A Simple and Versatile Reactor for Photochemistry

The Kornblum DeLaMare rearrangement in natural product synthesis: 25 years of innovation

Covering: 1998 up to the end of 2023Since its initial disclosure in 1951, the Kornblum DeLaMare rearrangement has proved an important synthetic transformation and has been widely adopted as a biomimetic step in natural product synthesis. Utilising the base catalysed decomposition of alkyl peroxides to yield a ketone and alcohol has found use in many syntheses as well as a key strategic step, including the unmasking of furans, as a biomimetic synthetic tool, and the use of the rearrangement to install oxygen enantioselectively. Since ca. 1998, its impact as a synthetic transformation has grown significantly, especially given the frequency of use in natural product syntheses, therefore this 25 year time period will be the focus of the review.

Process Intensification of the Continuous Synthesis of Bio-Derived Monomers for Sustainable Coatings Using a Taylor Vortex Flow Reactor

We describe the optimization and scale-up of two consecutive reaction steps in the synthesis of bio-derived alkoxybutenolide monomers that have been reported as potential replacements for acrylate-based coatings (Sci. Adv.2020, 6, eabe0026). These monomers are synthesized by (i) oxidation of furfural with photogenerated singlet oxygen followed by (ii) thermal condensation of the desired 5-hydroxyfuranone intermediate product with an alcohol, a step which until now has involved a lengthy batch reaction. The two steps have been successfully telescoped into a single kilogram-scale process without any need to isolate the 5-hydroxyfuranone between the steps. Our process development involved FTIR reaction monitoring, FTIR data analysis via 2D visualization, and two different photoreactors: (i) a semicontinuous photoreactor based on a modified rotary evaporator, where FTIR and 2D correlation spectroscopy (2D-COS) revealed the loss of the methyl formate coproduct, and (ii) our fully continuous Taylor Vortex photoreactor, which enhanced the mass transfer and permitted the use of near-stoichiometric equivalents of O2. The use of in-line FTIR monitoring and modeling greatly accelerated process optimization in the Vortex reactor. This led to scale-up of the photo-oxidation in 85% yield with a projected productivity of 1.3 kg day-1 and a space-time yield of 0.06 mol day-1 mL-1. Higher productivities could be achieved while sacrificing yield (e.g., 4 kg day-1 at 40% yield). The use of superheated methanol at 200 °C in a pressurized thermal flow reactor accelerated the second step, the thermal condensation of 5-hydroxyfuranone, from a 20 h batch reflux reaction (0.5 L, 85 g) to a space time of <1 min in a reactor only 3 mL in volume operating with projected productivities of >700 g day-1. Proof of concept for telescoping the two steps was established with an overall two-step yield of 67%, producing a process with a projected productivity of 1.1 kg day-1 for the methoxybutenolide monomer without any purification of the 5-hydroxyfuranone intermediate.

A field guide to flow chemistry for synthetic organic chemists

Flow chemistry has unlocked a world of possibilities for the synthetic community, but the idea that it is a mysterious "black box" needs to go. In this review, we show that several of the benefits of microreactor technology can be exploited to push the boundaries in organic synthesis and to unleash unique reactivity and selectivity. By "lifting the veil" on some of the governing principles behind the observed trends, we hope that this review will serve as a useful field guide for those interested in diving into flow chemistry.

Hydrazone-based boron difluoride complexes as triplet photosensitizers for singlet oxygen generation

Due to the highly selective nature of singlet oxygen as an oxidant, it has received considerable interest in various areas of (organic) chemistry. Two green light activated hydrazone-based boron difluoride triplet photosensitizers possessing high quantum yields for ¹O₂ formation are reported. These photostable complexes are promising in applications in synthesis and catalysis.

A 3D printed photoreactor for investigating variable reaction geometry, wavelength, and fluid flow

Research in the field of photochemistry, including photocatalysis and photoelectrocatalysis, has been revitalized due to the potential that photochemical reactions show in the sustainable production of chemicals. Therefore, there is a need for flexible photoreactor equipment that allows for the evaluation of the geometry, light wavelength, and intensity of the vessel, along with the fluid flow in various photochemical reactions. Light emitting diodes (LEDs) have narrow emission spectra and can be either pulsed or run continuously; being flexible, they can be arranged to fit the dimensions of various types of the reactor vessel, depending on the application. This study presents a 3D printed photoreactor with the ability to adjust distances easily and switch between high-power LED light sources. The reactor design utilizes customized printed circuit boards to mount varying numbers and types of LEDs, which enables multiple wavelengths to be used simultaneously. These LED modules, comprised of heat sinks and cooling fans, fulfill the higher heat dissipation requirements of high-power LEDs. The flexibility of the reactor design is useful for optimizing the reaction geometry, flow conditions, wavelength, and intensity of photochemical reactions on a small scale. The estimates for incident light intensity under five possible reactor configurations using ferrioxalate actinometry are reported so that comparisons with other photoreactors can be made. The performance of the photoreactor for differing vessel sizes and distances, in both the flow and batch modes, is given for a photochemical reaction on 2-benzyloxyphenol-a model substance for lignin and applicable in the production of biobased chemicals.

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.

Highly Efficient Biobased Synthesis of Acrylic Acid

Petrochemical based polymers, paints and coatings are cornerstones of modern industry but our future sustainable society demands greener processes and renewable feedstock materials. A challenge is to access platform monomers from biomass resources while integrating the principles of green chemistry in their chemical synthesis. We present a synthesis route starting from biomass‐derived furfural towards the commonly used monomers maleic anhydride and acrylic acid, implementing environmentally benign photooxygenation, aerobic oxidation and ethenolysis reactions. Maleic anhydride and acrylic acid, transformed into sodium acrylate, were isolated in yields of 85 % (2 steps) and 81 % (4 steps), respectively. With minimal waste and high atom efficiency, this biobased route provides a viable alternative to access key monomers.

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.

Graphical abstract

A photochemical ring expansion of 6- to 8-membered nitrogen heterocycles by [1,3]-sigmatropic rearrangement

A new route to azocines and benzoazocines from furopyridinones is described through a photochemically induced [1,3]-sigmatropic rearrangement. The method gives access to these 8-membered nitrogen heterocycles from dimethyl squarate in four stages and with excellent atom economy by sequencing thermal and photochemical ring expansion steps under continuous flow.

Application of reactor engineering concepts in continuous flow chemistry: a review

The adoption of flow technology for the manufacture of chemical entities, and in particular pharmaceuticals, has seen rapid growth over the past two decades with the technology now blurring the lines between chemistry and chemical engineering.

Radiometric measurement techniques for in-depth characterization of photoreactors – part 2: 3 dimensional and integral radiometry

The development and potentials of a three-dimensionally resolving radiometric scanning method, complemented by integrating sphere measurements are presented for the evaluation of the radiation field of photoreactors.

A coating from nature

For almost a century, petrochemical-based monomers like acrylates have been widely used as the basis for coatings, resins, and paints. The development of sustainable alternatives, integrating the principles of green chemistry in starting material, synthesis process, and product function, offers tremendous challenges for science and society. Here, we report on alkoxybutenolides as a bio-based alternative for acrylates and the formation of high-performance coatings. Starting from biomass-derived furfural and an environmentally benign photochemical conversion using visible light and oxygen in a flow reactor provides the alkoxybutenolide monomers. This is followed by radical (co)polymerization, which results in coatings with tunable properties for applications on distinct surfaces like glass or plastic. The performance is comparable to current petrochemical-derived industrial coatings.

Manufacturing chemicals with light: any role in the circular economy?

We outline how recent developments in photochemistry can contribute to the realization of the 1912 vision of the pioneering Italian scientist Giacomo Ciamician, namely world-wide chemical-using industry-based chemical plants fuelled solely by the Sun. We then show how a combination of organic photochemistry and flow chemistry could contribute to the circular economy by harnessing the ability of light to provide the energy to promote reactions without the need for some of the added reagents that are necessary in more traditional chemical routes, so-called 'reagentless' chemistry. Photochemistry has a long history but recently it has undergone a renaissance, particularly with the rise in interest in photoredox chemistry. Continuous photoreactors offer a route to scaling up such reactions to a productivity needed for smaller scale pharmaceutical manufacture. We describe some reactor designs from our own laboratory and outline some of their applications. We then relate these to the requirements of the circular economy and the need to conserve the stocks of the less abundant chemical elements. This article is part of a discussion meeting issue 'Science to enable the circular economy'.

Regioselective Photooxidation of Citronellol: A Way to Monomers for Functionalized Bio-Polyesters

Dye-sensitized photooxygenation reaction of bio-based double bond-containing substrates is proposed as sustainable functionalization of terpenes and terpenoids to transform them into polyoxygenated compounds to be employed for the synthesis of new bio-based polyesters. As proof of concept, citronellol 1 has been regioselectively converted into diol 4 using singlet oxygen (¹O₂), a traceless reagent that can be generated from air, visible light and zeolite supported-photosensitizer (Thionine-NaY). With our synthetic approach, diol 4 has been obtained in two-steps, with good regioselectivity, using green reagents such as light and air, and finally a solvent-free oxidation step. From this compound, a citronellol-based copolyester of poly(butylene succinate) (PBS) has been synthesized and fully characterized. The results obtained evidence that the proposed copolymerization of PBS with the citronellol-based building blocks allows to obtain a more flexible and functionalizable material, by exploiting a largely available natural molecule modified through a green synthetic path.

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.

One-Pot Synthesis of Diverse γ-Lactam Scaffolds Facilitated by a Nebulizer-Based Continuous Flow Photoreactor

The use of a modified prototype continuous flow reactor (CFR) as a pivotal part of a number of versatile singlet oxygen-mediated reaction sequences is presented herein. These sequences target rapid access to structural complexity and diversity. The prototype reactor achieves high conversions and productivities by attaining large specific surface areas for these biphasic reactions. In the reactor, the reaction solution is nebulized (using either oxygen or air) and the resulting aerosol is irradiated by an LED jacket that surrounds the Pyrex reaction chamber. The one pot procedures developed herein are, according to many different criteria, both highly efficient and green. The key common intermediates and the source of both the complexity and variety of the final products are N-acyl imminium ions (NAI; protonated N-acyl enamines). The initial substrates are simple and readily accessible furans and the diverse array of products is composed of different complex γ-lactams. Many of the products are of particular interest due to their close relationships to known biologically active molecules.

Synthesis of cyclopent-2-enones from furans using a nebulizer-based continuous flow photoreactor

A series of hydroxycyclopent-2-enones and methoxycyclopent-2-enones have been synthesized in a single operation from simple furan substrates using an innovative continuous flow nebulizer system (NebPhotOX). Photooxygenation of the furan substrates takes place in an aerosol within the NebPhotOX system.

Controlled photorelease of alkynoic acids and their decarboxylative deprotection for copper-catalyzed azide/alkyne cycloaddition

A controlled photorelease of alkynoic acids from a photoremovable protecting group (PPG) facilitates their subsequent decarboxylation to deliver terminal alkynes for a Cu^I-catalyzed azide/alkyne cycloaddition.

Continuous Photo-Oxidation in a Vortex Reactor: Efficient Operations Using Air Drawn from the Laboratory

We report the construction and use of a vortex reactor which uses a rapidly rotating cylinder to generate Taylor vortices for continuous flow thermal and photochemical reactions. The reactor is designed to operate under conditions required for vortex generation. The flow pattern of the vortices has been represented using computational fluid dynamics, and the presence of the vortices can be easily visualized by observing streams of bubbles within the reactor. This approach presents certain advantages for reactions with added gases. For reactions with oxygen, the reactor offers an alternative to traditional setups as it efficiently draws in air from the lab without the need specifically to pressurize with oxygen. The rapid mixing generated by the vortices enables rapid mass transfer between the gas and the liquid phases allowing for a high efficiency dissolution of gases. The reactor has been applied to several photochemical reactions involving singlet oxygen (1O2) including the photo-oxidations of α-terpinene and furfuryl alcohol and the photodeborylation of phenyl boronic acid. The rotation speed of the cylinder proved to be key for reaction efficiency, and in the operation we found that the uptake of air was highest at 4000 rpm. The reactor has also been successfully applied to the synthesis of artemisinin, a potent antimalarial compound; and this three-step synthesis involving a Schenk-ene reaction with 1O2, Hock cleavage with H+, and an oxidative cyclization cascade with triplet oxygen (3O2), from dihydroartemisinic acid was carried out as a single process in the vortex reactor.

Improving oxidation efficiency through plasma coupled thin film processing

Plasma liquid processing efficiency improves by reducing the liquid film thickness.