With the growing use of flow chemistry at process scale, the demand for micro-scale reaction chemistry has afforded new approaches for R&D chemists. Flow chemistry is a process of performing chemical reactions through a continuous feed of chemicals. Traditional methods typically rely on batch production recipes that employ parallel chemical synthesizers or lab reactors.

In flow chemistry, reactions take place in tubes or microfluidic chips. Different streams of chemicals are channeled into the system using a syringe pump or a high-end pumping module. The chemical reactions are controlled by adjusting the flow rate of the chemical streams to achieve the desired concentration levels, which can then be precisely heated for a set amount of time.

One of the biggest advantages of flow chemistry systems is that they typically produce higher product yields. As a result, chemical synthesis can be performed on a smaller scale using less starting materials. In addition, reactions tend to be faster than batch processes, allowing for quick reaction optimization and easy scale-up method development.

UK-based Syrris offers several flow chemistry systems, ranging from manual to fully automated systems complete with HPLC analysis. Its Asia Series systems can be configured for manual operation or automated for single or multiple flow experiments. The Asia systems are designed for synthesis, rapid optimization and scale-up production for yielding milligram to kilogram quantities of product. The company also manufactures the Africa Series, which is designed for discovery and process development. The Africa system is a fully automated system that employs microfluidics technology as the microreactor.

Other flow chemistry suppliers include Uniqsis and FutureChemistry. Based in the UK, Uniqsis is an alliance between Asynt and Grant Instruments. It manufactures the FlowSyn system, a compact integrated continuous flow reactor. The FlowSyn employs two high pressure pumps that deliver reagents via a mixer into electrically heated or cooled flow reactors. Back pressure regulators are used to pressurize the system to allow solvents to be superheated.

FutureChemistry offers the FlowStart Evo, an integrated manual system, and the fully automated FlowExpert. Both systems utilize microfluidic chips from Micronit and are capable of producing milligram to gram quantities of product per day.

Flow chemistry is not new to the chemicals and petrochemical industries, particularly for process-scale applications. However, the use of flow microreactors has now also become an important part of biopharmaceutical development.

The total market for flow chemistry microreactors is estimated at about $5 million and offers significant promise as the technology improves and matures.

Flow Chemistry Microreactors

at a Glance:

Leading Suppliers

• Syrris

• Uniqsis

• FutureChemistry

Largest Markets

• Pharmaceutical

• Chemical

• Biotechnology

Instrument Cost

• $5,000–$20,000