A Continuous Hydrogenation Reactor Based on a Powdered Catalyst Enmeshed in an Expanded Poly(tetrafluoroethylene) Matrix

IF 3.1 3区化学 Q2 CHEMISTRY, APPLIED

Organic Process Research & Development Pub Date : 2025-01-14 DOI:10.1021/acs.oprd.4c00303

Sean Breen, Purnima Barua, Yuan-Qing Fang, David D. Ford, Ali Hasan, Manish Joshi, Sara Mason, Kevin D. Nagy, Sifat bin Quadery, Grace Russell, Vladimiros Nikolakis, John D. Holcombe, Andrea Adamo, Lorenzo Milani

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Abstract

Fixed bed catalytic reactors are commonly used for hydrogenation in the commodity chemical industry, but adoption in the pharmaceutical industry has been limited by the lack of available catalyst pellets in sizes suitable both for process research and development at scales of 1–50 g substrate per experiment and also for to manufacturing at the metric ton scale. Herein, we describe an approach for continuous flow hydrogenation using catalytic cartridges of powdered catalysts (palladium on carbon in this example) enmeshed in an expanded poly(tetrafluoroethylene) (ePTFE) matrix. Using a modular design, the catalytic layers and supplemental components can be arranged to suit specific reaction conditions, desired results, and throughput. The reactor was demonstrated with three classes of hydrogenation reactions: nitro reduction, debenzylation, and alkene reduction. All substrates could achieve high or full conversion after optimization. The study also includes longevity experiments to understand the long-term reliability of the reactor as well as preliminary results for scaling up to a larger membrane size. The results make this technology promising for scale-up opportunities by using the same modular design.

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基于扩展聚四氟乙烯基质的粉末催化剂连续加氢反应器

固定床催化反应器通常用于商品化学工业的加氢，但在制药工业的采用受到限制，因为缺乏适用于每个实验1-50克底物规模的工艺研究和开发以及以公吨规模生产的可用催化剂颗粒。在这里，我们描述了一种连续流动加氢的方法，使用粉末状催化剂（在本例中为碳上钯）的催化盒包裹在膨胀的聚四氟乙烯（ePTFE）基质中。采用模块化设计，可以安排催化层和补充组件，以适应特定的反应条件，期望的结果和吞吐量。反应器用三种类型的加氢反应进行了演示：硝基还原、脱苯和烯烃还原。经优化后，所有基板均可实现高转化率或全转化率。该研究还包括寿命实验，以了解反应器的长期可靠性，以及扩大膜尺寸的初步结果。结果表明，通过使用相同的模块化设计，该技术有望扩大规模。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Organic Process Research & Development 化学-应用化学

CiteScore

6.90

自引率

14.70%

发文量

251

审稿时长

2 months

期刊介绍： The journal Organic Process Research & Development serves as a communication tool between industrial chemists and chemists working in universities and research institutes. As such, it reports original work from the broad field of industrial process chemistry but also presents academic results that are relevant, or potentially relevant, to industrial applications. Process chemistry is the science that enables the safe, environmentally benign and ultimately economical manufacturing of organic compounds that are required in larger amounts to help address the needs of society. Consequently, the Journal encompasses every aspect of organic chemistry, including all aspects of catalysis, synthetic methodology development and synthetic strategy exploration, but also includes aspects from analytical and solid-state chemistry and chemical engineering, such as work-up tools，process safety, or flow-chemistry. The goal of development and optimization of chemical reactions and processes is their transfer to a larger scale; original work describing such studies and the actual implementation on scale is highly relevant to the journal. However, studies on new developments from either industry, research institutes or academia that have not yet been demonstrated on scale, but where an industrial utility can be expected and where the study has addressed important prerequisites for a scale-up and has given confidence into the reliability and practicality of the chemistry, also serve the mission of OPR&D as a communication tool between the different contributors to the field.