Catalytic Static Mixers for the Continuous Flow Hydrogenation of a Key Intermediate of Linezolid (Zyvox)

Copper-Catalyzed Continuous-Flow Transfer Hydrogenation of Nitroarenes to Anilines: A Scalable and Reliable Protocol

A robust supported catalyst that is made up of copper nanoparticles on Celite has been successfully prepared for the selective transfer hydrogenation of aromatic nitrobenzenes to anilines under continuous flow. The method is efficient and environmentally benign thanks to the absence of hydrogen gas and precious metals. Long-term stability studies show that the catalytic system is able to achieve very high nitrobenzene conversion (>99%) when working for up to 145 h. The versatility of the transfer hydrogenation system has been tested using representative examples of nitroarenes, with moderate-to-excellent yields being obtained. The packed bed reactor (PBR) permits the use of a setup that can provide products via simple isolation by SPE without the need for further purification. The recovery and reuse of either EG or the ion-exchange resin leads to consistent waste reduction; therefore, E-factor distribution analysis has highlighted the environmental efficiency of this synthetic protocol.

Static Mixers Producible by Additive Manufacturing: Novel Rapid Automatic Optimisation and Practical Evaluation

In the extrusion of plastics, the thermal and material homogeneity of the plastic melt at the die entry are of high importance for the extrudate quality. While static mixers are widely used to improve the melt homogeneity, previous attempts at optimisation for reduced pressure loss and improved mixing had to be performed by hand and human experience, limiting the degrees of freedom and efficiency. A new automatic optimisation method based on the open source software OpenFOAM was developed. Using immersed boundary methods, new target functions in the pre-existing routine adjointShapeOptimizationFoam and an additional algorithm checking the suitability for additive manufacturing and fixing the geometry during run-time is presented. The new algorithm is used to optimise an existing static mixer based on an X-type geometry with integrated oil channels, maximising the heat exchange between oil and melt. Based on the results of these simulative optimisations, the best candidates were manufactured using selective laser melting and experimental trials were run. Experimental validation shows that with our optimisation algorithm, a pressure loss reduction of 10% could be achieved. The core melt temperature was reduced by 6 ∘C, improving the thermal homogenisation as well. While the main advantage of this method is the rapid optimisation taking the operating point into account, the trials also showed positive results in off-design operating points. This allows the low-cost design and manufacture of individualised static mixers.

Bayesian Optimization of Computer-Proposed Multistep Synthetic Routes on an Automated Robotic Flow Platform

Computer-aided synthesis planning (CASP) tools can propose retrosynthetic pathways and forward reaction conditions for the synthesis of organic compounds, but the limited availability of context-specific data currently necessitates experimental development to fully specify process details. We plan and optimize a CASP-proposed and human-refined multistep synthesis route toward an exemplary small molecule, sonidegib, on a modular, robotic flow synthesis platform with integrated process analytical technology (PAT) for data-rich experimentation. Human insights address catalyst deactivation and improve yield by strategic choices of order of addition. Multi-objective Bayesian optimization identifies optimal values for categorical and continuous process variables in the multistep route involving 3 reactions (including heterogeneous hydrogenation) and 1 separation. The platform's modularity, robotic reconfigurability, and flexibility for convergent synthesis are shown to be essential for allowing variation of downstream residence time in multistep flow processes and controlling the order of addition to minimize undesired reactivity. Overall, the work demonstrates how automation, machine learning, and robotics enhance manual experimentation through assistance with idea generation, experimental design, execution, and optimization.

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.

3D-printed capillary force trap reactors (CFTRs) for multiphase catalytic flow chemistry

Figure of 3D illustration of a capillary trap force reactor (CFTR) with transiently trapped liquid nanoparticle catalysts in dimple-shaped capillary traps in the presence of a gas–liquid segmented flow, for the hydrogenation of 1-hexene to n-hexane.

Greener Synthesis of Pristane by Flow Dehydrative Hydrogenation of Allylic Alcohol Using a Packed-Bed Reactor Charged by Pd/C as a Single Catalyst

Our previous work established a continuous-flow synthesis of pristane, which is a saturated branched alkane obtained from a Basking Shark. The dehydration of an allylic alcohol that is the key to a tetraene was carried out using a packed-bed reactor charged by an acid–silica catalyst (HO-SAS) and flow hydrogenation using molecular hydrogen via a Pd/C catalyst followed. The present work relies on the additional propensity of Pd/C to serve as an acid catalyst, which allows us to perform a flow synthesis of pristane from the aforementioned key allylic alcohol in the presence of molecular hydrogen using Pd/C as a single catalyst, which is applied to both dehydration and hydrogenation. The present one-column-two-reaction-flow system could eliminate the use of an acid catalyst such as HO-SAS and lead to a significant simplification of the production process.

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).

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.

Advanced Real-Time Process Analytics for Multistep Synthesis in Continuous Flow*

In multistep continuous flow chemistry, studying complex reaction mixtures in real time is a significant challenge, but provides an opportunity to enhance reaction understanding and control. We report the integration of four complementary process analytical technology tools (NMR, UV/Vis, IR and UHPLC) in the multistep synthesis of an active pharmaceutical ingredient, mesalazine. This synthetic route exploits flow processing for nitration, high temperature hydrolysis and hydrogenation reactions, as well as three inline separations. Advanced data analysis models were developed (indirect hard modeling, deep learning and partial least squares regression), to quantify the desired products, intermediates and impurities in real time, at multiple points along the synthetic pathway. The capabilities of the system have been demonstrated by operating both steady state and dynamic experiments and represents a significant step forward in data-driven continuous flow synthesis.

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.

3D Printing in Heterogeneous Catalysis-The State of the Art

This paper describes the process of additive manufacturing and a selection of three-dimensional (3D) printing methods which have applications in chemical synthesis, specifically for the production of monolithic catalysts. A review was conducted on reference literature for 3D printing applications in the field of catalysis. It was proven that 3D printing is a promising production method for catalysts.

Recent Progress in Continuous-Flow Hydrogenation

To achieve a safe, efficient, and sustainable (even fully automated) production for the continuous-flow hydrogenation reactions, which is among the most often used reactions in chemical synthesis, new catalyst types and immobilization methods as well as flow reactors and technologies have been developed over the last years; in addition, these approaches have been combined with new and transformational technologies in other fields such as artificial intelligence. Thus, attention from academic and industry practitioners has increasingly focused on improving the performance of hydrogenation in flow mode by reducing the reaction times, increasing selectivities, and achieve safe operation. This Minireview aims to summarize the most recent research results on this topic with focus on the advantages, current limitations, and future directions of flow chemistry.

Liquid Phase Hydrogenation of Pharmaceutical Interest Nitroarenes over Gold-Supported Alumina Nanowires Catalysts

In this work, Au nanoparticles, supported in Al₂O₃ nanowires (ANW) modified with (3-aminopropyl)trimethoxysilane were synthetized, for their use as catalysts in the hydrogenation reaction of 4-(2-fluoro-4-nitrophenyl)-morpholine and 4-(4-nitrophenyl)morpholin-3-one. ANW was obtained by hydrothermal techniques and the metal was incorporated by the reduction of the precursor with NaBH₄ posterior to superficial modification. The catalysts were prepared at different metal loadings and were characterized by different techniques. The characterization revealed structured materials in the form of nanowires and a successful superficial modification. All catalysts show that Au is in a reduced state and the shape of the nanoparticles is spherical, with high metal dispersion and size distributions from 3.7 to 4.6 nm. The different systems supported in modified-ANW were active and selective in the hydrogenation reaction of both substrates, finding for all catalytic systems a selectivity of almost 100% to the aromatic amine. Catalytic data showed pseudo first-order kinetics with respect to the substrate for all experimental conditions used in this work. The solvent plays an important role in the activity and selectivity of the catalyst, where the highest efficiency and operational stability was achieved when ethanol was used as the solvent.

Strategies towards the synthesis of anti-tuberculosis drugs

In this report, we reviewed the strategies towards the synthesis of anti-tuberculosis drugs. They include semisynthetic approaches, resolution based strategies, microbial transformations, solid phase synthesis, and asymmetric synthesis.