Continuous-Flow Synthesis of Methyl Sulfone with Microchannel Reactors: A Safer and Efficient Production Strategy

IF 3.1 3区化学 Q2 CHEMISTRY, APPLIED

Organic Process Research & Development Pub Date : 2023-07-13 DOI:10.1021/acs.oprd.3c00106

Zhiquan Chen, Jian Liu, Lei Ni*, Juncheng Jiang*, Yuan Yu and Yong Pan,

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Abstract

The traditional batch production process for methyl sulfone (MSM) from dimethyl sulfoxide (DMSO) is highly exothermic and poses serious safety risks. In this work, we present a continuous-flow synthesis strategy using microchannel reactors to enhance the safety and efficiency of industrial-scale MSM production. Four specifications of microchannel reactors have been constructed and then were applied for the continuous-flow synthesis of MSM with both high yield and purity. The effects of the channel diameter, water bath temperature, catalytic dosage, residence time, and segmented temperature control on MSM yield were systematically investigated. By gradually optimizing the design parameters, the yield of MSM in the industrialized microchannel reactor reached 95.3%, and the average annual time yield of MSM was 18.36 t·a^–1. In addition, the maximum overlimit temperature in the continuous flow does not exceed 10 °C, and the overtemperature time is less than 20 s. Dual temperature-controlled continuous-flow process was more beneficial to increase the yield of MSM. The microchannel continuous-flow amplification process can greatly improve the productivity of MSM while ensuring the high yield of MSM, which is a promising strategy for the efficient and safe production of MSM at an industrial scale.

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微通道反应器连续流合成甲基砜:一种安全高效的生产策略

传统的二甲亚砜(DMSO)批量生产甲基砜(MSM)的工艺是高放热的，存在严重的安全隐患。在这项工作中，我们提出了一种使用微通道反应器的连续流合成策略，以提高工业规模MSM生产的安全性和效率。构建了四种规格的微通道反应器，并将其应用于连续流合成高收率、高纯度的MSM。系统考察了通道直径、水浴温度、催化用量、停留时间和分段温度控制对MSM收率的影响。通过对设计参数的逐步优化，工业化微通道反应器中MSM的产率达到95.3%，MSM年平均时间产率为18.36 t·a-1。另外，连续流中最高超温不超过10℃，超温时间小于20 s。双温控连续流工艺更有利于提高MSM的收率。微通道连续流放大工艺可以在保证高成品率的同时，大大提高MSM的生产效率，是实现MSM工业化高效、安全生产的一种很有前景的策略。

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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.