Flow fine synthesis with heterogeneous catalysts

Organic synthesis in flow mode by selective liquid-phase hydrogenation over heterogeneous non-noble metal catalysts

Flow hydrogenation performed over heterogeneous catalysts makes organic synthesis more economical, safe and environmentally friendly. Over the past two decades, a significant amount of research with a major focus on noble metal catalysts has been carried out in this area. However, catalysts based on non-noble metals (Ni, Cu, Co, etc.) are more promising for practical use due to their low cost and high availability. This review article discusses the use of supported and bulk non-noble metal catalysts for the liquid-phase hydrogenation of bi- and polyfunctional organic compounds in flow mode. The main attention is paid to the selective reduction of one functional group (NO2, CC, CN, CO, and CN) in the presence of other substituents. In addition, cascade synthetic protocols involving hydrogenation are presented.

Structure-Directed Quaternary Ammonium Hydroxide Resins: High-Performance Heterogeneous Base Catalysts for Continuous-Flow Carbon-Carbon Bond-Forming Reactions

Quaternary ammonium hydroxide resins are widely recognized for their effectiveness as immobilized bases and are frequently utilized as commodity chemicals for anion-exchange applications. However, despite their accessibility, chemically controlling their properties has proven challenging, hindering research and development efforts toward their use as solid base catalysts. This study investigates the synthetic factors that are crucial for achieving high functional performance in polystyrene resins. Using commercially available resin as a benchmark and the continuous-flow Henry reaction as a model system, we explore and evaluate newly synthesized resin catalysts to maximize their basic catalytic activity.

Continuous-Flow Catalysis Using Phosphine-Metal Complexes on Porous Polymers: Designing Ligands, Pores, and Reactors

Continuous-flow syntheses using immobilized catalysts can offer efficient chemical processes with easy separation and purification. Porous polymers have gained significant interests for their applications to catalytic systems in the field of organic chemistry. The porous polymers are recognized for their large surface area, high chemical stability, facile modulation of surface chemistry, and cost-effectiveness. It is crucial to immobilize transition-metal catalysts due to their difficult separation and high toxicity. Supported phosphine ligands represent a noteworthy system for the effective immobilization of metal catalysts and modulation of catalytic properties. Researchers have been actively pursuing strategies involving phosphine-metal complexes supported on porous polymers, aiming for high activities, durabilities, selectivities, and applicability to continuous-flow systems. This review provides a concise overview of phosphine-metal complexes supported on porous polymers for continuous-flow catalytic reactions. Polymer catalysts are categorized based on pore sizes, including micro-, meso-, and macroporous polymers. The characteristics of these porous polymers are explored concerning their efficiency in immobilized catalysis and continuous-flow systems.

Synthetic Chemistry in Flow: From Photolysis & Homogeneous Photocatalysis to Heterogeneous Photocatalysis

Photocatalytic synthesis of value-added chemicals has gained increasing attention in recent years owing to its versatility in driving many important reactions under ambient conditions. Selective hydrogenation, oxidation, coupling, and halogenation with a high conversion of the reactants have been realized using designed photocatalysts in batch reactors with small volumes at a laboratory scale; however, scaling-up remains a critical challenge due to inefficient utilization of incident light and active sites of the photocatalysts, resulting in poor catalytic performance that hinders its practical applications. Flow systems are considered one of the solutions for practical applications of light-driven reactions and have experienced great success in photolytic and homogeneous photocatalysis, yet their applications in heterogeneous photocatalysis are still under development. In this perspective, we have summarized recent progress in photolytic and photocatalytic synthetic chemistry performed in flow systems from the view of reactor design with a special focus on heterogeneous photocatalysis. The advantages and limitations of different flow systems, as well as some practical considerations of design strategies are discussed.

Ultrafast Flow Synthesis of o-Functionalized Benzenesulfonyl Fluorides and Subsequent SuFEx Connections via Lithiated Chemistry

Herein we present a flow-based, rapid, and straightforward approach to synthesize diverse functionalized sulfonyl fluorides by harnessing an aryllithium intermediate. The aryllithium intermediate was fully utilized under optimized conditions (0.016 s, -18 °C) to afford various functionalized sulfonyl fluorides and also intramolecular SuFEx cyclization products in high yields (27-94%). Furthermore, the integrated synthesis incorporating subsequent SuFEx connections with even unstable organolithium nucleophiles facilitated one-flow molecular assembly in high yields (42-72%).

Recent Advancements in Continuous-Flow Suzuki-Miyaura Coupling Utilizing Immobilized Molecular Palladium Complexes

Immobilized Pd-catalyzed Suzuki-Miyaura coupling under continuous-flow conditions using a packed-bed reactor, representing an efficient, automated, practical, and safe technology compared to conventional batch-type reactions. The core objective of this study is the development of an active and durable catalyst. In contrast to supported Pd nanoparticles, the attachment of Pd complexes onto solid supports through well-defined coordination sites is considered a favorable approach for preparing highly dispersed and stabilized Pd species. These species can be directly employed in various flow reactions without the need for pre-treatment. This concept paper explores recent achievements involving the application of immobilized Pd complexes as precatalysts for continuous-flow Suzuki-Miyaura coupling. Our focus is to elucidate the significance of the designed catalyst structures in relation to their catalytic performance under flow conditions. Additionally, we highlight various reaction systems and catalyst packing methods, emphasizing their crucial roles in establishing a practical synthesis process.

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.

Enhancing continuous-flow reactions via compression-molding of solid catalysts and dilutants in packed-bed systems

In this study, we present an improved packed-bed system designed for continuous-flow reactions using platinum (Pt)-black powder and silica gel (SiO2). The Pt-leaching from the reaction column is suppressed via compression-molding of the Pt and SiO2. Scanning electron microscopy results and particle-size distribution analysis demonstrate that crushed and downsized SiO2 is effective in suppressing outflow. Furthermore, we successfully conducted a scaled-up experiment of the flow reaction using a large column, achieving excellent productivity.

Improved Process for the Continuous Acylation of 1,3-Benzodioxole

The acylation of 1,3-benzodioxole was studied in a continuous process using a recyclable heterogeneous substoichiometric catalyst. In a short time period (30 min), at 100 °C, the conversion rate was 73%, with a selectivity of 62% of the desired acylated product; the reaction was run continuously for 6 h, showing excellent stability and selectivity. Moreover, the unreacted starting material, 1,3-benzodioxole, can be easily separated by distillation and recycled.

Surface-Modified Pd/CeO2 Single-Atom Catalyst Shows Increased Activity for Suzuki Cross-Coupling

Single-atom catalysts (SACs) comprise catalytically active atoms dispersed on supports; they combine the high activity and site uniformity of homogeneous catalysts with the ease of separability of heterogeneous catalysts. However, SACs lack fine control over the active site, provided by ligands in homogeneous catalysts. In this work, we demonstrate that modification of the support with an organic monolayer is a viable approach to improving the catalytic performance. The addition of catechol-type monolayers to a Pd/CeO2 SAC increases its catalytic activity for Suzuki cross-coupling, a central reaction in the synthesis of fine chemicals and pharmaceuticals. Kinetic trials reveal that the coating reduces the activation energy from 49 ± 9 to 22 ± 5 kJ/mol and produces a 4-fold rate enhancement at 25 °C, an effect we attribute to π-π interactions between the reactant and the catechol coating. Further development of this approach could vastly increase the utility of SACs in organic synthesis.

MOF-based heterogeneous catalysis in continuous flow via incorporation onto polymer-based spherical activated carbon supports

We present an approach to harnessing the tuneable catalytic properties of complex nanomaterials for continuous flow heterogeneous catalysis by combining them with the scalable and industrially implementable properties of carbon pelleted supports. This approach, in turn, will enable these catalytic materials, which largely currently exist in forms unsuitable for this application (e.g. powders), to be fully integrated into large scale, chemical processes. A composite heterogeneous catalyst consisting of a metal-organic framework-based Lewis acid, MIL-100(Sc), immobilised onto polymer-based spherical activated carbon (PBSAC) support has been developed. The material was characterised by focused ion beam-scanning electron microscopy-energy dispersive X-ray analysis, powder X-ray diffraction, N2 adsorption, thermogravimetric analysis, atomic absorption spectroscopy, light scattering and crush testing with the catalytic activity studied in continuous flow. The mechanically robust spherical geometry makes the composite material ideal for application in packed-bed reactors. The catalyst was observed to operate without any loss in activity at steady state for 9 hours when utilised as a Lewis acid catalyst for the intramolecular cyclisation of (±)-citronellal as a model reaction. This work paves the way for further development into the exploitation of MOF-based continuous flow heterogeneous catalysis.

A Telescoped Continuous Flow Enantioselective Process for Accessing Intermediates of 1-Aryl-1,3-diols as Chiral Building Blocks

A telescoped continuous flow process is reported for the enantioselective synthesis of chiral precursors of 1-aryl-1,3-diols, intermediates in the synthesis of ezetimibe, dapoxetine, duloxetine, and atomoxetine. The two-step sequence consists of an asymmetric allylboration of readily available aldehydes using a polymer-supported chiral phosphoric acid catalyst to introduce asymmetry, followed by selective epoxidation of the resulting alkene. The process is highly stable for at least 7 h and represents a transition-metal free enantioselective approach to valuable 1-aryl-1,3-diols.

Advances in Continuous Flow Fluorination Reactions

Fluorination reactions are important in constructing organofluorine motifs, which contribute to favorable biological properties in pharmaceuticals and agrochemicals. However, fluorination reagents and reactions are associated with various problems, such as their hazardous nature, high exothermicity, and poor selectivity and scalability. Continuous flow has emerged as a transformative technology to provide many advantages relative to batch syntheses. This review article summarizes recent continuous flow techniques that address the limitations and challenges of fluorination reactions. Approaches based on different flow techniques are discussed, including gas-liquid reactions, packed-bed reactors, in-line purifications, streamlined multistep synthesis, large-scale reactions well as flow photoredox- and electrocatalysis.

Isothiocyanate-functionalized silica as an efficient heterogeneous catalyst for carotenoid isomerization

Daily consumption of carotenoids is associated with multiple health benefits, but their bioavailability is generally extremely low. In this context, the Z-isomerization is receiving attention as a method for increasing carotenoid bioavailability because this approach is superior to conventional physical approaches. Here we investigated the feasibility of using isothiocyanate-functionalized silica (Si-NCS) as a heterogeneous catalyst for carotenoid isomerization. We found that this catalyst promoted Z-isomerization of (all-E)-carotenoids with high efficiency, e.g., when lycopene and astaxanthin solutions were incubated at 50 °C with 10 mg/mL Si-NCS, their total Z-isomer ratios increased by approximately 80 and 50 %, respectively. Furthermore, the Z-isomerization was successfully performed continuously by introducing carotenoid solution into a column packed with Si-NCS. Materials rich in carotenoid Z-isomers have not been used in practical applications due to high production cost and quality limitations (e.g., low Z-isomer ratio). The use of Si-NCS has sufficient potential to solve both these issues.

Supported Ionic Liquid Phase Catalysts Dedicated for Continuous Flow Synthesis

Heterogeneous catalysis, although known for over a century, is constantly improved and plays a key role in solving the present problems in chemical technology. Thanks to the development of modern materials engineering, solid supports for catalytic phases having a highly developed surface are available. Recently, continuous-flow synthesis started to be a key technology in the synthesis of high added value chemicals. These processes are more efficient, sustainable, safer and cheaper to operate. The most promising is the use of heterogeneous catalyst with column-type fixed-bed reactors. The advantages of the use of heterogeneous catalyst in continuous flow reactors are the physical separation of product and catalyst, as well as the reduction in inactivation and loss of the catalyst. However, the state-of-the-art use of heterogeneous catalysts in flow systems compared to homogenous ones remains still open. The lifetime of heterogeneous catalysts remains a significant hurdle to realise sustainable flow synthesis. The goal of this review article was to present a state of knowledge concerning the application of Supported Ionic Liquid Phase (SILP) catalysts dedicated for continuous flow synthesis.

Preprints in Chemistry: a Research Team's Journey

The benefits of publishing research papers first in preprint form are substantial and long-lasting also in chemistry. Recounting the outcomes of our team's nearly six-year journey through preprint publishing, we show evidence that preprinting research substantially benefits both early career and senior researchers in today's highly interdisciplinary chemical research. These findings are of general value, as shown by analyzing the case of four more research teams based in economically developed and developing countries.

Selective monoallylation of anilines to N-allyl anilines using reusable zirconium dioxide supported tungsten oxide solid catalyst

The monoallylation of aniline to give N-allyl aniline is a fundamental transformation process that results in various kinds of valuable building block allyl compounds, which can be used in the production of pharmaceuticals and electronic materials. For decades, sustainable syntheses have been gaining much attention, and the employment of allyl alcohol as an allyl source can follow the sustainability due to the formation of only water as a coproduct through dehydrative monoallylation. Although the use of homogeneous metal complex catalysts is a straightforward choice for the acceleration of dehydrative monoallylation, the use of soluble catalysts tends to contaminate products. We herein present a 10 wt% WO3/ZrO2 catalyzed monoallylation process of aniline to give N-allyl anilines in good yields with excellent selectivity, which enables the continuous selective flow syntheses of N-allyl aniline with 97-99% selectivity. The performed detailed study about the catalytic mechanism suggests that the dispersed WO3 with the preservation of the W(vi) oxidation state of 10 wt% WO3/ZrO2 with appropriate acidity and basicity is crucial for the monoallylation. The inhibition of the over allylation of the N-allyl anilines is explained by the unwilling contact of the N-allyl aniline with the active sites of WO3/ZrO2 due to the steric hindrance.

Continuous-Flow Synthesis of (R)-Tamsulosin Utilizing Sequential Heterogeneous Catalysis

We describe the continuous-flow synthesis of (R)-tamsulosin, a blockbuster therapeutic drug employed for dysuria associated with urinary stones and benign prostatic hyperplasia, by utilizing sequential heterogeneous catalysis. Two heterogeneous catalysts have been developed for the synthesis, and the key step involves reductive amination of nitriles using dimethylpolysilane-modified Pd on activated carbon/calcium phosphate. Overall, (R)-tamsulosin was obtained in 60 % yield and 64 % ee (99 % ee after recrystallization) in a flow stream through four catalytic transformations without the need for the isolation or purification of any intermediates or byproduct.

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.

Scalable Subsecond Synthesis of Drug Scaffolds via Aryllithium Intermediates by Numbered-up 3D-Printed Metal Microreactors

Continuous-flow microreactors enable ultrafast chemistry; however, their small capacity restricts industrial-level productivity of pharmaceutical compounds. In this work, scale-up subsecond synthesis of drug scaffolds was achieved via a 16 numbered-up printed metal microreactor (16N-PMR) assembly to render high productivity up to 20 g for 10 min operation. Initially, ultrafast synthetic chemistry of unstable lithiated intermediates in the halogen-lithium exchange reactions of three aryl halides and subsequent reactions with diverse electrophiles were carried out using a single microreactor (SMR). Larger production of the ultrafast synthesis was achieved by devising a monolithic module of 4 numbered-up 3D-printed metal microreactor (4N-PMR) that was integrated by laminating four SMRs and four bifurcation flow distributors in a compact manner. Eventually, the 16N-PMR system for the scalable subsecond synthesis of three drug scaffolds was assembled by stacking four monolithic modules of 4N-PMRs.

Highly Selective Hydrogenative Conversion of Nitriles into Tertiary, Secondary, and Primary Amines under Flow Reaction Conditions

Flow reaction methods have been developed to selectively synthesize tertiary, secondary, and primary amines depending on heterogeneous platinum-group metal species under catalytic hydrogenation conditions using nitriles as starting materials. A 10 % Pd/C-packed catalyst cartridge affords symmetrically substituted tertiary amines in good to excellent yields. A 10 % Rh/C-packed catalyst cartridge enables the divergent synthesis of secondary and primary amines, with either cyclohexane or acetic acid as a solvent, respectively. Reaction parameters, such as the metal catalyst, solvent, and reaction temperature, and continuous-flow conditions, such as flow direction and second support of the catalyst in a catalyst cartridge, are quite important for controlling the reaction between the hydrogenation of nitriles and nucleophilic attack of in situ-generated amines to imine intermediates. A wide variety of aliphatic and aromatic nitriles could be highly selectively transformed into the corresponding tertiary, secondary, and primary amines by simply changing the metal species of the catalyst or flow parameters. Furthermore, the selective continuous-flow methodologies are applied over at least 72 h to afford three different types of amines in 80-99 % yield without decrease in catalytic activities.

Automated Flow and Real-Time Analytics Approach for Screening Functional Group Tolerance in Heterogeneous Catalytic Reactions

Heterogeneous hydrogenation reactions are widely used in synthesis, and performing them using continuous flow technologies addresses many of the safety, scalability and sustainability issues. However, one of the main potential...

Recent advances in the asymmetric reduction of imines by recycled catalyst systems

Recent advances relating to the asymmetric reduction of imines to afford optically active amines via recyclable catalyst systems are reviewed.

Revisiting aromatic diazotization and aryl diazonium salts in continuous flow: highlighted research during 2001–2021

Aryl diazonium salts play an important role in chemical transformations; however their explosive nature limits their applications in batch.

Aerobic oxidation of alcohols enabled by nitrogen-doped copper nanoparticle catalysts

Heterogeneous nitrogen-doped carbon-incarcerated copper nanoparticle catalysts have been developed.

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.

An enantio- and diastereoselective approach to indoloquinolizidines in continuous flow

A solvent-free enantioselective Michael addition mediated by a polymer-supported Jørgensen–Hayashi catalyst and a domino Pictet–Spengler plus lactamisation sequence has been reported in continuous flow.

Catalytic hydrogenation of nitrocyclohexane as an alternative pathway for the synthesis of value-added products

Catalytic hydrogenation of nitrocyclohexane could be an alternative source of various useful chemicals: cyclohexanone oxime, cyclohexanone, cyclohexanol, cyclohexylamine and dicyclohexylamine. Each one of these compounds found application in the modern...

Development of highly efficient Friedel-Crafts alkylations with alcohols using heterogeneous catalysts under continuous-flow conditions

The development of Friedel–Crafts alkylations with alcohols under continuous-flow conditions using heterogeneous catalysts is reported. The reactivities and durabilities of the examined catalysts were systematically investigated, which showed that montmorillonite clay is the best catalyst for these reactions. A high turnover frequency of 9.0 × 10² h⁻¹ was recorded under continuous-flow conditions, and the continuous operation was successfully maintained over one week.

Efficient and highly durable catalysts were developed for Friedel–Crafts alkylation using alcohols under continuous flow conditions.

Bismuth Subnitrate-Catalyzed Markovnikov-Type Alkyne Hydrations under Batch and Continuous Flow Conditions

Bismuth subnitrate is reported herein as a simple and efficient catalyst for the atom-economical synthesis of methyl ketones via Markovnikov-type alkyne hydration. Besides an effective batch process under reasonably mild conditions, a chemically intensified continuous flow protocol was also developed in a packed-bed system. The applicability of the methodologies was demonstrated through hydration of a diverse set of terminal acetylenes. By simply switching the reaction medium from methanol to methanol-d₄, valuable trideuteromethyl ketones were also prepared. Due to the ready availability and nontoxicity of the heterogeneous catalyst, which eliminated the need for any special additives and/or harmful reagents, the presented processes display significant advances in terms of practicality and sustainability.