A Simple Continuous Flow Microwave Reactor

Microflow chemistry and its electrification for sustainable chemical manufacturing

Sustainability is vital in solving global societal problems. Still, it requires a holistic view by considering renewable energy and carbon sources, recycling waste streams, environmentally friendly resource extraction and handling, and green manufacturing. Flow chemistry at the microscale can enable continuous sustainable manufacturing by opening up new operating windows, precise residence time control, enhanced mixing and transport, improved yield and productivity, and inherent safety. Furthermore, integrating microfluidic systems with alternative energy sources, such as microwaves and plasmas, offers tremendous promise for electrifying and intensifying modular and distributed chemical processing. This review provides an overview of microflow chemistry, electrification, their integration toward sustainable manufacturing, and their application to biomass upgrade (a select number of other processes are also touched upon). Finally, we identify critical areas for future research, such as matching technology to the scale of the application, techno-economic analysis, and life cycle assessment.

Domino synthesis of functionalized pyridine carboxylates under gallium catalysis: Unravelling the reaction pathway and the role of the nitrogen source counter anion

The catalytic potential of various metal Lewis acid catalysts have been assessed to derive a high-yielding, multi-component domino synthesis of functionalized pyridines from (E)-3-(dimethylamino)-1-aryl/heteroaryl-prop-2-en-1-ones, 1,3-dicarbonyl compounds, and an ammonium salt (as the nitrogen precursor). Amongst the various metal halides, tetrafluoroborates, perchlorates, and triflates used as the catalyst GaI3 proved to be the most effective. The mechanistic course of the most plausible pathway has been outlined as the intermediate formation of imine/enamine by the reaction of the 1,3-dicarbonyl compound with ammonia (liberated in situ from the ammonium salt used as the nitrogen source), which participates in the domino nucleophilic Michael reaction to the (2E)-3-(dimethylamino)-1-aryl/hetroarylprop-2-en-1-one by its active methylene carbon through its enamine form followed by intramolecular cyclization and aromatization. The effect of different ammonium salts as the nitrogen source has been investigated and NH4OAc was found to be best. The influence of the acetate counter anion of NH4OAc on the progress of the reaction was studied and its specific role in the cyclization and subsequent aromatization has been revealed. This work offers distinct advantages compared to the literature reported methodologies on the count of several green index parameters.

Preparation of Tenuifolin from Polygala senega L. Root Using a Hydrolytic Continuous Flow System under High-Temperature, High-Pressure Conditions

An improved process for preparing tenuifolin (presenegenin 3-β-d-glucopyranoside) from the root of Polygala senega L. was developed. A crude saponin mixture extracted from P. senega was subjected to hydrolysis, and the reactivity of compounds in the extract was controlled by utilizing the combination of a flow reactor and experimental design. In addition, column chromatography with HP 20, a synthetic polystyrenic adsorbent, allowed the gram-scale preparation of tenuifolin in a continuous manner with fewer steps. This approach shortens the total time required for gram-scale preparation from 16 to 5 h in a continuous manner while improving the yield from 0.59% to 2.08% (w/w).

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.

Continuous Flow Synthesis of Heterocycles: A Recent Update on the Flow Synthesis of Indoles

Indole derivatives are among the most useful and interesting heterocycles employed in drug discovery and medicinal chemistry. In addition, flow chemistry and flow technology are changing the synthetic paradigm in the field of modern synthesis. In this review, the role of flow technology in the preparation of indole derivatives is showcased. Selected examples have been described with the aim to provide readers with an overview on the tactics and technologies used for targeting indole scaffolds.

Continuous syntheses of carbon-supported Pd and Pd@Pt core-shell nanoparticles using a flow-type single-mode microwave reactor

Continuous syntheses of carbon-supported Pd@Pt core–shell nanoparticles were performed using microwave-assisted flow reaction in polyol to synthesize carbon-supported core Pd with subsequent direct coating of a Pt shell. By optimizing the amount of NaOH, almost all Pt precursors contributed to shell formation without specific chemicals.

Continuous syntheses of carbon-supported Pd@Pt core–shell nanoparticles were performed using flow processes including microwave-assisted Pd core–nanoparticle formation.

DMSO-Triggered Complete Oxygen Transfer Leading to Accelerated Aqueous Hydrolysis of Organohalides under Mild Conditions

Addition of DMSO is found to greatly accelerate the aqueous hydrolysis of organohalides to alcohols, providing a neutral, more efficient, milder and more economic process. Mechanistic studies using ¹⁸ O-DMSO and ¹⁸ O-H₂ O showed that, contrary to the opinion that DMSO works as a dipolar solvent to enhance water's nucleophilicity, the accelerating effect comes from a complete oxygen transfer from DMSO to organohalides through generation of ROS⁺ Me₂ ⋅X^- salts through C-O bond formation, followed by O-S bond disassociative hydrolysis of ROS⁺ Me₂ ⋅X^- with water. This method is applicable to a wide range of organohalides and thus may have potential for practical industrial application, owing to easy recovery of DMSO from the H₂ O/DMSO mixture by regular vacuum rectification.

Application of the Microwave Technique in Continuous Flow Processing of Organophosphorus Chemical Reactions

The microwave (MW) technique is an efficient tool in the realization of organic reactions, as well as in the analytical field and in the food industry. The continuous flow approach is of special interest as a promising way to scale-up MW-assisted syntheses. Besides summarizing the batch precedents, this review focuses on the utilization of the MW technique in the continuous-flow realization of organophosphorus transformations. The advantages of the continuous flow technique against the batch accomplishment are also shown. A few materials chemistry-related applications are also mentioned.

Practical and Scalable Organic Reactions with Flow Microwave Apparatus

Microwave irradiation has been used for accelerating organic reactions as a heating method and has been proven to be useful in laboratory scale organic synthesis. The major drawback of microwave chemistry is the difficulty in scaling up, mainly because of the low penetration depth of microwaves. The combination of microwave chemistry and flow chemistry is considered to overcome the problem in scaling up of microwave-assisted organic reactions, and some flow microwave systems have been developed in both academic and industrial communities. In this context, we have demonstrated the scale-up of fundamental organic reactions using a novel flow microwave system developed by the academic-industrial alliance between the University of Shizuoka, Advanced Industrial Science and Technology, and SAIDA FDS. In this Personal Account, we summarize the recent progress of our scalable microwave-assisted continuous synthesis using the SAIDA flow microwave apparatus.

Microwaves in the Catalytic Valorisation of Biomass Derivatives

The application of microwave irradiation in the transformation of biomass has been receiving particular interest in recent years due to the use of polar media in such processes and it is now well-known that for biomass conversion, and particularly for lignocellulose hydrolysis, microwave irradiation can dramatically increase reaction rates with no negative consequences on product selectivity. However, it is only in the last ten years that the utilisation of microwaves has been coupled with catalysis aiming towards valorising biomass components or their derivatives via a range of reactions where high selectivity is required in addition to enhanced conversions. The reduced reaction times and superior yields are particularly attractive as they might facilitate the transition towards flow reactors and intensified production. As a consequence, several reports now describe the catalytic transformation of biomass derivatives via hydrogenation, oxidation, dehydration, esterification and transesterification using microwaves. Clearly, this technology has a huge potential for biomass conversion towards chemicals and fuels and will be an important tool within the biorefinery toolkit. The aim of this chapter is to give the reader an overview of the exciting scientific work carried out to date where microwave reactors and catalysis are combined in the transformation of biomass and its derivatives to higher value molecules and products.

Development of a highly efficient single-mode microwave applicator with a resonant cavity and its application to continuous flow syntheses

A new microwave applicator specifically designed for continuous flow synthesis has been developed and tested in the Fischer indole synthesis and in the Diels–Alder reaction to afford the reaction products at a scale of 100 g h⁻¹.

Batch and continuous flow preparation of Hantzsch 1,4-dihydropyridines under microwave heating and simultaneous real-time monitoring by Raman spectroscopy. An exploratory study

Dialkyl 1,4-dihydro-2,6-dimethylpyridine-3,5-dicarboxylates have been prepared in a batch mode under conventional heating as well as under continuous flow conditions in the Miniflow 200SS, Sairem’s microwave-assisted batch and continuous flow equipment. Real-time monitoring of the reactions by Raman spectroscopy enabled to compare both heating modes and to determine (optimized) reaction times.

One-step synthesis of pyridines and dihydropyridines in a continuous flow microwave reactor

The Bohlmann-Rahtz pyridine synthesis and the Hantzsch dihydropyridine synthesis can be carried out in a microwave flow reactor or using a conductive heating flow platform for the continuous processing of material. In the Bohlmann-Rahtz reaction, the use of a Brønsted acid catalyst allows Michael addition and cyclodehydration to be carried out in a single step without isolation of intermediates to give the corresponding trisubstituted pyridine as a single regioisomer in good yield. Furthermore, 3-substituted propargyl aldehydes undergo Hantzsch dihydropyridine synthesis in preference to Bohlmann-Rahtz reaction in a very high yielding process that is readily transferred to continuous flow processing.

Flow Microwave Technology and Microreactors in Synthesis

A bespoke microwave reactor with a glass containment cell has been developed for performing continuous flow reactions under microwave heating. The prototype unit has been evaluated using a series of standard organic chemical transformations enabling scale-up of these chemical processes. As part of the development, a carbon-doped PTFE reactor insert was utilized to allow the heating of poorly absorbing reaction media, increasing the range of solvents and scope of reactions that can be performed in the device.

Synthesis of an Isoindoline-Annulated, Tricyclic Sultam Library via Microwave-Assisted, Continuous-Flow Organic Synthesis (MACOS)

A microwave-assisted, continuous-flow organic synthesis (MACOS) protocol for the synthesis of an isoindoline-annulat-ed, tricyclic sultam library, utilizing a Heck-aza-Michael (HaM) strategy, is reported. This sequence involves a Heck reaction on vi-nylsulfonamides with batch microwave heating followed by a one-pot, sequential intramolecular aza-Michael cyclization/Boc-deprot-ection using MACOS. Subsequent cyclization with either 1,1'-carbonyldiimidazole or chloromethyl pivalate using MACOS provided an array of tricyclic sultams. This efficient three-step protocol requires only a few hours to produce the target sultams starting from simple starting materials. Using this strategy, a 38-member library of isoindoline-annulated sultams was generated in good to excellent overall yields (53-87%).

Continuous-flow hydration-condensation reaction: Synthesis of α,β-unsaturated ketones from alkynes and aldehydes by using a heterogeneous solid acid catalyst

A simple, practical and efficient continuous-flow hydration-condensation protocol was developed for the synthesis of α,β-unsaturated ketones starting from alkynes and aldehydes by employing a heterogeneous catalyst in a flow microwave. The procedure presents a straightforward and convenient access to valuable differently substituted chalcones and can be applied on multigram scale.

Gram-scale synthesis of the p38α MAPK-inhibitor VX-745 for preclinical studies into Werner syndrome

BACKGROUND

The ATP-competitive p38α MAPK inhibitor VX-745 exhibits an exquisite kinase selectivity profile, is effective in blocking p38 stress signaling in Werner syndrome dermal fibroblasts, has efficacy in clinical trials and may have therapeutic value against Werner syndrome. Previous synthetic routes, however, have only resulted in milligram quantities suitable for cell-based studies, whereas gram quantities would be required for in vivo use.

RESULTS & DISCUSSION

Microwave irradiation using a stop-flow monomodal microwave reactor has been found to facilitate scale-up of the synthesis of VX-745. Ullmann-type C-S bond formation using thiophenol, chloropyridazine, copper(I) catalyst and diol ligand proceeds rapidly and efficiently in this apparatus for elaboration to the pyrimido[1,6-b]pyridazinone core of VX-745 on gram scale and with good overall yield.

CONCLUSION

This method delivers the p38 inhibitor VX-745 in sufficient quantities for preclinical studies to rescue the aging phenotype in Werner syndrome.

Continuous synthesis of monodispersed silver nanoparticles using a homogeneous heating microwave reactor system

Continuous synthesis of silver nanoparticles based on a polyol process was conducted using a microwave-assisted flow reactor installed in a cylindrical resonance cavity. Silver nitrate (AgNO(3)) and poly(N-vinylpyrrolidone) (PVP) dissolved in ethylene glycol were used respectively as a silver metal precursor and as a capping agent of nanoparticles. Ethylene glycol worked as the solvent and simultaneously as the reductant. Silver nanoparticles of narrow size distributions were synthesized steadily for 5 h, maintaining almost constant yield (>93%) and quality. The reaction was achieved within 2.8 s of residence time, although nanoparticles were not formed under this flow rate by conventional heating. A narrower particle size distribution was realized by the increased flow rate of the reaction solution. Nanoparticles of 9.8 nm average size with a standard deviation of 0.9 nm were synthesized at the rate of 100 ml h(-l).