Scale-up of a Luminescent Solar Concentrator-Based Photomicroreactor via Numbering-up

Full-cycle study on developing a novel structured micromixer and evaluating the nanoparticle products as mRNA delivery carriers

Achieving precise control of nanoparticle size while maintaining consistency and high uniformity is of paramount importance for improving the efficacy of nanoparticle-based therapies and minimizing potential side effects. Although microfluidic technologies are widely used for reliable nanoparticle synthesis, they face challenges in meeting critical homogeneity requirements, mainly due to imperfect mixing efficiency. Furthermore, channel clogging during continuous operation presents a significant obstacle in terms of quality control, as it progressively impedes the mixing behavior necessary for consistent nanoparticle production for therapeutic delivery and complicates the scaling-up process. This study entailed the development of a 3D-printed novel micromixer embedded with hemispherical baffle microstructures, a dual vortex mixer (DVM), which integrates Dean vortices to generate two symmetrical counter-rotating intensified secondary flows. The DVM with a relatively large mixer volume showed rapid mixing characteristics even at a flow rate of several mL min-1 and produced highly uniform lipids, liposomes, and polymer nanoparticles in a size range (50-130 nm) and polydispersity index (PDI) values below 0.15. For the evaluation of products, SARS-CoV-2 Spike mRNA-loaded lipid nanoparticles were examined to verify protein expression in vitro and in vivo using firefly luciferase (FLuc) mRNA. This showed that the performance of the system is comparable to that of a commercial toroidal mixer. Moreover, the vigorous in-situ dispersion of nanoparticles by harnessing the power of vortex physically minimizes the occurrence of aggregation, ensuring consistent production performance without internal clogging of a half-day operation and facilitating quality control of the nanoparticles at desired scales.

Rapid and Replaceable Luminescent Coating for Silicon-Based Microreactors Enabling Energy-Efficient Solar Photochemistry

The sun is the most sustainable source of photons on the earth but is rarely used in photochemical transformations due its relatively low and variable intensity, broad wavelength range, and lack of focus. Luminescent solar concentrator-based photomicroreactors (LSC-PMs) can be an answer to all these issues, but widespread adoption is plagued by challenges associated with their complicated manufacturing. Herein, we developed a new strategy to accelerate and ease the production of LSC-PMs by depositing a thin luminescent film on commercially and widely available silicon-based microreactors. The protocol is fast and operationally simple, and the luminescent coating can be easily removed and replaced. This enables rapid tuning of the luminescent coating to fit the requirements of the photocatalytic system and to increase the photon flux inside the microreactor channels.

Förster Resonance Energy Transfer in Luminescent Solar Concentrators

Luminescent solar concentrators (LSCs) are an emerging technology to collect and channel light from a large absorption area into a smaller one. They are a complementary technology for traditional solar photovoltaics (PV), particularly suitable for application in urban or indoor environments where their custom colors and form factors, and performance under diffuse light conditions may be advantageous. Förster resonance energy transfer (FRET) has emerged as a valuable approach to overcome some of the intrinsic limitations of conventional single lumophore LSCs, such as reabsorption or reduced quantum efficiency. This review outlines the potential of FRET to boost LSC performance, using highlights from the literature to illustrate the key criteria that must be considered when designing an FRET-LSC, including both the photophysical requirements of the FRET lumophores and their interaction with the host material. Based on these criteria, a list of design guidelines intended to aid researchers when they approach the design of a new FRET-LSC system is presented. By highlighting the unanswered questions in this field, the authors aim to demonstrate the potential of FRET-LSCs for both conventional solar-harvesting and emerging LSC-inspired technologies and hope to encourage participation from a diverse researcher base to address this exciting challenge.

A Superimposed QD-Based Optical Antenna for VLC: White LED Source

Visible light communication (VLC) is a versatile enabling technology for following high-speed wireless communication because of its broad unlicensed spectrum. In this perspective, white light-emitting diodes (LED) provide both illumination and data transmission simultaneously. To accomplish a VLC system, receiver antennas play a crucial role in receiving light signals and guiding them toward a photodetector to be converted into electrical signals. This paper demonstrates an optical receiver antenna based on luminescent solar concentrator (LSC) technology to exceed the conservation of etendue and reach a high signal-to-noise ratio. This optical antenna is compatible with all colors of LEDs and achieves an optical efficiency of 3.75%, which is considerably higher than the similar reported antenna. This antenna is fast due to the small attached photodetector—small enough that it can be adapted for electronic devices—which does not need any tracking system. Moreover, numerical simulation is performed using a Monte Carlo ray-tracing model, and results are extracted in the spectral domain. Finally, the fate of each photon and the chromaticity diagram of the collected photons’ spectra are specified.

A Proposal for Optical Antenna in VLC Communication Receiver System

Visible Light Communication (VLC) is an important emerging choice for high-speed wireless communication. In this perspective, light-emitting diodes as illuminators will be modulated to transmit data simultaneously. However, the receivers bring severe difficulties due to cost, response time, and sensitivity with a wide Field Of View (FOV). To avoid these problems, one approach is to apply a large area photodetector; however, this solution is slow and costly. Another method is to focus light on a fast photodetector by optical components, but the photodetector’s FOV decreases, resulting from the conservation of etendue. Another option is Luminescent Solar Concentrators (LSCs). This paper demonstrates a novel shape of LSC with advantages such as inexpensive, fast response time, small antenna area for VLC purposes with significant geometrical gain, FOV, and ultra-broad bandwidth. It does not require any complex tracking system and active pointing but, due to its tiny size, it can also be adapted in integrating and mobile devices. Numerical simulation is done using Monte-Carlo raytracing, and the results are demonstrated in the spectral domain. The optical efficiency of the proposed antenna is obtained at 1.058%, which is about 0.4% better than the efficiency levels reported in other works, and the geometric gain of the antenna is reported to be 44, which is significant.

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.

A Perspective on Heterogeneous Catalysts for the Selective Oxidation of Alcohols

Selective oxidation of higher alcohols using heterogeneous catalysts is an important reaction in the synthesis of fine chemicals with added value. Though the process for primary alcohol oxidation is industrially established, there is still a lack of fundamental understanding considering the complexity of the catalysts and their dynamics under reaction conditions, especially when higher alcohols and liquid‐phase reaction media are involved. Additionally, new materials should be developed offering higher activity, selectivity, and stability. This can be achieved by unraveling the structure–performance correlations of these catalysts under reaction conditions. In this regard, researchers are encouraged to develop more advanced characterization techniques to address the complex interplay between the solid surface, the dissolved reactants, and the solvent. In this mini‐review, we report some of the most important approaches taken in the field and give a perspective on how to tackle the complex challenges for different approaches in alcohol oxidation while providing insight into the remaining challenges.

The development of luminescent solar concentrator-based photomicroreactors: a cheap reactor enabling efficient solar-powered photochemistry

Sunlight strikes our planet every day with more energy than we consume in an entire year. Therefore, many researchers have explored ways to efficiently harvest and use sunlight energy for the activation of organic molecules. However, implementation of this energy source in the large-scale production of fine chemicals has been mostly neglected. The use of solar energy for chemical transformations suffers from potential drawbacks including scattering, reflections, cloud shading and poor matches between the solar emission and absorption characteristics of the photochemical reaction. In this account, we provide an overview of our efforts to overcome these issues through the development of Luminescent Solar Concentrator-based PhotoMicroreactors (LSC-PM). Such reactors can efficiently convert solar energy with a broad spectral distribution to concentrated and wavelength-shifted irradiation which matches the absorption maximum of the photocatalyst. Hence, the use of these conceptually new photomicroreactors provides an increased solar light harvesting capacity, enabling efficient solar-powered photochemistry.

CFD Study of the Numbering up of Membrane Microreactors for CO2 Capture

Carbon dioxide (CO2) is one of the major atmospheric greenhouse gases (GHG). The continuous increase of CO2 concentration and its long atmospheric lifetime may cause long-term negative effects on the climate. It is important to develop technologies to capture and minimize those emissions into the atmosphere. The objective of this work is to design and study theoretically and experimentally a numbering-up/scale-out membrane microreactor in order to be used as a capture system. The main aim of the work is to obtain an even flow distribution at each plate of the reactor. Nearly uniform flow distribution was achieved at each layer of the numbering-up microreactor according to the carried-out CFD models. The maximum difference between the average velocities was less than 6% for both gas and liquid flows. To obtain better flow distribution into the microreactor, the radius of the inlet/outlet tube was optimized. Results from CFD and experimental simulations do not match, and slightly maldistribution in achieved in the experimental system due to phase breakthrough and imperfections on the fabrication of the plates. Moreover, comparing the single channel microreactor to the scale-out microreactor, the latter showed poorer performance on CO2 removal while expecting the reactors to have similar performance. By installing inserts with different channel widths, the experimental results were identical to the original case.

Characterisation of oxygen defects and nitrogen impurities in TiO2 photocatalysts using variable-temperature X-ray powder diffraction

TiO₂-based powder materials have been widely studied as efficient photocatalysts for water splitting due to their low cost, photo-responsivity, earthly abundance, chemical and thermal stability, etc. In particular, the recent breakthrough of nitrogen-doped TiO₂, which enhances the presence of structural defects and dopant impurities at elevated temperatures, exhibits an impressive visible-light absorption for photocatalytic activity. Although their electronic and optical properties have been extensively studied, the structure-activity relationship and photocatalytic mechanism remain ambiguous. Herein, we report an in-depth structural study of rutile, anatase and mixed phases (commercial P25) with and without nitrogen-doping by variable-temperature synchrotron X-ray powder diffraction. We report that an unusual anisotropic thermal expansion of the anatase phase can reveal the intimate relationship between sub-surface oxygen vacancies, nitrogen-doping level and photocatalytic activity. For highly doped anatase, a new cubic titanium oxynitride phase is also identified which provides important information on the fundamental shift in absorption wavelength, leading to excellent photocatalysis using visible light.

Bandwidth limits of luminescent solar concentrators as detectors in free-space optical communication systems

Luminescent solar concentrators (LSCs) have recently emerged as a promising receiver technology in free-space optical communications due to their inherent ability to collect light from a wide field-of-view and concentrate it into small areas, thus leading to high optical gains. Several high-speed communication systems integrating LSCs in their detector blocks have already been demonstrated, with the majority of efforts so far being devoted to maximising the received optical power and the system's field-of-view. However, LSCs may pose a severe bottleneck on the bandwidth of such communication channels due to the comparably slow timescale of the fluorescence events involved, a situation further aggravated by the inherent reabsorption in these systems, and yet, an in-depth study into such dynamic effects remains absent in the field. To fill this gap, we have developed a comprehensive analytical solution that delineates the fundamental bandwidth limits of LSCs as optical detectors in arbitrary free-space optical links, and establishes their equivalence with simple RC low-pass electrical circuits. Furthermore, we demonstrate a time-domain Monte Carlo simulation platform, an indispensable tool in the multiparameter optimisation of LSC-based receiver systems. Our work offers vital insight into LSC system dynamic behaviour and paves the way to evaluate the technology for a wide range of applications, including visible light communications, high-speed video recording, and real-time biological imaging, to name a few.

Dawn of a new era in industrial photochemistry: the scale-up of micro- and mesostructured photoreactors

Photochemical activation routes are gaining the attention of the scientific community since they can offer an alternative to the traditional chemical industry that mainly utilizes thermochemical activation of molecules. Photoreactions are fast and selective, which would potentially reduce the downstream costs significantly if the process is optimized properly. With the transition towards green chemistry, the traditional batch photoreactor operation is becoming abundant in this field. Process intensification efforts led to micro- and mesostructured flow photoreactors. In this work, we are reviewing structured photoreactors by elaborating on the bottleneck of this field: the development of an efficient scale-up strategy. In line with this, micro- and mesostructured bench-scale photoreactors were evaluated based on a new benchmark called photochemical space time yield (mol·day⁻¹·kW⁻¹), which takes into account the energy efficiency of the photoreactors. It was manifested that along with the selection of the photoreactor dimensions and an appropriate light source, optimization of the process conditions, such as the residence time and the concentration of the photoactive molecule is also crucial for an efficient photoreactor operation. In this paper, we are aiming to give a comprehensive understanding for scale-up strategies by benchmarking selected photoreactors and by discussing transport phenomena in several other photoreactors.

A scalable synthesis of ternary nanocatalysts for a high-efficiency electrooxidation catalysis by microfluidics

Microfluidic synthesis has attracted extensive attention due to the ability for the multistep precise control of the synthesis parameters, continuous and reproducible preparation, and its ease of integration. However, its commercial application is still affected by its low production efficiency. In this case, we report a high-throughput continuous flow synthesis of highly dispersed PtFeCu/C nanocatalysts using a metal microchip setup with four parallel channels. The high flow rate and integrated channels enabled improving the throughput, whereby 1.33 g h^-1 of catalysts could be achieved with the flow rate of 1200 mL h^-1 under the experimental conditions. The as-prepared PtFeCu/C exhibited excellent performance, 1.94 times higher than Pt/C for methanol oxidation. More importantly, the yield of the PtFeCu/C nanocatalysts could be further increased through designing numerous parallel channels, which might provide a promising approach for large-scale commercialization of the catalysts. Such a high-throughput fabrication pathway is significant for the large-scale industrial production of nanomaterials.

Scale-up Design of a Fluorescent Fluid Photochemical Microreactor by 3D Printing

The integration of light-converting media and microflow chemistry renders new opportunities for high-efficient utilization of solar energy to drive chemical reactions. Recently, we proposed a design of fluorescent fluid photochemical microreactor (FFPM) with a separate light channel and reaction channel, which displays excellent advantages in energy efficiency, flexibility, and general use. However, the limitations of the scalability of the microchannel reactor are still a big challenge to be overcome. Herein, we illustrate the scalability of such an FFPM via a 2 ⁿ numbering-up strategy by 3D printing technology. Channel shape, number, and interchannel spacing have been optimized, and the serpentine FFPM shows the best scalability with an excellent conversion rate and massive throughput. Reactors with up to eight channels have been fabricated and displayed conversions comparable to that obtained in a single-channel reactor, which provides a feasible strategy and an optimized structure model for batch production of fine chemicals.

Compact reaction-module on a pad for scalable flow-production of organophosphates as drug scaffolds

Continuous pharmaceutical manufacturing receives intense attention as an alternative way to meet flexible market needs with the assurance of higher safety and quality control. Here, we report a compact reaction-module on a pad (CRP, 170 × 170 × 1.2 mm) for scale-up production of drug precursors in a continuous-flow. The CRP system was devised by stacking 9 films of the patterned polyimide to integrate micro-flow circuits, combining the functions of the even distribution of feeds, being completely mixed in less than a few milliseconds. A methodology of using a highly reactive species for the single-step synthesis of α-phosphonyloxy ketone, a drug scaffold, required the synthesis time of a few seconds in microfluidics. The fast reaction in the single CRP was capable of producing 19.2 g h-1 drug precursor, which indicates a solid step toward kilogram-scale pharmaceutical manufacturing in small footage.

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.

A numbering-up metal microreactor for the high-throughput production of a commercial drug by copper catalysis

Microreactors are emerging as an efficient, sustainable synthetic tool compared to conventional batch reactors. Here, we present a new numbering-up metal microreactor by integrating a flow distributor and a copper catalytic module for high productivity of a commercial synthetic drug. A flow distributor and an embedded baffle disc were manufactured by CNC machining and 3D printing of stainless steel (S/S), respectively, whereas a catalytic reaction module was composed of 25 copper coiled capillaries configured in parallel. Eventually, the numbering-up microreactor system assembled with functional modules showed uniform flow distribution and high mixing efficiency regardless of clogging, and achieved high-throughput synthesis of the drug "rufinamide", an anticonvulsant medicine, via a Cu(i)-catalyzed azide-alkyne cycloaddition reaction under optimized conditions.

Fluorescent Fluid in 3D-Printed Microreactors for the Acceleration of Photocatalytic Reactions

The photochemical microreactor has been a burgeoning field with important application in promoting photocatalytic reactions. The integration of light-converting media and microflow chemistry renders new opportunity for efficient utilization of light and high conversion rate. However, the flexibility of emission light wavelength regulation and the universality of the microreactor remain significant problems to be solved. Here, a photochemical microreactor filled with fluorescent fluid is fabricated by a 3D printing technique. The light-converting medium in the fluorescent fluid is used to collect and convert light, and then delivers light energy to the embedded continuous-flow reaction channels to promote the chemical reaction process. With the merits of flowability, different light-converting media can be replaced, making it a general tool for photocatalytic reactions in rapid screening, parameters optimization, and kinetic mechanism research.

Scalability of Visible-Light-Induced Nickel Negishi Reactions: A Combination of Flow Photochemistry, Use of Solid Reagents, and In-Line NMR Monitoring

The scale up of light-induced nickel-catalyzed Negishi reactions is reported herein, with output rates reaching multigram quantities per hour. This level of throughput is suitable to support preclinical medicinal chemistry programs in late lead optimization, where tens of grams to hundreds of grams of final product is needed. Adjusting reaction times and concentrations was critical in achieving this robust output. This example demonstrates how visible photochemistry and use of solid metal reagent can be used and how the progress of the reaction can be followed by in-line NMR monitoring.

A Laser Driven Flow Chemistry Platform for Scaling Photochemical Reactions with Visible Light

Visible-light-promoted organic reactions can offer increased reactivity and selectivity via unique reaction pathways to address a multitude of practical synthetic problems, yet few practical solutions exist to employ these reactions for multikilogram production. We have developed a simple and versatile continuous stirred tank reactor (CSTR) equipped with a high-intensity laser to drive photochemical reactions at unprecedented rates in continuous flow, achieving kg/day throughput using a 100 mL reactor. Our approach to flow reactor design uses the Beer-Lambert law as a guideline to optimize catalyst concentration and reactor depth for maximum throughput. This laser CSTR platform coupled with the rationale for design can be applied to a breadth of photochemical reactions.

Numbering-up of capillary microreactors for homogeneous processes and its application in free radical polymerization

Different numbered-up capillary microreactor systems were assembled with commercially available parts for homogeneous processes with significant variation of fluid properties (e.g., free radical polymerization), and statistical analysis was performed to reveal its flow distribution performance.

Continuous flow chemistry: where are we now? Recent applications, challenges and limitations

A general outlook of the changing face of chemical synthesis is provided in this article through recent applications of continuous flow processing in both industry and academia. The benefits, major challenges and limitations associated with the use of this mode of processing are also given due attention as an attempt to put into perspective the current position of continuous flow processing, either as an alternative or potential combinatory technology for batch processing.

Solar Photochemistry in Flow

In recent years, photochemistry has been a highly active research field. This renaissance is linked to the upsurge of photoredox catalysis, a versatile platform for synthetic methodologies using visible light photons as a traceless reagent. In contrast with UV, visible light constitutes almost half of the ground solar irradiance, making the use of solar light in chemistry a sustainable and viable possibility. However, the direct use of sunlight to power chemical reactions is still little explored. This can be explained by both the hurdles associated with solar radiation (e.g., its variability, irreproducibility, high IR content, etc.) and the need for a specialized photoreactor. Most of these issues can be tackled with technological solutions, and especially with the recourse to flow chemistry. Flow chemistry goes hand in hand with photochemistry thanks to the uniform irradiation it provides to the reaction. Furthermore, a continuous-flow reactor can be easily integrated with different solar collectors (including compound parabolic concentrators and luminescent solar concentrators) and constitutes the most efficient approach to solar photochemistry. After a description of the characteristics of the solar radiation relevant to chemistry, this chapter critically describes the different type of solar photoreactors and their applications in synthetic organic chemistry. Finally, an outlook on the future of solar photochemistry in flow is included.

A 3D-printed flow distributor with uniform flow rate control for multi-stacked microfluidic systems

In the scale-up of chemical production in a microfluidic system, it is challenging to prevent flow maldistribution from a single inlet into stacked multiple microchannel exits. In the present study, a compact flow distributor equipped with a fluidic damper is developed by computational fluid dynamics (CFD) along with experimental validation. A microfluidic flow distributor, which is equipped with an optimized fluidic damper and consists of 25 exit channels, is fabricated as an integrated body using a digital light processing (DLP) type 3D printer. The 3D printed flow distributor with a CFD-optimized fluidic damper is found to achieve a low maldistribution factor (MF) of 2.2% for the average flow rate over 25 exit channels while inducing only a minor increment (<6%) in the pressure drop. A generalized manual is proposed for the design of optimal flow distributors with different scale-up dimensions. Using the manual, an optimal flow distributor with 625 stacked microchannels with a MF of only 1.2% is successfully designed. It is expected that the design manual and the rapid printing platform will allow the efficient development of multi-channel stacked micro-devices such as those in drug delivery and energy conversion systems where equidistribution of fluid flow is highly demanded.