Asymmetric Carbon–Carbon Bond Formation under Continuous‐Flow Conditions with Chiral Heterogeneous Catalysts

Catalytic asymmetric carbon–carbon bond‐forming reactions provide one of the most efficient ways to synthesize optically active compounds, and, accordingly, many chiral catalysts for these reactions have been developed in the past two decades. However, the efficiency of the catalysts in terms of turnover number (TON) is often lower than that of some other reactions, such as asymmetric hydrogenation, and this has been one of the obstacles for industrial applications. Although there are some difficulties in increasing the efficiency, the issues might be solved by using continuous flow in the presence of chiral heterogeneous catalysts. Indeed, continuous‐flow systems have several advantages over conventional batch systems. Here we summarize the recent progress in asymmetric C? C bond‐forming reactions under continuous‐flow conditions with chiral heterogeneous catalysts.     

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.     

A Fast‐Initiating Ionically Tagged Ruthenium Complex: A Robust Supported Pre‐catalyst for Batch‐Process and Continuous‐Flow Olefin Metathesis

In this study, a new pyridinium‐tagged Ru complex was designed and anchored onto sulfonated silica, thereby forming a robust and highly active supported olefin‐metathesis pre‐catalyst for applications under batch and continuous‐flow conditions. The involvement of an oxazine–benzylidene ligand allowed the reactivity of the formed Ru pre‐catalyst to be efficiently controlled through both steric and electronic activation. The oxazine scaffold facilitated the introduction of the pyridinium tag, thereby affording the corresponding cationic pre‐catalyst in good yield. Excellent activities in ring‐closing (RCM), cross (CM), and enyne metathesis were observed with only 0.5 mol % loading of the pre‐catalyst. When this powerful pre‐catalyst was immobilized onto a silica‐based cationic‐exchange resin, a versatile catalytically active material for batch reactions was generated that also served as fixed‐bed material for flow reactors. This system could be reused at 1 mol % loading to afford metathesis products in high purity with very low ruthenium contamination under batch conditions (below 5 ppm). Scavenging procedures for both batch and flow processes were conducted, which led to a lowering of the ruthenium content to as little as one tenth of the original values.     

Blue‐Light‐Induced Carbene‐Transfer Reactions of Diazoalkanes

Carbenes are very important reactive intermediates to access a variety of complex molecules and are applied widely in organic synthesis and drug discovery. Typically, their chemistry is accessed by the use of transition metal catalysts. Herein, we describe the application of low‐energy blue light for the photochemical generation of carbenes from donor–acceptor diazoalkanes. This catalyst‐free and operationally simple approach enables highly efficient cyclopropenation reactions with alkynes and the rearrangement of sulfides under mild reaction conditions, which can be utilized for both batch and continuous‐flow processes.     

Self‐Supported Chiral Titanium Cluster (SCTC) as a Robust Catalyst for the Asymmetric Cyanation of Imines under Batch and Continuous Flow at Room Temperature

A robust heterogeneous self‐supported chiral titanium cluster (SCTC) catalyst and its application in the enantioselective imine‐cyanation/Strecker reaction is described under batch and continuous processes. One of the major hurdles in the asymmetric Strecker reaction is the lack of availability of efficient and reusable heterogeneous catalysts that work at room temperature. We exploited the readily hydrolyzable nature of titanium alkoxide to synthesize a self‐supported chiral titanium cluster (SCTC) catalyst by the controlled hydrolysis of a preformed chiral titanium‐alkoxide complex. The isolated SCTC catalysts were remarkably stable and showed up to 98 % enantioselectivity (ee) with complete conversion of the imine within 2 h for a wide variety of imines at room temperature. The heterogeneous catalysts were recyclable more than 10 times without any loss in activity or selectivity. The robustness, high performance, and recyclability of the catalyst enabled it to be used in a packed‐bed reactor to carry out the cyanation under continuous flow. Up to 97 % ee and quantitative conversion with a throughput of 45 mg h^?1 were achieved under optimized flow conditions at room temperature in the case of benzhydryl imine. Furthermore, a three‐component Strecker reaction was performed under continuous flow by using the corresponding aldehydes and amines instead of the preformed imines. A good product distribution was obtained for the formation of amino nitriles with ee values of up to 98 %. Synthetically useful ee values were also obtained for challenging α‐branched aliphatic aldehyde by using the three‐component continuous Strecker reaction.     

Flow fine synthesis with heterogeneous catalysts

In the past few decades, organic reactions under flow conditions have attracted increasing attention. Flow reactions have a number of advantages over batch reactions in terms of environmental compatibility, efficiency, and safety. In particular, flow reactions with heterogeneous catalysts that yield desired products without significant levels of by-product formation can enable purification processes to be avoided. This feature can allow flow reactions to be assembled in a multi-step and continuous manner for the synthesis of complex molecules. These new techniques have opened up new approaches to the synthesis of fine chemicals and are expected to play a prominent role in future chemical manufacturing processes. In this context, this review aims to summarize recent developments in continuous-flow reactions with heterogeneous catalysts for synthesis of fine chemicals.     

Pybox monolithic miniflow reactors for continuous asymmetric cyclopropanation reaction under conventional and supercritical conditions

Supported catalysts having pybox chiral moieties were prepared as macroporous monolithic miniflow systems. These catalysts are based on styrene-divinylbenzene polymeric backbones having different compositions and pybox chiral moieties. Their corresponding ruthenium complexes were tested for the continuous flow cyclopropanation reaction between styrene and ethyldiazoacetate (EDA) under conventional conditions and in supercritical carbon dioxide (scCO2). Ru-Pybox monolithic miniflow reactors not only provided a highly efficient and robust heterogeneous chiral catalyst but also allowed us to develop more environmental reaction conditions without sacrificing the global efficiency of the process.     

One-component bimetallic aluminium(salen)-based catalysts for cyclic carbonate synthesis and their immobilization

The development of one-component, bimetallic μ-oxoaluminium(salen) complexes as highly active catalysts for the synthesis of cyclic carbonates from terminal epoxides is described. The resulting homogeneous catalysts are used in batch reactions at room temperature and one atmosphere pressure. The catalysts have also been immobilized onto various support materials and used in either batch reactions or gas-phase flow reactions with ethylene and propylene oxides. Catalyst lifetime, deactivation and reactivation have been studied in both batch and flow reactions, and it has been shown that of the impurities present in power station flue gas, only sulfur trioxide deactivates the catalyst and at the concentrations of sulfur trioxide present in flue gas, this deactivation would require more than one years exposure of the catalyst to flue gas.     

Composite Polymer/Oxide Hollow Fiber Contactors: Versatile and Scalable Flow Reactors for Heterogeneous Catalytic Reactions in Organic Synthesis

Flexible composite polymer/oxide hollow fibers are used as flow reactors for heterogeneously catalyzed reactions in organic synthesis. The fiber synthesis allows for a variety of supported catalysts to be embedded in the walls of the fibers, thus leading to a diverse set of reactions that can be catalyzed in flow. Additionally, the fiber synthesis is scalable (e.g. several reactor beds containing many fibers in a module may be used) and thus they could potentially be used for the large‐scale production of organic compounds. Incorporating heterogeneous catalysts in the walls of the fibers presents an alternative to a traditional packed‐bed reactor and avoids large pressure drops, which is a crucial challenge when employing microreactors.     

A Monte Carlo Method to Quantify the Effect of Reactor Residence Time Distribution on Polyolefins Made with Heterogeneous Catalysts: Part I—Catalyst/Polymer Particle Size Distribution Effects

Polyolefins are commercially produced in continuous reactors that have a broad residence time distribution (RTD). Most of these polymers are made with heterogeneous catalysts that also have a particle size distribution (PSD). These are totally segregated systems, in which the catalyst/polymer particle can be seen as a microreactor operated in semibatch mode, where the reagents (olefins, hydrogen, etc.) are fed continuously to the catalyst/polymer particle, but no polymer particle can leave. The reactor RTD has a large influence on the PSD of the polymer particles leaving the reactor, as well as in polymer microstructure and properties, polymerization yield, and composition of reactor blends. This article proposes a Monte Carlo model that can describe how particle RTD in a single or a series of reactors can affect the PSD of polymer particles made under a variety of operation conditions. It is believed that this is the most flexible model ever proposed to model this phenomenon, and can be easily modified to track all properties of interest during polyolefin production in continuous reactors with heterogeneous catalysts.     

Towards a Molecular Understanding of Asymmetric Heterogeneous Catalysis: Hydrogenation of 1-Phenyl-1,2-Propanedione1

The present work comprises a detailed investigation of a complex reaction system, revealing features of reaction mechanisms that are general for asymmetric heterogeneous catalysis. Heterogeneous enantioselective hydrogenation of 1-phenyl-1,2-propanedione was studied over cinchonidine modified Pt catalysts producing (R)-1-hydroxy-1-phenylpropanone as the main product with an enantiomeric excess (ee) of 65% at maximum yield, which could be further increased above 90% due to kinetic resolution. The results of kinetic studies in batch and continuous reactors, catalyst screening and characterization results, as well as quantum chemical calculations, are summarized, and pertinent mechanistic aspects are discussed.     

Highly effective methane conversion to aromatic hydrocarbons by means of microwave and rf-induced catalysis

Conversion of methane to higher hydrocarbon products, in particular, aromatic hydrocarbons has been achieved with good methane conversion and selectivity to aromatic products over heterogeneous catalysts using both high power pulsed microwave and rf energy. For example, under microwave irradiation > 85% conversion of methane and 60% selectivity to aromatics could be achieved. Cu, Ni, Fe and Al metallic materials are highly effective catalysts for the aromatization of methane via microwave heating; however, with a variety of supported catalysts the major products were C₂ hydrocarbons and the conversion of methane was low. The use of sponge, wire and net forms of these metal catalysts was found advantageous in effective methane conversion. The reactions are considered to be free radical in nature and to proceed through an intermediate stage involving formation of acetylene. The influence of catalyst nature and configuration, as well as the microwave and rf irradiation parameters on the reaction efficiency and product selectivity has been examined in both batch and continuous flow conditions.     

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).     

Continuous Synthesis of Aryl Amines from Phenols Utilizing Integrated Packed‐Bed Flow Systems

Aryl amines are important pharmaceutical intermediates among other numerous applications. Herein, an environmentally benign route and novel approach to aryl amine synthesis using dehydrative amination of phenols with amines and styrene under continuous‐flow conditions was developed. Inexpensive and readily available phenols were efficiently converted into the corresponding aryl amines, with small amounts of easily removable co‐products (i.e., H₂O and alkanes), in multistep continuous‐flow reactors in the presence of heterogeneous Pd catalysts. The high product selectivity and functional‐group tolerance of this method allowed aryl amines with diverse functional groups to be selectively obtained in high yields over a continuous operation time of one week.     

Accelerating Biphasic Biocatalysis through New Process Windows

Process intensification through continuous flow reactions has increased the production rates of fine chemicals and pharmaceuticals. Catalytic reactions are accelerated through an unconventional and unprecedented use of a high‐performance liquid/liquid counter current chromatography system. Product generation is significantly faster than in traditional batch reactors or in segmented flow systems, which is exemplified through stereoselective phase‐transfer catalyzed reactions. This methodology also enables the intensification of biocatalysis as demonstrated in high yield esterifications and in the sesquiterpene cyclase‐catalyzed synthesis of sesquiterpenes from farnesyl diphosphate as high‐value natural products with applications in medicine, agriculture and the fragrance industry. Product release in sesquiterpene synthases is rate limiting due to the hydrophobic nature of sesquiterpenes, but a biphasic system exposed to centrifugal forces allows for highly efficient reactions.     

Self-supported chiral titanium cluster (SCTC) as a robust catalyst for the asymmetric cyanation of imines under batch and continuous flow at room temperature

A robust heterogeneous self-supported chiral titanium cluster (SCTC) catalyst and its application in the enantioselective imine-cyanation/Strecker reaction is described under batch and continuous processes. One of the major hurdles in the asymmetric Strecker reaction is the lack of availability of efficient and reusable heterogeneous catalysts that work at room temperature. We exploited the readily hydrolyzable nature of titanium alkoxide to synthesize a self-supported chiral titanium cluster (SCTC) catalyst by the controlled hydrolysis of a preformed chiral titanium-alkoxide complex. The isolated SCTC catalysts were remarkably stable and showed up to 98 % enantioselectivity (ee) with complete conversion of the imine within 2 h for a wide variety of imines at room temperature. The heterogeneous catalysts were recyclable more than 10 times without any loss in activity or selectivity. The robustness, high performance, and recyclability of the catalyst enabled it to be used in a packed-bed reactor to carry out the cyanation under continuous flow. Up to 97 % ee and quantitative conversion with a throughput of 45 mg h(-1) were achieved under optimized flow conditions at room temperature in the case of benzhydryl imine. Furthermore, a three-component Strecker reaction was performed under continuous flow by using the corresponding aldehydes and amines instead of the preformed imines. A good product distribution was obtained for the formation of amino nitriles with ee values of up to 98 %. Synthetically useful ee values were also obtained for challenging α-branched aliphatic aldehyde by using the three-component continuous Strecker reaction.     

Continuous flow enzyme-catalyzed polymerization in a microreactor

Enzymes immobilized on solid supports are increasingly used for greener, more sustainable chemical transformation processes. Here, we used microreactors to study enzyme-catalyzed ring-opening polymerization of ε-caprolactone to polycaprolactone. A novel microreactor design enabled us to perform these heterogeneous reactions in continuous mode, in organic media, and at elevated temperatures. Using microreactors, we achieved faster polymerization and higher molecular mass compared to using batch reactors. While this study focused on polymerization reactions, it is evident that similar microreactor based platforms can readily be extended to other enzyme-based systems, for example, high-throughput screening of new enzymes and to precision measurements of new processes where continuous flow mode is preferred. This is the first reported demonstration of a solid supported enzyme-catalyzed polymerization reaction in continuous mode.     

Highly Efficient Photocatalysts and Continuous‐Flow Photocatalytic Reactors for Degradation of Organic Pollutants in Wastewater

One of the most important applications for photocatalysis is engineered water treatment that photodegrades organic pollutants in wastewater at low cost. To overcome the low efficiency of batch degradation methods, continuous‐flow photocatalytic reactors have been proposed and have become the most promising method for mass water treatment. However, most commercial semiconductor photocatalysts are granular nanoparticles with low activity and a narrow active light wavelength band; this creates difficulties for direct use in continuous‐flow photocatalytic reactors. Therefore, a high‐performance photodegradation photocatalyst with proper morphology or structure is key for continuous photocatalytic degradation. Moreover, a well‐designed photocatalytic device is another important component for continuous‐flow photocatalysis and determines the efficiency of photocatalysis in practical water treatment. This review describes the basic design principles and synthesis of photocatalysts with excellent performance and special morphologies suitable for a filtering photocatalysis process. Certain promising continuous photodegradation reactors are also categorized and summarized. Additionally, selected scientific and technical problems that must be urgently solved are suggested.     

A Carbon Nanotube Confinement Strategy to Implement Homogeneous Asymmetric Catalysis in the Solid Phase

A readily recyclable asymmetric catalyst has been developed based on the self‐assembly of a homogeneous catalyst in a fibrous network of multiwalled carbon nanotubes (MWNTs). Dimerization of an amide‐based chiral ligand with a suitable spacer allows for the efficient formation of a heterogeneous catalyst by self‐assembly on addition of Er(OiPr)₃. The self‐assembly proceeds in the MWNT fibrous network and small clusters of assembled catalyst are confined in the MWNTs, producing an easily handled solid‐phase catalyst. The resulting MWNT‐confined catalyst exhibits a good catalytic performance in a catalytic asymmetric Mannich‐type reaction, which can be conducted in a repeated batch system and in a continuous‐flow platform.     

Supramolecular Strategies for the Recycling of Homogeneous Catalysts

Supramolecular approaches are increasingly used in the development of homogeneous catalysts and they also provide interesting new tools for the recycling of metal-based catalysts. Various non-covalent interactions have been utilized for the immobilization homogeneous catalysts on soluble and insoluble support. By non-covalent anchoring the supported catalysts obtained can be recovered via (nano-) filtration or such catalytic materials can be used in continuous flow reactors. Specific benefits from the reversibility of catalyst immobilization by non-covalent interactions include the possibility to re-functionalize the support material and the use as “boomerang” type catalyst systems in which the catalyst is captured after a homogeneous reaction. In addition, new reactor design with implemented recycling strategies becomes possible, such as a reverse-flow adsorption reactor (RFA) that combines a homogeneous reactor with selective catalyst adsorption/desorpion. Next to these non-covalent immobilization strategies, supramolecular chemistry can also be used to generate the support, for example by generation of self-assembled gels with catalytic function. Although the stability is a challenging issue, some self-assembled gel materials have been successfully utilized as reusable heterogeneous catalysts. In addition, catalytically active coordination cages, which are frequently used to achieve specific activity or selectivity, can be bound to support by ionic interactions or can be prepared in structured solid materials. These new heterogenized cage materials also have been used successfully as recyclable catalysts.