Continuous Flow Hydrogenation of Flavorings and Fragrances Using 3D-Printed Catalytic Static Mixers

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.

Catalytic Hydropyrolysis of Lignin for the Preparation of Cyclic Hydrocarbon-Based Biofuels

The demand for biomass utilization is increasing because of the depletion of fossil resources that are non-renewable in nature. Lignin is the second most renewable organic carbon source, but currently it has limited scope for application in the chemical and fuel industries. Lignin is a side product of the paper and pulp, sugar, and 2G bioethanol industries. Many research groups are working on the value-addition of lignin. Among the lignin depolymerization methods, catalytic hydropyrolysis is gaining attention and is playing a crucial role in developing biorefinery. The hydropyrolysis of lignin was conducted at a higher temperature in the presence of H2. The hydropyrolysis of lignin results in the selective formation of non-oxygenated cyclic hydrocarbons in a shorter reaction time. It is possible to use the cyclic hydrocarbons directly as a fuel or they can be blended with conventional gasoline. This review focuses on the prior art of pyrolysis and hydropyrolysis of lignin. Possible products of lignin hydropyrolysis and suitable synthetic routes to obtain non-oxygenated cyclic hydrocarbons are also discussed. The influence of various process parameters, such as type of reactor, metal catalyst, nature of catalytic supports, reaction temperature, and H2 pressure are discussed with regard to the hydropyrolysis of lignin to achieve good selectivity of cyclic hydrocarbons.

Solvent-Free Hydrogenation of Squalene Using Parts per Million Levels of Palladium Supported on Carbon Nanotubes: Shift from Batch Reactor to Continuous-Flow System

The transition from batch catalytic processes to continuous flow processes requires highly active and stable catalysts that still need to be developed. The preparation and characterization of catalysts where palladium single atoms and nanoparticles are simultaneously present on carbon nanotubes were recently reported by us. These catalysts are considerably more active than commercial or previously described catalysts for the liquid phase hydrogenation of terpenes. Herein is shown that under solvent-free conditions, squalene (SQE) could be converted into squalane (SQA,>98 %) using only 300 ppm of Pd in less than 1.4 h at 20 bar H₂ and 120 °C. Catalyst stability was assessed in a lab-scale flow reactor, and long-term experiments led to turnover number (TON) higher than 300000 without any detectable loss in the activity. Then, the implementation of this catalyst in a commercial intensified continuous-flow milli-reactor pilot was achieved. High purity SQA (>98 %) could be obtained by continuous hydrogenation of solvent-free SQE at 180 °C and 30 bar H₂ with a contact time below 15 min. A production capacity of 3.6 kg per day of SQA could be obtained with an effective reactor volume (V_R ) of 43.2 mL for this complex 3 phase reaction. Large-scale production can now be foreseen thanks to seamless scale-up provided by the continuous flow pilot supplier.

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...

3D printed nickel catalytic static mixers made by corrosive chemical treatment for use in continuous flow hydrogenation

Catalytic static mixers, 3D printed from nickel alloys, were treated with etching or leaching solutions to activate their surfaces for use in hydrogenation of alkenes, aldehydes and nitro-groups.

Continuous-flow reactor setup for operando x-ray absorption spectroscopy of high pressure heterogeneous liquid-solid catalytic processes

A continuous-flow reactor and a continuous-flow setup compatible with operando x-ray absorption spectroscopy (XAS) were designed for safely studying liquid-phase reactions on solid high atomic number transition metal catalysts (e.g., Au, Pd, and Pt) under pressures up to 100 bars with temperatures up to 100 °C. The reactor has a stainless-steel body, 2 mm thick polyether ether ketone (PEEK) x-ray windows, and a low internal volume of 0.31 ml. The rectangular chamber (6 × 5 × 1 mm³) between the PEEK x-ray windows allows us to perform XAS studies of packed beds or monoliths in the transmission mode at any position in the cell over a length of 60 mm. A 146° wide-angle beam access also allows recording complementary x-ray fluorescence or x-ray diffraction signals. The setup was engineered to continuously feed a single-phase liquid flow saturated with one or more gaseous reactants to the liquid-solid XAS reactor containing no free gas phase for enhanced process safety and sample homogeneity. The proof of concept for the continuous-flow XAS cell and high-pressure setup was provided by operando XAS measurements during the direct synthesis of hydrogen peroxide at room temperature and 40 bars using a 35 ± 5 mg catalyst (1 wt. % Pd/TiO₂) and inline near-infrared spectroscopy. The experiments prove that the system is well suited to follow the reaction in the liquid phase while recording high-quality XAS data, paving the way for detailed studies on the catalyst structure and structure-activity relationships.

3D printed ceramics as solid supports for enzyme immobilization: an automated DoE approach for applications in continuous flow

In recent years, 3D printing has emerged in the field of chemical engineering as a powerful manufacturing technique to rapidly design and produce tailor-made reaction equipment. In fact, reactors with complex internal geometries can be easily fabricated, optimized and interchanged in order to respond to precise process needs, such as improved mixing and increased surface area. These advantages make them interesting especially for catalytic applications, since customized structured bed reactors can be easily produced. 3D printing applications are not limited to reactor design, it is also possible to realize functional low cost alternatives to analytical equipment that can be used to increase the level of process understanding while keeping the investment costs low. In this work, in-house designed ceramic structured inserts printed via vat photopolymerization (VPP) are presented and characterized. The flow behavior inside these inserts was determined with residence time distribution (RTD) experiments enabled by in-house designed and 3D printed inline photometric flow cells. As a proof of concept, these structured inserts were fitted in an HPLC column to serve as solid inorganic supports for the immobilization of the enzyme Phenolic acid Decarboxylase (bsPAD), which catalyzes the decarboxylation of cinnamic acids. The conversion of coumaric acid to vinylphenol was chosen as a model system to prove the implementation of these engineered inserts in a continuous biocatalytic application with high product yield and process stability. The setup was further automated in order to quickly identify the optimum operating conditions via a Design of Experiments (DoE) approach. The use of a systematic optimization, together with the adaptability of 3D printed equipment to the process requirements, render the presented approach highly promising for a more feasible implementation of biocatalysts in continuous industrial processes. Graphical abstract.

Supplementary Information

The online version contains supplementary material available at 10.1007/s41981-021-00163-4.

Continuous Hydrogenation: Triphasic System Optimization at Kilo Lab Scale Using a Slurry Solution

Despite their widespread use in the chemical industries, hydrogenation reactions remain challenging. Indeed, the nature of reagents and catalysts induce intrinsic safety challenges, in addition to demanding process development involving a 3-phase system. Here, to address common issues, we describe a successful process intensification study using a meso-scale flow reactor applied to a hydrogenation reaction of ethyl cinnamate at kilo lab scale with heterogeneous catalysis. This method relies on the continuous pumping of a catalyst slurry, delivering fresh catalyst through a structured flow reactor in a continuous fashion and a throughput up to 54.7 g/h, complete conversion and yields up to 99%. This article describes the screening of equipment, reactions conditions and uses statistical analysis methods (Monte Carlo/DoE) to improve the system further and to draw conclusions on the key influential parameters (temperature and residence time).