FLOW CHEMISTRY
Advanced-Flow manufacturing of chemicals and APIs
Dr Yi Jiang of Corning shares some case studies
The continuous manufacturing of chemicals and APIs represents a paradigm shift in the production of essential compounds. Traditional batch processing, while still prevalent, is increasingly being replaced or supplemented by continuous flow processing methods.
This shift is driven by the need for greater efficiency, sustainability, precision and the inherent safety of the continuous flow system, especially in industries with stringent quality and regulatory requirements such as pharmaceuticals. A key enabler of this transition to continuous manufacturing is the use of flow reactors such as Corning Advanced-Flow Reactors( AFR).
Advantages of continuous
In batch processing, reactions and processes are carried out in predefined steps. Conversely, continuous processing methods operate in a steady state, allowing raw materials to be introduced, processed and transformed into the desired products in an ongoing flow. Flow offers several advantages including:
• Enhanced efficiency: Continuous processes are inherently faster, minimising time-consuming startup and shut-down phases
• Scalability: Processes can be scaled up through a combination of approaches including the seamless scale-up of single reactor unit and / or utilising several of the same reactor units in parallel. Both processes help eliminate the need for complex pilot tests and redesigns
Sulfonation Substitution
Salt formation
Polymerisation Photochlorination
Oxidation 11 %
Inside Corning ' s AFPT lab
Others 14 %
Bromination
Acyl chlorine Addito
I
Nitration 29 %
Butyl lithium 4 % Chlorination
4 % Cyclization 4 %
Diazotisation 6 %
Esterifaction 4 %
Fluorination 4 %
Hydrogenation 5 %
Neutraliztion
Figure 1- Corning industrial installations by chemistries
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