Research and developmentBusiness content

Continuous flow synthetic technology

Continuous-flow synthesis is a chemical synthetic method in which raw materials are mixed and reacted by being continuously supplied to a tubular reactor. It has been attracting attention as an environment-friendly and sustainable manufacturing process that saves more energy than a conventional batch-type synthesis.

In addition, many advantages can be expected to it in the synthetic field of APIs and its intermediates, such as handling dangerous materials or higher toxic substances more easily, controlling reactions precisely, and higher productivity than batch type synthesis.

Our company has been applying the so-called five fundamental reactions such as oxidation reactions, reduction reactions and esterification reactions, etc. to flow method. To achieve to adapt them to flow synthesis, new technologies such as fixed catalysis or photoreaction etc are actively incorporated and we are taking full advantages of flow synthesis technology for the synthesis of APIs and its intermediates. Additionally, to make our flow technology development accelerated, we are doing not only in-house R&D, but also being actively engaged in joint research with universities etc. and we are making effort to go for early commercialization of continuous flow synthesis.

Equipment

Pumps and Reactors

Pump (syringe pump, plunger pump, diaphragm pump)
Catalyst packed column (5×100 mm、10×100 mm、10×250 mm、20×300 mm)
Coil Reactor
(φ1/8~1/4 inches×500~2000 cm(SUS)、φ1/8~3/8 inches×400 cm(HC)
Photoreactors
Mass flow meter (H₂ gas, O₂ gas)
H₂ gas generator
Mixer (Static Mixer etc.)

Purification Equipment

Liquid-liquid separator
Continuous stirred-tank reactor (CSTR)

Analysis Equipment

PAT(Process Analytical Technology) Equipment (FlowIR、FBRM、PVM)

Continuous Flow Technology

Example 1 - Continuous Hydrogenation

We have developed novel metal catalysts that show high productivity in continuous hydrogenation of nitro groups to apply it to continuous-flow synthesis. We were able to dramatically improve higher reaction efficiency than conventional commercially available metal catalysts. We can develop high-performance catalysts to meet the customers’ request.

Example 2 - Regioselective Photo Bromination

We have developed highly-regioselective photo bromination of benzyl position with high yield and high productivity by precisely controlling the bromination of benzyl position and aromatic ring in a flow reactor under photo irradiation.

Continuous Flow Technology Implementation Example

Kilo-Lab

We have implemented a Hastelloy coil reactor that can be utilized in high-temperature or high-pressure reactions. In some projects, its productivity can be reached to several tons per year.

Catalyst Life-Time Evaluation Equipment

Catalyst Life-Time Evaluation Equipment has been implemented in our lab to evaluate the immobilized catalyst for continuous flow synthesis. Every equipment is centrally controlled from a computer, and it is possible to evaluate the life time of catalysts in reaction condition with hydrogen gas under 24 hours/365 days unmanned surveillance.

Catalyst Life-Time Evaluation Equipment (Photo)