Continuous‐Flow Technology—A Tool for the Safe Manufacturing of Active Pharmaceutical Ingredients

In the past few years, continuous‐flow reactors with channel dimensions in the micro‐ or millimeter region have found widespread application in organic synthesis. The characteristic properties of these reactors are their exceptionally fast heat and mass transfer. In microstructured devices of this type, virtually instantaneous mixing can be achieved for all but the fastest reactions. Similarly, the accumulation of heat, formation of hot spots, and dangers of thermal runaways can be prevented. As a result of the small reactor volumes, the overall safety of the process is significantly improved, even when harsh reaction conditions are used. Thus, microreactor technology offers a unique way to perform ultrafast, exothermic reactions, and allows the execution of reactions which proceed via highly unstable or even explosive intermediates. This Review discusses recent literature examples of continuous‐flow organic synthesis where hazardous reactions or extreme process windows have been employed, with a focus on applications of relevance to the preparation of pharmaceuticals.     

Microwave Flow: A Perspective on Reactor and Microwave Configurations and the Emergence of Tunable Single‐Mode Heating Toward Large‐Scale Applications

Microwave heating in chemical reactions was first reported in 1986. There have since been many reports employing microwave heating in organic chemistry, where microwave heating has afforded higher yields of products in shorter time periods. However, such reactions are challenging to scale in batch due to the limited penetration depth of microwaves as well as the wave propagation dependence on cavity size. Continuous flow has addressed both these issues, enabling scalability of microwave processes. As such, a host of reports employing microwave flow chemistry have emerged, employing various microwave heating and reactor configurations in the context of either custom‐built or commercial apparatus. The focus of this review is to present the benefits of microwave heating in the context of continuous flow and to characterize the different types of microwave flow apparatus by their design (oscillator, cavity type and reactor vessel). We advocate the adoption of tunable, solid‐state oscillator single‐mode microwave flow reactors which are more versatile heaters, impart better process control and energy efficiency toward laboratory and larger‐scale synthetic chemistry applications.     

Heterogeneous Versus Homogeneous Palladium Catalysts for Ligandless Mizoroki–Heck Reactions: A Comparison of Batch/Microwave and Continuous‐Flow Processing

Mizoroki–Heck couplings of aryl iodides and bromides with butyl acrylate were investigated as model systems to perform transition‐metal‐catalyzed transformations in continuous‐flow mode. As a suitable ligandless catalyst system for the Mizoroki–Heck couplings both heterogeneous and homogeneous Pd catalysts (Pd/C and Pd acetate) were considered. In batch mode, full conversion with excellent selectivity for coupling was achieved applying high‐temperature microwave conditions with Pd levels as low as 10^?3 mol %. In continuous‐flow mode with Pd/C as a catalyst, significant Pd leaching from the heterogeneous catalyst was observed as these Mizoroki–Heck couplings proceed by a homogeneous mechanism involving soluble Pd colloids/nanoparticles. By applying low levels of Pd acetate as homogeneous Pd precatalyst, successful continuous‐flow Mizoroki–Heck transformations were performed in a high‐temperature/pressure flow reactor. For both aryl iodides and bromides, high isolated product yields of the cinnamic esters were obtained. Mechanistic issues involving the Pd‐catalyzed Mizoroki–Heck reactions are discussed.     

Sintered Silicon Carbide: A New Ceramic Vessel Material for Microwave Chemistry in Single‐Mode Reactors

Silicon carbide (SiC) is a strongly microwave absorbing chemically inert ceramic material that can be utilized at extremely high temperatures due to its high melting point and very low thermal expansion coefficient. Microwave irradiation induces a flow of electrons in the semiconducting ceramic that heats the material very efficiently through resistance heating mechanisms. The use of SiC carbide reaction vessels in combination with a single‐mode microwave reactor provides an almost complete shielding of the contents inside from the electromagnetic field. Therefore, such experiments do not involve electromagnetic field effects on the chemistry, since the semiconducting ceramic vial effectively prevents microwave irradiation from penetrating the reaction mixture. The involvement of electromagnetic field effects (specific/nonthermal microwave effects) on 21 selected chemical transformations was evaluated by comparing the results obtained in microwave‐transparent Pyrex vials with experiments performed in SiC vials at the same reaction temperature. For most of the 21 reactions, the outcome in terms of conversion/purity/product yields using the two different vial types was virtually identical, indicating that the electromagnetic field had no direct influence on the reaction pathway. Due to the high chemical resistance of SiC, reactions involving corrosive reagents can be performed without degradation of the vessel material. Examples include high‐temperature fluorine–chlorine exchange reactions using triethylamine trihydrofluoride, and the hydrolysis of nitriles with aqueous potassium hydroxide. The unique combination of high microwave absorptivity, thermal conductivity, and effusivity on the one hand, and excellent temperature, pressure and corrosion resistance on the other hand, makes this material ideal for the fabrication of reaction vessels for use in microwave reactors.     

Neutral‐Eosin‐Y‐Photocatalyzed Silane Chlorination Using Dichloromethane

Chlorosilanes are versatile reagents in organic synthesis and material science. A mild pathway is now reported for the quantitative conversion of hydrosilanes to silyl chlorides under visible‐light irradiation using neutral eosin Y as a hydrogen‐atom‐transfer photocatalyst and dichloromethane as a chlorinating agent. Stepwise chlorination of di‐ and trihydrosilanes was achieved in a highly selective fashion assisted by continuous‐flow micro‐tubing reactors. The ability to access silyl radicals using photocatalytic Si?H activation promoted by eosin Y offers new perspectives for the synthesis of valuable silicon reagents in a convenient and green manner.     

Microwave‐Assisted Aqueous Synthesis: A Rapid Approach to Poly‐functionalized Indoline‐Spiro Benzofurodiazepines

New cycloaddition has been established for the synthesis of indoline‐spiro benzofurodiazepine derivatives. Those reactions were conducted by reacting readily available and inexpensive starting materials, such as benzene‐1,2‐diamines, tetronic acid and indoline‐2,3‐diones, in aqueous solution under microwave irradiation. When mono‐substituted benzene‐1,2‐diamines as an amine component was employed, the reaction regioselectively resulted in the poly‐functionalized indoline‐spiro benzofurodiazepine with good yields. The present green synthesis shows attractive characteristics such as the use of water as reaction media, concise one‐pot conditions, short reaction periods, easy work‐up/purification and reduced waste production without the use of any strong acids or metal promoters.     

Continuous‐Flow Microwave Synthesis of Metal–Organic Frameworks: A Highly Efficient Method for Large‐Scale Production

Metal–organic frameworks are having a tremendous impact on novel strategic applications, with prospective employment in industrially relevant processes. The development of such processes is strictly dependent on the ability to generate materials with high yield efficiency and production rate. We report a versatile and highly efficient method for synthesis of metal–organic frameworks in large quantities using continuous flow processing under microwave irradiation. Benchmark materials such as UiO‐66, MIL‐53(Al), and HKUST‐1 were obtained with remarkable mass, space–time yields, and often using stoichiometric amounts of reactants. In the case of UiO‐66 and MIL‐53(Al), we attained unprecedented space–time yields far greater than those reported previously. All of the syntheses were successfully extended to multi‐gram high quality products in a matter of minutes, proving the effectiveness of continuous flow microwave technology for the large scale production of metal–organic frameworks.     

Continuous Heterogeneous Photocatalysis in Serial Micro‐Batch Reactors

Solid reagents, leaching catalysts, and heterogeneous photocatalysts are commonly employed in batch processes but are ill‐suited for continuous‐flow chemistry. Heterogeneous catalysts for thermal reactions are typically used in packed‐bed reactors, which cannot be penetrated by light and thus are not suitable for photocatalytic reactions involving solids. We demonstrate that serial micro‐batch reactors (SMBRs) allow for the continuous utilization of solid materials together with liquids and gases in flow. This technology was utilized to develop selective and efficient fluorination reactions using a modified graphitic carbon nitride heterogeneous catalyst instead of costly homogeneous metal polypyridyl complexes. The merger of this inexpensive, recyclable catalyst and the SMBR approach enables sustainable and scalable photocatalysis.     

Silica‐supported synthesis of some 1,3,5‐trisubstituted 2‐pyrazolines under solvent‐free and microwave irradiation conditions

A simple method for the synthesis of 2‐pyrazolines is described which occurs on silica surface under solvent‐free conditions within 110‐180 sec using microwave irradiation. The results obtained indicate that the use of silica gel as a support in pyrazoline formation reactions can have a profound effect on reaction rates and yields and cause cleaner reaction conditions.     

Microwave‐Assisted Tandem Transformation on an Ionic‐Liquid Support: Efficient Synthesis of Pyrrolo/Pyridobenzimidazolones and Isoindolinone‐Fused Benzimidazoles

A tandem transformation that involves the formation of three bonds and two heterocyclic rings in a one‐pot fashion through amino‐alkylation of an ionic‐liquid‐immobilized diamine with keto acids followed by successive double intramolecular cyclizations to afford a tricyclic framework has been explored. This tandem cyclization has been utilized to develop a rapid and efficient method to synthesize various pyrrolo[1,2‐a]benzimidazolones and pyrido[1,2‐a]benzimidazolones on an ionic‐liquid support by using focused microwave irradiation. The application of this tandem cyclization was further extended to the aromatic keto acids to provide isoindolinone‐fused benzimidazoles, a structurally heterogeneous library with skeletal diversity. The outcome of the cascade reaction was confirmed by the X‐ray crystallographic study of the product directly attached to the ionic‐liquid support. Use of the ionic liquid as a soluble support facilitates purification by simple precipitation along with advantages like high loading capacity, homogeneous reaction conditions, and monitoring of the reaction progress by regular conventional spectroscopic methods, whereas application of microwave irradiation greatly accelerates the rate of the reactions.     

Alkyne–Azide Cycloadditions with Copper Powder in a High‐Pressure Continuous‐Flow Reactor: High‐Temperature Conditions versus the Role of Additives

A safe and efficient flow‐chemistry‐based procedure is presented for 1,3‐dipolar cycloaddition reactions between organic azides and acetylenes. This simple and inexpensive technique eliminates the need for costly special apparatus and utilizes Cu powder as a plausible Cu^I source. To maximize the reaction rates, high‐pressure/high‐temperature conditions are utilized; alternatively, the harsh reaction conditions can be moderated at room temperature by the joint application of basic and acidic additives. A comparison of the performance of these two approaches in a series of model reactions has resulted in the formation of useful 1,4‐disubstituted 1,2,3‐triazoles in excellent yields. The risks that are associated with the handling of azides are lowered, thanks to the benefits of flow processing, and gram‐scale production has been safely implemented. The synthetic capability of this continuous‐flow technique is demonstrated by the efficient syntheses of some highly functionalized derivatives of the antifungal cispentacin.     

Phenyl‐, benzyl‐, and unsymmetrical hydroxy‐methylenebisphosphonates as dronic acid ester analogues from α‐oxophosphonates by microwave‐assisted syntheses

The microwave (MW)‐assisted addition of dialkyl phosphites to α‐oxophosphonates was investigated and optimized under solventless conditions to provide the phenyl‐ and benzyl‐hydroxy‐methylenebisphosphonates efficiently by suppressing the rearrangement side reaction. Methyl‐hydroxy‐methylenebisphosphonates with mixed ester functionalities and an analogous diester‐diacid were also synthesized. It was found that the α‐oxophosphonates may also be converted to hydroxy‐methylenebisphosphonates and/or rearranged products without using dialkyl phosphite as the reagent and with the careful exclusion of water, simply on standing at room temperature, on thermal treatment, or on MW irradiation. These novel reactions taking place via the controlled decomposition of the precursor and resulting in the intermediate formation of dialkyl phosphite were also studied in detail. © 2011 Wiley Periodicals, Inc. Heteroatom Chem 22:640–648, 2011; View this article online at wileyonlinelibrary.com . DOI 10.1002/hc.20727     

Tricholoroisocyanuric Acid as a Useful Reagent in Microwave‐assisted Aromatization of 1,3,5‐Trisubstituted 2‐Pyrazolines

An efficient aromatization of 1,3,5‐trisubstituted 2‐pyrazolines to their corresponding pyrazoles has been performed by tricholoroisocyanuric acid [TCCA] under microwave irradiation in excellent yields. It has been observed that the reactions occur more rapidly under microwave irradiation conditions, and the amount of the reagent TCCA consumed is considerably reduced to afford better yields when compared with conventional thermal conditions at the same temperature.     

Practical and Scalable Organic Reactions with Flow Microwave Apparatus

Microwave irradiation has been used for accelerating organic reactions as a heating method and has been proven to be useful in laboratory scale organic synthesis. The major drawback of microwave chemistry is the difficulty in scaling up, mainly because of the low penetration depth of microwaves. The combination of microwave chemistry and flow chemistry is considered to overcome the problem in scaling up of microwave‐assisted organic reactions, and some flow microwave systems have been developed in both academic and industrial communities. In this context, we have demonstrated the scale‐up of fundamental organic reactions using a novel flow microwave system developed by the academic‐industrial alliance between the University of Shizuoka, Advanced Industrial Science and Technology, and SAIDA FDS. In this Personal Account, we summarize the recent progress of our scalable microwave‐assisted continuous synthesis using the SAIDA flow microwave apparatus.     

Continuous Consecutive Reactions with Inter‐Reaction Solvent Exchange by Membrane Separation

Pharmaceutical production typically involves multiple reaction steps with separations between successive reactions. Two processes which complicate the transition from batch to continuous operation in multistep synthesis are solvent exchange (especially high‐boiling‐ to low‐boiling‐point solvent), and catalyst separation. Demonstrated here is membrane separation as an enabling platform for undertaking these processes during continuous operation. Two consecutive reactions are performed in different solvents, with catalyst separation and inter‐reaction solvent exchange achieved by continuous flow membrane units. A Heck coupling reaction is performed in N,N‐dimethylformamide (DMF) in a continuous membrane reactor which retains the catalyst. The Heck reaction product undergoes solvent exchange in a counter‐current membrane system where DMF is continuously replaced by ethanol. After exchange the product dissolved in ethanol passes through a column packed with an iron catalyst, and undergoes reduction (>99 % yield).     

Fluorogenic Strain‐Promoted Alkyne–Diazo Cycloadditions

Fluorogenic reactions, in which non‐ or weakly fluorescent reagents produce highly fluorescent products, are attractive for detecting a broad range of compounds in the fields of bioconjugation and material sciences. Herein, we report that a dibenzocyclooctyne derivative modified with a cyclopropenone moiety (Fl‐DIBO) can undergo fast strain‐promoted cycloaddition reactions under catalyst‐free conditions with azides, nitrones, nitrile oxides, as well as mono‐ and disubstituted diazo‐derivatives. Although the reaction with nitrile oxides, nitrones, and disubstituted diazo compounds gave cycloadducts with low quantum yield, monosubstituted diazo reagents produced 1H‐pyrazole derivatives that exhibited an approximately 160‐fold fluorescence enhancement over Fl‐DIBO combined with a greater than 10 000‐fold increase in brightness. Concluding from quantum chemical calculations, fluorescence quenching of 3H‐pyrazoles, which are formed by reaction with disubstituted diazo‐derivatives, is likely due to the presence of energetically low‐lying (n,π*) states. The fluorogenic probe Fl‐DIBO was successfully employed for the labeling of diazo‐tagged proteins without detectable background signal. Diazo‐derivatives are emerging as attractive reporters for the labeling of biomolecules, and the studies presented herein demonstrate that Fl‐DIBO can be employed for visualizing such biomolecules without the need for probe washout.     

An Unexpected and Green Synthetic Protocol for Ethyl 1‐Aroyl/Aroylmethyl‐5‐methyl‐3‐methylthiopyrazole‐4‐carboxylates: High Regioselectivity in Alkylation and Acylation Reactions between N‐1 and N‐2 of a Pyrazole Ring

Two series, totaling twelve, of new compounds, ethyl 1‐aroyl/(aroylmethyl)‐5‐methyl‐3‐methylthiopyrazole‐4‐carboxylates ( 5 / 6 ), have been synthesized via highly regioselectively acylation and alkylation reactions of ethyl 3‐methyl‐5‐methylthio‐1 H‐pyrazole‐4‐carboxylate ( 2a ) with aroyl chloride ( 3 ) and eco‐friendly reagents alpha‐tosyloxysubstituted acetophenones ( 4 ), respectively, and a green protocol has been developed. The acylation reactions were carried out under ultrasound irradiation, and the alkylation reactions were under microwave irradiation and ultrasound irradiation, respectively. Conventional reaction conditions, as well as the use of alpha‐bromosubstituted acetophenone ( 4 ′) have also been applied in the synthesis of some randomly selected compounds in both series and have generated identical compounds correspondingly. Unexpected structures of compounds were unambiguously determined by X‐ray crystallographic analysis.     

Perspectives of Microwaves‐Enhanced Heterogeneous Catalytic Gas‐Phase Processes in Flow Systems

The paper discusses the currents status and future perspectives of the utilization of microwaves, as a selective and locally controlled heating method, in heterogeneous catalytic flow reactors. Various factors related to the microwave‐catalyst interaction and the design of microwave‐assisted catalytic reactor systems are analyzed. The analysis clearly shows the superiority of the traveling‐wave systems over the mono‐mode and multi‐mode cavity‐based systems when it comes to the design and application of microwave flow reactors at relevant production scales.     

A Single‐Molecule‐Level Mechanistic Study of Pd‐Catalyzed and Cu‐Catalyzed Homocoupling of Aryl Bromide on an Au(111) Surface

On‐surface Pd‐ and Cu‐catalyzed C?C coupling reactions between phenyl bromide functionalized porphyrin derivatives on an Au(111) surface have been investigated under ultra‐high vacuum conditions by using scanning tunneling microscopy and kinetic Monte Carlo simulations. We monitored the isothermal reaction kinetics by allowing the reaction to proceed at different temperatures. We discovered that the reactions catalyzed by Pd or Cu can be described as a two‐phase process that involves an initial activation followed by C?C bond formation. However, the distinctive reaction kinetics and the C?C bond‐formation yield associated with the two catalysts account for the different reaction mechanisms: the initial activation phase is the rate‐limiting step for the Cu‐catalyzed reaction at all temperatures tested, whereas the later phase of C?C formation is the rate‐limiting step for the Pd‐catalyzed reaction at high temperature. Analysis of rate constants of the Pd‐catalyzed reactions allowed us to determine its activation energy as (0.41±0.03) eV.     

A Multicomponent,Catalyst‐free,One‐Pot Synthesis of Functionalized 1,4‐Dihydroquinolines and Their Antimicrobial Studies

An atom‐efficient, catalyst‐free, and environmentally friendly approach towards the synthesis of substituted 1,4‐dihydroquinolines ( 5a , 5b , 5c , 5d , 5e , 5f , 5g , 5h , 5i , 5j ) through a one‐pot multicomponent reaction involving resorcinol, aromatic aldehyde, acetoacetanilide, and ammonium acetate has been developed. The reactions were carried out under both conventional and microwave irradiation conditions. In general, improvement in rate and yield were observed when reactions were carried out under microwave irradiation compared with classical conditions. Most of the new compounds possessed moderate to significant antibacterial and antifungal activities.