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.

Development of a modular photoreactor for the upscaling of continuous flow photochemistry

The upscaling of biphasic photochemical reactions is challenging because of the inherent constraints of liquid-gas mixing and light penetration. Using semi-permeable coaxial flow chemistry within a modular photoreactor, the photooxidation of the platform chemical furfural was scaled up to produce routinely 29 gram per day of biobased building block hydroxybutenolide, a precursor to acrylate alternatives.

Technological Innovations in Photochemistry for Organic Synthesis: Flow Chemistry, High-Throughput Experimentation, Scale-up, and Photoelectrochemistry

Photoinduced chemical transformations have received in recent years a tremendous amount of attention, providing a plethora of opportunities to synthetic organic chemists. However, performing a photochemical transformation can be quite a challenge because of various issues related to the delivery of photons. These challenges have barred the widespread adoption of photochemical steps in the chemical industry. However, in the past decade, several technological innovations have led to more reproducible, selective, and scalable photoinduced reactions. Herein, we provide a comprehensive overview of these exciting technological advances, including flow chemistry, high-throughput experimentation, reactor design and scale-up, and the combination of photo- and electro-chemistry.

Visible Light-Induced Aerobic Oxidative Dehydrogenation of C-N/C-O to C=N/C=O Bonds Using Metal-Free Photocatalysts: Recent Developments

Performing synthetic transformation using visible light as energy source, in the presence of a photocatalyst as a promoter, is currently of high interest, and oxidation reactions carried out under these conditions using oxygen as the final oxidant are particularly convenient from an environmental point of view. This review summarizes the recent developments achieved in the oxidative dehydrogenation of C-N and C-O bonds, leading to C=N and C=O bonds, respectively, using air or pure oxygen as oxidant and metal-free homogeneous or recyclable heterogeneous photocatalysts under visible light irradiation.

Intensification of Heterogeneous Photocatalytic Reactions Without Efficiency Losses: The Importance of Surface Catalysis

Advances in LED and photoreactor technology have brought semiconductor photocatalysis to the verge of feasibility of industrial application for the synthesis of value-added chemicals. However, the often observed efficiency losses under intensified illumination conditions still present a great challenge. This perspective discusses the origin of these efficiency losses and what needs to be done to prevent or counteract it and pave the way for efficient, intensified heterogeneous photocatalytic processes. The role of surface catalysis is particularly highlighted as one of the rate-limiting steps.

Graphic Abstract

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.

Au nanobipyramids@mSiO2 core-shell nanoparticles for plasmon-enhanced singlet oxygen photooxygenations in segmented flow microreactors

The plasmonic features of gold nanomaterials provide intriguing optical effects which can find potential applications in various fields. These effects depend strongly on the size and shape of the metal nanostructures. For instance, Au bipyramids (AuBPs) exhibit intense and well-defined plasmon resonance, easily tunable by controlling their aspect ratio, which can act synergistically with chromophores for enhancing their photophysical properties. In Rose Bengal-nanoparticle systems it is now well established that the control of the dye-to-nanoparticle distance ranging from 10 to 20 nm as well as spectral overlaps is crucial to achieve appropriate coupling between the plasmon resonance and the dye, thus affecting its ability to generate singlet oxygen (¹O₂). We have developed AuBPs@mSiO₂ core-shell nanostructures that provide control over the distance between the metal surface and the photosensitizers for improving the production of ¹O₂ (metal-enhanced ¹O₂ production - ME¹O₂). A drastic enhancement of ¹O₂ generation is evidenced for the resulting AuBPs and AuBPs@mSiO₂ in the presence of Rose Bengal, using a combination of three indirect methods of ¹O₂ detection, namely in operando Electron Paramagnetic Resonance (EPR) with 2,2,6,6-tetramethylpiperidine (TEMP) as a chemical trap, photooxygenation of the fluorescence probe anthracene-9,10-dipropionic acid (ADPA), and photooxygenation of methionine to methionine sulfoxide in a segmented flow microreactor.

Investigation of the reaction kinetics of photocatalytic pollutant degradation under defined conditions with inkjet-printed TiO2 films – from batch to a novel continuous-flow microreactor

Reaction kinetics was studied for photocatalytic pollutant degradation with inkjet-printed TiO₂ in a batch and a continuous-flow microreactor.

Mass transfer in falling film microreactors: measurement techniques and effect of operational parameters

Falling film microreactors have contributed to the pursuit of process intensification strategies and have, over the years, been recognized for their potential in performing demanding reactions. In the last few decades, modifications in the measurement techniques and operational parameters of these microstructured devices have been the focus of many research studies with a common target on process improvement. In this work, we present a review dedicated to falling film microreactors, focusing on the recent advances in their design and operation, with particular emphasis on mass transfer enhancement. Analysis of the recent techniques for the measurement of mass transfer as well as the operational parameters used and their effect on the target objective, particularly in the liquid phase (being the limiting phase reactant), are included in the review. The relationship between the hydrodynamics of falling thin liquid films and the microreactor design, the discrepancies between measured and model results, the major challenges, and the future outlook for these promising microreactors are also presented.

Continuous flow chemistry: where are we now? Recent applications, challenges and limitations

A general outlook of the changing face of chemical synthesis is provided in this article through recent applications of continuous flow processing in both industry and academia. The benefits, major challenges and limitations associated with the use of this mode of processing are also given due attention as an attempt to put into perspective the current position of continuous flow processing, either as an alternative or potential combinatory technology for batch processing.

Continuous-flow synthesis of fluorine-containing fine chemicals with integrated benchtop NMR analysis

Fluorine fine chemical synthesis takes a step ahead using integrated NMR online-analysis with a benchtop NMR spectrometer.

Singlet oxygen oxidations in homogeneous continuous flow using a gas–liquid membrane reactor

Safe supply of oxygen through a permeable membrane was used to carry out singlet oxygen chemistry in homogeneous flow regime.