A Fully Continuous-Flow Process for the Synthesis of p-Cresol: Impurity Analysis and Process Optimization

Csp2-H functionalization of phenols: an effective access route to valuable materials via Csp2-C bond formation

In the vast majority of top-selling pharmaceutical and industrial products, phenolic structural motifs are highly prevalent. Non-functionalized simple phenols serve as building blocks in the synthesis of value-added chemicals. It is worth mentioning that lignin, being the largest renewable biomass source of aromatic building blocks in nature, mainly consists of phenolic units, which enable the production of structurally diverse phenols. Given their remarkable applicability in the chemical value chain, many efforts have been devoted to increasing the molecular complexity of the phenolic scaffold. Among the key techniques, direct functionalization of Csp2-H is a powerful tool, enabling the construction of new Csp2-C bonds in an economical and atomic manner. Herein we present and summarize the large plethora of direct Csp2-H functionalization methods that enables scaffold diversification of simple, unprotected phenols, leading to the formation of new Csp2-C bonds. In this review article, we intend to summarize the contributions that appeared in the literature mainly in the last 5 years dealing with the functionalization of unprotected phenols, both catalytic and non-catalytic. Our goal is to highlight the key findings and the ongoing challenges in the stimulating and growing research dedicated to the development of new protocols for the valorization of phenols.

Modeling Temperature and Species Concentration Profiles on a Continuous-Flow Reactor Applied to Aldol Condensation

This paper presents the modeling of a continuous-flow reactor used for the synthesis of organic products. The finite element method software, COMSOL Multiphysics, was used to model transport phenomena and reaction kinetics. The temperature is one of the most important kinetic factors that may modify the reaction. A rise in temperature can generate a positive reaction but also secondary side reactions. The design of our system and of many other continuous systems makes it impossible, however, to measure the temperature throughout the reactor. In this paper, we modeled the temperature profile within the reactors as a function of the flow rate, temperature set point, and type of reactor material. The results demonstrated that although it is not a good thermal conductor, polytetrafluoroethylene can be used like other materials. The desired temperature was not reached for any of the reactor material likely to affect the product yield. The model gave the residence time required to reach the stabilized temperature. The comparison of calculated and experimental values of outlet temperature showed good agreement, with a maximum relative difference of only 5%. Knowledge of the temperature profile made it possible to control the concentration distribution of the chemical species in the reactor. The aldol condensation was chosen to determine the kinetic parameters of this reaction as the products of this reaction are found in many natural molecules and drugs. To integrate the chemical model, the kinetic parameters were determined by using experimental data. An equilibrium concentration of 0.2 mol/L was found with initial reactant concentrations of 0.45 mol/L. The chemical modeling gave the species concentrations throughout the reactor. Calculated concentrations were in good agreement with experimental data, with a maximum relative difference of less than 9%. By modeling this reaction, the reaction yield as a function of reactant concentration, temperature, and residence times was estimated.

Development of Scaled-Up Synthetic Method for Retinoid X Receptor Agonist NEt-3IB Contributing to Sustainable Development Goals

Small-molecular drugs, which are generally inexpensive compared with biopharmaceuticals and can often be taken orally, may contribute to the Sustainable Development Goals (SDGs) adopted by the United Nations. We previously reported the retinoid X receptor (RXR) agonist 4-(ethyl(3-isobutoxy-4-isopropylphenyl)amino)benzoic acid (NEt-3IB, 1) as a small-molecular drug candidate to replace biopharmaceuticals for the treatment of inflammatory bowel disease. The previous synthetic method to 1 required a large amount of organic solvent and extensive purification. In line with the SDGs, we aimed to develop an environmentally friendly, inexpensive method for the large-scale synthesis of 1. The developed method requires only a hydrophobic ether and EtOH as reaction and extraction solvents. The product was purified by recrystallization twice to afford 99% pure 1 at 100 mmol scale in about 30% yield. The optimized process showed a 35-fold improvement of the E-factor (an index of environmental impact) compared to the original method. This work, which changes the solvent used to environmentally preferable ones based on the existing synthetic method for 1, illustrates how synthetic methods for small-molecular drugs can be adapted and improved to contribute to the SDGs.

Reactor design and selection for effective continuous manufacturing of pharmaceuticals

Pharmaceutical production remains one of the last industries that predominantly uses batch processes, which are inefficient and can cause drug shortages due to the long lead times or quality defects. Consequently, pharmaceutical companies are transitioning away from outdated batch lines, in large part motivated by the many advantages of continuous manufacturing (e.g., low cost, quality assurance, shortened lead time). As chemical reactions are fundamental to any drug production process, the selection of reactor and its design are critical to enhanced performance such as improved selectivity and yield. In this article, relevant theories, and models, as well as their required input data are summarized to assist the reader in these tasks, focusing on continuous reactions. Selected examples that describe the application of plug flow reactors (PFRs) and continuous-stirred tank reactors (CSTRs)-in-series within the pharmaceutical industry are provided. Process analytical technologies (PATs), which are important tools that provide real-time in-line continuous monitoring of reactions, are recommended to be considered during the reactor design process (e.g., port design for the PAT probe). Finally, other important points, such as density change caused by thermal expansion or solid precipitation, clogging/fouling, and scaling-up, are discussed.

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Continuous-flow diazotization of red base KD hydrochloride suspensions in a microreaction system

A continuous-flow microreaction system has been developed to perform the diazotization reaction of red base KD suspensions. The yield of the diazotization reaction could reach over 99% in 21.2 s under optimized conditions.

Selective hydrogenation of nitroaromatics to N-arylhydroxylamines in a micropacked bed reactor with passivated catalyst

In this contribution, a protocol was established for the selective catalytic hydrogenation of nitroarenes to the corresponding N-arylhydroxylamines. The reduction of 1-(4-chlorophenyl)-3-((2-nitrobenzyl)oxy)-1H-pyrazole, an intermediate in the synthesis of the antifungal reagent pyraclostrobin that includes carbon–chlorine bonds, benzyl groups, carbon–carbon double bonds and other structures that are easily reduced, was chosen as the model reaction for catalyst evaluation and condition optimization. Extensive passivant evaluation showed that RANEY®-nickel treated with ammonia/DMSO (1 : 10, v/v) afforded the optimal result, especially with a particle size of 400–500 mesh. To combine the modified catalyst with continuous-flow reaction technology, the reaction was conducted at room temperature, rendering the desired product with a conversion rate of 99.4% and a selectivity of 99.8%. The regeneration of catalytic activity was also studied, and an in-column strategy was developed by pumping the passivate liquid overnight. Finally, the generality of the method was explored, and 7 substrates were developed, most of which showed a good conversion rate and selectivity, indicating that the method has a certain degree of generality.

High selective hydrogenation of nitroaromatics to n-arylhydroxylamines in a micropacked bed reactor with passivated catalyst.

Green and catalyst-free synthesis of deoxyarbutin in continuous-flow

Highly efficient catalyst-free continuous-flow reaction and recycle process for the synthesis of deoxyarbutin.