Using Continuous Processes to Increase Production

Batch and Flow Green Microwave-Assisted Catalytic Conversion Of Levulinic Acid to Pyrrolidones

This paper reports a new sustainable protocol for the microwave-assisted catalytic conversion of levulinic acid into N-substituted pyrrolidones over tailor-made mono (Pd, Au) or bimetallic (PdAu) catalysts supported on either highly mesoporous silica (HMS) or titania-doped HMS, exploiting the advantages of dielectric heating. MW-assisted reductive aminations of levulinic acid with several amines were first optimized in batch mode under hydrogen pressure (5 bar) in solvent-free conditions. Good-to-excellent yields were recorded at 150 °C in 90 min over the PdTiHMS and PdAuTiHMS, that proved recyclable and almost completely stable after six reaction cycles. Aiming to scale-up this protocol, a MW-assisted flow reactor was used in combination with different green solvents. Cyclopentyl methyl ether (CPME) provided a 99 % yield of N-(4-methoxyphenyl) pyrrolidin-2-one at 150 °C over PdTiHMS. The described MW-assisted flow synthesis proves to be a safe procedure suitable for further industrial applications, while averting the use of toxic organic solvents.

The outlooks and key challenges in renewable biomass feedstock utilization for value-added platform chemical via bioprocesses

The conversion of renewable biomass feedstock into value-added products via bioprocessing platforms has become attractive because of environmental and health concerns. Process performance and cost competitiveness are major factors in the bioprocess design to produce desirable products from biomass feedstock. Proper pretreatment allows delignification and hemicellulose removal from the liquid fraction, allowing cellulose to be readily hydrolyzed to monomeric sugars. Several industrial products are produced via sugar fermentation using either naturally isolated or genetically modified microbes. Microbial platforms play an important role in the synthesis of several products, including drop-in chemicals, as-in products, and novel compounds. The key elements in developing a fermentation platform are medium formulation, sterilization, and active cells for inoculation. Downstream bioproduct recovery may seem like a straightforward chemical process, but is more complex, wherein cost competitiveness versus recovery performance becomes a challenge. This review summarizes the prospects for utilizing renewable biomass for bioprocessing.

Rapid in situ generation of 2-(halomethyl)-5-phenylfuran and nucleophilic addition in a microflow reactor

2,5-Disubstituted furans are frequently found in pharmaceuticals and bioactive natural products. Nucleophilic substitution reactions on the carbon atom adjacent to the furan ring are useful for producing various furan derivatives. However, the formation of 5-substituted 2-halomethylfuran and the subsequent nucleophilic substitution reactions are often limited by severe undesired reactions caused by the highly reactive halomethylfurans. This paper reports the successful rapid synthesis of various 2,5-disubstituted furans using microflow technology, which suppresses undesired reactions including dimerization and ring opening of the furans. We observed that Brønsted acids had a significant effect on the nucleophilic substitution reaction and the use of HBr and HI gave the best results. A plausible mechanism of the Brønsted acid-mediated nucleophilic substitutions in the developed approach was proposed.

Recent advances in catalytic and non-catalytic epoxidation of terpenes: a pathway to bio-based polymers from waste biomass

Epoxides derived from waste biomass are a promising avenue for the production of bio-based polymers, including polyamides, polyesters, polyurethanes, and polycarbonates. This review article explores recent efforts to develop both catalytic and non-catalytic processes for the epoxidation of terpene, employing a variety of oxidizing agents and techniques for process intensification. Experimental investigations into the epoxidation of limonene have shown that these methods can be extended to other terpenes. To optimize the epoxidation of bio-based terpene, there is a need to develop continuous processes that address limitations in mass and heat transfer. This review discusses flow chemistry and innovative reactor designs as part of a multi-scale approach aimed at industrial transformation. These methods facilitate continuous processing, improve mixing, and either eliminate or reduce the need for solvents by enhancing heat transfer capabilities. Overall, the objective of this review is to contribute to the development of commercially viable processes for producing bio-based epoxides from waste biomass.

Design and Investigation of a Photocatalytic Setup for Efficient Biotransformations Within Recombinant Cyanobacteria in Continuous Flow

Photo- and biocatalysis show many advantages as more sustainable solutions for the production of fine chemicals. In an effort to combine the benefits and the knowledge of both these areas, a continuous photobiocatalytic setup was designed and optimized to carry out whole-cell biotransformations within cells of the cyanobacterium Synechocystis sp. PCC 6803 expressing the gene of the ene-reductase YqjM from B. subtilis. The effect of the light intensity and flow rate on the specific activity in the stereoselective reduction of 2-methyl maleimide was investigated via a design-of-experiments approach. The cell density in the setup was further increased at the optimal operating conditions without loss in specific activity, demonstrating that the higher surface area/volume ratio in the coil reactor improved the illumination efficiency of the process. Furthermore, different reactor designs were compared, proving that the presented approach was the most cost- and time-effective solution for intensifying photobiotransformations within cyanobacterial cells.

Photochemical Deracemization of a Medicinally-Relevant Benzopyran using an Oscillatory Flow Reactor

Dynamic deracemization processes, such as crystallization-induced diastereomer transformations (CIDTs), offer the opportunity to combine racemization and resolution processes, to provide high yields of enantiomerically pure compounds. To date, few of these processes have incorporated photochemical racemization. By combining batch crystallization with a flow photoreactor for efficient irradiation, it is possible to perform such deracemization in an effective, scalable and high yielding manner. After applying design of experiment (DoE) principles and mathematical modelling, the most efficient parameter set could be identified, leading to excellent results in just 4 h reaction time: isolated yield of 82 % and assay ee of 96 %. Such photochemical racemization methods can serve to open new avenues for preparation of enantiomerically pure functional molecules on both small and industrially-relevant scales.

Design and Optimization of the Single-Stage Continuous Mixed Suspension-Mixed Product Removal Crystallization of 2-Chloro-N-(4-methylphenyl)propenamide

A continuously operated single-stage mixed suspension-mixed product removal (MSMPR) crystallizer was developed for the continuous cooling crystallization of 2-chloro-N-(4-methylphenyl)propanamide (CNMP) in toluene from 25 to 0 °C. The conversion of the previous batch to a continuous process was key to developing a methodology linking the synthesis and purification unit operations of CNMP and gave further insight in the development of continuous process trains for active pharmaceutical ingredient materials. By monitoring how parameters such as cooling and agitation rates influence particle size and the yield, two batch start-up strategies were compared. The second part of the study focused on developing and optimizing the continuous cooling crystallization of CNMP in the MSMPR crystallizer in relation to the yield by determining the effects of varying the residence time and the agitation rates. During the MSMPR operation, the plot of the focused beam reflectance measurement total counts versus time oscillates and reaches an unusual state of control. Despite the oscillations, the dissolved concentration was constant. The yield and production rate from the system were constant after two residence times, as supported by FTIR data. The overall productivity was higher at shorter residence times (τ), and a productivity of 69.51 g/h for τ = 20 min was achieved for the isolation of CNMP.

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.

Generation of Tosyl Azide in Continuous Flow Using an Azide Resin, and Telescoping with Diazo Transfer and Rhodium Acetate-Catalyzed O-H Insertion

Generation of tosyl azide 12 in acetonitrile in flow under water-free conditions using an azide resin and its use in diazo transfer to a series of aryl acetates are described. Successful telescoping with a rhodium acetate-catalyzed O-H insertion has been achieved, thereby transforming the aryl acetate 8 to α-hydroxy ester 10, a key intermediate in the synthesis of clopidogrel 11, without requiring isolation or handling of either tosyl azide 12 or α-aryl-α-diazoacetate 9, or indeed having significant amounts of either present at any point. Significantly, the solution of α-diazo ester 9 was sufficiently clean to progress directly to the rhodium acetate-catalyzed step without any detrimental impact on the efficiency of the O-H insertion. In addition, the rhodium acetate-catalyzed O-H insertion process is cleaner in flow than under traditional batch conditions. Use of the azide resin offers clear safety advantages and, in addition, this approach complements earlier protocols for the generation of tosyl azide 12 in flow; this protocol is especially useful with less acidic substrates.

Integrated Suzuki Cross-Coupling/Reduction Cascade Reaction of meta-/para-Chloroacetophenones and Arylboronic Acids under Batch and Continuous Flow Conditions

Overcoming the incompatibility of a pair of conflicting catalysts via a flow methodology has great significance in the practical applications for multistep organic transformations. In this study, a multiple continuous-flow system is developed, which can boost the reactivity and selectivity in a sequential enantioselective cascade reaction. During this process, a periodic mesoporous organosilica-supported Pd/carbene species as a Suzuki cross-coupling catalyst is packed in the first column reactor, whereas another periodic mesoporous organosilica-supported Ru/diamine species as an asymmetric transfer hydrogenation catalyst is packed in the second column reactor. As we envisioned, the initially Pd-catalyzed cross-coupling reaction of meta-/para-chloroacetophenones and aryl boronic acids followed by the subsequentially Ru-catalyzed reduction provides chiral biarylols with enhanced yields and enantioselectivities. Furthermore, the advantages of the easy handling and the simple procedure make this system an attractive application in a scale-up preparation of optically pure organic molecules under environmentally-friendly conditions.

Rapid and Mild Lactamization Using Highly Electrophilic Triphosgene in a Microflow Reactor

Lactams are cyclic amides that are indispensable as drugs and as drug candidates. Conventional lactamization includes acid-mediated and coupling-agent-mediated approaches that suffer from narrow substrate scope, much waste, and/or high cost. Inexpensive, less-wasteful approaches mediated by highly electrophilic reagents are attractive, but there is an imminent risk of side reactions. Herein, a methods using highly electrophilic triphosgene in a microflow reactor that accomplishes rapid (0.5-10 s), mild, inexpensive, and less-wasteful lactamization are described. Methods A and B, which use N-methylmorpholine and N-methylimidazole, respectively, were developed. Various lactams and a cyclic peptide containing acid- and/or heat-labile functional groups were synthesized in good to high yields without the need for tedious purification. Undesired reactions were successfully suppressed, and the risk of handling triphosgene was minimized by the use of microflow technology.

Biomass-derived chemical substitutes for bisphenol A: recent advancements in catalytic synthesis

Bisphenol A is an oil-derived, large market volume chemical with a wide spectrum of applications in plastics, adhesives and thermal papers. However, bisphenol A is not considered safe due to its endocrine disrupting properties and reproductive toxicity. Several functional substitutes of bisphenol A have been proposed in the literature, produced from plant biomass. Unless otherwise specified, the present review covers the most significant contributions that appeared in the time span January 2015-August 2019, describing the sustainable catalytic synthesis of rigid diols from biomass derivatives. The focus is thereupon on heterogeneous catalysis, use of green solvents and mild conditions, cascade processes in one-pot, and continuous flow setups. More than 500 up-to-date references describe the various substitutes proposed and the catalytic methods for their manufacture, broken down according to the main biomass types from which they originate.

Stereoselective organocatalysis and flow chemistry

Organic synthesis has traditionally been performed in batch. Continuous-flow chemistry was recently rediscovered as an enabling technology to be applied to the synthesis of organic molecules. Organocatalysis is a well-established methodology, especially for the preparation of enantioenriched compounds. In this chapter we discuss the use of chiral organocatalysts in continuous flow. After the classification of the different types of catalytic reactors, in Section 2, each class will be discussed with the most recent and significant examples reported in the literature. In Section 3 we discuss homogeneous stereoselective reactions in flow, with a look at the stereoselective organophotoredox transformations in flow. This research topic is emerging as one of the most powerful method to prepare enantioenriched products with structures that would otherwise be challenging to make. Section 4 describes the use of supported organocatalysts in flow chemistry. Part of the discussion will be devoted to the choice of the support. Examples of packed-bed, monolithic and inner-wall functionalized reactors will be introduced and discussed. We hope to give an overview of the potentialities of the combination of (supported) chiral organocatalysts and flow chemistry.

N-Chloroamines as substrates for metal-free photochemical atom-transfer radical addition reactions in continuous flow

Photochemical ATRA reactions of N-chloroamines represent an efficient and green method of alkene functionalization. N-Chloroamine generation, purification and reaction in flow enables an efficient process, with a variety of irradiation wavelengths.

Selective oxidation of bio-based platform molecules and their conversion products over metal nanoparticle catalysts: a review

The conversion of bio-renewable raw materials into valuable products (biofuels, bifunctional carbonyls/carboxyls) that serve as the basis for biopolymers, has become one of the most important areas in the development of novel hybrid catalysts.

Carbon nanotube columns for flow systems: influence of synthesis parameters

Flow reactors are expected to play an increasingly important role in the production of chemicals. A simple carbon-based scaffold to easily develop flow systems is here detailed. Using a chemical vapour deposition technique, the controlled in situ growth of vertically aligned (VA) multi-wall carbon nanotubes (MWCNTs) into quartz columns with 2 mm inner diameter is achieved. Several of the described MWCNT columns (CNCs) can be produced at a time. The influence of synthesis parameters on the formation of these VA-MWCNT scaffolds is reported and discussed (e.g. injection time of the precursor, carrier gas flow rate, inner diameter and length of the quartz column, position in the furnace during synthesis). Raman spectroscopy, optical microscopy, scanning and transmission electron microscopy are used to assess the coverage of the inner channel of the quartz column with VA-MWCNTs and their overall quality. The length of the CNCs together with the carrier gas flow rate are found to be key parameters to control the MWCNT length profile within the CNCs. Fluoresceinamine molecules and platinum nanoparticles are successfully immobilised within these MWCNT scaffolds. The benefits of the CNCs for flow system design are summarised as the controlled filling with MWCNTs makes the detailed CNCs versatile scaffolds for flow catalysis and filtration.

Cluster Preface: Integrated Synthesis Using Continuous-Flow Technologies

Shinichiro Fuse was born in 1977 in Japan. He earned his B.S. degree in 2000 and his Ph.D. in 2005 from Tokyo Institute of Technology under the supervision of Prof. Takashi Takahashi. He was a researcher at ChemGenesis Incorporated between 2005 and 2006, and a postdoctoral fellow from 2006 to 2008 at Harvard University in the group of Prof. Daniel E. Kahne. In 2008, he joined the faculty at the Tokyo Institute of Technology as an assistant professor. He then moved to the Chemical Resources Laboratory at the same university as an associate professor in 2015. He was appointed as a professor at Nagoya University in 2019. His research is aimed toward the development of efficient synthetic processes based on a deep understanding of organic chemistry using flow synthesis, automated synthesis, theoretical calculations, and machine-learning technologies.

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Continuous Ultrasonic Reactors: Design, Mechanism and Application

Ultrasonic small scale flow reactors have found increasing popularity among researchers as they serve as a very useful platform for studying and controlling ultrasound mechanisms and effects. This has led to the use of these reactors for not only research purposes, but also various applications in biological, pharmaceutical and chemical processes mostly on laboratory and, in some cases, pilot scale. This review summarizes the state of the art of ultrasonic flow reactors and provides a guideline towards their design, characterization and application. Particular examples for ultrasound enhanced multiphase processes, spanning from immiscible fluid-fluid to fluid-solid systems, are provided. To conclude, challenges such as reactor efficiency and scalability are addressed.

Evolution of flow-oriented design strategies in the continuous preparation of pharmaceuticals

This review focuses on the flow-oriented design (FOD) in the multi-step continuous-flow synthesis of active pharmaceutical ingredients.

The rise of continuous flow biocatalysis – fundamentals, very recent developments and future perspectives

Very recent developments in the field of biocatalysis in continuously operated systems. Special attention on the future perspectives in this key emerging technological area ranging from process analytical technologies to digitalization.

Continuous-Flow Oxidation of HMF to FDCA by Resin-Supported Platinum Catalysts in Neat Water

The oxidation reaction of 5-hydroxymethylfurfural to the bioplastic monomer 2,5-furandicarboxylic acid over heterogenous resin-supported Pt catalysts was investigated in detail, under continuous flow, base-free conditions, and in neat water. The product was continuously obtained in 99 % yield by running the reaction at 120 °C, 303 s residence time, 1.2 mL min^-1 O₂ flow rate, and 7.7 bar O₂ pressure. The product was isolated with a high space-time-yield of 46.0 g L^-1  h^-1 without purifications or acid/base treatments.

A Holistic Approach to Streamlining Pharmaceutical Processes: A Conversation

Nearly 10 years ago, Frank Gupton and I had a chance encounter where we learned that we both had interest in creating efficient routes to generic medicines. Lucky for me, Frank and I began mentoring each other—Frank teaching me wisdom gained from 30 years in industry and I sharing what I knew about the academic world. As some who know Frank will understand, his lessons in some cases seem devilishly obvious and should be chanted daily like a zen koan while others are subtle and complex, requiring many years of reflection. Frank was asked by OPR&D to offer these lessons in a condensed form so that others might learn what I have. Frank and I decided that a transcript of our many conversations condensed into one document might do the trick.