Vortex Fluidic Chemical Transformations

Spinning Reactors for Process Intensification of Flow Photochemistry

The design of new and more sustainable synthetic protocols to access new materials or valuable compounds will have a high impact on the broader chemistry community. In this sense, continuous-flow photochemistry has emerged as a powerful technique which has been employed successfully in various areas such as biopharma, organic chemistry, as well as materials science. However, it is important to note that chemical processes must not only advance towards new or improved chemical transformations, but also implement new technologies that enable new process opportunities. For this reason, the design of novel photoreactors is key to advancing photochemical strategies. In this sense, the use of equipment and techniques embracing processes intensification is important in developing more sustainable protocols. Among the most recent applications, spinning continuous flow reactors, such as rotor reactors or vortex reactors, have shown promising performance as new synthetic tools. Nevertheless, there is currently no review in the literature that effectively summarizes and showcases the most recent applications of such type of photoreactors. Herein, we highlight fundamental aspects and applications of two categories of spinning reactors, the Spinning Disc Reactors (SDRs) and Thin Film Vortex reactors, critiquing the scope and limitations of these advanced processing technologies. Further, we take a view on the future of spinning reactors in flow as a synthetic toolbox to explore new photochemical transformations.

Multiphasic Continuous-Flow Reactors for Handling Gaseous Reagents in Organic Synthesis: Enhancing Efficiency and Safety in Chemical Processes

The use of reactive gaseous reagents for the production of active pharmaceutical ingredients (APIs) remains a scientific challenge due to safety and efficiency limitations. The implementation of continuous-flow reactors has resulted in rapid development of gas-handling technology because of several advantages such as increased interfacial area, improved mass- and heat transfer, and seamless scale-up. This technology enables shorter and more atom-economic synthesis routes for the production of pharmaceutical compounds. Herein, we provide an overview of literature from 2016 onwards in the development of gas-handling continuous-flow technology as well as the use of gases in functionalization of APIs.

Vortex fluidic regulated phospholipid equilibria involving liposomes down to sub-micelle size assemblies

Conventional channel-based microfluidic platforms have gained prominence in controlling the bottom-up formation of phospholipid based nanostructures including liposomes. However, there are challenges in the production of liposomes from rapidly scalable processes. These have been overcome using a vortex fluidic device (VFD), which is a thin film microfluidic platform rather than channel-based, affording ∼110 nm diameter liposomes. The high yielding and high throughput continuous flow process has a 45° tilted rapidly rotating glass tube with an inner hydrophobic surface. Processing is also possible in the confined mode of operation which is effective for labelling pre-VFD-prepared liposomes with fluorophore tags for subsequent mechanistic studies on the fate of liposomes under shear stress in the VFD. In situ small-angle neutron scattering (SANS) established the co-existence of liposomes ∼110 nm with small rafts, micelles, distorted micelles, or sub-micelle size assemblies of phospholipid, for increasing rotation speeds. The equilibria between these smaller entities and ∼110 nm liposomes for a specific rotational speed of the tube is consistent with the spatial arrangement and dimensionality of topological fluid flow regimes in the VFD. The prevalence for the formation of ∼110 nm diameter liposomes establishes that this is typically the most stable structure from the bottom-up self-assembly of the phospholipid and is in accord with dimensions of exosomes.

Enhanced mechanical strength of vortex fluidic mediated biomass-based biodegradable films composed from agar, alginate and kombucha cellulose hydrolysates

Biodegradable, biomass derived kombucha cellulose films with increased mechanical strength from 9.98 MPa to 18.18 MPa were prepared by vortex fluidic device (VFD) processing. VFD processing not only reduced the particle size of kombucha cellulose from approximate 2 μm to 1 μm, but also reshaped its structure from irregular to round. The increased mechanical strength of these polysaccharide-derived films is the result of intensive micromixing and high shear stress of a liquid thin film in a VFD. This arises from the incorporation at the micro-structural level of uniform, unidirectional strings of kombucha cellulose hydrolysates, which resulted from the topological fluid flow in the VFD. The biodegradability of the VFD generated polymer films was not compromised relative to traditionally generated films. Both films were biodegraded within 5 days.

Vortex fluidic high shear induced crystallisation of fullerene C70 into nanotubules

Hollow C₇₀ nanotubules are formed under high shear within the thin film of a vortex fluidic device (VFD) without the need for using auxiliary reagents, high temperatures and pressures, and/or requiring downstream processing. This novel bottom-up crystallisation process involves intense micro mixing of two liquids (toluene solution of C₇₀ and anti-solvent, isopropyl alcohol) within a thin film in the VFD to precisely control the hierarchical assembly of C₇₀ molecules into hollow nanotubules. The mechanism of self-assembly was consistent with them being a mould of the high shear double helical topological flow from Faraday waves coupled with Coriolis forces generated within the thin film.

Hydrogel-Film-Fabricated Fluorescent Biosensors with Aggregation-Induced Emission for Albumin Detection through the Real-Time Modulation of a Vortex Fluidic Device

Hydrogels have various promising prospects as a successful platform for detecting biomarkers, and human serum albumin (HSA) is an important biomarker in the diagnosis of kidney diseases. However, the difficult-to-control passive diffusion kinetics of hydrogels is a major factor affecting detection performance. This study focuses on using hydrogels embedded with aggregation-induced emission (AIE) fluorescent probe TC426 to detect HSA in real time. The vortex fluidic device (VFD) technology is used as a rotation strategy to control the reaction kinetics and micromixing during measurement. The results show that the introduction of VFD could significantly accelerate its fluorescence response and effectively improve the diffusion coefficient, while VFD processing could regulate passive diffusion into active diffusion, offering a new method for future sensing research.

High Shear Thin Film Synthesis of Partially Oxidized Gallium and Indium Composite 2D Sheets

Reducing resistance in silicon-based devices is important as they get miniaturized further. 2D materials offer an opportunity to increase conductivity whilst reducing size. A scalable, environmentally benign method is developed for preparing partially oxidized gallium/indium sheets down to 10 nm thick from a eutectic melt of the two metals. Exfoliation of the planar/corrugated oxide skin of the melt is achieved using the vortex fluidic device with a variation in composition across the sheets determined using Auger spectroscopy. From an application perspective, the oxidized gallium indium sheets reduce the contact resistance between metals such as platinum and silicon (Si) as a semiconductor. Current-voltage measurements between a platinum atomic force microscopy tip and a Si-H substrate show that the current switches from being a rectifier to a highly conducting ohmic contact. These characteristics offer new opportunities for controlling Si surface properties at the nanoscale and enable the integration of new materials with Si platforms.

Process intensification in continuous flow organic synthesis with enabling and hybrid technologies

Industrial organic synthesis is time and energy consuming, and generates substantial waste. Traditional conductive heating and mixing in batch reactors is no longer competitive with continuous-flow synthetic methods and enabling technologies that can strongly promote reaction kinetics. These advances lead to faster and simplified downstream processes with easier workup, purification and process scale-up. In the current Industry 4.0 revolution, new advances that are based on cyber-physical systems and artificial intelligence will be able to optimize and invigorate synthetic processes by connecting cascade reactors with continuous in-line monitoring and even predict solutions in case of unforeseen events. Alternative energy sources, such as dielectric and ohmic heating, ultrasound, hydrodynamic cavitation, reactive extruders and plasma have revolutionized standard procedures. So-called hybrid or hyphenated techniques, where the combination of two different energy sources often generates synergistic effects, are also worthy of mention. Herein, we report our consolidated experience of all of these alternative techniques.

Continuous flow fabrication of green graphene oxide in aqueous hydrogen peroxide

Highly processible graphene oxide (GO) has a diversity of applications as a material readily dispersed in aqueous media. However, methods for preparing such free-standing GO use hazardous and toxic reagents and generate significant waste streams. This is an impediment for uptake of GO in any application, for developing sustainable technologies and industries, and overcoming this remains a major challenge. We have developed a robust scalable continuous flow method for fabricating GO directly from graphite in 30% aqueous hydrogen peroxide which dramatically minimises the generation of waste. The process features the continuous flow thin film microfluidic vortex fluidic device (VFD), operating at specific conditions while irradiated sequentially by UV LED than a NIR pulsed laser. The resulting 'green' graphene oxide (gGO) has unique properties, possessing highly oxidized edges with large intact sp² domains which gives rise to exceptional electrical and optical properties, including purple to deep blue emission of narrow full width at half maximum (<35 nm). Colloidally stable gGO exhibits cytotoxicity owing to the oxidised surface groups while solid-state films of gGO are biocompatible. The continuous flow method of generating gGO also provides unprecedented control of the level of oxidation and its location in the exfoliated graphene sheets by harnessing the high shear topological fluid flows in the liquid, and varying the wavelength, power and pulse frequency of the light source.

Novel α-Aminophosphonates and α-Aminophosphonic Acids: Synthesis, Molecular Docking and Evaluation of Antifungal Activity against Scedosporium Species

The Scedosporium genus is an emerging pathogen with worldwide prevalence and high mortality rates that gives multidrug resistance to antifungals; therefore, pharmacological alternatives must be sought for the treatment of diseases caused by this fungus. In the present project, six new α-aminophosphates were synthesized by the Kabachnik–Fields multicomponent reaction by vortex agitation, and six new monohydrolyzed α-aminophosphonic acids were synthesized by an alkaline hydrolysis reaction. Antifungal activity was evaluated using the agar diffusion method as an initial screening to determine the most active compound compared to voriconazole; then it was evaluated against 23 strains of the genus Scedosporium following the M38-A2 protocol from CLSI (activity range: 648.76–700 µg/mL). Results showed that compound 5f exhibited the highest antifungal activity according to the agar diffusion method (≤1 mg/mL). Cytotoxicity against healthy COS-7 cells was also evaluated by the MTT assay and it was shown that compound 5f exhibits a lower toxicity in comparison to voriconazole at the same concentration (1000 µM). A docking study was conducted afterwards, showing that the possible mechanism of action of the compound is through the inhibition of allosteric 14-α-demethylase. Taking these results as a basis, 5f is presented as a compound with attractive properties for further studies.

Vortex fluidic induced mass transfer across immiscible phases

Mixing immiscible liquids typically requires the use of auxiliary substances including phase transfer catalysts, microgels, surfactants, complex polymers and nano-particles and/or micromixers. Centrifugally separated immiscible liquids of different densities in a 45° tilted rotating tube offer scope for avoiding their use. Micron to submicron size topological flow regimes in the thin films induce high inter-phase mass transfer depending on the nature of the two liquids. A hemispherical base tube creates a Coriolis force as a 'spinning top' (ST) topological fluid flow in the less dense liquid which penetrates the denser layer of liquid, delivering liquid from the upper layer through the lower layer to the surface of the tube with the thickness of the layers determined using neutron imaging. Similarly, double helical (DH) topological flow in the less dense liquid, arising from Faraday wave eddy currents twisted by Coriolis forces, impact through the less dense liquid onto the surface of the tube. The lateral dimensions of these topological flows have been determined using 'molecular drilling' impacting on a thin layer of polysulfone on the surface of the tube and self-assembly of nanoparticles at the interface of the two liquids. At high rotation speeds, DH flow also occurs in the denser layer, with a critical rotational speed reached resulting in rapid phase demixing of preformed emulsions of two immiscible liquids. ST flow is perturbed relative to double helical flow by changing the shape of the base of the tube while maintaining high mass transfer between phases as demonstrated by circumventing the need for phase transfer catalysts. The findings presented here have implications for overcoming mass transfer limitations at interfaces of liquids, and provide new methods for extractions and separation science, and avoiding the formation of emulsions.

Technological Innovations in Photochemistry for Organic Synthesis: Flow Chemistry, High-Throughput Experimentation, Scale-up, and Photoelectrochemistry

Photoinduced chemical transformations have received in recent years a tremendous amount of attention, providing a plethora of opportunities to synthetic organic chemists. However, performing a photochemical transformation can be quite a challenge because of various issues related to the delivery of photons. These challenges have barred the widespread adoption of photochemical steps in the chemical industry. However, in the past decade, several technological innovations have led to more reproducible, selective, and scalable photoinduced reactions. Herein, we provide a comprehensive overview of these exciting technological advances, including flow chemistry, high-throughput experimentation, reactor design and scale-up, and the combination of photo- and electro-chemistry.

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.

Exploiting angled thin film vortex microfluidics for expeditious syntheses of iminosugars

Iminosugars are important compounds in the area of carbohydrate-based therapeutics. A simple synthetic methodology utilizing the vortex fluidic thin film microfluidic reactor is effective in the synthesis of such compounds for diverse reaction types, with the optimal tilt angle of the reactor at 45° and the optimal rotational speed dependent on the nature of the liquid.

Iminosugars are important compounds in the area of carbohydrate-based therapeutics. The vortex fluidic thin film microfluidic reactor is effective in the synthesis of such compounds.

High shear in situ exfoliation of 2D gallium oxide sheets from centrifugally derived thin films of liquid gallium

A diversity of two-dimensional nanomaterials has recently emerged with recent attention turning to the post-transition metal elements, in particular material derived from liquid metals and eutectic melts below 330 °C where processing is more flexible and in the temperature regime suitable for industry. This has been explored for liquid gallium using an angled vortex fluidic device (VFD) to fabricate ultrathin gallium oxide (Ga₂O₃) sheets under continuous flow conditions. We have established the nanosheets to form highly insulating material and have electrocatalytic activity for hydrogen evolution, with a Tafel slope of 39 mV dec^-1 revealing promoting effects of the surface oxidation (passivation layer).

In Situ Monitored Vortex Fluidic-Mediated Protein Refolding/Unfolding Using an Aggregation-Induced Emission Bioprobe

Protein folding is important for protein homeostasis/proteostasis in the human body. We have established the ability to manipulate protein unfolding/refolding for β-lactoglobulin using the induced mechanical energy in the thin film microfluidic vortex fluidic device (VFD) with monitoring as such using an aggregation-induced emission luminogen (AIEgen), TPE-MI. When denaturant (guanidine hydrochloride) is present with β-lactoglobulin, the VFD accelerates the denaturation reaction in a controlled way. Conversely, rapid renaturation of the unfolded protein occurs in the VFD in the absence of the denaturant. The novel TPE-MI reacts with exposed cysteine thiol when the protein unfolds, as established with an increase in fluorescence intensity. TPE-MI provides an easy and accurate way to monitor the protein folding, with comparable results established using conventional circular dichroism. The controlled VFD-mediated protein folding coupled with in situ bioprobe AIEgen monitoring is a viable methodology for studying the denaturing of proteins.

Sub-micron moulding topological mass transport regimes in angled vortex fluidic flow

Shear stress in dynamic thin films, as in vortex fluidics, can be harnessed for generating non-equilibrium conditions, but the nature of the fluid flow is not understood. A rapidly rotating inclined tube in the vortex fluidic device (VFD) imparts shear stress (mechanical energy) into a thin film of liquid, depending on the physical characteristics of the liquid and rotational speed, ω, tilt angle, θ, and diameter of the tube. Through understanding that the fluid exhibits resonance behaviours from the confining boundaries of the glass surface and the meniscus that determines the liquid film thickness, we have established specific topological mass transport regimes. These topologies have been established through materials processing, as spinning top flow normal to the surface of the tube, double-helical flow across the thin film, and spicular flow, a transitional region where both effects contribute. The manifestation of mass transport patterns within the film have been observed by monitoring the mixing time, temperature profile, and film thickness against increasing rotational speed, ω. In addition, these flow patterns have unique signatures that enable the morphology of nanomaterials processed in the VFD to be predicted, for example in reversible scrolling and crumbling graphene oxide sheets. Shear-stress induced recrystallisation, crystallisation and polymerisation, at different rotational speeds, provide moulds of high-shear topologies, as 'positive' and 'negative' spicular flow behaviour. 'Molecular drilling' of holes in a thin film of polysulfone demonstrate spatial arrangement of double-helices. The grand sum of the different behavioural regimes is a general fluid flow model that accounts for all processing in the VFD at an optimal tilt angle of 45°, and provides a new concept in the fabrication of novel nanomaterials and controlling the organisation of matter.

A comprehensive review of flow chemistry techniques tailored to the flavours and fragrances industries

Due to their intrinsic physical properties, which includes being able to perform as volatile liquids at room and biological temperatures, fragrance ingredients/intermediates make ideal candidates for continuous-flow manufacturing. This review highlights the potential crossover between a multibillion dollar industry and the flourishing sub-field of flow chemistry evolving within the discipline of organic synthesis. This is illustrated through selected examples of industrially important transformations specific to the fragrances and flavours industry and by highlighting the advantages of conducting these transformations by using a flow approach. This review is designed to be a compendium of techniques and apparatus already published in the chemical and engineering literature which would constitute a known solution or inspiration for commonly encountered procedures in the manufacture of fragrance and flavour chemicals.

Scalability of photochemical reactions in continuous flow mode

Continuous flow photochemistry as a field has witnessed an increasing popularity over the last decade in both academia and industry. Key drivers for this development are safety, practicality as well as the ability to rapidly access complex chemical structures. Continuous flow reactors, whether home-built or from commercial suppliers, additionally allow for creating valuable target compounds in a reproducible and automatable manner. Recent years have furthermore seen the advent of new energy efficient LED lamps that in combination with innovative reactor designs provide a powerful means to increasing both the practicality and productivity of modern photochemical flow reactors. In this review article we wish to highlight key achievements pertaining to the scalability of such continuous photochemical processes.

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Application of microfluidic technology in food processing

Microfluidic technology is interdisciplinary with a diversity of applications including in food processing. The rapidly growing global population demands more advanced technologies in food processing to produce more functional and safer food, and for such processing microfluidic devices are a popular choice. This review critically critiques the state-of-the-art designs of microfluidic devices and their applications in food processing, and identifies the key research trends and future research directions for maximizing the value of microfluidic technology. Capillary, planar, and terrace droplet generation systems are currently used in the design of microfluidic devices, each with their strengths and weaknesses as applied in food processing, for emulsification, food safety measurements, and bioactive compound extraction. Conventional channel-based microfluidic devices are prone to clogging, and have high labor costs and low productivity, and their "directional pressure" restricts scaling-up capabilities. These disadvantages can be overcome by using "inside-out centrifugal force" and the new generation continuous flow thin-film microfluidic Vortex Fluidic Device (VFD) which facilitates translating laboratory processing into commercial products. Also highlighted is controlling protein-polysaccharide interactions and the applications of the produced ingredients in food formulations as targets for future development in the field.

Azide-alkyne cycloadditions in a vortex fluidic device: enhanced "on water" effects and catalysis in flow

The Vortex Fluidic Device is a flow reactor that processes reactions in thin films. Running the metal-free azide-alkyne cycloaddition in this reactor revealed a dramatic enhancement of the "on water" effect. For the copper-catalyzed azide-alkyne cycloaddition, stainless steel or copper jet feeds were effective reservoirs of active copper catalyst.

Vortex fluidic mediated encapsulation of functional fish oil featuring in situ probed small angle neutron scattering

Major challenges for optimizing the benefits of fish oil on human health are improved bioavailability while overcoming the strong odor and avoiding significant oxidation of the omega-3 polyunsaturated fatty acids (PUFAs). The scalable continuous flow thin film vortex fluidic device (VFD) improves the Tween 20 encapsulation of fish oil relative to conventional homogenization processing, with the fish oil particles significantly smaller and the content of the valuable omega-3 fatty acids higher. In addition, after 14 days storage the remaining omega-3 fatty acids content was higher, from ca 31.0% for raw fish oil to ca 62.0% of freeze-dried encapsulated fish oil. The VFD mediated encapsulated fish oil was used to enrich the omega-3 fatty acid content of apple juice, as a model water-based food product, without changing its sensory values. The versatility of the VFD was further demonstrated in forming homogenous suspensions of fish oil containing water-insoluble bioactive molecules, curcumin and quercetin. We have also captured, for the first time, real-time structural changes in nanoencapsulation by installing a VFD with in in situ small angle neutron scattering. Real-time measurements afford valuable insights about self-assembly in solution.

Tuning Surface Morphology of Fluorescent Hydrogels Using a Vortex Fluidic Device

In recent decades, microfluidic techniques have been extensively used to advance hydrogel design and control the architectural features on the micro- and nanoscale. The major challenges with the microfluidic approach are clogging and limited architectural features: notably, the creation of the sphere, core-shell, and fibers. Implementation of batch production is almost impossible with the relatively lengthy time of production, which is another disadvantage. This minireview aims to introduce a new microfluidic platform, a vortex fluidic device (VFD), for one-step fabrication of hydrogels with different architectural features and properties. The application of a VFD in the fabrication of physically crosslinked hydrogels with different surface morphologies, the creation of fluorescent hydrogels with excellent photostability and fluorescence properties, and tuning of the structure-property relationship in hydrogels are discussed. We conceive, on the basis of this minireview, that future studies will provide new opportunities to develop hydrogel nanocomposites with superior properties for different biomedical and engineering applications.

Continuous flow vortex fluidic-mediated exfoliation and fragmentation of two-dimensional MXene

MXene (Ti₂CT _x ) is exfoliated in a vortex fluidic device (VFD), as a thin film microfluidic platform, under continuous flow conditions, down to ca 3 nm thin multi-layered two-dimensional (2D) material, as determined using AFM. The optimized process, under an inert atmosphere of nitrogen to avoid oxidation of the material, was established by systematically exploring the operating parameters of the VFD, along with the concentration of the dispersed starting material and the choice of solvent, which was a 1 : 1 mixture of isopropyl alcohol and water. There is also some fragmentation of the 2D material into nanoparticles ca 68 nm in diameter.

A hyper-branched polymer tunes the size and enhances the fluorescent properties of aggregation-induced emission nanoparticles

The host-guest interaction approach, specifically via the formation of hydrogen bonds, is an effective strategy for preparing luminescent hyper-branched polymers. The challenge here is how to optimize the binding strength and particle size to tune fluorescence properties. The aim of the current study was to optimize the guest (aggregation-induced emission molecule, AIE)-host (hyper-branched polymer, HBP) interaction in the development of an HBP/AIE complex (AIE-HBP) with tunable luminescence properties via the formation of strong hydrogen bonds. Overall, a simple one-step method for the preparation of AIE-HBP was demonstrated. The method was based on the formation of hydrogen bonds among AIE molecules and HBP molecules, resulting in the development of a stable AIE-polymer complex. Compared to other techniques (direct polymerization or post-functionalization), the proposed technique was much simpler. The fluorescence properties of AIE-HBP were significantly enhanced compared to AIE alone and could be tuned during the formation of AIE-HBP by using a novel vortex fluidic device (VFD). The as-prepared AIE-HBP can be used to simultaneously enhance the mechanical properties of hydrogels while increasing the fluorescence properties.

Vortex fluidics-mediated DNA rescue from formalin-fixed museum specimens

DNA from formalin-preserved tissue could unlock a vast repository of genetic information stored in museums worldwide. However, formaldehyde crosslinks proteins and DNA, and prevents ready amplification and DNA sequencing. Formaldehyde acylation also fragments the DNA. Treatment with proteinase K proteolyzes crosslinked proteins to rescue the DNA, though the process is quite slow. To reduce processing time and improve rescue efficiency, we applied the mechanical energy of a vortex fluidic device (VFD) to drive the catalytic activity of proteinase K and recover DNA from American lobster tissue (Homarus americanus) fixed in 3.7% formalin for >1-year. A scan of VFD rotational speeds identified the optimal rotational speed for recovery of PCR-amplifiable DNA and while 500+ base pairs were sequenced, shorter read lengths were more consistently obtained. This VFD-based method also effectively recovered DNA from formalin-preserved samples. The results provide a roadmap for exploring DNA from millions of historical and even extinct species.

Continuous Flow Photochemistry for the Preparation of Bioactive Molecules

The last decade has witnessed a remarkable development towards improved and new photochemical transformations in response to greener and more sustainable chemical synthesis needs. Additionally, the availability of modern continuous flow reactors has enabled widespread applications in view of more streamlined and custom designed flow processes. In this focused review article, we wish to evaluate the standing of the field of continuous flow photochemistry with a specific emphasis on the generation of bioactive entities, including natural products, drugs and their precursors. To this end we highlight key developments in this field that have contributed to the progress achieved to date. Dedicated sections present the variety of suitable reactor designs and set-ups available; a short discussion on the relevance of greener and more sustainable approaches; and selected key applications in the area of bioactive structures. A final section outlines remaining challenges and areas that will benefit from further developments in this fast-moving area. It is hoped that this report provides a valuable update on this important field of synthetic chemistry which may fuel developments in the future.

Vortex Fluidic Ethenolysis, Integrating a Rapid Quench of Ruthenium Olefin Metathesis Catalysts

Ruthenium-catalysed ethenolysis occurs in a vortex fluidic device (VFD) – a scalable, thin-film microfluidic continuous flow process. This process takes advantage of the efficient mass transfer of gaseous reagents into the dynamic thin film of liquid. Also reported is the rapid quenching of the ruthenium-based olefin metathesis catalyst by the addition of a saturated solution of N-acetyl-l-cysteine in MeCN, as a convenient alternative to previously reported quenching methods.

Dynamic thin film mediated slicing of boron nitride nanotubes

A method has been developed to slice boron nitride nanotubes BNNTs under continuous flow in a vortex fluidic device (VFD), along with a method to partially purify the as received BNNT containing material. The latter involves heating the BNNTs to 600 °C followed by dispersing in a 1 : 3 isopropyl alcohol (IPA) and water mixture at 100 °C. The VFD mediated slicing of the BNNTs comprises irradiating the rapidly rotating glass tube (20 mm OD) with a pulsed Nd:YAG laser. Systematically exploring the operating parameter space of the VFD established slicing of ca. 200 μm long purified BNNTs down to 340 nm to 400 nm, in ca. 53% yield, in a 1 : 1 mixture of IPA and water, in the absence of reagents/harsh chemicals, at a flow rate of 0.45 mL min^-1, a concentration of 0.1 mg mL^-1 BNNTs and an 8.5k rpm rotational speed, with the pulsed laser operating at 1064 nm and 250 mJ per pulse.

Vertically aligned laser sliced MWCNTs

Applications of multi-walled carbon nanotubes (MWCNTs) benefit from the availability of specific lengths of the material while keeping the outer walls pristine, for example, for applications requiring vertically aligned tubes. To this end, a simple and effective continuous flow 'top down' process to control the length of sliced MWCNTs has been developed using a vortex fluidic device (VFD) coupled with a 1064 nm pulse laser, with the process in the absence of chemicals and any auxiliary substances. Three different length distributions of the sliced MWCNTs, centered at 75 ± 2.1 nm, 300 ± 1.8 nm and 550 ± 1.4 nm, have been generated with the length depending on the VFD operating parameters and laser energy, with the processing resulting in a decrease in side wall defects of the material. We also show the ability to vertically self assemble short MWCNTs on a silicon substrate with control of the surface density coverage using a simple dipping and rinsing method.

High-Yield Continuous-Flow Synthesis of Spheroidal C60@Graphene Composites as Supercapacitors

Graphene spheres confining fullerene C₆₀ are quantitatively formed under high-shear and continuous-flow processing using a vortex fluidic device (VFD). This involves intense micromixing a colloidal suspension of graphite in DMF and an o-xylene solution of C₆₀ at room temperature in the absence of surfactants and other auxiliary substances. The diameters of the composite spheres, C₆₀@graphene, can be controlled with size distributions ranging from 1.5 to 3.5 μm, depending on the VFD operating parameters, including rotational speed, flow rate, relative ratio of C₆₀ to graphite, and the concentration of fullerene. An electrode of the composite material has high cycle stability, with a high areal capacitance of 103.4 mF cm^-2, maintaining its capacitances to 24.7 F g^-1 and 86.4 mF cm^-2 (83.5%) at a high scan rate of 100 mV s^-1.

Continuous flow photolytic reduction of graphene oxide

Reduced graphene oxide (rGO) is generated from GO dispersed in water under continuous flow in the absence of harsh reducing agents, in a vortex fluidic device, such that the processing is scalable with uniformity of the product. This involves simultaneously UV irradiating (λ = 254 nm, 20 W) the dynamic thin film in the rapidly rotating glass tube in the microfluidic platform. The rGO is comparable to that formed using waste generating chemical based processing, with a film of the material having a resistance of 2.2 × 105 Ω and a remarkably high conductivity of 2 × 104 S cm-1.

Three-step-in-one synthesis of supercapacitor MWCNT superparamagnetic magnetite composite material under flow

Composites of multi-walled carbon nanotubes (MWCNTs) and superparamagnetic magnetite nanoparticles, Fe₃O₄@MWCNT, were synthesized in DMF in a vortex fluidic device (VFD). This involved in situ generation of the iron oxide nanoparticles by laser ablation of bulk iron metal at 1064 nm using a pulsed laser, over the dynamic thin film in the microfluidic platform. The overall processing is a three-step in one operation: (i) slicing MWCNTs, (ii) generating the superparamagnetic nanoparticles and (iii) decorating them on the surface of the MWCNTs. The Fe₃O₄@MWCNT composites were characterized by transmission electron microscopy, scanning transmission electron microscope, TG analysis, X-ray diffraction and X-ray photoelectron spectroscopy. They were used as an active electrode for supercapacitor measurements, establishing high gravimetric and areal capacitances of 834 F g^-1 and 1317.7 mF cm^-2 at a scan rate of 10 mV s^-1, respectively, which are higher values than those reported using similar materials. In addition, the designer material has a significantly higher specific energy of 115.84 W h kg^-1 at a specific power of 2085 W kg^-1, thereby showing promise for the material in next-generation energy storage devices.

Vortex fluidic mediated transformation of graphite into highly conducting graphene scrolls

Two-dimensional graphene has remarkable properties that are revolutionary in many applications. Scrolling monolayer graphene with precise tunability would create further potential for niche applications but this has proved challenging. We have now established the ability to fabricate monolayer graphene scrolls in high yield directly from graphite flakes under non-equilibrium conditions at room temperature in dynamic thin films of liquid. Using conductive atomic force microscopy we demonstrate that the graphene scrolls form highly conducting electrical contacts to highly oriented pyrolytic graphite (HOPG). These highly conducting graphite-graphene contacts are attractive for the fabrication of interconnects in microcircuits and align with the increasing interest in building all sp²-carbon circuits. Above a temperature of 450 °C the scrolls unravel into buckled graphene sheets, and this process is understood on a theoretical basis. These findings augur well for new applications, in particular for incorporating the scrolls into miniaturized electronic devices.

Neutron imaging and modelling inclined vortex driven thin films

The vortex fluidic device (VFD) is a thin film microfluidic platform which has a wide range of applications in synthesis and other areas of science, and it is important to understand the nature of the thin film of liquid in its inclined rapidly rotating tube. Neutron imaging has been used to determine the thickness of the film in a quartz tube with its shape modelled mathematically, showing good agreement between the model and experiments. The resultant equations are useful for studying VFD mediated processing in general, for which the optimal tilt angle of the tube is typically 45°. This includes its utility for the intelligent scale-up of organic syntheses, as demonstrated in the present study by the scaling up of an imine and amide synthesis to >1 g/min.

Turbo thin film continuous flow production of biodiesel from fungal biomass

Direct biodiesel production from wet fungal biomass may significantly reduce production costs, but there is a lack of fast and cost-effective processing technology. A novel thin film continuous flow process has been applied to study the effects of its operational parameters on fatty acid (FA) extraction and FA to fatty acid methyl ester (FAME) conversion efficiencies. Single factor experiments evaluated the effects of catalyst concentration and water content of biomass, while factorial experimental designs determined the interactions between catalyst concentration and biomass to methanol ratio, flow rate, and rotational speed. Direct transesterification (DT) of wet Mucor plumbeus biomass at ambient temperature and pressure achieved a FA to FAME conversion efficiency of >90% using 3 wt/v % NaOH concentration, if the water content was ≤50% (w/w). In comparison to existing DT methods, this continuous flow processing technology has an estimated 90-94% reduction in energy consumption, showing promise for up-scaling.

Chemoselective and Continuous Flow Hydrogenations in Thin Films Using a Palladium Nanoparticle Catalyst Embedded in Cellulose Paper

Cellulose immobilized palladium (0) nanoparticles (PdNPs) were prepared for the use in scalable catalytic reactions in flow. Preparation of the catalyst is remarkably simple and fast, where a palladium acetate solution is drop-casted onto cellulose paper and then exposed to 1 atm of hydrogen for a mere 90 s to produce embedded Pd(0) nanoparticles. This catalyst system is efficient in the hydrogenation of alkenes, nitroarenes, ketones, and enamides, with products formed in high yields, under ambient pressure and temperature. The system is also effective for transfer hydrogenation using ammonium formate as an alternative hydrogen source. A high catalyst stability and reusability are demonstrated along with the chemoselective and scalable synthesis of industrially important fine chemicals, including the biobased molecule cyrene.

Laboratory of the future: a modular flow platform with multiple integrated PAT tools for multistep reactions

The coupling of a modular microreactor platform, real-time inline analysis by IR and NMR, and online UPLC, leads to efficient optimization of a multistep organolithium transformation to a given product without the need for human intervention.

Inverted vortex fluidic exfoliation and scrolling of hexagonal-boron nitride

Exfoliation or scrolling of hexagonal boron nitride (h-BN) occurs in a vortex fluidic device (VFD) operating under continuous flow, with a tilt angle of −45° relative to the horizontal position. This new VFD processing strategy is effective in avoiding the build-up of material that occurs when the device is operated using the conventional tilt angle of +45°, where the h-BN precursor and scrolls are centrifugally held against the wall of the tube. At a tilt angle of −45° the downward flow aided by gravity facilitates material exiting the tube with the exfoliation of h-BN and formation of h-BN scrolls then optimized by systematically varying the other VFD operating parameters, including flow rate and rotational speed, along with concentration of h-BN and the choice of solvent. Water was the most effective solvent, which enhances the green chemistry metrics of the processing.

Exfoliation or scrolling of h-BN occurs in a vortex fluidic device under downward continuous flow.

p-Phosphonic acid calix[8]arene mediated synthesis of ultra-large, ultra-thin, single-crystal gold nanoplatelets

Large, ultrathin, single-crystal gold platelets are produced in the presence of p-phosphonic acid calix[8]arene as both a catalyst and stabiliser.

Integrating thin film microfluidics in developing a concise synthesis of DGJNAc: A potent inhibitor of α-N-acetylgalctosaminidases

A simple synthesis, which utilizes a thin film microfluidic reactor for a problematic step, of a potent inhibitor of α-N-acetylhexosaminidases, DGJNAc, has been developed.

The Use of Molecular Oxygen for Liquid Phase Aerobic Oxidations in Continuous Flow

Molecular oxygen (O₂) is the ultimate “green” oxidant for organic synthesis. There has been recent intensive research within the synthetic community to develop new selective liquid phase aerobic oxidation methodologies as a response to the necessity to reduce the environmental impact of chemical synthesis and manufacture. Green and sustainable chemical processes rely not only on effective chemistry but also on the implementation of reactor technologies that enhance reaction performance and overall safety. Continuous flow reactors have facilitated safer and more efficient utilization of O₂, whilst enabling protocols to be scalable. In this article, we discuss recent advancements in the utilization of continuous processing for aerobic oxidations. The translation of aerobic oxidation from batch protocols to continuous flow processes, including process intensification (high T/p), is examined. The use of “synthetic air”, typically consisting of less than 10% O₂ in N₂, is compared to pure O₂ (100% O₂) as an oxidant source in terms of process efficiency and safety. Examples of homogeneous catalysis and heterogeneous (packed bed) catalysis are provided. The application of flow photoreactors for the in situ formation of singlet oxygen (¹O₂) for use in organic reactions, as well as the implementation of membrane technologies, green solvents and recent reactor solutions for handling O₂ are covered.

Continuous flow biodiesel production from wet microalgae using a hybrid thin film microfluidic platform

A novel continuous flow turbo-thin film device (T2FD) has been developed. The microfluidic platform is effective in high yielding production of biodiesel from wet microalgae at room temperature under continuous flow conditions. These findings open the possibility of cost effective production of biodiesel directly from wet microalgae.

Vortex fluidic mediated direct transesterification of wet microalgae biomass to biodiesel

A bottleneck in the production of biodiesel from microalgae is the dewatering and lipid extraction process which is the dominant energy penalty and cost. A novel biodiesel production platform based on vortex fluidic device (VFD)-assisted direct transesterification (DT) of wet microalgal biomass of Chloroparva pannonica was developed and evaluated. Fatty acid extraction and fatty acid to FAME conversion efficiencies were used at different parameter settings to evaluate performance of the processing technology in confined and continuous mode. A response surface method based on Box-Behnken experimental design was used to determine the effects of water content, the ratio of biomass to methanol and residence time in the VFD. Average extraction efficiencies were 41% and conversion efficiencies >90% with the processing technology showing a broad tolerance to parameter settings. The findings suggest that VFD-assisted DT is a simple and effective way to produce biodiesel directly from wet microalgae biomass at room temperature.

Laser-Ablated Vortex Fluidic-Mediated Synthesis of Superparamagnetic Magnetite Nanoparticles in Water Under Flow

Selective formation of only one iron oxide phase is a major challenge in conventional laser ablation process, as is scaling up the process. Herein, superparamagnetic single-phase magnetite nanoparticles of hexagonal and spheroidal-shape, with an average size of ca. 15 nm, are generated by laser ablation of bulk iron metal at 1064 nm in a vortex fluidic device (VFD). This is a one-step continuous flow process, in air at ambient pressure, with in situ uptake of the nanoparticles in the dynamic thin film of water in the VFD. The process minimizes the generation of waste by avoiding the need for any chemicals or surfactants and avoids time-consuming purification steps in reducing any negative impact of the processing on the environment.

Controlling the growth of fullerene C60 cones under continuous flow

Micromixing of an o-xylene solution of C60 with N-N-dimethylformamide (DMF) at room temperature under continuous flow in a vortex fluidic device (VFD) results in the formation of symmetrical right cones in high yield with diameters 0.5 to 2.5 μm, pitch angle 25° to 55° and wall thickness 120 to 310 nm. Their formation is in the absence of surfactants and any other reagents, and is scalable. The cones are formed at specific operating parameters of the VFD, including rotational speed, flow rate and concentration, and varying these results in other structures such as grooved fractals. Other aromatic solvents in place of o-xylene results in the formation of rods, spicules and prisms, respectively for m-xylene, p-xylene and mesitylene.