Optimising a vortex fluidic device for controlling chemical reactivity and selectivity

Multiphasic Continuous-Flow Reactors for Handling Gaseous Reagents in Organic Synthesis: Enhancing Efficiency and Safety in Chemical Processes

The use of reactive gaseous reagents for the production of active pharmaceutical ingredients (APIs) remains a scientific challenge due to safety and efficiency limitations. The implementation of continuous-flow reactors has resulted in rapid development of gas-handling technology because of several advantages such as increased interfacial area, improved mass- and heat transfer, and seamless scale-up. This technology enables shorter and more atom-economic synthesis routes for the production of pharmaceutical compounds. Herein, we provide an overview of literature from 2016 onwards in the development of gas-handling continuous-flow technology as well as the use of gases in functionalization of APIs.

Hydrogel-Film-Fabricated Fluorescent Biosensors with Aggregation-Induced Emission for Albumin Detection through the Real-Time Modulation of a Vortex Fluidic Device

Hydrogels have various promising prospects as a successful platform for detecting biomarkers, and human serum albumin (HSA) is an important biomarker in the diagnosis of kidney diseases. However, the difficult-to-control passive diffusion kinetics of hydrogels is a major factor affecting detection performance. This study focuses on using hydrogels embedded with aggregation-induced emission (AIE) fluorescent probe TC426 to detect HSA in real time. The vortex fluidic device (VFD) technology is used as a rotation strategy to control the reaction kinetics and micromixing during measurement. The results show that the introduction of VFD could significantly accelerate its fluorescence response and effectively improve the diffusion coefficient, while VFD processing could regulate passive diffusion into active diffusion, offering a new method for future sensing research.

Exploiting angled thin film vortex microfluidics for expeditious syntheses of iminosugars

Iminosugars are important compounds in the area of carbohydrate-based therapeutics. A simple synthetic methodology utilizing the vortex fluidic thin film microfluidic reactor is effective in the synthesis of such compounds for diverse reaction types, with the optimal tilt angle of the reactor at 45° and the optimal rotational speed dependent on the nature of the liquid.

In Situ Monitored Vortex Fluidic-Mediated Protein Refolding/Unfolding Using an Aggregation-Induced Emission Bioprobe

Protein folding is important for protein homeostasis/proteostasis in the human body. We have established the ability to manipulate protein unfolding/refolding for β-lactoglobulin using the induced mechanical energy in the thin film microfluidic vortex fluidic device (VFD) with monitoring as such using an aggregation-induced emission luminogen (AIEgen), TPE-MI. When denaturant (guanidine hydrochloride) is present with β-lactoglobulin, the VFD accelerates the denaturation reaction in a controlled way. Conversely, rapid renaturation of the unfolded protein occurs in the VFD in the absence of the denaturant. The novel TPE-MI reacts with exposed cysteine thiol when the protein unfolds, as established with an increase in fluorescence intensity. TPE-MI provides an easy and accurate way to monitor the protein folding, with comparable results established using conventional circular dichroism. The controlled VFD-mediated protein folding coupled with in situ bioprobe AIEgen monitoring is a viable methodology for studying the denaturing of proteins.

High shear spheroidal topological fluid flow induced coating of polystyrene beads with C60 spicules

Spheroidal spicular like topological fluid flow in an angled vortex fluidic device (VFD) housing a 20 mm diameter tube with a hemispherical base rotating at 4k rpm and tilted at 45° is effective in reducing the thermodynamic equilibrium concentration of fullerene C60 in toluene, with the formation of spicules of the material under continuous flow processing. Under the same operational conditions in the presence of polystyrene beads 2 to 6 μm in diameter, spicules of C60ca. 150 nm in length grow on their surfaces. This establishes that the spheroidal topological fluid flow in the VFD prevails while enveloping spheroidal like particles of such size.

High shear vortex fluidic morphologically controlled polysulfone formed under anhydrous conditions

Polysulfone (PSF) was prepared under anhydrous conditions in DMSO, under high shear in a vortex fluidic device (VFD) operating under confined mode thereby avoiding the use of chlorinated solvents, unlike in conventional batch processing.

Vortex fluidic mediated synthesis of polysulfone

Polysulfone (PSF) was prepared under high shear in a vortex fluidic device (VFD) operating in confined mode, and its properties compared with that prepared using batch processing. This involved reacting the pre-prepared disodium salt of bisphenol A (BPA) with a 4,4'-dihalodiphenylsulfone under anhydrous conditions. Scanning electron microscopy (SEM) established that in the thin film microfluidic platform, the PSF particles are sheet-like, for short reaction times, and fibrous for long reaction times, in contrast to spherical like particles for the polymer prepared using the conventional batch synthesis. The operating parameters of the VFD (rotational speed of the glass tube, its tilt angle and temperature) were systematically varied for establishing their effect on the molecular weight (M w), glass transition temperature (T g) and decomposition temperature, featuring gel permeation chromatography (GPC), differential scanning calorimetry (DSC) and thermal gravimetric analysis (TGA) respectively. The optimal VFD prepared PSF was obtained at 6000 rpm rotational speed, 45° tilt angle and 160 °C, for 1 h of processing with M w ∼10 000 g mol-1, T g ∼158 °C and decomposition temperature ∼530 °C, which is comparable to the conventionally prepared PSF.

Vertically aligned laser sliced MWCNTs

Applications of multi-walled carbon nanotubes (MWCNTs) benefit from the availability of specific lengths of the material while keeping the outer walls pristine, for example, for applications requiring vertically aligned tubes. To this end, a simple and effective continuous flow 'top down' process to control the length of sliced MWCNTs has been developed using a vortex fluidic device (VFD) coupled with a 1064 nm pulse laser, with the process in the absence of chemicals and any auxiliary substances. Three different length distributions of the sliced MWCNTs, centered at 75 ± 2.1 nm, 300 ± 1.8 nm and 550 ± 1.4 nm, have been generated with the length depending on the VFD operating parameters and laser energy, with the processing resulting in a decrease in side wall defects of the material. We also show the ability to vertically self assemble short MWCNTs on a silicon substrate with control of the surface density coverage using a simple dipping and rinsing method.

High-Yield Continuous-Flow Synthesis of Spheroidal C60@Graphene Composites as Supercapacitors

Graphene spheres confining fullerene C60 are quantitatively formed under high-shear and continuous-flow processing using a vortex fluidic device (VFD). This involves intense micromixing a colloidal suspension of graphite in DMF and an o-xylene solution of C60 at room temperature in the absence of surfactants and other auxiliary substances. The diameters of the composite spheres, C60@graphene, can be controlled with size distributions ranging from 1.5 to 3.5 μm, depending on the VFD operating parameters, including rotational speed, flow rate, relative ratio of C60 to graphite, and the concentration of fullerene. An electrode of the composite material has high cycle stability, with a high areal capacitance of 103.4 mF cm-2, maintaining its capacitances to 24.7 F g-1 and 86.4 mF cm-2 (83.5%) at a high scan rate of 100 mV s-1.

Three-step-in-one synthesis of supercapacitor MWCNT superparamagnetic magnetite composite material under flow

Composites of multi-walled carbon nanotubes (MWCNTs) and superparamagnetic magnetite nanoparticles, Fe3O4@MWCNT, were synthesized in DMF in a vortex fluidic device (VFD). This involved in situ generation of the iron oxide nanoparticles by laser ablation of bulk iron metal at 1064 nm using a pulsed laser, over the dynamic thin film in the microfluidic platform. The overall processing is a three-step in one operation: (i) slicing MWCNTs, (ii) generating the superparamagnetic nanoparticles and (iii) decorating them on the surface of the MWCNTs. The Fe3O4@MWCNT composites were characterized by transmission electron microscopy, scanning transmission electron microscope, TG analysis, X-ray diffraction and X-ray photoelectron spectroscopy. They were used as an active electrode for supercapacitor measurements, establishing high gravimetric and areal capacitances of 834 F g-1 and 1317.7 mF cm-2 at a scan rate of 10 mV s-1, respectively, which are higher values than those reported using similar materials. In addition, the designer material has a significantly higher specific energy of 115.84 W h kg-1 at a specific power of 2085 W kg-1, thereby showing promise for the material in next-generation energy storage devices.

Continuous Flow Copper Laser Ablation Synthesis of Copper(I and II) Oxide Nanoparticles in Water

Copper(I) oxide (Cu2O) nanoparticles (NPs) are selectively prepared in high yields under continuous flow in a vortex fluidic device (VFD), involving irradiation of a copper rod using a pulsed laser operating at 1064 nm and 600 mJ. The plasma plume generated inside a glass tube (20 mm O.D.), which is rapidly rotating (7.5 k rpm), reacts with the enclosed air in the microfluidic platform, with then high mass transfer of material into the dynamic thin film of water passing up the tube. The average size of the generated Cu2ONPs is 14 nm, and they are converted to copper(II) oxide (CuO) nanoparticles with an average diameter of 11 nm by heating the as-prepared solution of Cu2ONPs in air at 50 °C for 10 h.

Vortex fluidic mediated transformation of graphite into highly conducting graphene scrolls

Two-dimensional graphene has remarkable properties that are revolutionary in many applications. Scrolling monolayer graphene with precise tunability would create further potential for niche applications but this has proved challenging. We have now established the ability to fabricate monolayer graphene scrolls in high yield directly from graphite flakes under non-equilibrium conditions at room temperature in dynamic thin films of liquid. Using conductive atomic force microscopy we demonstrate that the graphene scrolls form highly conducting electrical contacts to highly oriented pyrolytic graphite (HOPG). These highly conducting graphite-graphene contacts are attractive for the fabrication of interconnects in microcircuits and align with the increasing interest in building all sp²-carbon circuits. Above a temperature of 450 °C the scrolls unravel into buckled graphene sheets, and this process is understood on a theoretical basis. These findings augur well for new applications, in particular for incorporating the scrolls into miniaturized electronic devices.

Chemoselective and Continuous Flow Hydrogenations in Thin Films Using a Palladium Nanoparticle Catalyst Embedded in Cellulose Paper

Cellulose immobilized palladium (0) nanoparticles (PdNPs) were prepared for the use in scalable catalytic reactions in flow. Preparation of the catalyst is remarkably simple and fast, where a palladium acetate solution is drop-casted onto cellulose paper and then exposed to 1 atm of hydrogen for a mere 90 s to produce embedded Pd(0) nanoparticles. This catalyst system is efficient in the hydrogenation of alkenes, nitroarenes, ketones, and enamides, with products formed in high yields, under ambient pressure and temperature. The system is also effective for transfer hydrogenation using ammonium formate as an alternative hydrogen source. A high catalyst stability and reusability are demonstrated along with the chemoselective and scalable synthesis of industrially important fine chemicals, including the biobased molecule cyrene.

p-Phosphonic acid calix[8]arene mediated synthesis of ultra-large, ultra-thin, single-crystal gold nanoplatelets

Large, ultrathin, single-crystal gold platelets are produced in the presence of p-phosphonic acid calix[8]arene as both a catalyst and stabiliser.

Integrating thin film microfluidics in developing a concise synthesis of DGJNAc: A potent inhibitor of α-N-acetylgalctosaminidases

A simple synthesis, which utilizes a thin film microfluidic reactor for a problematic step, of a potent inhibitor of α-N-acetylhexosaminidases, DGJNAc, has been developed.

Vortex fluidic mediated direct transesterification of wet microalgae biomass to biodiesel

A bottleneck in the production of biodiesel from microalgae is the dewatering and lipid extraction process which is the dominant energy penalty and cost. A novel biodiesel production platform based on vortex fluidic device (VFD)-assisted direct transesterification (DT) of wet microalgal biomass of Chloroparva pannonica was developed and evaluated. Fatty acid extraction and fatty acid to FAME conversion efficiencies were used at different parameter settings to evaluate performance of the processing technology in confined and continuous mode. A response surface method based on Box-Behnken experimental design was used to determine the effects of water content, the ratio of biomass to methanol and residence time in the VFD. Average extraction efficiencies were 41% and conversion efficiencies >90% with the processing technology showing a broad tolerance to parameter settings. The findings suggest that VFD-assisted DT is a simple and effective way to produce biodiesel directly from wet microalgae biomass at room temperature.

Laser-Ablated Vortex Fluidic-Mediated Synthesis of Superparamagnetic Magnetite Nanoparticles in Water Under Flow

Selective formation of only one iron oxide phase is a major challenge in conventional laser ablation process, as is scaling up the process. Herein, superparamagnetic single-phase magnetite nanoparticles of hexagonal and spheroidal-shape, with an average size of ca. 15 nm, are generated by laser ablation of bulk iron metal at 1064 nm in a vortex fluidic device (VFD). This is a one-step continuous flow process, in air at ambient pressure, with in situ uptake of the nanoparticles in the dynamic thin film of water in the VFD. The process minimizes the generation of waste by avoiding the need for any chemicals or surfactants and avoids time-consuming purification steps in reducing any negative impact of the processing on the environment.

Controlling the growth of fullerene C60 cones under continuous flow

Micromixing of an o-xylene solution of C60 with N-N-dimethylformamide (DMF) at room temperature under continuous flow in a vortex fluidic device (VFD) results in the formation of symmetrical right cones in high yield with diameters 0.5 to 2.5 μm, pitch angle 25° to 55° and wall thickness 120 to 310 nm. Their formation is in the absence of surfactants and any other reagents, and is scalable. The cones are formed at specific operating parameters of the VFD, including rotational speed, flow rate and concentration, and varying these results in other structures such as grooved fractals. Other aromatic solvents in place of o-xylene results in the formation of rods, spicules and prisms, respectively for m-xylene, p-xylene and mesitylene.

Lithium ion storage ability, supercapacitor electrode performance, and photocatalytic performance of tungsten disulfide nanosheets

Few layered WS₂ nanosheets for energy and environmental applications.

Continuous flow synthesis of phosphate binding h-BN@magnetite hybrid material

Hexagonal boron nitride (h-BN) is rendered magnetically responsive in aqueous media by binding superparamagnetic magnetite nanoparticles 8.5–18.5 nm in diameter on the surface. The composite material was generated under continuous flow in water in a dynamic thin film in a vortex fluidic device (VFD) with the source of iron generated by laser ablation of a pure iron metal target in the air above the liquid using a Nd:YAG pulsed laser operating at 1064 nm and 360 mJ. Optimum operating parameters of the VFD were a rotational speed of 7.5k rpm for the 20 mm OD (17.5 mm ID) borosilicate glass tube inclined at 45 degrees, with a h-BN concentration at 0.1 mg mL⁻¹, delivered at 1.0 mL min⁻¹ using a magnetically stirred syringe to keep the h-BN uniformly dispersed in water prior to injection into the base of the rapidly rotating tube. The resulting composite material, containing 5.75% weight of iron, exhibited high phosphate ion adsorption capacity, up to 171.2 mg PO₄³⁻ per gram Fe, which was preserved on recycling the material five times.

Vortex fluidic fabricated h-BN@magnetite under continuous flow in water exhibits recyclable high phosphate ion adsorption capacity.

Vortex Fluidic Chemical Transformations

Driving chemical transformations in dynamic thin films represents a rapidly thriving and diversifying research area. Dynamic thin films provide a number of benefits including large surface areas, high shearing rates, rapid heat and mass transfer, micromixing and fluidic pressure waves. Combinations of these effects provide an avant-garde style of conducting chemical reactions with surprising and unusual outcomes. The vortex fluidic device (VFD) has proved its capabilities in accelerating and increasing the efficiencies of numerous organic, materials and biochemical reactions. This Minireview surveys transformations that have benefited from VFD-mediated processing, and identifies concepts driving the effectiveness of vortex-based dynamic thin films.

Ten-Minute Protein Purification and Surface Tethering for Continuous-Flow Biocatalysis

Nature applies enzymatic assembly lines to synthesize bioactive compounds. Inspired by such capabilities, we have developed a facile method for spatially segregating attached enzymes in a continuous-flow, vortex fluidic device (VFD). Fused Hisn -tags at the protein termini allow rapid bioconjugation and consequent purification through complexation with immobilized metal affinity chromatography (IMAC) resin. Six proteins were purified from complex cell lysates to average homogeneities of 76 %. The most challenging to purify, tobacco epi-aristolochene synthase, was purified in only ten minutes from cell lysate to near homogeneity (>90 %). Furthermore, this "reaction-ready" system demonstrated excellent stability during five days of continuous-flow processing. Towards multi-step transformations in continuous flow, proteins were arrayed as ordered zones on the reactor surface allowing segregation of catalysts. Ordering enzymes into zones opens up new opportunities for continuous-flow biosynthesis.

Improving oxidation efficiency through plasma coupled thin film processing

Plasma liquid processing efficiency improves by reducing the liquid film thickness.

Shear Stress Induced Fabrication of Dandelion-Shaped Lanthanide Phosphate Nanoparticles

Lanthanide phosphate nanoparticles were co-precipitated under continuous flow in a vortex fluidic device in the presence of polyvinylpyrrolidone (PVP) of different molecular weights and at varying rotational speeds and tilt angles. Dandelion-shaped lanthanide phosphate particles were produced at rotation speeds of 5000 rpm and 7000 rpm. In contrast, individual rods formed at 9000 rpm. Transition electron microscope images reveal changes in morphology of the dandelion-shaped nanoparticles with changes in the chain length of PVP or tilt angle of the tube of the vortex fluidic device. These morphological changes are likely to arise from different wrapping and aggregation of the nanoparticles induced by the PVP polymer under shear.

Vortex fluidics synthesis of polymer coated superparamagnetic magnetite nanoparticles

Polymer coated superparamagnetic magnetite nanoparticles with improved magnetic properties are accessible under continuous flow conditions within a vortex fluidic device.

Accelerating Enzymatic Catalysis Using Vortex Fluidics

Enzymes catalyze chemical transformations with outstanding stereo- and regio-specificities, but many enzymes are limited by their long reaction times. A general method to accelerate enzymes using pressure waves contained within thin films is described. Each enzyme responds best to specific frequencies of pressure waves, and an acceleration landscape for each protein is reported. A vortex fluidic device introduces pressure waves that drive increased rate constants (kcat ) and enzymatic efficiency (kcat /Km ). Four enzymes displayed an average seven-fold acceleration, with deoxyribose-5-phosphate aldolase (DERA) achieving an average 15-fold enhancement using this approach. In solving a common problem in enzyme catalysis, a powerful, generalizable tool for enzyme acceleration has been uncovered. This research provides new insights into previously uncontrolled factors affecting enzyme function.

Harnessing Thin-Film Continuous-Flow Assembly Lines

Inspired by nature's ability to construct complex molecules through sequential synthetic transformations, an assembly line synthesis of α-aminophosphonates has been developed. In this approach, simple starting materials are continuously fed through a thin-film reactor where the intermediates accrue molecular complexity as they progress through the flow system. Flow chemistry allows rapid multistep transformations to occur via reaction compartmentalization, an approach not amenable to using conventional flasks. Thin film processing can also access facile in situ solvent exchange to drive reaction efficiency, and through this method, α-aminophosphonate synthesis requires only 443 s residence time to produce 3.22 g h(-1) . Assembly-line synthesis allows unprecedented reaction flexibility and processing efficiency.

Fluid dynamics: an emerging route for the scalable production of graphene in the last five years

Fluid dynamics emerging as a promising scalable and efficient way for graphene production is highlighted, with the emphasis set on vortex fluidic devices and pressure- and mixer-driven fluid dynamics and the perspectives on the open key issues.

Manipulating three-dimensional gel network entanglement by thin film shearing

A novel method of combining thin-film shearing with SANS resulted in complete disruption of 3-D network of fluorous bis-urea gel. In contrast, non-fluorinated analogue undergoes partial disruption which emphasizes the resistance of non-fluorous bis-urea gelators towards shear.

Plasma enhanced vortex fluidic device manipulation of graphene oxide

A vortex fluid device (VFD) with non-thermal plasma liquid processing within dynamic thin films has been developed.

Towards aryl C-N bond formation in dynamic thin films

C-N bond forming reactions are important in organic chemistry. A thin film microfluidic vortex fluidic device (VFD) operating under confined mode affords N-aryl compounds from 2-chloropyrazine and the corresponding amine, without the need for a transition metal catalyst.

Rapid Vortex Fluidics: Continuous Flow Synthesis of Amides and Local Anesthetic Lidocaine

Thin film flow chemistry using a vortex fluidic device (VFD) is effective in the scalable acylation of amines under shear, with the yields of the amides dramatically enhanced relative to traditional batch techniques. The optimized monophasic flow conditions are effective in ≤80 seconds at room temperature, enabling access to structurally diverse amides, functionalized amino acids and substituted ureas on multigram scales. Amide synthesis under flow was also extended to a total synthesis of local anesthetic lidocaine, with sequential reactions carried out in two serially linked VFD units. The synthesis could also be executed in a single VFD, in which the tandem reactions involve reagent delivery at different positions along the rapidly rotating tube with in situ solvent replacement, as a molecular assembly line process. This further highlights the versatility of the VFD in organic synthesis, as does the finding of a remarkably efficient debenzylation of p-methoxybenzyl amines.

Shear induced fabrication of intertwined single walled carbon nanotube rings

Thin film microfluidic shearing of a mixture of toluene dispersed single walled carbon nanotubes (SWCNTs) and water in a vortex fluidic device results in SWCNT nanorings (and related structures), diameters 100 to 200 nm or 300 to 700 nm, for respectively 10 mm or 20 mm diameter rotating tubes.

Shear induced carboplatin binding within the cavity of a phospholipid mimic for increased anticancer efficacy

Vesicles 107 ± 19 nm in diameter, based on the self-assembly of tetra-para-phosphonomethyl calix[4]- arene bearing n-hexyl moieties attached to the phenolic oxygen centres, are effective in binding carboplatin within the cavity of the macrocycle under shear induced within a dynamic thin film in a continuous flow vortex fluidic device. Post shearing the vesicles maintain similar diameters and retain carboplatin within the cavity of the calixarene in a hierarchical structure, with their size and morphology investigated using DLS, TEM, SEM and AFM. Location of the carboplatin was confirmed using NMR, FTIR, ESI-MS and EFTEM, with molecular modelling favouring the polar groups of carboplatin hydrogen bonded to phosphonic acid moieties and the four member cyclobutane ring directed into the cavity of the calixarene. The loading efficiency and release profile of carboplatin was investigated using LC-TOF/MS, with the high loading of the drug achieved under shear and preferential released at pH 5.5, offering scope for anti-cancer drug delivery. The hierarchical structured vesicles increase the efficacy of carboplatin by 4.5 fold on ovarian cancer cells, lowered the IC₅₀ concentration by 10 fold, and markedly increased the percent of cells in the S-phase (DNA replication) of the cell cycle.

Room temperature vortex fluidic synthesis of monodispersed amorphous proto-vaterite

Monodispersed particles of amorphous calcium carbonate (ACC) 90 to 200 nm in diameter are accessible at room temperature in ethylene glycol and water using a vortex fluidic device (VFD). The ACC material is stable for at least two weeks under ambient conditions.

Shear-stress-mediated refolding of proteins from aggregates and inclusion bodies

Recombinant protein overexpression of large proteins in bacteria often results in insoluble and misfolded proteins directed to inclusion bodies. We report the application of shear stress in micrometer-wide, thin fluid films to refold boiled hen egg white lysozyme, recombinant hen egg white lysozyme, and recombinant caveolin-1. Furthermore, the approach allowed refolding of a much larger protein, cAMP-dependent protein kinase A (PKA). The reported methods require only minutes, which is more than 100 times faster than conventional overnight dialysis. This rapid refolding technique could significantly shorten times, lower costs, and reduce waste streams associated with protein expression for a wide range of industrial and research applications.

Continuous flow Fischer esterifications harnessing vibrational-coupled thin film fluidics

Organic synthesis under shear: high yielding, acid catalysed, continuous flow synthesis of esters involves coupling of vibrations in thin film fluidics, as rapid environmentally friendly organic methodology.

Microencapsulation of bacterial strains in graphene oxide nano-sheets using vortex fluidics

Microencapsulation of bacterial cells with different shapes in graphene oxide (GO) layers is effective using a vortex fluidic device, with the bacterial cells showing restricted cellular growth with their biological activity sustained.