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Continuous processing for challenging reactions, improved process control, and safer scale-up.

Flow Chemistry

BioDuro develops flow chemistry approaches for reactions that can benefit from continuous processing. By improving heat and mass transfer and reducing the amount of reactive material present at one time, flow systems can provide greater control for demanding chemistries and support more consistent scale-up.

Capabilities include microchannel, plug-flow, and continuous stirred-tank reactor technologies, with applications across high-temperature, high-pressure, photochemical, and other specialized reaction conditions.

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Why Flow Chemistry?

For the right chemistry, continuous processing can offer practical advantages over conventional batch methods.

Improved Heat & Material Transfer

Efficient heat and mass transfer can improve reaction performance while supporting better selectivity and impurity-profile control.

Greater Consistency

Continuous processing can reduce some of the challenges associated with increasing batch size, helping maintain more consistent reaction conditions as quantities increase.

Enhanced Safety

Smaller reaction volumes can reduce the amount of hazardous or highly reactive material present in the system at one time.

Reduced Waste

Flow processes can use materials more efficiently and, for suitable reactions, reduce waste compared with conventional approaches.

Representative Applications

Flow chemistry can be applied to a variety of reaction types that may be difficult to execute using traditional batch approaches.

  • Dehydration reactions involving strong acids
  • Photochemical reactions under different light sources
  • Azide chemistry using sodium azide
  • TEMPO oxidation in NaClO solutions
  • High-temperature elimination and solvent-free reactions
  • Ion coupling under cryogenic conditions
  • High-temperature and high-pressure amination
  • Generation of unstable formate and zinc reagents
  • High-temperature decarboxylation reactions

Reactor Technologies

Different reactor configurations can be selected based on process requirements and reaction characteristics.

Microchannel Reactor

Provides efficient mixing and heat transfer in a small reaction volume, making it useful for reactions where rapid and precise control is important.

Plug Flow Reactor (PFR)

Provides controlled residence time as reagents move continuously through the reactor, supporting stable and reproducible processing conditions.

Continuous Stirred Tank Reactor (CSTR)

Provides continuous mixing and processing for reactions that benefit from a well-mixed reaction environment.

Designed for Demanding Reaction Conditions

Continuous processing can be particularly useful when reaction conditions are difficult to manage in conventional batch equipment.

BioDuro’s flow chemistry capabilities can support reactions involving:

  • High temperatures
  • High pressures
  • Cryogenic conditions
  • Photochemistry
  • Short-lived intermediates
  • Reactive or unstable compounds

These capabilities can provide greater control and consistency when working under demanding reaction conditions.

From Flow Development to Scale-Up

Flow chemistry can be incorporated into broader Process R&D programs when it provides a practical advantage for the route. BioDuro’s process chemistry teams can evaluate the reaction, select an appropriate reactor approach, and develop conditions with later-scale requirements in mind.

As the process advances, flow development can connect with BioDuro’s broader process development, analytical, safety, and manufacturing capabilities.

Flow Chemistry Resources

Explore case studies, technical content, and scientific insights covering continuous processing, reaction engineering, process optimization, and flow chemistry applications for challenging synthetic transformations.

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Enabling challenging reactions through flow chemistry
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Enabling Challenging Reactions through Flow Chemistry

BioDuro provides versatile flow chemistry solutions to support efficient route development and scale-up....

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