Chemical Science: Review
Chemical Science: Review
Chemical Science: Review
Science
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REVIEW View Journal | View Issue
Flow chemistry has unlocked a world of possibilities for the synthetic community, but the idea that it is
a mysterious “black box” needs to go. In this review, we show that several of the benefits of microreactor
Received 22nd February 2023
Accepted 15th March 2023
technology can be exploited to push the boundaries in organic synthesis and to unleash unique
reactivity and selectivity. By “lifting the veil” on some of the governing principles behind the observed
DOI: 10.1039/d3sc00992k
trends, we hope that this review will serve as a useful field guide for those interested in diving into flow
rsc.li/chemical-science chemistry.
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already allow one to begin setting up ow experiments. reaction mixture: the better the mass transfer, the more efficient
Furthermore, recent advancements in “Do It Yourself”-assem- the mixing.
bled ow setups,10–12 3D-printing technology,13 and cheap elec- This parameter is especially crucial in the case of multiphase
tronic toolkits14 have made technology more intuitive, reactions, e.g. gas–liquid reactions where one of the reagents
accessible and affordable. As a consequence, adoption of ow needs to migrate by diffusion from one phase to another.18
technology in synthetic organic chemistry has been growing in As an example, Noël and co-workers reported the photo-
recent years. With the rise of photo- and electrochemistry, ow catalytic Giese-type alkylation using gaseous light hydrocarbons
technology has become a popular and indispensable choice due (i.e., methane, ethane, propane, isobutane) via hydrogen atom
to its capability to handle the scalability challenges of these transfer photocatalysis in ow (Fig. 1).19 Hereto, the authors
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synthetic modes. Flow chemistry is also favored for its ability in exploited the decatungstate anion (DT, W10O324−) as a versatile
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safely and effectively conducting reactions with challenging or and inexpensive polyoxometalate-based hydrogen atom transfer
hazardous reagents, expanding the chemical frontiers. (HAT) photocatalyst:20 upon activation by UV-light irradiation,
Frequently, our lab gets asked to help young MSc and PhD this photocatalyst can cleave homolytically C(sp3)–H bonds to
students start using the technology.15,16 Although they may feel yield C-centered radicals which can be subsequently exploited
intimidated at rst, we oen see how quickly they grasp the for various synthetic purposes.21 While this chemistry is docu-
concepts and start reaping the benets of ow technology for mented to be efficient in the case of homogeneous solutions
their research. To further increase the adoption of ow chem- (i.e., single solution phase), the activation of gaseous alkanes is
istry in synthetic organic chemistry, this review seeks to provide more challenging due to their limited solubility in common
some basic guidelines for the use of continuous-ow reactors. organic solvents. The immediate consequence is that the tar-
The goal is to deliver a concise overview to help researchers gain geted chemistry is particularly slow due to poor gas-to-liquid
a basic understanding of the principles behind this technology, mass transfer limitations. The authors tackled this challenge
allowing them to get the most out of their experiments. We have by resorting to ow chemistry: by increasing the pressure in the
highlighted three relevant examples to clarify each fundamental reactor through use of simple back-pressure regulators, the
principle. Our aim is not to provide an exhaustive overview of gaseous alkanes could be forced into the liquid phase,
continuous-ow chemistry,17 but rather to offer simple and increasing the odds of C(sp3)–H bond activation of the gaseous
easy-to-follow guidelines for readers to determine if ow components. Thus, when a CD3CN : H2O (7 : 1) solution of olen
chemistry is relevant to their research. Consequently, our 1.1 was irradiated with UV light (365 nm, 150 W) in the presence
objective is to educate the broader synthetic community about of tetrabutylammonium decatungstate and methane (20 equiv.)
this innovative technology and demonstrate how and when it at a pressure of 45 bar, the corresponding methylated product
can make a difference. 1.2 was obtained in 42% yield aer 6 hours residence time.
Intriguingly, ow chemistry allowed to conduct the entire scope
2. Mass transfer (38 examples) at high pressure in a timely and scalable yet safe
fashion, which is by no means possible in conventional batch
The rst, and arguably most potent, advantage of ow chem- reactors. Very recently, the same authors extended this tech-
istry for synthetic organic chemists is the improved mass nology for the C(sp3)–H carbonylation with gaseous carbon
transfer. Mass transfer is dened as the net movement of one monoxide (CO), obtaining unsymmetrical ketones (41 exam-
species, e.g. one of the reactants, from one point to another ples) in good to excellent yields.22
within the reactor due to diffusion and/or convection. In other Another synthetic discipline that relies heavily on the
words, mass transfer denes the degree of mixing in the optimal mass transfer offered by microow technology is that of
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4. Multi-step synthesis
The possibility to streamline several transformations in
a “single, continuous and uninterrupted reactor network”47 is
a riveting opportunity offered by ow chemistry. In fact, multi-
step syntheses in batch are tedious, time-consuming and labor-
intensive undertakings. For example, the product of one step
must oen be puried before the subsequent one can be
executed. In contrast, organic chemists can use a one-ow,
multi-step synthesis approach to expedite their synthetic
Fig. 5 Combining Grignard reagent synthesis with iron-catalyzed
routes. However, to be successful, some major challenges have
cross-coupling reaction in a telescoped flow process for C(sp)–C(sp3) to be tackled, such as solvent compatibilities and byproduct
bond formation. formation, requiring oen inline purication strategies.
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Jamison and co-workers reported the continuous-ow pharmaceuticals: notably, the corresponding batch synthesis
synthesis of the antibiotic linezolid by combining seven required more than 60 hours.
consecutive steps without purication of any intermediate Interestingly, the concept of multi-step ow synthesis is also
(Fig. 7A).48 Notably, all of the steps are compatible with each receiving a great deal of attention from the pharmaceutical
other, requiring neither solvent exchanges nor intermediate industry.49 Continuous manufacturing has tremendous advan-
work-ups. The entire process involves a convergent synthesis tages over batch manufacturing in terms of improved perfor-
based on three modules. In the rst module, (+)-epichlorohy- mance and safety, together with decreased capital expenditures.
drine 7.1 was reacted with boron triuoride etherate as a stoi- This is even more true when the concept of small-volume
chiometric Lewis acid in the presence of acetonitrile to obtain continuous manufacturing (SVCM) is adopted. In such
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the corresponding Ritter product; next, epoxide formation was a scenario, small-size equipment that ts a exible environ-
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achieved under basic conditions to get 7.2. Second, in parallel ment, such as a standard laboratory fumehood, is operated in
with the rst module, aniline 7.4 was obtained from nitroarene a continuous fashion to reach productivities of several kg per
7.3 via SNAr with morpholine and subsequent heterogeneous day. For example, scientists at Eli Lilly reported the synthesis of
hydrogenation with a palladium packed-bed reactor. In the prexasertib monolactate monohydrate, a checkpoint kinase 1
third module, the streams containing 7.2 and 7.4 were inhibitor, on a kilogram scale by taking advantage of the SVCM
combined to afford linezolid (7.6) aer reaction with N,N-car- concept (Fig. 7B).50 Starting from compound 7.7, pyrazole 7.8
bonyldiimidazole (7.5). Overall, linezolid was synthesized in was prepared by reaction with hazardous NH2NH2: unlike
73% yield with a total residence time of 27 minutes, corre- batch, the ow approach required only a slight excess of
sponding to a productivity of 816 mg h−1. This protocol show- hydrazine and allowed to minimize exposure to the operators.
cases how a careful tuning of the reaction conditions and the Aer a solvent exchange in an automated 20 L rotary evaporator,
ow parameters allows to accelerate the synthesis of a SNAr reaction was conducted with pyrazine 7.9 to afford
Fig. 7 Application of flow chemistry for multi-step synthesis. PAT: process analytical technology. TFAA: trifluoroacetic anhydride.
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olenation chemistry, exploiting the intrinsic modularity of gradually in three steps using ow technology. In the rst step,
ow chemistry, to append hydroalkanes with an allyl functional 3.5 kg of 10.1 was converted to 10.3 in 88 LCAP and 94% assay
group. First, an acetonitrile solution of acrylate 9.2, benzo- yield with a residence time of 3.75 minutes; in the second step,
dioxole (9.1) and decatungstate as the photocatalyst was injec- 50 kg of 10.1 was converted to 10.3 in 91 LCAP and 93% assay
ted into a Vapourtec UV-150 photochemical reactor (tR = 5 min) yield with a residence time of 1.5 minutes. Finally, the
equipped with a 60 W UV-A LED light source (l = 365 nm) to researchers adopted a numbering-up approach to deliver more
deliver the corresponding Giese adduct. In contrast, when the than 100 kg per day (91 LCAP and 94% assay yield) of the
same reaction was conducted in batch, full conversion was product. In this case, the synthetic advantage offered by ow
reached only aer 20 hours. Second, the stream containing the chemistry is the improved chemoselectivity because it enabled
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Giese adduct was subsequently merged with a stream contain- a precise control over reaction time, which prevented undesired
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ing LiOtBu and paraformaldehyde to perform a HWE olena- reactions such as overbromination of 10.1.
tion. By doing so, the allylated product 9.3 was isolated in an
overall 70% yield, requiring no intermediate purication. The
developed two-step ow process could be subsequently 6. Electrochemistry
extended to a wide variety of aliphatic and aromatic aldehydes,
Another eld that has beneted signicantly from the adoption
as well as deuterated paraformaldehyde, to prepare various
of microuidic technologies is electrochemistry.67–71 Electro-
highly functionalized allylated compounds. These moieties are
chemical reactions are by denition heterogeneous processes,
difficult to prepare via conventional radical allylation
as they rely on a redox event between an electrode surface and
approaches.63,64
a molecule in solution. Accordingly, mass transfer from the
As a nal example, scientists at Merck have reported a scal-
bulk to the electrode surface becomes a very important
able continuous-ow photochemical process for the bromina-
consideration. However, using microuidic setups, the impact
tion of intermediate 10.1, which is required to produce
of poor mass transfer can be minimized due to the larger
belzutifan (Fig. 10), a drug for the treatment of renal cell
surface-to-volume ratio. Notably, the small interelectrode
carcinoma.65,66 In the traditional synthetic route, the radical
distances in microreactors reduces the observed ohmic voltage
benzylic bromination was achieved through the use of azobisi-
drop, enabling a net reduction of the amount of supporting
sobutyronitrile (AIBN) as initiator and reagent 10.2 as the
electrolyte needed in the reaction mixture.
bromine source. Under these reaction conditions, 10.1 is rela-
A collaborative effort between Buchwald, Jensen et al.
tively unstable and undergoes sudden di-bromination and de-
resulted in the development of a mRN-eChem (microuidic
ketalization. By replacing AIBN with blue light, the authors
redox-neutral electrochemical) cell to perform redox-neutral
found that the reaction could be conveniently stopped to get the
transformations (Fig. 11).72 Although these transformations
product in 91% LCAP (Liquid Chromatography Area Percent) in
could in principle be run under photoredox catalytic conditions,
batch in only 3 minutes. The scale up of the process occurred
the use of photocatalysts might bring around some inconve-
niences, such as the challenging tuning of redox potentials, the
use of expensive transition metals and the instability of pho-
tocatalysts under operating conditions. The ow cell consists of
two laser-micromachined glassy carbon electrodes separated by
Fig. 10 Adoption of flow chemistry in an industrial setting to improve Fig. 11 Microfluidic electrochemical cells with short inter-electrode
chemoselectivity and facilitate scalability in the synthesis of 10.3, an gaps enable redox-neutral transformations in the absence of sup-
intermediate en route to belzutifan. porting electrolytes. GC: glassy carbon.
4236 | Chem. Sci., 2023, 14, 4230–4247 © 2023 The Author(s). Published by the Royal Society of Chemistry
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a FEP gasket with a reduced thickness (25 mm). Due to the short (e.g., Pt) on a relatively small scale (gram scale). However, the
inter-electrode distance, it is possible to reduce the time authors managed to translate the reaction to ow on a 120 g
required for interelectrode migration (as governed by the scale by using cheap electrodes: a graphite anode and two
following equation: t = d2/D; d: interelectrode distance, D: stainless steel cathodes, connected in a monopolar fashion. Full
molecular diffusivity) signicantly, so that it is shorter than the electrolysis was reached in 10 hours under galvanostatic
lifetime of open-shell intermediates generated upon electrol- conditions at 2.5 A, delivering ca. 100 g of 12.2 (85% yield aer
ysis, which paves the way to efficient redox-neutral manifolds. isolation), which corresponds to a productivity of 10.1 g h−1. In
For example, the authors coupled Kolbe electrolysis with arene comparison, when the reaction was run in batch on a 5 g-scale,
reduction to develop a decarboxylative arylation by capitalizing a productivity of 0.75 g h−1 was achieved. Finally, compound
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on the persistent radical effect.73 Thus, arene 11.2 is reduced at 12.2 was converted to 12.3 via reduction by Red-Al and esteri-
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the cathode generating a persistent radical anion 11.2c−; the cation. Overall, ow chemistry enabled in this specic case
latter radical intermediate migrates towards the anode, where a straightforward and safe scale up of a value-added interme-
Kolbe electrolysis yields transient alkyl radicals. Subsequent diate (12.2), which should facilitate the development of a safe
radical–radical anion coupling occurs to afford the arylated industrial process of 12.3.
product 11.3 aer decyanation. Intriguingly, the small inter- Flow electrochemistry is also extremely appealing to the
electrode gap also reduces the ohmic drop, thus eliminating chemical industry due to the ability to use “green” electricity
the need for additional supporting electrolyte. A similar derived from solar and wind energy. Furthermore, the reduced
approach could be used for different alkyl radical progenitors inter-electrode gap introduces a series of advantages that cut
(e.g., arylamines or triuoroborate salts). the costs of conducting electrochemical reactions. Indeed,
Baran and co-workers used a ow electrochemical approach voltages needed to promote reactivity are generally lower (due to
to synthesize compound 12.2, an intermediate for the synthesis a reduced overpotential), which also allows to reduce the
of cyclobutane-containing tetranitric esters (Fig. 12).74 One of amount of expensive supporting electrolyte and thus facilitates
these compounds, namely cyclobutane-1,1,2,2- the purication processes. Flow electrochemistry is also safer
tetrayltetrakis(methylene) tetranitrate (12.3), proved to be compared to batch because it enables a tighter heat manage-
valuable as a potential melt-castable energetic. As the original ment control, avoiding thermal runaways,31 and due to its
route for the synthesis of 12.2 posed several concerns in terms continuous nature, it also prevents occurrence of dead zones
of safety and expenses,75 the authors were eager to nd a more (i.e., regions in a reactor where the reaction mixture is
practical alternative. Compound 12.1 was synthesized starting stagnant).
from Meldrum's acid followed by acidic hydrolysis; next, elec- Very recently, scientists at Merck developed a scalable ow
trolytic conditions were adopted to promote cyclization to give process for the selective anodic oxidation of thioethers.76 In this
compound 12.2. In the original route, the latter step was con- process, thioether (13.1) was oxidized to the corresponding
ducted in batch and required the use of expensive electrodes sulfone (13.2) (Fig. 13). Compound 13.1 is a fragment of a drug
candidate but its chemical oxidation with classical oxidants
(e.g., oxone, m-CPBA, periodate or tungstate) led to a complex
Fig. 12 Flow electrochemistry facilitates the safe scale-up of Fig. 13 Adoption of flow electrochemistry in an industrial context for
a promising melt-castable energetic intermediate. C: graphite elec- the highly scalable, selective anodic oxidation of thioether 13.1. trecirc:
trode; S. S: stainless steel electrode. time of recirculation.
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mixture of the corresponding sulfoxide and sulfone. Aer ideal mixing between the oxygen and the liquid solution.
a brief reaction optimization in batch, the authors successfully Within 90 minutes of residence time and 5 mol% TBADT
translated their protocol into ow by exploiting a recirculating loading, the authors demonstrated that artemisinin (14.1) could
mode operation. It was possible to gradually scale the process be converted to its natural derivative artemisitone-9 in 59%
from gram-to kilogram-scale by systematically increasing the yield (14.2, 5 mmol scale) with this methodology. Furthermore,
electrode surface area, whilst keeping the current density and most of the activated and unactivated aliphatic bonds (30
electron equivalents constant. Ultimately, it was possible to examples) such as (−)-ambroxide 14.3, pregnenolone acetate
prepare 1.11 kg of 13.2 using 1600 cm2 electrodes and applying 14.4, eucalyptol 14.5 and (+)-sclareolide 14.6, could be selec-
a current density of 30 mA cm−2, a current of 48 A, 4.5 F mol−1, tively oxidized in moderate to excellent yield (43–91%).
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for ca. 19 h of processing time, thus meeting the criteria for pilot In addition to safely handling toxic reagents in ow, micro-
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production (1.21 kg per day). reactor technology allows for the generation and utilization of
sensitive reaction intermediates without the need to store
hazardous quantities of materials. For example, dinitrogen
7. Safety trioxide (N2O3) is a powerful nitrosating reagent with an
In addition to fast heat and mass transfer of microreactor appealing atom economy, but it is only stable under cryogenic
technology, the overall safety of the process is greatly improved conditions and in a NO atmosphere. Furthermore, nitrosation
due to the small reactor volumes and precise control of reaction with pure N2O3 is fast and highly exothermic, which limits its
conditions.32,77,78 Hazardous reactions or even reactions that are use both in laboratories and industry. Recently, Monbaliu et al.
impossible in conventional conditions can be carried out with developed a continuous-ow methodology for the synthesis and
relatively low risk in ow conditions, such as processes use of anhydrous N2O3 solution, minimizing the safety
involving toxic, reactive gases and explosive reagents. concerns associated with this toxic gas and exothermic reac-
It is understandable that the use of toxic and dangerous tions (Fig. 15).83 The anhydrous N2O3 solution (up to 1 M) was
gases is highly restricted in modern synthetic laboratories. In generated in a ow setup using NO and O2 streams as starting
order to perform gas-based transformations and achieve decent materials. A telescoped method was then developed to synthe-
results, dedicated high-pressure gas reactors with multiple size two types of N-heterocycles (i.e., benzotriazoles 15.1 and 3-
detectors are required. This is why the direct use of molecular substituted sydnones, >30 examples) in moderate to excellent
oxygen79,80 as a simple, green oxidant is discouraged in yield (54–99%).
conventional batch systems. However, Noël et al. developed Diazonium salts, which are typically unstable and generate
a simple, selective, and safe decatungstate-photocatalytic large volumes of nitrogen gas during synthetic transformations,
aerobic oxidation of C(sp3)–H bonds under ow conditions can be problematic to scale up in batch systems and raise many
(Fig. 14).81 The oxygen stream was delivered by a mass ow safety concerns. Chemists at Novartis have reported a scalable
controller (MFC) and merged with the liquid stream infused by and multi-step continuous-ow procedure for synthesizing 2H-
a syringe pump, delivering a uniform segmented ow regime in indazoles in which hazardous diazonium salt and azide
the continuous-ow photoreactor (PFA tubing, 750 mm I.D.). A
typical interfacial area from 3400 to 9000 m2 m−3 could be ob-
tained through Taylor recirculation patterns,82 leading to an
Fig. 14 Decatungstate-mediated C(sp3)–H oxidation with oxygen in Fig. 15 Continuous-flow setup for the generation of N2O3 and its
continuous flow. TBADT: Tetra-n-butylammonium decatungstate. subsequent use in synthetically-relevant contexts. CV: check valve;
Reproduced from ref. 81 with the permission of Wiley-VCH, copyright 6PV: six-position switch valve. MFC: Mass-Flow Controller. Repro-
2018. duced from ref. 83 with the permission of Wiley-VCH, copyright 2022.
4238 | Chem. Sci., 2023, 14, 4230–4247 © 2023 The Author(s). Published by the Royal Society of Chemistry
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from the enhanced mass and heat transfer of the ow system.
Kappe et al. reported a ve-step continuous ow process, facil-
itating this highly exothermic C-glycosylation (Fig. 17A).90
Before translating the reported reaction conditions to ow, they
Fig. 16 Continuous flow synthesis of indazole 16.5, involving a three-
repeated the reaction in batch to rule out the potential issues,
step synthetic sequence containing diazonium salts and azide
generation. TFA: trifluoroacetic acid. such as the formation of solids directly aer the addition of 1,2-
bis(chlorodimethylsilyl)ethane (BCDSE) in the rst step. The
precipitation was assumed to be the protonated by-product of
chemistries are safely handled on a 200 gram scale (Fig. 16).84 heterocycle 17.1 and its formation would lead to microreactor
The key intermediate, 2H-indazole 16.5, is used to synthesize clogging. The solid was indeed observed within approximately
compound 16.6, a highly potent and selective inhibitor for the 5 s at ambient temperature, leaving only a narrow window to
treatment of autoimmune disorders. The researchers initiated add a base for scavenging HCl. Such a short residence time can
the synthetic route with amino-aldehyde 16.1 and applied be easily achieved in ow. Through a careful analysis of the
a diazotization and azidation protocol using sodium nitrite with reaction sequence and precise control of the process parame-
triuoroacetic acid followed by a reaction with sodium azide at ters, the authors achieved a 60% yield of glycosylated product
17.3 at a moderate temperature (−30 °C) in a total residence
a lower temperature to obtain azide 16.3. Instead of isolating
the latter compound, the researchers obtained a 0.3 M solution time of only 8 s. A stable and scalable process was further
of azide in dichloroethane (91% yield and 14.1 g h−1 produc- demonstrated for 2 h (Fig. 17B), providing a throughput of 8.5 g
tivity). Aer further concentrating the azide solution to 0.45 M, h−1 (10.4 kg L−1 h−1 space-time yield) within a small reactor
a cyclization reaction was conducted with amine 16.4 through volume of only 0.815 mL. These results present the potential to
two 10 mL copper coils to afford 217 g of indazole 16.5 in 94% reach even higher production of the key glycosylated interme-
purity and 95% yield (86% total yield). 16.5 was then used diate 17.3 and remdesivir exploiting the general scale-up strat-
without additional purication in the subsequent steps to egies in ow, such as numbering up.
Numbering up is a common strategy in the scale-up of ow
obtain the target compound 16.6 in high quality and acceptable
yield. Notably, the continuous-ow procedures were suitable for chemistry because it enables the retention of the hydrodynamics
scale up with only minor modications, affording 16.5 on and transfer properties associated with the micro-environment
a kilogram scale. (e.g., mixing, heat transfer, irradiation efficiency). This allows
reactions to occur under conditions that are identical to those in
an individual microreactor. Kim and co-workers presented a scale-
8. Scalability up process of ultrafast sub-second chemistry to synthesize drug
scaffolds via 16 numbered-up printed metal microreactors (16N-
The use of ow chemistry in large-scale production has several
PMR).91 As previously mentioned, reactions with organolithium
advantages over traditional batch chemistry, among which an
reagents are fast and highly exothermic. To precisely control the
easier adaptation of laboratory-scale reactions to larger
lithiated intermediates, an optimal residence time of around 16
production scales without sacricing reaction performance.85,86
ms with a ow rate of 7.5 mL min−1 was used, which created
Two approaches can be followed for scaling up ow chemistry
a signicant pressure drop in the microreactor. To address this
reactions: numbering up and sizing up.54,87 Numbering up
issue, the authors developed a modied microreactor with a larger
involves increasing the number of channels in the microreactor,
circular channel diameter, reducing the pressure drop by 28 times
while sizing up involves increasing the length and/or diameter
under the same ow conditions (Fig. 18A). Aer simulating the
of the channels. These strategies can be described mathemati-
maldistribution factor of the internal bifurcation distributor
cally by the equation of the volume of the microreactor, where V,
(<1%), a monolithic 4N-PMR with a validated structure was
N, L, and D represent the volume of the reactor, the number of
fabricated, which was further demonstrated with ultrafast chem-
channels, the length of the channels, and the diameter of the
istry, giving yields of 84–99% of 12 products. To further scale up
channels, respectively.87
this type of chemistry, a 16N-PMR was assembled by connecting
p four 4N-PMRs and four external ow distributors with 1/8-inch
V¼ NLD2
4 tubes (Fig. 18B). The 16N-PMR module exhibited a high output
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Fig. 17 Continuous-flow process to generate remdesivir intermediates. LDA: lithium diisopropylamide. Reproduced from ref. 90 with the
permission of American Chemical Society, copyright 2021.
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and automation
By integrating high-throughput experimentation (HTE)106–109 allowing to produce a large dataset of 5760 reactions at a rate of
with process analytical technology (PAT),110–113 optimization of over 1500 samples per day.120
continuous-ow reactions can be done efficiently and with Stephenson and colleagues also developed a droplet-based
a wealth of data (Fig. 20). This integration results in fast data microuidic platform for ow-based HTE to generate pharma-
acquisition, closed-loop experimentation,114,115 and improved ceutically relevant compound libraries (Fig. 21).121 The platform
discovery and reproducibility of organic synthesis in ow, utilized an oscillatory ow photoreactor and electrospray
leading to data-driven or algorithm-driven autonomous ionization-mass spectrometry (ESI-MS) to analyse the reactions.
experimentation.116,117 With a throughput of 0.3 samples per second, ESI-MS detected
Batch-based HTE106,108,109,118,119 suffers from some limitations, 37 hit conditions, and seven of nine selected reactions were
such as a lack of pressure and temperature screening, the need successfully validated through product isolation. This droplet-
for non-volatile solvents, and the potential for cross- based method can quickly discover photochemical reactions
contamination. In contrast, Pzer researchers showed that and generate compound libraries in ow (e.g., 21.1–21.3).
ow-based HTE with two LC/MS instruments could be effec- More researchers have been exploring automated telescoped
tively handled to screen thousands of Pd-catalyzed Suzuki– multistep ow synthesis,111,122–128 with a common approach
Miyaura couplings under high pressure and temperature being to combine modular unit devices in a linear sequence,
conditions, by simply adding a back pressure regulator, known as “Lego-like synthesis”.122,129 The integration of process
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analytical technology (PAT) tools and advanced data analysis industry as a way to explore high-dimensional chemical space
models can further improve reaction understanding and and achieve optimal conditions with fewer experiments.107,130–136
acceleration of the optimization rate.111 There have also been There are three main types of algorithms applied for self-
reports of unique approaches, such as a radical synthesizer with optimization experimentation: local optimization algorithms
a central hub and access to individual reactors, enabling the such as design of experiments (DoE)137,138 and Nelder–Mead
storage of chemical intermediates and removing limitations simplex,139,140 global optimization algorithms like SNOBFIT141,142
from previous steps.128 Using this strategy, several analogues of and Bayesian Optimizations,114,130,143–145 and machine learning
runamide were prepared without the need for physical algorithms like deep reinforcement learning.146
reconguration of the system. Jensen et al. are pioneers in this growing eld, having
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Another approach combines solid-phase synthesis and developed various versions of automated continuous-ow plat-
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continuous-ow chemistry to perform automated multistep forms, including a fridge-size recongurable platform,147
synthesis of active pharmaceutical ingredients (APIs) a ‘plug-and-play’ platform,142 and a robotic platform.148 Their
(Fig. 22)124. In this method, starting materials are covalently most recent development is a bayesian optimization-driven
attached to a solid support and undergo growth through automated robotic ow platform that includes computer-
sequential treatment with different reagents, avoiding inter- aided synthesis planning (CASP),149 multi-objective optimiza-
mediate isolation and compatibility issues. A compact system tion and robotic-enhanced multistep synthesis (Fig. 23).150 To
design, including multi-position selection valves, pumps, and demonstrate the power of this platform, the authors selected
a stainless-steel column reactor, was able to perform a six-step a high-ranked synthetic pathway for the molecule sonidegib
synthesis of prexasertib with a 65% isolated yield in 32 hours 23.4 using open-source CASP soware (ASKCOS) and manual
of continuous execution. The procedures were converted to assessment of synthetic feasibility. This pathway was then
a computerized chemical recipe le (CRF) and successfully used optimized on a modular platform that included a fast-moving 4-
for the synthesis of 23 prexasertib analogues with moderate to axis gantry robot, two types of reactors (heated and packed bed),
good yields (e.g., 22.1–22.6, 49–70%). and three analytical modules (inline FT-IR, LC-MS, HPLC). Five
Besides the use of human intervention to rene the auto- optimization variables (two categorical parameters, i.e. activa-
mated continuous-ow platforms, algorithm-driven optimiza- tion reagent and coupling reactor volume, and three continuous
tion has gained signicant attention in both academia and parameters, i.e. activation time, 23.1 : 23.3 ratio and coupling
Fig. 22 Schematic representation of an automated SPS-flow synthesis of prexasertib and derivatives. LDA: lithium diisopropylamide. Repro-
duced from ref. 124 with the permission of Springer Nature, copyright 2021.
4242 | Chem. Sci., 2023, 14, 4230–4247 © 2023 The Author(s). Published by the Royal Society of Chemistry
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Fig. 23 Overall approach for bayesian optimization algorithm-driven multistep-synthesis of Sonidegib on an automated robotic platform.
DIPEA: N,N-diisopropylethylamine, HATU: hexafluorophosphate azabenzotriazole tetramethyl uronium. Reproduced from ref. 150 with the
permission of American Chemical Society, copyright 2022.
temperature) and two objective functions (yield and produc- overlooked by the community. However, as shown in this
tivity of sonidegib) were considered in a multiple-step campaign review, ow chemistry is packed with perks that can push the
using the bayesian optimization algorithm. In just 15 total boundaries and unleash unique reactivity and selectivity in
experiments over a 13 hours period (8 initialization and 7 synthetic organic chemistry. Flow reactors not only make new
renement runs), the algorithm identied the optimal condi- synthetic routes a reality, they fast-track them from lab to large
tions with simultaneous high yields and productivities of the scale production. And, as ow chemists master both chemical
product (93% yield, 7.4 g h−1), showcasing the potential for and engineering principles, they become valuable links between
machine learning, automation, and robotics to enhance lab discovery and production engineering.
manual experimentation. With this review showcasing how ow chemistry can team up
Finally, the integration of automated and ow-based high- with methodological development, we aimed to provide a helpful
throughput experimentation (HTE) platforms enables fast and eld guide for those eager to dive in. And with the continued
large-scale data generation, opening the door to data-driven growth of interest in ow chemistry, we expect even more explo-
techniques151–154 for discovering valuable reactivity insights ration and optimization of synthetic organic chemistry. We believe
and exploring novel synthesis strategies. Contributing to the ow technology will become a must-have in every chemical lab and
open reaction database155 or following the FAIR principles156 in be just as familiar as the classic round-bottom ask.
data sharing will further facilitate the integration of data
science in organic synthesis. As the eld continues to evolve, it
holds signicant potential for closed-loop experimentation and
Data availability
full autonomy in synthesis operations. The most common hurdles to enter the eld of ow chemistry
and an overview of essential accessories are provided in the
ESI.†
10. Conclusions
Synthetic chemistry has been a major player in discovering new Author contributions
medicines, materials, and ne chemicals. While the primary
focus of synthetic chemists has always been on the development L. C. and Z. W. wrote the review and contributed equally. The
of new reactivity concepts, the reactor has systematically been concept and the editing of this review was done by T. N.
© 2023 The Author(s). Published by the Royal Society of Chemistry Chem. Sci., 2023, 14, 4230–4247 | 4243
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program under the Marie S. Curie Grant Agreement (L. C.: HAT-
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