In the early 1990s, Manz and colleagues introduced the concept of a micro-analysis system. By 1995, they had reported the use of microfluidic technology for chemical synthesis, marking the beginning of a new era in reaction engineering. Since then, this technology has been successfully applied to numerous important organic reactions, offering significant advantages over traditional macro-scale methods. With its unique capabilities, microfluidic technology has shown great potential and is now a growing focus in the field of organic chemistry.
Microreactors, as defined by the widely accepted concept of microsystems, are small-scale reaction systems created using micromachining and precision manufacturing techniques. The channels within these reactors typically have dimensions ranging from 10 to 300 micrometers. When chemical synthesis is performed in such a reactor, it is referred to as microfluidic synthesis. Compared to conventional reactors, microfluidic synthesis offers several key benefits.
First, microfluidic systems exhibit high heat and mass transfer efficiency. The surface area-to-volume ratio of a microreactor is significantly larger—up to 1.0×10^4 to 5.0×10^4 m²/m³—compared to just 1.0×10² to 1.0×10³ m²/m³ in traditional systems. This leads to faster heat conduction, with rates reaching up to 1.0×10^4 W/m²/K. The small size also reduces the diffusion distance of reactants, allowing for rapid mixing due to the inverse relationship between diffusion coefficient and the square of the diffusion distance.
Second, microfluidic synthesis allows for more precise control of reaction parameters. The fast heat transfer enables accurate regulation of temperature and reaction time, which can be adjusted by changing the flow rate. Additionally, the small quantity of reagents used minimizes the risk of hazardous conditions, such as high pressure, high temperature, or explosive reactions. This makes microreactors ideal for studying dangerous or sensitive chemical processes.
Third, the efficiency of the reaction is greatly improved. High heat transfer allows for better temperature control, reducing side reactions and increasing product selectivity, yield, and purity. For exothermic reactions, the heat can be quickly dissipated, preventing hot spots and improving safety.
Fourth, microfluidic synthesis is more environmentally friendly. The reduced use of toxic and expensive reagents and solvents lowers waste production, making it an attractive option for sustainable chemistry.
Fifth, online monitoring becomes easier with microreactors. The small volume of products produced matches the injection volume of modern analytical instruments, enabling real-time reaction monitoring.
Sixth, the research and development cycle is shortened. Microreactors generate large amounts of data in a short time, and their integration with other analytical tools enhances screening efficiency for new compounds and drug development.
Lastly, post-reaction processing is simplified. In cases where immobilized catalysts are used, the product can be easily separated from the catalyst without additional steps, unlike in conventional reactors that require filtration.
Overall, microreactors have transformed organic synthesis and chemical processes. Their ability to reduce reagent usage, minimize environmental impact, and improve safety makes them particularly suitable for exploring reaction conditions and advancing green chemistry. As microfluidic synthesis continues to evolve, more chemical companies are expected to adopt this innovative technology to replace outdated and inefficient production methods.
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