale production of single-component MOFs, rapid synthesis of multicomponent MOFs presents greater challenges. Multicomponent systems subjected to rapid synthesis conditions have the opportunity to form separate kinetic phases that are each built up using just one linker. We sought to investigate whether continuous flow chemistry could be adapted to the rapid formation of multicomponent MOFs, exploring the UMCM-1 and MUF-77 series. Surprisingly, phase pure, highly crystalline multicomponent materials emerge under these conditions. To explore this, in situ WAXS was undertaken to gain an understanding of the formation mechanisms at play during flow synthesis. Key differences were found between the ternary UMCM-1 and the quaternary MUF-7, and key details about how the MOFs form were then uncovered. Counterintuitively, despite consisting of just two ligands UMCM-1 proceeds via MOF-5, whereas MUF-7 consists of three ligands but is generated directly from the reaction mixture. By taking advantage of the scalable high-quality materials produced, C6 separations were achieved in breakthrough settings.

Enabling Technology for Supramolecular Chemistry

Supramolecular materials-materials that exploit non-covalent interactions-are increasing in structural complexity, selectivity, function, stability, and scalability, but their use in applications has been comparatively limited. In this Minireview, we summarize the opportunities presented by enabling technology-flow chemistry, high-throughput screening, and automation-to wield greater control over the processes in supramolecular chemistry and accelerate the discovery and use of self-assembled systems. Finally, we give an outlook for how these tools could transform the future of the field.

Recent advances in process engineering and upcoming applications of metal-organic frameworks

Progress in metal-organic frameworks (MOFs) has advanced from fundamental chemistry to engineering processes and applications, resulting in new industrial opportunities. The unique features of MOFs, such as their permanent porosity, high surface area, and structural flexibility, continue to draw industrial interest outside the traditional MOF field, both to solve existing challenges and to create new businesses. In this context, diverse research has been directed toward commercializing MOFs, but such studies have been performed according to a variety of individual goals. Therefore, there have been limited opportunities to share the challenges, goals, and findings with most of the MOF field. In this review, we examine the issues and demands for MOF commercialization and investigate recent advances in MOF process engineering and applications. Specifically, we discuss the criteria for MOF commercialization from the views of stability, producibility, regulations, and production cost. This review covers progress in the mass production and formation of MOFs along with future applications that are not currently well known but have high potential for new areas of MOF commercialization.

From circular synthesis to material manufacturing: advances, challenges, and future steps for using flow chemistry in novel application area

We review the emerging use of flow technologies for circular chemistry and material manufacturing, highlighting advances, challenges, and future directions.

One-Step Synthesis of Spin Crossover Nanoparticles Using Flow Chemistry and Supercritical CO2

Switchable materials are increasingly considered for implementation in devices or multifunctional composites leading to a strong need in terms of reliable synthetic productions of well-defined objects. Here, an innovative and robust template-free continuous process was developed to synthesize nanoparticles of a switchable coordination polymer, including the use of supercritical CO₂ , aiming at both quenching the particle growth and drying the powder. This all-in-one process offers a 12-fold size reduction in a few minutes while maintaining the switching properties of the selected spin crossover coordination polymer.

Metal-Free ATRP Catalyzed by Visible Light in Continuous Flow

ATRP of methyl methacrylate catalyzed by Eosin Y, an inexpensive and an environmental benign dye, was performed in a continuous flow reactor made of FEP tubing and irradiated by visible light green LEDs. The reaction under flow conditions was significantly more rapid and controlled compared to that in batch giving 90% of polymerization after only 3 h of irradiation. The formed polymers in flow have M n measured by GPC and DOSY NMR in accordance with the theoretical values and show low dispersities (Ð < 1.5). The livingness of the polymers has been confirmed by LED on and LED off experiments and by the synthesis of block copolymers. The protocol described herein serves as a "proof of concept" of using Eosin Y as a photocatalyst for controlled polymerization and of using 1D and 2D NMR for polymer characterization. The protocol could be replicated in the future for other reversible-deactivation radical polymerizations.

Rapid Millifluidic Synthesis of Stable High Magnetic Moment FexCy Nanoparticles for Hyperthermia

A millifluidic reactor with a 0.76 mm internal diameter was utilized for the synthesis of monodisperse, high magnetic moment, iron carbide (FexCy) nanoparticles by thermal decomposition of iron pentacarbonyl (Fe(CO)5) in 1-octadecene in the presence of oleylamine at 22 min nominal residence time. The effect of reaction conditions (temperature and pressure) on the size, morphology, crystal structure, and magnetic properties of the nanoparticles was investigated. The system developed facilitated the thermal decomposition of precursor at reaction conditions (up to 265 °C and 4 bar) that cannot be easily achieved in conventional batch reactors. The degree of carbidization was enhanced by operating at elevated temperature and pressure. The nanoparticles synthesized in the flow reactor had size 9-18 nm and demonstrated high saturation magnetization (up to 164 emu/gFe). They further showed good stability against oxidation after 2 months of exposure in air, retaining good saturation magnetization values with a change of no more than 10% of the initial value. The heating ability of the nanoparticles in an alternating magnetic field was comparable with other ferrites reported in the literature, having intrinsic loss power values up to 1.52 nHm2 kg-1.

Continuous-Flow Synthesis of ZIF-8 Biocomposites with Tunable Particle Size

Zeolitic imidazolate framework (ZIF) biocomposites show the capacity to protect and deliver biotherapeutics. To date, the progress in this research area is based on laboratory batch methods. Now, the first continuous flow synthetic method is presented for the encapsulation of a model protein (bovine serum albumin, BSA) and a clinical therapeutic (α1-antitrypsin, AAT) in ZIF-8. The in situ kinetics of nucleation, growth, and crystallization of BSA@ZIF-8 were studied by small-angle X-ray scattering. By controlling the injection time of ethanol, the particle growth could be quenched by ethanol-induced crystallization from amorphous particles to ZIF-8 crystals. The particle size of the biocomposite was tuned in the 40-100 nm range by varying residence time prior to introduction of ethanol. As a proof-of-concept, this procedure was used for the encapsulation of AAT in ZIF-8. Upon release of the biotherapeutic from the composite, the trypsin inhibitor function of AAT was preserved.

Continuous syntheses of carbon-supported Pd and Pd@Pt core-shell nanoparticles using a flow-type single-mode microwave reactor

Continuous syntheses of carbon-supported Pd@Pt core-shell nanoparticles were performed using microwave-assisted flow reaction in polyol to synthesize carbon-supported core Pd with subsequent direct coating of a Pt shell. By optimizing the amount of NaOH, almost all Pt precursors contributed to shell formation without specific chemicals.

Flow-controlled synthesis of gold nanoparticles in a biphasic system with inline liquid–liquid separation

4-Dimethylaminopyridine-stabilised gold nanoparticles are synthesised in a biphasic flow reactor system using organic/aqueous membrane separators and gas-permeable tubing.

Rapid production of block copolymer nano-objects via continuous-flow ultrafast RAFT dispersion polymerisation

Continuous-flow reactors are exploited for conducting ultrafast RAFT dispersion polymerisation for the preparation of diblock copolymer nanoparticles.

Continuous-Flow Oxidation of HMF to FDCA by Resin-Supported Platinum Catalysts in Neat Water

The oxidation reaction of 5-hydroxymethylfurfural to the bioplastic monomer 2,5-furandicarboxylic acid over heterogenous resin-supported Pt catalysts was investigated in detail, under continuous flow, base-free conditions, and in neat water. The product was continuously obtained in 99 % yield by running the reaction at 120 °C, 303 s residence time, 1.2 mL min^-1 O₂ flow rate, and 7.7 bar O₂ pressure. The product was isolated with a high space-time-yield of 46.0 g L^-1  h^-1 without purifications or acid/base treatments.

Synthesis of Fused Indolines by Interrupted Fischer Indolization in a Microfluidic Reactor

This study describes our development of a microfluidic reaction scheme for the synthesis of fused indoline ring systems found in several bioactive compounds. We have utilized a continuous-flow microfluidic reactor for the reaction of hydrazines with latent aldehydes through the interrupted Fischer indolization reaction to form fused indoline and azaindoline products. We have identified optimal conditions and evaluated the scope of this microfluidic reaction using various hydrazine and latent aldehyde surrogates. This green chemistry approach can be of general utility to rapidly produce indoline scaffolds and intermediates in a continuous manner.

All-aqueous continuous-flow RAFT dispersion polymerisation for efficient preparation of diblock copolymer spheres, worms and vesicles

A continuous-flow platform enables rapid kinetic profiling and accelerated production of block copolymer nano-objects via RAFT aqueous dispersion polymerization.

Emerging porous materials in confined spaces: from chromatographic applications to flow chemistry

Porous materials confined within capillary columns/microfluidic devices are discussed, and progress in chromatographic and membrane separations and catalysis is reviewed.

Ultrafast synthesis of zeolites: breakthrough, progress and perspective

An ultrafast route was established to synthesize industrially important zeolites in several minutes, which represents a breakthrough in the field of zeolite synthesis.

Continuous flow synthesis of ordered porous materials: from zeolites to metal–organic frameworks and mesoporous silica

Herein we review the concepts, challenges and recent developments on the continuous flow synthesis of ordered porous materials.

Low-Temperature Continuous-Flow Dehydration of Xylose Over Water-Tolerant Niobia-Titania Heterogeneous Catalysts

The sustainable conversion of vegetable biomass-derived feeds to useful chemicals requires innovative routes meeting environmental and economical criteria. The approach herein pursued is the synthesis of water-tolerant, unconventional solid acid monolithic catalysts based on a mixed niobia-titania skeleton building up a hierarchical open-cell network of meso- and macropores, and tailored for use under continuous-flow conditions. The materials were characterized by spectroscopic, microscopy, and diffraction techniques, showing a reproducible isotropic structure and an increasing Lewis/Brønsted acid sites ratio with increasing Nb content. The catalytic dehydration reaction of xylose to furfural was investigated as a representative application. The efficiency of the catalyst was found to be dramatically affected by the niobia content in the titania lattice. The presence of as low as 2 wt % niobium resulted in the highest furfural yield at 140 °C under continuous-flow conditions, by using H₂ O/γ-valerolactone as a safe monophasic solvent system. The interception of a transient 2,5-anhydroxylose species suggested the dehydration process occurs via a cyclic intermediates mechanism. The catalytic activity and the formation of the anhydro intermediate were related to the Lewis acid sites (LAS)/Brønsted acid sites (BAS) ratio and indicated a significant contribution of xylose-xylulose isomerization. No significant catalyst deactivation was observed over 4 days usage.

Sonochemical preparation of alumina-spheres loaded with Pd nanoparticles for 2-butyne-1,4-diol semi-hydrogenation in a continuous flow microwave reactor

A novel protocol for microwave-assisted alkyne semi-hydrogenation under heterogeneous catalysis in a continuous flow reactor is reported herein. This challenging task has been accomplished using a multifaceted strategy which includes the ultrasound-assisted preparation of Pd nanoparticles (average Ø 3.0 ± 0.5 nm) that were synthesized on the μ-metric pores of sintered alumina spheres (Ø 0.8 mm) and a continuous flow reaction under H2 (flow rate 7.5 mL min-1) in a microwave reactor (counter-pressure 4.5 bar). The semi-hydrogenation of 2-butyne-1,4-diol in ethanol was chosen as a model reaction for the purposes of optimization. The high catalyst efficiency of the process, in spite of the low Pd loading (Pd content 111.15 mg kg-1 from ICP-MS), is due to the pivotal role of ultrasound in generating a regular distribution of Pd nanoparticles across the entire support surface. Ultrasound promotes the nucleation, rather than the growth, of crystalline Pd nanoparticles and does so within a particularly narrow Gaussian size distribution. High conversion (>90.5%) and selectivity to (Z)-2-butene-1,4-diol (95.20%) have been achieved at an alkyne solution flow rate of 10 mL min-1. The lead-free, alumina-stabilized Pd catalyst was fully characterized by TEM, HR-TEM, EDX, IR, XRPD and AAS. Highly dispersed Pd nanoparticles have proven themselves to be stable under the reaction conditions employed. The application of the method is subject to the dielectric properties of substrates and solvents, and is therefore hardly applicable to apolar alkynes. Considering the small volume of the reaction chamber, microwave-assisted flow hydrogenation has proven itself to be a safe procedure and one that is suitable for further scaling up to industrial application.

Covalent organic frameworks (COFs): perspectives of industrialization

In this highlight, we review the state-of-the-art development of COFs from an industrial point of view in five aspects, including their types, growth mechanisms, synthetic methods, processability and applications.

Continuous-flow chemistry for the determination of comonomer reactivity ratios

Continuous-flow chemistry provides an operationally simple and reproducible method for the determination of comonomer reactivity ratios in a single afternoon.