In the early 1990s, Manz and colleagues introduced the concept of a micro-analysis system. By 1995, they had reported the first use of microfluidic technology for chemical synthesis. Since then, this technique has been successfully applied in numerous significant organic reactions, outperforming traditional large-scale methods and showing great potential for unique and broad applications. As materials science, manufacturing techniques, and micro-mixing technologies advanced, microfluidic technology became a key area of research in organic chemistry.
According to the widely accepted definition of microsystems, microreactors are small reaction systems created using micromachining and precision engineering. The microchannels within these reactors typically range from 10 to 300 micrometers in size. When chemical synthesis is carried out in such a reactor, it is referred to as microfluidic synthesis. Compared to conventional reactors, microfluidic synthesis offers several advantages:
First, it provides high heat and mass transfer efficiency. The specific surface area of the reactor can reach up to 1.0×10^2 to 1.0×10^3 m²/m³, while the reactor itself may have a surface area as high as 1.0×10^4 to 5.0×10^4 m²/m³. This leads to a heat transfer rate of up to 1.0×10^4 W/m²/K, which is significantly higher than that of conventional systems. Due to the small size, the diffusion distance of materials is minimal, and since the diffusion coefficient is inversely proportional to the square of the distance, mixing occurs very rapidly inside the microreactor.
Second, microfluidic synthesis allows for more precise control over reaction parameters, making it safer. The fast heat transfer enables accurate regulation of temperature and reaction time. Adjusting the flow rate can easily modify the reaction duration. Additionally, because only small amounts of reagents are used, the risk associated with toxic substances, high temperatures, or explosive reactions is greatly reduced. This makes microreactors ideal for studying hazardous processes.
Third, the technology enhances reaction efficiency. High heat transfer allows for better temperature control during both high and low-temperature reactions, reducing the need for extreme conditions. It also shortens reaction times significantly. For highly exothermic reactions, heat can be quickly dissipated, preventing hot spots and minimizing side reactions, thus improving product selectivity, yield, and purity.
Fourth, microfluidic synthesis is environmentally friendly. The use of smaller quantities of reactants and solvents reduces the amount of waste generated, making it an excellent platform for green chemistry development.
Fifth, it supports real-time monitoring. The volume of product produced in a microreactor is similar to the injection volume of modern analytical instruments, allowing direct online analysis of the reaction progress.
Sixth, it accelerates scientific research. Microreactors generate a large amount of data per unit volume and time. Combined with parallel and series integration technologies, they make the screening of new compounds and drugs more efficient, lowering costs and shortening research timelines.
Seventh, post-reaction processing is simpler. For instance, when using an immobilized catalyst microreactor, the product exits the reactor without additional treatment and can be easily separated from the catalyst, unlike in traditional setups where filtration is required.
Microreactors have had a major impact on organic synthesis and chemical processes. Their ability to reduce the use of toxic and expensive reagents, along with lower pollution levels, makes them ideal for exploring reaction conditions and advancing green chemistry. Moreover, the reduced risk of dangerous reactions makes them particularly useful for studying hazardous processes.
As microfluidic synthesis continues to evolve, more chemical companies are likely to adopt this advanced technology to replace outdated and inefficient production methods.
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