Parallel Microflow Photochemistry: Process Optimization, Scale-up, and Library Synthesis

Addressing Reproducibility Challenges in High-Throughput Photochemistry

Light-mediated reactions have emerged as an indispensable tool in organic synthesis and drug discovery, enabling novel transformations and providing access to previously unexplored chemical space. Despite their widespread application in both academic and industrial research, the utilization of light as an energy source still encounters challenges regarding reproducibility and data robustness. Herein we present a comprehensive head-to-head comparison of commercially available batch photoreactors, alongside the introduction of the use of batch and flow photoreactors in parallel synthesis. Hence, we aim to establish a reliable and consistent platform for light-mediated reactions in high-throughput mode. Herein, we showcase the identification of several platforms aligning with the rigorous demands for efficient and robust high-throughput experimentation screenings and library synthesis.

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.

Direct Photocatalyzed Hydrogen Atom Transfer (HAT) for Aliphatic C-H Bonds Elaboration

Direct photocatalyzed hydrogen atom transfer (d-HAT) can be considered a method of choice for the elaboration of aliphatic C–H bonds. In this manifold, a photocatalyst (PC_HAT) exploits the energy of a photon to trigger the homolytic cleavage of such bonds in organic compounds. Selective C–H bond elaboration may be achieved by a judicious choice of the hydrogen abstractor (key parameters are the electronic character and the molecular structure), as well as reaction additives. Different are the classes of PCs_HAT available, including aromatic ketones, xanthene dyes (Eosin Y), polyoxometalates, uranyl salts, a metal-oxo porphyrin and a tris(amino)cyclopropenium radical dication. The processes (mainly C–C bond formation) are in most cases carried out under mild conditions with the help of visible light. The aim of this review is to offer a comprehensive survey of the synthetic applications of photocatalyzed d-HAT.

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.

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.

Acid Catalyzed Formation of C⁻C and C⁻S Bonds via Excited State Proton Transfer

The behavior of 2-naphthol and 7-bromo-2-naphthol as organic photoacids are exploited in organic synthesis for the preparation of benzyl sulfides (using a trichloroacetimidate derivative as the starting substrate) and polycyclic amines via acid catalyzed condensation of 1,2,3,4-tetrahydroisoquinoline with aldehydes.

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.

A Combined Experimental and Theoretical Study on the Reaction Mechanism and Molecular Structure of 4-(Diphenylamino)-3-iodo-2(5H)-furanone

The simultaneous α-iodination and Nβ-arylation mechanism of 5-alkyloxy-4-phenylamino-2(5H)-furanone by (diacetoxyiodo)benzene was investigated by means of density functional theory (DFT) with B3LYP/6-31G*//LANL2DZ, selecting 4-(diphenylamino)-5-methyloxy-3-iodo-2(5H)-furanone as the calculation model. In addition, the effect of solvent on the reaction pathway was investigated using the Polarisable Continuum Model (PCM). Good agreement was found between the computational and the experimental results. Furthermore, single crystals of 4-(diphenylamino)-5-ethoxy-3-iodo-2(5H)-furanone were grown by slow evaporation technique. The molecular structure analysis was performed by single crystal X-ray analysis and theoretical calculations using a semi-empirical quantum chemical method and DFT/B3LYP methods with a LANL2DZ as basis set.

Studies in organic and physical photochemistry - an interdisciplinary approach

Traditionally, organic photochemistry when applied to synthesis strongly interacts with physical chemistry. The aim of this review is to illustrate this very fruitful interdisciplinary approach and cooperation. A profound understanding of the photochemical reactivity and reaction mechanisms is particularly helpful for optimization and application of these reactions. Some typical reactions and particular aspects are reported such as the Norrish-Type II reaction and the Yang cyclization and related transformations, the [2 + 2] photocycloadditions, particularly the Paternò-Büchi reaction, photochemical electron transfer induced transformations, different kinds of catalytic reactions such as photoredox catalysis for organic synthesis and photooxygenation are discussed. Particular aspects such as the structure and reactivity of aryl cations, photochemical reactions in the crystalline state, chiral memory, different mechanisms of hydrogen transfer in photochemical reactions or fundamental aspects of stereoselectivity are discussed. Photochemical reactions are also investigated in the context of chemical engineering. Particularly, continuous flow reactors are of interest. Novel reactor systems are developed and modeling of photochemical transformations and different reactors play a key role in such studies. This research domain builds a bridge between fundamental studies of organic photochemical reactions and their industrial application.

Applications of Continuous-Flow Photochemistry in Organic Synthesis, Material Science, and Water Treatment

Continuous-flow photochemistry in microreactors receives a lot of attention from researchers in academia and industry as this technology provides reduced reaction times, higher selectivities, straightforward scalability, and the possibility to safely use hazardous intermediates and gaseous reactants. In this review, an up-to-date overview is given of photochemical transformations in continuous-flow reactors, including applications in organic synthesis, material science, and water treatment. In addition, the advantages of continuous-flow photochemistry are pointed out and a thorough comparison with batch processing is presented.

Combining photochemistry and catalysis: rapid access to sp3 - rich polyheterocycles from simple pyrroles

Use of FEP flow reactor technology allows access to gram quantities of photochemically-generated tricyclic aziridines. These undergo a range of novel palladium-catalyzed ring-opening and cycloaddition reactions, likely driven by their inherent strain, allowing incorporation of further functionality by fusing additional heterocyclic rings onto these already complex polycyclic cores. This rapid, 2-step access to complex sp3 - rich heterocycles should be of interest to those in the fields of drug discovery and natural product synthesis.

Construction of a multipurpose photochemical reactor with on-line spectrophotometric detection

A versatile photoreactor was constructed from commercially available parts, which is capable of recording high quality kinetic traces in homogeneous and heterogeneous photoreactions and also easily adaptable to flow-through operation.

A convenient numbering-up strategy for the scale-up of gas–liquid photoredox catalysis in flow

An operationally simple numbering-up strategy for the scale-up of gas–liquid photocatalytic reactions was developed, which provides an excellent flow distribution (SD_w < 10%).

Liquid phase oxidation chemistry in continuous-flow microreactors

This review gives an exhaustive overview of the engineering principles, safety aspects and chemistry associated with liquid phase oxidation in continuous-flow microreactors.

Stereoselective Synthesis of 1,3-Diaminotruxillic Acid Derivatives: An Advantageous Combination of C-H-ortho-Palladation and On-Flow [2+2]-Photocycloaddition in Microreactors

The stereoselective synthesis of ε-isomers of dimethyl esters of 1,3-diaminotruxillic acid in three steps is reported. The first step is the ortho-palladation of (Z)-2-aryl-4-aryliden-5(4H)-oxazolones 1 to give dinuclear complexes 2 with bridging carboxylates. The reaction occurs through regioselective activation of the ortho-CH bond of the 4-arylidene ring in carboxylic acids. The second step is the [2+2]-photocycloaddition of the CC exocyclic bonds of the oxazolone skeleton in 2 to afford the corresponding dinuclear ortho-palladated cyclobutanes 3. This key step was performed very efficiently by using LED light sources with different wavelengths (465, 525 or 625 nm) in flow microreactors. The final step involved the depalladation of 3 by hydrogenation in methanol to afford the ε-1,3-diaminotruxillic acid derivatives as single isomers.

Photochemically induced radical reactions with furanones

Radicals are easily generated via hydrogen transfer form secondary alcohols or tertiary amines using photochemical sensitization with ketones. They can subsequently add to the electron deficient double bond of furanones. The addition of the alcohols is particularly efficient. Therefore, this reaction was used to characterize and to compare the efficiency of different photochemical continuous flow microreactors. A range of micro-structured reactors were tested and their performances evaluated. The enclosed microchip enabled high space-time-yields but its microscopic dimensions limited its productivity. In contrast, the open microcapillary model showed a greater potential for scale-up and reactor optimization. A 10-microcapillary reactor was therefore constructed and utilized for typical R&D applications. Compared to the corresponding batch processes, the microreactor systems gave faster conversions, improved product qualities and higher yields. Similar reactions have also been carried out with electronically excited furanones and other α,β-unsaturated ketones. In this case, hydrogen is transferred directly to the excited olefin. This reaction part may occur either in one step, i.e., electron and proton are transferred simultaneously, or it may occur in two steps, i.e., the electron is transferred first and the proton follows. In the first case, a C–C bond is formed in the α position of the α,β-unsaturated carbonyl compound and in the second case this bond is formed in the β position. For the first reaction, the influence of stereochemical elements of the substrate on the regioselectivity of the hydrogen abstraction on the side chain has been studied.

Fabrication of an inexpensive and high efficiency microphotoreactor using CO2 laser technique for photocatalytic water treatment applications

In this study, a micro-photoreactor with catalyst-immobilized micro-channels was designed and fabricated using CO2 laser as a simple and inexpensive technique. The micro-photoreactor is composed of an array of micro-channels, a quartz plate, and an array of UV-LEDs. The micro-channels with the dimension of 400 µm width, 50 µm depth, and 80 cm length were inscribed on a flat plate of poly(methyl methacrylate) (PMMA). The illuminated specific surface area for the designed micro-reactor was calculated to be 25000 m(-1). To examine the performance of miniaturized photoreactor, the photocatalytic degradation of 4-Nitrophenol as a refractory pollutant was investigated. The effects of operational variables on the performance of micro-photoreactor were studied. Higher photocatalytic degradation is obtained for low flow rates, high light intensities, long micro-channels lengths, and low inlet concentrations. Also, the performance of micro-photoreactor was examined in the presence of different types of TiO2 catalysts with an average particle size between 5 and 27 nm (such as P25, PC500, Merck, and UV100) and textile dyes with different chemical structures (such as Acid Orange 7, Acid Violet 19, Basic Red 46, Methyl Orange, and Malachite Green). Finally, the reusability of miniaturized photoreactor was evaluated and the results showed satisfactory stability and reusability for the designed micro-reactor in the photocatalytic degradation of organic pollutants.

Microreactor-Mediated Benzylic Bromination in Concentrated Solar Radiation

Sunlight-induced bromination of benzylic compounds was conducted in a capillary microreactor, resulting in mono-brominated compounds with yields of up to 94 %. These reactions can be considered to be eco-friendly since they were carried out without an artificial light source or additional temperature control. In addition, up to 257.9 mmol could be produced daily using cost-effective molecular bromine, which leads to potential improvement of industrial processes.

Photodecarboxylative Benzylations of N-Methoxyphthalimide under Batch and Continuous-Flow Conditions

A series of photodecarboxylative benzylations of N-methoxyphthalimide were successfully realised using easily accessible starting materials. The reactions proceeded smoothly and the corresponding benzylated hydroxyphthalimidines were obtained in moderate to good yields of 52–73 %. No competing photoinduced dealkoxylation of the N-methoxy group was observed. The reaction with potassium phenylacetate was subsequently investigated in an advanced continuous-flow photoreactor. The reactor allowed rapid optimization of the reaction conditions and gave the desired benzylated product in higher yield and shorter irradiation time compared with the batch process.