Design, Execution, and Analysis of Time-Varying Experiments for Model Discrimination and Parameter Estimation in Microreactors

Simultaneous reaction- and analytical model building using dynamic flow experiments to accelerate process development

In modern pharmaceutical research, the demand for expeditious development of synthetic routes to active pharmaceutical ingredients (APIs) has led to a paradigm shift towards data-rich process development. Conventional methodologies encompass prolonged timelines for the development of both a reaction model and analytical models. The development of both methods are often separated into different departments and can require an iterative optimization process. Addressing this issue, we introduce an innovative dual modeling approach, combining the development of a Process Analytical Technology (PAT) strategy with reaction optimization. This integrated approach is exemplified in diverse amidation reactions and the synthesis of the API benznidazole. The platform, characterized by a high degree of automation and minimal operator involvement, achieves PAT calibration through a "standard addition" approach. Dynamic experiments are executed to screen a broad process space and gather data for fitting kinetic parameters. Employing an open-source software program facilitates rapid kinetic parameter fitting and additional in silico optimization within minutes. This highly automated workflow not only expedites the understanding and optimization of chemical processes, but also holds significant promise for time and resource savings within the pharmaceutical industry.

An optimization-based model discrimination framework for selecting an appropriate reaction kinetic model structure during early phase pharmaceutical process development

A model discrimination workflow to develop fit for purpose kinetic models of new pharmaceutical compounds in early stages of drug development involving complex reaction networks with limited prior information and provision to run new experiments.

Automated generation of photochemical reaction data by transient flow experiments coupled with online HPLC analysis

Competing homo- and crossdimerization reactions between coumarin and 1-methyl-2-quinolinone are investigated by transient continuous-flow experiments combined with online HPLC, enabling the generation and acquisition of large reaction data sets.

Characterization of reaction enthalpy and kinetics in a microscale flow platform

We report an isothermal flow calorimeter for characterization of reaction enthalpy and kinetics.

Model-based design of transient flow experiments for the identification of kinetic parameters

Rapid and precise estimation of kinetic parameters is facilitated by transient flow experiments designed using model-based design of experiments.

An autonomous microreactor platform for the rapid identification of kinetic models

Rapid estimation of kinetic parameters with high precision is facilitated by automation combined with online Model-Based Design of Experiments.

Algorithms for the self-optimisation of chemical reactions

Self-optimising chemical systems have experienced a growing momentum in recent years. Herein, we review algorithms used for the self-optimisation of chemical reactions in an accessible way for the general chemist.

Model-Based Methods in the Biopharmaceutical Process Lifecycle

Model-based methods are increasingly used in all areas of biopharmaceutical process technology. They can be applied in the field of experimental design, process characterization, process design, monitoring and control. Benefits of these methods are lower experimental effort, process transparency, clear rationality behind decisions and increased process robustness. The possibility of applying methods adopted from different scientific domains accelerates this trend further. In addition, model-based methods can help to implement regulatory requirements as suggested by recent Quality by Design and validation initiatives. The aim of this review is to give an overview of the state of the art of model-based methods, their applications, further challenges and possible solutions in the biopharmaceutical process life cycle. Today, despite these advantages, the potential of model-based methods is still not fully exhausted in bioprocess technology. This is due to a lack of (i) acceptance of the users, (ii) user-friendly tools provided by existing methods, (iii) implementation in existing process control systems and (iv) clear workflows to set up specific process models. We propose that model-based methods be applied throughout the lifecycle of a biopharmaceutical process, starting with the set-up of a process model, which is used for monitoring and control of process parameters, and ending with continuous and iterative process improvement via data mining techniques.

The Hitchhiker's Guide to Flow Chemistry ∥

Flow chemistry involves the use of channels or tubing to conduct a reaction in a continuous stream rather than in a flask. Flow equipment provides chemists with unique control over reaction parameters enhancing reactivity or in some cases enabling new reactions. This relatively young technology has received a remarkable amount of attention in the past decade with many reports on what can be done in flow. Until recently, however, the question, "Should we do this in flow?" has merely been an afterthought. This review introduces readers to the basic principles and fundamentals of flow chemistry and critically discusses recent flow chemistry accounts.

Rapid multistep kinetic model generation from transient flow data

S_NAr reaction profiles were generated using an automated reactor, collected in less than 3 hours, and allowed accurate estimation of kinetic parameters.

Today, the generation of kinetic models is still seen as a resource intensive and specialised activity. We report an efficient method of generating reaction profiles from transient flows using a state-of-the-art continuous-flow platform. Experimental data for multistep aromatic nucleophilic substitution reactions are collected from an automated linear gradient flow ramp with online HPLC at the reactor outlet. Using this approach, we generated 16 profiles, at 3 different inlet concentrations and 4 temperatures, in less than 3 hours run time. The kinetic parameters, 4 rate constants and 4 activation energies were fitted with less than 4% uncertainty. We derived an expression for the error in the observed rate constants due to dispersion and showed that such error is 5% or lower. The large range of operational conditions prevented the need to isolate individual reaction steps. Our approach enables early identification of the sensitivity of product quality to parameter changes and early use of unit operation models to identify optimal process-equipment combinations in silico, greatly reducing scale up risks.

Liquid–liquid microflow reaction engineering

Engineering characteristics of liquid–liquid microflow and its advantages in chemical reactions.

The application of reaction engineering to biocatalysis

Biocatalysis is a growing area of synthetic and process chemistry with the ability to deliver not only improved processes for the synthesis of existing compounds, but also new routes to new compounds.