Catalytic static mixers were used for the continuous flow hydrogenation of alkenes, alkynes, carbonyls, nitro-and diazo-compounds, nitriles, imines, and halides. This technique relies on tubular reactors fitted with 3D printed static mixers which are coated with a catalytic metal layer, either Pd or Ni. Additive manufacturing of the metal mixer scaffold results in maximum design flexibility and is compatible with deposition methods such as metal cold spraying which allow for mass production and linear process scale up. High to full conversion was achieved for the majority of substrates, demonstrating the flexibility and versatility of the catalytic static mixer technology. In the example of an alkyne reduction, the selectivity of the flow reactor could be directed to either yield an alkene or alkane product by simply changing the reactor pressure.

Catalytic static mixers (CSMs) were used for the efficient preparation of a key intermediate of the antimicrobial drug linezolid (Zyvox). The approach combines 3D printing and additive manufacturing techniques with continuous flow processing to produce a general method for catalytic hydrogenations and the rapid production of the target molecule without the need for catalyst removal or recovery.

No abstract

This work describes a multi-stage continuous flow polymerisation process for the synthesis of block copolymers using the RAFT polymerization method. The process retains all the benefits and versatility of the RAFT method and has been adapted for a series of monomer combinations, including acrylates, acrylamides, and vinyl monomers. It resulted in polymers with molecular weights between 13500 and 34100 g mol–1, and dispersities typically between 1.21 and 1.58. Different architectures were prepared (including combinations of hydrophilic and hydrophobic blocks) which are soluble in a range of different solvents including aqueous and organic media.