FLOW CHEMISTRY
After the G 1
, Corning continued to build out its product lines , addressing applications at various scales in pharma and fine chemical manufacturing . All of these products incorporate the integrated fluidic module and engineered reactor plate , typically made of speciality glass , which allows for rapid scaleup from lab scale to commercial production , as well as improved heat transfer , mass transfer and mixing . Given the wider breadth of products developed over time , the business ’ s name changed from microreactors to Advanced-Flow Reactors ( AFRs ) in 2009 .
Scaling for industrial needs
In addition to lab- and process development-based reactors , largercapacity reactors were needed for industrial-scale facilities . In 2011 , the company developed and commercialised higher-throughput reactor models , collaborating with manufacturers to demonstrate the improved specifications .
The G4 reactor accommodates hightemperature caustic applications and reactions involving fluorine gas and hydrofluoric acid by making the fluidic modules out of durable silicon carbide ( SiC ). This gives superior corrosion resistance and product versatility , leading to higher throughput while maintaining excellent heat transfer and mixing performance .
In 2015 , Corning worked with Medichem to demonstrate commercial scale continuous-flow production of APIs using the G4 . In 2020 , the company launched its G5 reactor for larger-scale production . That same year , Zhejiang Weihua New Materials , in collaboration with Corning Advanced- Flow Reactor Technology and Shanghai Hybrid-Chem Technology , achieved a 10,000 tonnes / year throughput of agrochemicals using the G5 .
AFR technology is an inherently safer technology than traditional batch chemical processing and can drive higher-quality chemical processing . Additional benefits include energy savings , increased efficiency of chemical synthesis , lower production costs and reduced environmental impact . To date , it has been used in various hazardous chemical and photochemical reactions , including nitration , chlorination , hydrogenation , diazotisation , fluorination , bromination and oxidation .
Recent developments
To build awareness of continuous flow technology amongst the next generation of chemical engineers and chemists , the AFR team launched the Corning Advanced- Flow Technology Academy in Changzhou , China to deliver interactive live training on the company ’ s flow chemistry education platform , the Corning Nebula Education Kits .
Since 2021 , more than 500 students have attended live demonstration classes offered by the academy . The company also works with academic institutions and customers to offer flow chemistry-based trainings and access to demonstrations , experimental trials , feasibility testing and chemical reaction process development through a global network of established AFR Application Qualified Labs .
Most recently , in April 2023 , at CPHI North America in Philadelphia , the AFR team launched a servicesoriented entity called Corning Advanced Flow Pharmaceutical Technology ( AFPT ). This entity was also showcased at CPHI China in June . The launch of this new entity builds on more than two decades of experience in continuous flow manufacturing that have seen over 800 equipment installations worldwide . ●
Dr Yi Jiang
DIVISION VP
CORNING , INC .
J j jiangy @ corning . com www . corning . com / reactors
G4 ( left ) & G1 ( right ) reactors
48 SPECIALITY CHEMICALS MAGAZINE ESTABLISHED 1981