How to approach flow chemistry

Integrating continuous flow reaction and work-up: chiral amine resolution, separation and purification using a novel coalescing filter system

To maximize the benefits of a continuous flow reaction, a continuous work-up is also needed. Herein, we present a process design and novel equipment for a continuous amine resolution reaction, integrated with liquid-liquid (L-L) extraction, back-extraction into a different solvent, and crystallisation purification for product isolation. The reaction, in iso-propyl acetate, flows through a heated fixed-bed reactor with solid supported Candida antarctica lipase which catalyses the resolution of (rac)-1-phenylethylamine to give the (R)-amide in 50% conversion and 96% enantiomeric excess (ee). This is separated from the unreacted (S)-amine co-product by mixing with an acidic aqueous stream and separating the phases using our recently reported coalescence filter separator. The aqueous stream is neutralised by mixing with base and back-extracted into methyl-THF solvent before separating the phases using a membrane separator. Finally, a solid amine salt is isolated by filtration, achieved by mixing the free base with an organic acid to cause crystallisation to give the (S)-1-phenylethylamine in 43% yield and >99% ee from racemate. The work illustrates how typical reactions, work-up and purification steps that involve multiple phases can be telescoped together using both new and commercially available laboratory equipment. This continuous system uses mild reaction conditions, green solvents and minimises their use for reduced waste.

Advancing continuous flow techniques in effective trimethoprim oxidation: combatting bacterial resistance in wastewater

This work describes an innovative catalytic process for aqueous trimethoprim degradation, using a fixed-bed continuous flow reactor packed with a manganese(III) meso-substituted porphyrin covalently immobilized functionalized aminopropyl silica gel as the catalyst and H2O2 as a green oxidant. It exhibits remarkable activity and stability, maintaining its performance over extended periods (up to 8 hours) and achieving significant reductions in total organic carbon (TOC = 80%). Importantly, microbiological assays confirmed that this degradation process effectively converts trimethoprim into non-resistance-inducing products.

Avoiding Undesired Intramolecular Diketopiperazine Formation during Peptoid Chain Elongation Using a Microflow Reactor

Avoiding undesired intramolecular reactions during desired intermolecular reactions is an important challenge in synthetic organic chemistry. We successfully avoided undesired intramolecular diketopiperazine formation during desired N-alkylation in the synthesis of peptoids using a microflow reactor. Fifteen peptoids were synthesized in good to high yields, and a cyclic peptoid was synthesized on the gram scale using the developed microflow approach. The productivity and cost of our approach are significantly superior to those of the conventional solid-phase approach.

Fibrous catalyst based on atomic Pd and N-doped holey graphene functionalized cotton fiber for continuous-flow reaction

Continuous-flow catalysis bridges the gap between bench-scale laboratories and production-scale factories and thus should be a green and promising technology for the manufacture of value-added chemicals. Here, we present the construction of a continuous-flow catalytic system by integrating a tubular reactor with novel catalytic fibers, which are comprised of single-atomic Pd (Pd1) and nitrogen-doped holey graphene (NHG) functionalized cotton fibers (CFs). Due to the loosely packed structure, highly exposed dual-active sites (i.e., single-atomic PdN4 sites and activated C sites in the NHG carbocatalyst) of the CF@(Pd1/NHG) catalytic fibers, the corresponding flowing system exhibites remarkably high catalytic performance (activity and durability) and processing rate in organic reactions, including oxidative hydroxylation of phenylboronic acid and reduction of nitroarenes. Typically, the processing rate of the catalytic system toward 4-nitrophenol (a representative nitroarene) reduction can reach up to 2.46 × 10-3 mmol·mg-1·min-1, significantly higher than that of those packing catalysts reported in recent years.

Continuous flow synthesis of the antiviral drug tecovirimat and related sp3-rich scaffolds

Herein we report a 2-step continuous flow synthesis of the antiviral drug tecovirimat, which is used for the treatment of monkeypox and smallpox. This work exploits a high-temperature pericyclic cascade process between cycloheptatriene and maleic anhydride generating a key sp3-rich scaffold, which affords the desired API after further condensation with an acyl hydrazide. Additional investigations of the key intermediate in reactions with different hydrazines revealed the accessibility of different heterocyclic chemotypes, depending on the substitution pattern of the hydrazine used. Ultimately, the streamlined and scalable access to these sp3-rich scaffolds enables improved access to tecovirimat and structurally related entities with high drug-like character.

Synthetic routes to access dicarbonylated aryls and heteroaryls

1,2-Dicarbonyl compounds are privileged functionalities found in natural products, pharmaceuticals, bioactive molecules, and food items, and are important precursors in catalysis, asymmetric synthesis, polymer chemistry and synthesizing functionalized heterocycles. Herein, this comprehensive review focuses on various approaches for synthesizing 1,2-dicarbonylated aryls and heteroaryls in both intermolecular and intramolecular fashion, covering the dicarbonylation of indoles, imidazoheterocycles, indolizines, aminopyrazoles, pyrroloisoquinolines, coumarins, furan, anilines, phenols, anthranils, and benzil synthesis over the last decade (since 2015). Also, the present review highlights the scope and future perspectives of the approach.

Switching between P-acylation and O-acylation of H-phosphonates with chloroformates by changing acyl pyridinium and acyl ammonium ions in a microflow reactor

We report the first switchable acylation of H-phosphonate with chloroformate. The acylation site (P vs. O) in H-phosphonate was switched by changing the acyl pyridinium/ammonium ions. Unexpected phosphite formation was observed during the O-acylation of H-phosphonate. Twenty-six structurally diverse phosphotriesters and phosphonoformate esters were synthesized in microflow reactors.

Highly enantioselective synthesis of both enantiomers of tetrahydroquinoxaline derivatives via Ir-catalyzed asymmetric hydrogenation

A novel Ir-catalyzed asymmetric hydrogenation protocol for the synthesis of chiral tetrahydroquinoxaline (THQ) derivatives has been developed. By simply adjusting the reaction solvent, both enantiomers of mono-substituted chiral THQs could be selectively obtained in high yields with excellent enantioselectivities (toluene/dioxane: up to 93% yield and 98% ee (R); EtOH: up to 83% yield and 93% ee (S)). For 2,3-disubstituted chiral THQs, the cis-hydrogenation products were obtained with up to 95% yield, 20 : 1 dr, and 94% ee. Remarkably, this methodology was also applicable under continuous flow conditions, yielding gram-scale products with comparable yields and enantioselectivities (dioxane: 91% yield and 93% ee (R); EtOH: 90% yield and 87% ee (S)). Unlike previously reported Ir-catalyzed asymmetric hydrogenation protocols, this system exhibited a significant improvement as it required no additional additives. Furthermore, comprehensive mechanistic studies including deuterium-labeling experiments, control experiments, kinetic studies, and density functional theory (DFT) calculations were conducted to reveal the underlying mechanism of enantioselectivities for both enantiomers.

Recent advances in continuous flow synthesis of metal-organic frameworks and their composites

Metal-organic frameworks (MOFs) and their composites have garnered significant attention in recent years due to their exceptional properties and diverse applications across various fields. The conventional batch synthesis methods for MOFs and their composites often suffer from challenges such as long reaction times, poor reproducibility, and limited scalability. Continuous flow synthesis has emerged as a promising alternative for overcoming these limitations. In this short review, we discuss the recent advancements, challenges, and future perspectives of continuous flow synthesis in the context of MOFs and their composites. The review delves into a brief overview of the fundamental principles of flow synthesis, highlighting its advantages over batch methods. Key benefits, including precise control over reaction parameters, improved scalability and efficiency, rapid optimization capabilities, enhanced reaction kinetics and mass transfer, and increased safety and environmental sustainability, are addressed. Additionally, the versatility and flexibility of flow synthesis techniques are discussed. The article then explores various flow synthesis methods applicable to MOF and MOF composite production. The techniques covered include continuous flow solvothermal synthesis, mechanochemical synthesis, microwave and ultrasound-assisted flow synthesis, microfluidic droplet synthesis, and aerosol synthesis. Notably, the combination of flow chemistry and aerosol synthesis with real-time characterization is also addressed. Furthermore, the impact of flow synthesis on the properties and performance of MOFs is explored. Finally, the review discusses current challenges and future perspectives in the field of continuous flow MOF synthesis, paving the way for further development and broader application of this promising technique.

Engineering the physical properties and photocatalytic activities of a β-ketoenamine COF using continuous flow synthesis

Covalent Organic Frameworks (COF) having conjugated backbone are an interesting class of metal-free, visible light active, heterogeneous photocatalysts. Interestingly, synthesis of COF using continuous flow process has emerged as an efficient, alternative method when compared to the traditional batch process. Here, we demonstrate the possibility to engineer the physical properties and hence the adsorption and catalytic activities of a β-ketoenamine COF by varying monomer flow rate and microreactor design during the continuous flow synthesis. Crystallinity of the COF increases on varying the monomer flow rate from 100 (S-100) to 500 (S-500) and up to 1000 μLmin-1 (S-1000), in an S-shaped microreactor, resulting in an enhanced surface area: 525, 722 and 1119 m2g-1 respectively. The photophysical properties of the COF are also found to vary significantly with the change in flow synthesis conditions. S-1000 is characterized by the highest adsorption of MB, due to its high surface area and accessible pores. On the other hand, S-500 shows the highest photocurrent, a low recombination of photogenerated charges and the lowest charge transfer resistance. Thus, S-500 is found to be the best photocatalyst for the removal of a model pollutant (methylene blue, MB). Further, enhanced photocatalytic removal of MB using S-500 could be achieved by performing the photocatalysis in continuous flow.

An innovative chalcogenide transfer agent for improved aqueous quantum dot synthesis

An innovative approach to chalcogenide precursor synthesis and their subsequent use for the production of CdX (X = S, Se, Te) quantum dots (QDs) in water under scalable and intensified continuous flow conditions is introduced. Herein, tris(2-carboxyethyl)phosphine (TCEP) is identified as a novel, efficient and water-soluble vehicle for chalcogenide transfer to form CdX QDs under aqueous conditions. A comprehensive exploration of critical process parameters, including pH, chalcogen excess, and residence time, utilizing a Design of Experiments (DoE) approach is reported. Reaction kinetics are investigated in real-time using a combination of in situ Raman spectroscopy and in-line 31P NMR spectroscopy. The conversion of TCEP into TCEP[double bond, length as m-dash]X (X = S, Se, Te) species is seamlessly adapted to continuous flow conditions. TCEP[double bond, length as m-dash]X precursors are subsequently employed in the synthesis of CdX QDs. Scalability trials are successfully demonstrated, with experiments conducted at flow rates of up to 80 mL min-1 using a commercially available mesofluidic flow reactor with favorable metrics. Furthermore, biocompatible and aqueous CdSe/ZnS core-shell QDs are for the first time prepared in flow within a fully concatenated process. These results emphasize the potential for widespread biological or industrial applications of this novel protocol.

Effect of Brønsted Acids on the Activation of Mixed Anhydride/Mixed Carbonic Anhydride and C-Terminal-Free N-Methylated Peptide Synthesis in a Micro-Flow Reactor

Amidations employing mixed (carbonic) anhydrides have long been favoured in peptide synthesis because of their cost-effectiveness and less waste generation. Despite their long history, no study has compared the effects of additives on the activation of mixed anhydrides and carbonic anhydrides. In this study, we investigated the amidation of mixed (carbonic) anhydride in the presence of a base and/or Brønsted acids. The use of NMI⋅HCl significantly improved the conversion of the mixed carbonic anhydride, while expediting nucleophilic attacks on the desired carbonyl group. In contrast, in the case of mixed anhydrides, neither the conversion nor the desired nucleophilic attack improved significantly. We developed a C-terminus-free N-methylated peptide synthesis method using mixed carbonic anhydrides in a micro-flow reactor. Fourteen N-alkylated peptides were synthesized in moderate to high yields (55-99 %) without severe racemization (<1 %). Additionally, a significant enhancement in the amidation between mixed carbonic anhydrides and bis-TMS-protected N-methyl amino acids with the inclusion of NMI⋅HCl was observed for the first time. In addition, we observed unexpected C-terminal epimerization of the C-terminus-free N-methyl peptides.

Electro/Ni Dual-Catalyzed Decarboxylative C(sp3)-C(sp2) Cross-Coupling Reactions of Carboxylates and Aryl Bromide

Paired redox-neutral electrolysis offers an attractive green platform for organic synthesis by avoiding sacrificial oxidants and reductants. Carboxylates are non-toxic, stable, inexpensive, and widely available, making them ideal nucleophiles for C-C cross-coupling reactions. Here, we report the electro/Ni dual-catalyzed redox-neutral decarboxylative C(sp3)-C(sp2) cross-coupling reactions of pristine carboxylates with aryl bromides. At a cathode, a NiII(Ar)(Br) intermediate is formed through the activation of Ar-Br bond by a NiI-bipyridine catalyst and subsequent reduction. At an anode, the carboxylates, including amino acid, benzyl carboxylic acid, and 2-phenoxy propionic acid, undergo oxidative decarboxylation to form carbon-based free radicals. The combination of NiII(Ar)(Br) intermediate and carbon radical results in the formation of C(sp3)-C(sp2) cross-coupling products. The adaptation of this electrosynthesis method to flow synthesis and valuable molecule synthesis was demonstrated. The reaction mechanism was systematically studied through electrochemical voltammetry and density functional theory (DFT) computational studies. The relationships between the electrochemical properties of carboxylates and the reaction selectivity were revealed. The electro/Ni dual-catalyzed cross-coupling reactions described herein expand the chemical space of paired electrochemical C(sp3)-C(sp2) cross-coupling and represent a promising method for the construction of the C(sp3)-C(sp2) bonds because of the ubiquitous carboxylate nucleophiles and the innate scalability and flexibility of electrochemical flow-synthesis technology.

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.

Microflow, Sequential Coupling and Cyclization Approach for Synthesis of Cyclic Phosphotriesters from PCl3

An approach for the synthesis of cyclic phosphotriesters with various ring sizes (5- to 8-membered rings) from phosphorus trichloride and diols was developed. The major challenge in developing this approach is the suppression of the undesired reactions caused by substrates containing multiple highly reactive sites. These undesired reactions were successfully suppressed by microflow technology, which can precisely control the reaction time and temperature. Two optimal conditions were developed, depending on the speed of cyclization. Fifteen cyclic phosphotriesters and their analogs were synthesized. A plausible mechanism for suppressing undesired reactions is proposed.

Continuous flow reactions in the preparation of active pharmaceutical ingredients and fine chemicals

Herein, we present an overview of continuous flow chemistry, including photoflow and electroflow technologies in the preparation of active pharmaceutical ingredients (APIs) and fine chemical intermediates. Examples highlighting the benefits and challenges associated with continuous flow processes, mainly involving continuous thermal, photo- and electrochemical transformations, are drawn from the relevant literature, especially our experience and collaborations in this area, with emphasis on the synthesis and prospective scale-up.

Visible Light-Mediated Selective Aerobic Oxidation of Alcohols Catalyzed by Disulfide in Batch and Flow

Selective aerobic oxidation of alcohols in batch and flow can be realized under light irradiation, utilizing disulfide as the photocatalyst, and a variety of primary and secondary alcohols were converted to the corresponding aldehydes or ketones in up to 99% yield and high selectivity. The reaction efficiency could be increased even further by combining a continuous-flow strategy. Detailed mechanistic studies have also been achieved to determine the role of oxygen and disulfides in this oxidation.

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.

Synthesis of Substituted Pentafluorosulfanylpyrazoles Under Flow Conditions

The development of flow conditions for the synthesis of pentafluorosulfanylpyrazoles is reported. A range of alkyl- and aryl-substituted SF5-alkynes were used in combination with different diazoacetates for this transformation. The corresponding substituted SF5-pyrazoles were obtained in up to 90% yield (average of 74% for 21 examples) as a mixture of isomers (up to 73:27 ratio). Synthetic transformations starting from an SF5-containing pyrazole were also demonstrated.

Micro-flow heteroatom alkylation via TfOH-mediated rapid in situ generation of carbocations and subsequent nucleophile addition

A rapid nucleophilic substitution reaction was developed using carbocations generated from diarylmethanol and trifluoromethanesulfonic acid. Undesired reactions caused by the carbocations were suppressed, presumably due to the rapid and uniform generation of carbocations and the subsequent rapid and uniform distribution of nucleophiles by the micro-flow technology.

Enhancing continuous-flow reactions via compression-molding of solid catalysts and dilutants in packed-bed systems

In this study, we present an improved packed-bed system designed for continuous-flow reactions using platinum (Pt)-black powder and silica gel (SiO2). The Pt-leaching from the reaction column is suppressed via compression-molding of the Pt and SiO2. Scanning electron microscopy results and particle-size distribution analysis demonstrate that crushed and downsized SiO2 is effective in suppressing outflow. Furthermore, we successfully conducted a scaled-up experiment of the flow reaction using a large column, achieving excellent productivity.

Microflow Synthesis of Unsymmetrical H-Phosphonates via Sequential and Direct Substitution of Chlorine Atoms in Phosphorus Trichloride with Alkoxy Groups

Unsymmetrical H-phosphonates were synthesized by a rapid (<15 s) and mild (20 °C) process in a microflow reactor as the first example of the sequential direct substitution of the chlorine atoms in PCl3 with alkoxyl/aryloxy groups using equivalent amounts of PCl3 and alcohols. The optimal base concentration differed in each step, presumably attributed to differences in the Brønsted basicity of the electrophilic intermediates. Phosphite hydrolysis was observed, and the structure-hydrolysis relationship was quantitatively evaluated.

Application of an Oscillatory Plug Flow Reactor to Enable Scalable and Fast Reactions in Water Using a Biomass-Based Polymeric Additive

The utilization of water as a sustainable reaction medium has important advantages over traditional organic solvents. Hydroxypropyl methylcellulose has emerged as a biomass-based polymeric additive that enables organic reactions in water through hydrophobic effects. However, such conditions imply slurries as reaction mixtures, where the efficacy of mass transfer and mixing decreases with increasing vessel size. In order to circumvent this limitation and establish an effectively scalable platform for performing hydroxypropyl methylcellulose-mediated aqueous transformations, we utilized oscillatory plug flow reactors that feature a smart dimensioning design principle across different scales. Using nucleophilic aromatic substitutions as valuable model reactions, rapid parameter optimization was performed first in a small-scale instrument having an internal channel volume of 5 mL. The optimal conditions were then directly transferred to a 15 mL reactor, achieving a three-fold scale-up without re-optimizing any reaction parameters. By precisely fine-tuning the oscillation parameters, the system achieved optimal homogeneous suspension of solids, preventing settling of particles and clogging of process channels. Ultimately, this resulted in a robust and scalable platform for performing multiphasic reactions under aqueous conditions.

Efficient construction of a β-naphthol library under continuous flow conditions

A β-naphthol library has been efficiently constructed utilizing a mild continuous flow procedure, relying on a tandem Friedel-Crafts reaction and starting from readily available arylacetyl chloride and alkynes. Multiple functionalized β-naphthols can be acquired within 160 s in generally high yields (up to 83%). Using an electron-rich phenylacetyl chloride derivative (4-OH- or 4-MeO-) provides spirofused triene dione as the primary product. A scale-up preparation affords a throughput of 4.70 g h-1, indicating potential large-scale application. Herein, we present a rapid, reliable, and scalable method to obtain various β-naphthols in the compound library.

One-Flow Synthesis of Substituted Indoles via Sequential 1,2-Addition/Nucleophilic Substitution of Indolyl-3-Carbaldehydes

Substituted indoles are important as drugs. A number of valuable indoles have been synthesized via nucleophilic substitution at the 3'-position of indoles. However, the preparation of an indolylmethyl electrophile containing a tertiary carbon at the 3'-position and its subsequent nucleophilic substitution are challenging owing to the instability of the electrophile. Herein, we demonstrated the rapid one-flow synthesis of indoles via sequential 1,2-addition/nucleophilic substitution of indolyl-3-carbaldehydes. The use of a microflow technology helped in suppressing the undesired reactions caused by the unstable intermediates, resulting in significantly higher yields and reproducibility compared to those under batch conditions. A crown ether was effective when 1-alkylindole-3-carboxaldehyde was used as a substrate. However, the crown ether exerted a detrimental effect when 1H-indole-3-carboxaldehyde was used. A total of 15 structurally diverse indole derivatives were obtained in generally acceptable to good yields.

Key Fabrications of Chitosan Nanoparticles for Effective Drug Delivery Using Flow Chemistry Reactors

Introduction

Chitosan nanoparticles have garnered considerable interest in the field of drug delivery owing to their distinctive properties, including biocompatibility, biodegradability, low toxicity, and ability to encapsulate a wide range of drugs. However, the conventional methods (eg, the drop method) for synthesizing chitosan nanoparticles often face limitations in regard to controlling the particle size, morphology, and scalability, hindering their extensive application in drug delivery systems. To overcome these challenges, this study explores using a novel flow chemistry reactor design for fabricating clindamycin-loaded chitosan nanoparticles.

Methods

By varying two critical operating parameters of flow chemistry, namely, the flow rate ratio and total flow rate, the impact of these parameters on the properties of chitosan nanoparticles is investigated using a central composite experimental design.

Results

The optimized conditions for nanoparticle preparation yielded remarkable results, with chitosan nanoparticles exhibiting a small size of 371.60 nm and an extremely low polydispersity index of 0.042. Furthermore, using novel design flow chemistry reactor, the productivity of chitosan nanoparticles was estimated to be 25,402.17 mg/min, which was ~12.71 times higher than that obtained via batch synthesis.

Conclusion

The findings of this study indicate that the use of novel design flow chemistry reactor is promising for synthesizing clindamycin-loaded chitosan nanoparticles and other polymeric nanoparticles intended for drug delivery applications. This is primarily attributed to their ability to produce nanoparticles with a considerably reduced particle size distribution and smaller overall size. The demonstrated high productivity of this technique suggests the potential for industrial-scale nanoparticle manufacturing.

Advances in Continuous Flow Fluorination Reactions

Fluorination reactions are important in constructing organofluorine motifs, which contribute to favorable biological properties in pharmaceuticals and agrochemicals. However, fluorination reagents and reactions are associated with various problems, such as their hazardous nature, high exothermicity, and poor selectivity and scalability. Continuous flow has emerged as a transformative technology to provide many advantages relative to batch syntheses. This review article summarizes recent continuous flow techniques that address the limitations and challenges of fluorination reactions. Approaches based on different flow techniques are discussed, including gas-liquid reactions, packed-bed reactors, in-line purifications, streamlined multistep synthesis, large-scale reactions well as flow photoredox- and electrocatalysis.

Green carbon science: fundamental aspects

Carbon energy has contributed to the creation of human civilization, and it can be considered that the configuration of the carbon energy system is one of the important laws that govern the operation of everything in the universe. The core of the carbon energy system is the opposition and unity of two aspects: oxidation and reduction. The operation of oxidation and reduction is based on the ternary elemental system composed of the three elements of carbon, hydrogen and oxygen. Its operation produces numerous reactions and reaction products. Ancient Chinese philosophy helps us to understand in depth the essence of green carbon science, to explore its scientific basis, and to identify the related platforms for technology development.

Synthesis of cyclic carbonates from CO2 cycloaddition to bio-based epoxides and glycerol: an overview of recent development

Anthropogenic carbon dioxide (CO₂) emissions contribute significantly to global warming and deplete fossil carbon resources, prompting a shift to bio-based raw materials. The two main technologies for reducing CO₂ emissions are capturing and either storing or utilizing it. However, while capture and storage have high reduction potential, they lack economic feasibility. Conversely, by utilizing the CO₂ captured from streams and air to produce valuable products, it can become an asset and curb greenhouse gas effects. CO₂ is a challenging C1-building block due to its high kinetic inertness and thermodynamic stability, requiring high temperature and pressure conditions and a reactive catalytic system. Nonetheless, cyclic carbonate production by reacting epoxides and CO₂ is a promising green and sustainable chemistry reaction, with enormous potential applications as an electrolyte in lithium-ion batteries, a green solvent, and a monomer in polycarbonate production. This review focuses on the most recent developments in the synthesis of cyclic carbonates from glycerol and bio-based epoxides, as well as efficient methods for chemically transforming CO₂ using flow chemistry and novel reactor designs.

Efficient degassing and ppm-level oxygen monitoring flow chemistry system

Low oxygen levels are critical for a long range of chemical transformations carried out in both flow and batch chemistry. Here, we present an inline continuous flow degassing system based on a gas-permeable membrane inside a vacuum chamber for achieving and monitoring ppm-level oxygen concentrations in solutions. The oxygen presence was monitored with a molecular oxygen probe and a continuously running UV-vis spectrometer. An automated setup for discovering optimal reaction conditions for minimal oxygen presence was devised. The parameters tested were: flow rate, vacuum pressure, solvent back-pressure, tube material, tube length and solvent oxygen solubility. The inline degassing system was proven to be effective in removing up to 99.9% of ambient oxygen from solvents at a flow rate of 300 μl min^-1 and 4 mbar vacuum pressure inside the degassing chamber. Reaching lower oxygen concentrations was limited by gas permeation in the tubing following the degassing unit, which could be addressed by purging large volume flow reactors with an inert gas after degassing or by using tubing with lower gas permeability, such as stainless steel tubing. Among all factors, oxygen solubility in solvents was found to play a significant role in achieving efficient degassing of solvents. The data presented here can be used to choose optimal experimental parameters for oxygen-sensitive reactions in flow chemistry reaction setups. The data were also fitted to an analytically derived model from simple differential equations in physical context of the experiment.

Accelerated Chemical Reaction Optimization Using Multi-Task Learning

Functionalization of C-H bonds is a key challenge in medicinal chemistry, particularly for fragment-based drug discovery (FBDD) where such transformations require execution in the presence of polar functionality necessary for protein binding. Recent work has shown the effectiveness of Bayesian optimization (BO) for the self-optimization of chemical reactions; however, in all previous cases these algorithmic procedures have started with no prior information about the reaction of interest. In this work, we explore the use of multitask Bayesian optimization (MTBO) in several in silico case studies by leveraging reaction data collected from historical optimization campaigns to accelerate the optimization of new reactions. This methodology was then translated to real-world, medicinal chemistry applications in the yield optimization of several pharmaceutical intermediates using an autonomous flow-based reactor platform. The use of the MTBO algorithm was shown to be successful in determining optimal conditions of unseen experimental C-H activation reactions with differing substrates, demonstrating an efficient optimization strategy with large potential cost reductions when compared to industry-standard process optimization techniques. Our findings highlight the effectiveness of the methodology as an enabling tool in medicinal chemistry workflows, representing a step-change in the utilization of data and machine learning with the goal of accelerated reaction optimization.

C3-Alkylation of furfural derivatives by continuous flow homogeneous catalysis

The C3-functionalization of furfural using homogeneous ruthenium catalysts requires the preinstallation of an ortho-directing imine group, as well as high temperatures, which did not allow scaling up, at least under batch conditions. In order to design a safer process, we set out to develop a continuous flow process specifically for the C3-alkylation of furfural (Murai reaction). The transposition of a batch process to a continuous flow process is often costly in terms of time and reagents. Therefore, we chose to proceed in two steps: the reaction conditions were first optimized using a laboratory-built pulsed-flow system to save reagents. The optimized conditions in this pulsed-flow mode were then successfully transferred to a continuous flow reactor. In addition, the versatility of this continuous flow device allowed both steps of the reaction to be carried out, namely the formation of the imine directing group and the C3-functionalization with some vinylsilanes and norbonene.

Rapid plugged flow synthesis of nucleoside analogues via Suzuki-Miyaura coupling and heck Alkenylation of 5-Iodo-2'-deoxyuridine (or cytidine)

Nucleosides modification via conventional cross-coupling has been performed using different catalytic systems and found to take place via long reaction times. However, since the pandemic, nucleoside-based antivirals and vaccines have received widespread attention and the requirement for rapid modification and synthesis of these moieties has become a major objective for researchers. To address this challenge, we describe the development of a rapid flow-based cross-coupling synthesis protocol for a variety of C5-pyrimidine substituted nucleosides. The protocol allows for facile access to multiple nucleoside analogues in very good yields in a few minutes compared to conventional batch chemistry. To highlight the utility of our approach, the synthesis of an anti-HSV drug, BVDU was also achieved in an efficient manner using our new protocol.

Graphical abstract

Supplementary Information

The online version contains supplementary material available at 10.1007/s41981-023-00265-1.

Verification of preparations of (1H-indol-3-yl)methyl electrophiles and development of their microflow rapid generation and substitution

Although highly reactive (1H-indol-3-yl)methyl electrophiles such as (1H-indol-3-yl)methyl halides are potential precursors for the synthesis of various indole derivatives, some researchers have reported difficulties in their preparation due to concomitant undesired dimerization/oligomerization. Nevertheless, there have been some reports on the preparation of (1H-indol-3-yl)methyl halides. To resolve this contradiction, all the previously reported preparations of (1H-indol-3-yl)methyl halides were examined. However, we could not reproduce any of these preparations, and we revised several structures of indole derivatives. Here we show the rapid (0.02 s) and mild (25 °C) generation of an (1H-indol-3-yl)methyl electrophile that enables the rapid (0.1 s) and mild (25 °C) nucleophilic substitution in a microflow reactor. Eighteen unprotected indole analogues can be successfully synthesized using the developed microflow nucleophilic substitution with various nucleophiles.

Quid Pro Flow

How do you get into flow? We trained in flow chemistry during postdoctoral research and are now applying it in new areas: materials chemistry, crystallization, and supramolecular synthesis. Typically, when researchers think of "flow", they are considering predominantly liquid-based organic synthesis; application to other disciplines comes with its own challenges. In this Perspective, we highlight why we use and champion flow technologies in our fields, summarize some of the questions we encounter when discussing entry into flow research, and suggest steps to make the transition into the field, emphasizing that communication and collaboration between disciplines is key.

Continuously Flow Photothermal Catalysis Efficiently CO2 Reduction Over S-Scheme 2D/0D Bi5 O7 I-OVs/Cd0.5 Zn0.5 S Heterojunction with Strong Interfacial Electric Field

Using CO₂ , water, and sunlight to produce solar fuel is a very attractive process, which can synchronously reduce carbon and convert solar energy into hydrocarbons. However, photocatalytic CO₂ reduction is often limited by the low selectivity of reduction products and poor photocatalytic activity. In this study, S-scheme Bi₅ O₇ I-OVs/Cd_0.5 Zn_0.5 S (Bi₅ O₇ I-OVs/CZS-0.5) heterojunction with strong interfacial electric field (IEF) is prepared by in situ growth method. The performance of reduction CO₂ to CO is studied by continuous flow photothermal catalytic (PTC) CO₂ reduction platform. 12.5% Bi₅ O₇ I-OVs/CZS-0.5 shows excellent CO yield of 58.6 µmol g^-1  h^-1 and selectivity of 98.4%, which are 35.1 times than that of CZS-0.5 under visible light. The charge transfer path of the S-scheme through theoretical calculation (DFT), in situ irradiation Kelvin probe force microscope (ISI-KPFM) and in situ irradiation X-ray photoelectron spectroscopy (ISI-XPS) analysis, is verified. The study can provide useful guidance and reference for improving activity by oxygen vacancy induced strong IEF and the development of a continuous flow PTC CO₂ reduction system.

Will the next generation of chemical plants be in miniaturized flow reactors?

For decades, a production paradigm based on centralized, stepwise, large scale processes has dominated the chemical industry horizon. While effective to meet an ever increasing demand for high value-added chemicals, the so-called macroscopic batch reactors are also associated with inherent weaknesses and threats; some of the most obvious ones were tragically illustrated over the past decades with major industrial disasters and impactful disruptions of advanced chemical supplies. The COVID pandemic has further emphasized that a change in paradigm was necessary to sustain chemical production with an increased safety, reliable supply chains and adaptable productivities. More than a decade of research and technology development has led to alternative and effective chemical processes relying on miniaturised flow reactors (a.k.a. micro and mesofluidic reactors). Such miniaturised reactors bear the potential to solve safety concerns and to improve the reliability of chemical supply chains. Will they initiate a new paradigm for a more localized, safe and reliable chemical production?

Formation of Droplets of Shear-Thinning Non-Newtonian Fluids in Asymmetrical Parallelized Microchannels

Fluids containing polymers are frequently utilized in the chemical industry and exhibit shear-thinning characteristics. The flow distribution of non-Newtonian fluids in parallelized microchannels is a key issue to be solved during numbering-up. Numbering-up means increasing the number of parallelized microchannels. In this study, a high-speed camera is used to explore the distribution of fluid flow as well as the uniformity and stability of droplets in conceptual asymmetrical parallelized microchannels. Cyclohexane and carboxymethylcellulose sodium (CMC) aqueous solutions are used as the continuous phase and dispersed phase, respectively. The effects of fluctuation of pressure difference around the T-junction, the hydrodynamic resistance in microchannels, and the shear-thinning property of fluids on flow distribution and droplet formation are revealed. The uniformity and stability of droplets in microdevices with various cavity settings are compared, and an optimal configuration is proposed. Finally, prediction models for the flow distribution of shear-thinning fluids in asymmetrical parallelized microchannels are established.

Automated Library Generation and Serendipity Quantification Enables Diverse Discovery in Coordination Chemistry

Library generation experiments are a key part of the discovery of new materials, methods, and models in chemistry, but the question of how to generate high quality libraries to enable discovery is nontrivial. Herein, we use coordination chemistry to demonstrate the automation of many of the workflows used for library generation in automated hardware including the Chemputer. First, we explore the target-oriented synthesis of three influential coordination complexes, to validate key synthetic operations in our system; second, the generation of focused libraries in chemical and process space; and third, the development of a new workflow for prospecting library formation. This involved Bayesian optimization using a Gaussian process as surrogate model combined with a metric for novelty (or serendipity) quantification based on mass spectrometry data. In this way, we show directed exploration of a process space toward those areas with rarer observations and build a picture of the diversity in product distributions present across the space. We show that this effectively "engineers" serendipity into our search through the unexpected appearance of acetic anhydride, formed in situ, and solvent degradation products as ligands in an isolable series of three Co(III) anhydride complexes.

Continuous Flow Epoxidation of Alkenes Using a Homogeneous Manganese Catalyst with Peracetic Acid

Epoxidation of alkenes is a valuable transformation in the synthesis of fine chemicals. Described herein are the design and development of a continuous flow process for carrying out the epoxidation of alkenes with a homogeneous manganese catalyst at metal loadings as low as 0.05 mol%. In this process, peracetic acid is generated in situ and telescoped directly into the epoxidation reaction, thus reducing the risks associated with its handling and storage, which often limit its use at scale. This flow process lessens the safety hazards associated with both the exothermicity of this epoxidation reaction and the use of the highly reactive peracetic acid. Controlling the speciation of manganese/2-picolinic acid mixtures by varying the ligand:manganese ratio was key to the success of the reaction. This continuous flow process offers an inexpensive, sustainable, and scalable route to epoxides.

A versatile non-fouling multi-step flow reactor platform: demonstration for partial oxidation synthesis of iron oxide nanoparticles

In the last decade flow reactors for material synthesis were firmly established, demonstrating advantageous operating conditions, reproducible and scalable production via continuous operation, as well as high-throughput screening of synthetic conditions. Reactor fouling, however, often restricts flow chemistry and the common fouling prevention via segmented flow comes at the cost of inflexibility. Often, the difficulty of feeding reagents into liquid segments (droplets or slugs) constrains flow syntheses using segmented flow to simple synthetic protocols with a single reagent addition step prior or during segmentation. Hence, the translation of fouling prone syntheses requiring multiple reagent addition steps into flow remains challenging. This work presents a modular flow reactor platform overcoming this bottleneck by fully exploiting the potential of three-phase (gas-liquid-liquid) segmented flow to supply reagents after segmentation, hence facilitating fouling free multi-step flow syntheses. The reactor design and materials selection address the operation challenges inherent to gas-liquid-liquid flow and reagent addition into segments allowing for a wide range of flow rates, flow ratios, temperatures, and use of continuous phases (no perfluorinated solvents needed). This "Lego®-like" reactor platform comprises elements for three-phase segmentation and sequential reagent addition into fluid segments, as well as temperature-controlled residence time modules that offer the flexibility required to translate even complex nanomaterial synthesis protocols to flow. To demonstrate the platform's versatility, we chose a fouling prone multi-step synthesis, i.e., a water-based partial oxidation synthesis of iron oxide nanoparticles. This synthesis required I) the precipitation of ferrous hydroxides, II) the addition of an oxidation agent, III) a temperature treatment to initiate magnetite/maghemite formation, and IV) the addition of citric acid to increase the colloidal stability. The platform facilitated the synthesis of colloidally stable magnetic nanoparticles reproducibly at well-controlled synthetic conditions and prevented fouling using heptane as continuous phase. The biocompatible particles showed excellent heating abilities in alternating magnetic fields (ILP values >3 nH m² kg_Fe^-1), hence, their potential for magnetic hyperthermia cancer treatment. The platform allowed for long term operation, as well as screening of synthetic conditions to tune particle properties. This was demonstrated via the addition of tetraethylenepentamine, confirming its potential to control particle morphology. Such a versatile reactor platform makes it possible to translate even complex syntheses into flow, opening up new opportunities for material synthesis.

Continuous Flow Biocatalytic Reductive Amination by Co-Entrapping Dehydrogenases with Agarose Gel in a 3D-Printed Mould Reactor

Herein, we show how the merge of biocatalysis with flow chemistry aided by 3D-printing technologies can facilitate organic synthesis. This concept was exemplified for the reductive amination of benzaldehyde catalysed by co-immobilised amine dehydrogenase and formate dehydrogenase in a continuous flow micro-reactor. For this purpose, we investigated enzyme co-immobilisation by covalent binding, or ion-affinity binding, or entrapment. Entrapment in an agarose hydrogel turned out to be the most promising solution for this biocatalytic reaction. Therefore, we developed a scalable and customisable approach whereby an agarose hydrogel containing the co-entrapped dehydrogenases was cast in a 3D-printed mould. The reactor was applied to the reductive amination of benzaldehyde in continuous flow over 120 h and afforded 47 % analytical yield and a space-time yield of 7.4 g L day-1 using 0.03 mol% biocatalysts loading. This work also exemplifies how rapid prototyping of enzymatic reactions in flow can be achieved through 3D-printing technology.

Continuous‐Flow Divergent Lithiation of 2,3‐Dihalopyridines: Deprotolithiation versus Halogen Dance

We describe herein the first halogen dance (HD) in continuous flow on 2-chloro-3-bromopyridine by selectively trapping a (pyridin-4-yl)lithium species that is known to undergo the halogen-dance process. In addition, this lithiated intermediate was trapped at lower temperature before the HD occurs. The HD process was extended to fluoro-iodopyridines by using various electrophiles to afford 28 examples with yields ranging from 42 to 97 % with very short residence times. Finally, scale up of the reaction was demonstrated, affording a promising space-time yield (STY) of 4.2 kg.h^-1 .L^-1 .