Forgotten and forbidden chemical reactions revitalised through continuous flow technology

Telescoped Flow Synthesis of Azacyclic Scaffolds Exploiting the Chromoselective Photolysis of Vinyl Azides and Azirines

An efficient chromoselective photochemical process is presented for the synthesis of 2H-azirines and 1,3-diazabicylo[3.1.0]hex-3-enes from readily available vinyl azides. The method exploits continuous flow photochemistry to enable the safe consumption of the hazardous azide group and provides uniform irradiation using high-power LEDs at 365-450 nm. Additionally, a scaled telescoped process has been developed providing access to drug-like 1,6-dihydropyrimidines and pyrimidines via integrated ring-expansion and oxidation reactions. Given the prevalence of various azacyclic targets in pharmaceutical, agrochemical and materials applications it is anticipated that this methodology will enable further exploitations of these important scaffolds.

Development of a Continuous Flow Baldwin Rearrangement Process and Its Comparison to Traditional Batch Mode

A new and highly efficient continuous flow process is presented for the synthesis of aziridines via the thermal Baldwin rearrangement. The process was initially explored using traditional batch synthesis techniques but suffered from moderate yields, long reaction times, and moderate diastereoselectivities. Here we demonstrate that the process can be greatly improved upon its transfer to continuous flow, which afforded the aziridine targets in high yields, short reaction times, and consistently high diastereoselectivities, with the high-throughput process rendering multigram quantities of product in short periods of time. In addition, flow processing extended the substrate scope including several examples that had failed in batch mode, thus demonstrating the value of this overlooked entry into valuable aziridine species.

Amberlyst-A26-Mediated Corey-Chaykovsky Cyclopropanation of 9-Alkylidene-9H-fluorene under Continuous Process

Herein, we have developed a continuous-process for the direct cyclopropanation of various alkenes nonconjugated with carbonyl using trimethylsulfoxonium iodide as a methylene source via the Corey-Chaykovsky cyclopropanation reaction in the presence of Amberlyst-A26 as a heterogeneous base. Several 9-alkylidene-9H-fluorene derivatives successfully undergo Corey-Chaykovsky cyclopropanation to afford spiro[cyclopropane-1,9'-fluorene] in excellent yields under the continuous-process module. Furthermore, continuous process for the cyclopropanation of 3-benzylideneindolin-2-one derivatives using Amberlyst-A26 as a heterogeneous base has been described, which afford spiro[cyclopropane-1,3'-indolin]-2'-one derivatives.

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.

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.

Revisiting the Paradigm of Reaction Optimization in Flow with a Priori Computational Reaction Intelligence

The use of micro/meso-fluidic reactors has resulted in both new scenarios for chemistry and new requirements for chemists. Through flow chemistry, large-scale reactions can be performed in drastically reduced reactor sizes and reaction times. This obvious advantage comes with the concomitant challenge of re-designing long-established batch processes to fit these new conditions. The reliance on experimental trial-and-error to perform this translation frequently makes flow chemistry unaffordable, thwarting initial aspirations to revolutionize chemistry. By combining computational chemistry and machine learning, we have developed a model that provides predictive power tailored specifically to flow reactions. We show its applications to translate batch to flow, to provide mechanistic insight, to contribute reagent descriptors, and to synthesize a library of novel compounds in excellent yields after executing a single set of conditions.

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.

Carbene-controlled regioselectivity in photochemical cascades

A highly regioselective route to complex carbocyclic scaffolds through a continuous photochemical process is reported. Crucially, we uncovered that ortho substitutents on the right-hand aryl ring are placed away from a transient carbene species which induces the exclusive regioselectivity observed. By varying the non-symmetrically substituted aryl moiety, we demonstrate how the product outcome favors cyclobutenes for electron-poor and neutral substituents and cycloheptatrienes for more electron-rich systems. Additionally, a photochemically induced rearrangement was uncovered for highly electron-rich substrates that ultimately generates complex hydroperoxides. Overall, this facile one-step process is fast and high yielding and demonstrates the power of photochemistry towards the exploration of new chemical space.

Towards Antibiotic Synthesis in Continuous-Flow Processes

Continuous-flow chemistry has become a mainstream process and a notable trend among emerging technologies for drug synthesis. It is routinely used in academic and industrial laboratories to generate a wide variety of molecules and building blocks. The advantages it provides, in terms of safety, speed, cost efficiency and small-equipment footprint compared to analog batch processes, have been known for some time. What has become even more important in recent years is its compliance with the quality objectives that are required by drug-development protocols that integrate inline analysis and purification tools. There can be no doubt that worldwide government agencies have strongly encouraged the study and implementation of this innovative, sustainable and environmentally friendly technology. In this brief review, we list and evaluate the development and applications of continuous-flow processes for antibiotic synthesis. This work spans the period of 2012-2022 and highlights the main cases in which either active ingredients or their intermediates were produced under continuous flow. We hope that this manuscript will provide an overview of the field and a starting point for a deeper understanding of the impact of flow chemistry on the broad panorama of antibiotic synthesis.

Harnessing a Continuous-Flow Persulfuric Acid Generator for Direct Oxidative Aldehyde Esterifications

Persulfuric acid is a well-known oxidant in various industrial-scale purification procedures. However, due to its tendency toward explosive decomposition, its usefulness in organic synthesis remained largely underexplored. Herein, a continuous in situ persulfuric acid generator was developed and applied for oxidative esterification of aldehydes under flow conditions. Sulfuric acid served as a readily available and benign precursor to form persulfuric acid in situ. By taking advantage of the continuous-flow generator concept, safety hazards were significantly reduced, whilst a robust and effective approach was ensured for direct transformations of aldehydes to valuable esters. The process proved useful for the transformation of diverse aliphatic as well as aromatic aldehydes, while its preparative capability was verified by the multigram-scale synthesis of a pharmaceutically relevant key intermediate. The present flow protocol demonstrates the safe, sustainable, and scalable application of persulfuric acid in a manner that would not be amenable to conventional batch processing.

An Automated Computer-Vision "Bubble-Counting" Technique to Characterise CO2 Dissolution into an Acetonitrile Flow Stream in a Teflon AF-2400 Tube-in-Tube Flow Device

A Teflon AF-2400 based tube-in-tube device was used to generate flow streams of CO₂ in acetonitrile and a computer-vision based 'bubble counting' technique was used to estimate the amount of CO₂ that had passed into solution whilst in the tube-in-tube device by quantifying the amount of CO₂ that left solution (forming separate gas-phase segments) downstream of the back-pressure regulator. For both CO₂ pressures used, there appeared to be a minimum residence time below which no CO₂ was observed to leave solution. This was assumed to be due to residual CO₂ below (or close to) the saturation concentration at atmospheric pressure and, by taking this into account, we were able to fit curves corresponding to simple gradient-driven diffusion and which closely matched previously obtained colorimetric titration data for the same system. The estimated value for the residual concentration of CO₂ (0.37 M) is higher than, but in reasonable general correspondence with, saturation concentrations previously reported for CO₂ in acetonitrile (0.27 M).

Continuous Flow Synthesis of 1,4-Benzothiazines Using Ambivalent Reactivity of (E)-β-Chlorovinyl Ketones: A Point of Reaction Control Enabled by Flow Chemistry

A continuous flow system to 1,4-benzothiazines was developed using the point of reaction control, where the ambivalent (E)-β-chlorovinyl ketones and 2,2'-dithiodianilines were confined in a diffusion controlled flow setting. The successful segregation of reactive chemical species in a flow setting allowed more defined reaction pathways that are not feasible in traditional batch reaction conditions. The point of reaction control in flow systems helps to execute the reactions often plagued with the concurrent generation of multiple chemical species.

Flow synthesis of oxadiazoles coupled with sequential in-line extraction and chromatography

An efficient continuous flow process is reported for the synthesis of various 1,3,4-oxadiazoles via an iodine-mediated oxidative cyclisation approach. This entails the use of a heated packed-bed reactor filled with solid K2CO3 as a base. Using DMSO as solvent, this flow method generates the target heterocycles within short residence times of 10 minutes and in yields up to 93%. Scale-up of this flow process was achieved (34 mmol/h) and featured an integrated quenching and extraction step. Lastly, the use of an automated in-line chromatography system was exploited to realise a powerful flow platform for the generation of the heterocyclic targets.

Construction of an α-chiral pyrrolidine library with a rapid and scalable continuous flow protocol

The cost-efficient development of an α-chiral pyrrolidine library is achieved via a rapid continuous flow protocol under mild conditions.

An enantio- and diastereoselective approach to indoloquinolizidines in continuous flow

A solvent-free enantioselective Michael addition mediated by a polymer-supported Jørgensen–Hayashi catalyst and a domino Pictet–Spengler plus lactamisation sequence has been reported in continuous flow.

Continuous Flow Synthesis of Anticancer Drugs

Continuous flow chemistry is by now an established and valued synthesis technology regularly exploited in academic and industrial laboratories to bring about the improved preparation of a variety of molecular structures. Benefits such as better heat and mass transfer, improved process control and safety, a small equipment footprint, as well as the ability to integrate in-line analysis and purification tools into telescoped sequences are often cited when comparing flow to analogous batch processes. In this short review, the latest developments regarding the exploitation of continuous flow protocols towards the synthesis of anticancer drugs are evaluated. Our efforts focus predominately on the period of 2016-2021 and highlight key case studies where either the final active pharmaceutical ingredient (API) or its building blocks were produced continuously. It is hoped that this manuscript will serve as a useful synopsis showcasing the impact of continuous flow chemistry towards the generation of important anticancer drugs.