Webinars | Advanced-Flow Reactors | Corning

Recorded Webinars

• #1: Stepping into Corning® Advanced-Flow™ Reactor Technology: An Industrial Overview

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  Presenter: Dr. Guillaume Gauron

  What is flow chemistry? What are the advantages of running processes in a continuous way? How does Corning technology apply to it? This webinar focuses on several cases of flow chemistry applications that have been seamlessly transferred from lab scale directly to industrial production.

• #2: How to Analyse your Batch Process Data to Transition from Batch to Flow

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  Presenter: Dr. Philippe Roth

  Processes can be “translated” from traditional batch recipes to flow, or developed from scratch in flow. This course aims to help you apply the knowledge you have acquired in batch chemistry to get insight into flow chemistry. We’ll see how to analyse batch processing data in order to successfully transition from batch to flow and how to avoid common mistakes.

• #3: Making the Switch to Flow Chemistry: How to decide if implementing flow chemistry is feasible for your process.

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  Presenter: Mr. Marc Winter

  What are the ideal conditions and hurdles to move to flow chemistry? The benefits of microreactors and flow chemistry have been demonstrated across the chemical manufacturing industry for a variety of processes, but not every process is a good candidate.
  
  Watch this webinar to identify the potential benefits of switching to flow chemistry and gather general advice and hints that will help you decide if flow chemistry would be a good fit for your process.

• #4: How to Leverage Corning® Advanced-Flow™ Reactor Technology for Photochemistry Applications

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  Presenter: Dr. Philippe Roth

  Due to its interaction with matter, ultraviolet (UV) light can trigger specific reactions and open new routes. Photochemistry is a powerful tool but is often underused by scientists. However, with the improvement of global photochemistry technologies and increased adoption of flow chemistry, new options have emerged. This course highlights the key parameters to look at while performing photochemistry using Advanced-Flow Reactor Technology.

• #5: Necessary Equipment to Run a Continuous Flow Reactor: Upstream equipment

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  Presenter: Dr. Ancuta Musina

  Corning® Advanced-Flow™ Reactors have been designed to maximize mixing and heat transfer. Consistent and pulseless flow is a key parameter for flow chemistry as any fluctuation in the flow of the chemical can cause the final product to drift out of tolerance. Therefore the selection of appropriate dosing pumps is paramount for a successful continuous-flow process. In the same time, to benefit of the reactor's heat transfer efficiency, the choice of the heat exchange unit is very important. Watch this webinar to learn how to pair material dosing lines (e.g., pumps, flow meters) and temperature controllers (e.g., chillers, heat exchangers) with your continuous flow reactor.

• #6: Corning AFR Qualified Lab work – Citos - Reactions with molecular oxygen: from the preparation of active pharmaceuticals to the neutralization of chemical warfare agents

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  Presenter: Dr. Jean-Christophe Monbaliu

  This webinar illustrates the rationale behind the development of continuous flow processes relying on molecular oxygen. The use of oxygen for large scale preparative applications is often seen as challenging in organic chemistry both for safety and practical issues. The direct use of molecular oxygen will be illustrated for the preparation of value-added intermediates for pharmaceutical production or other high-end applications. The generation and use of much more reactive oxygenated species, such as singlet oxygen, will be documented as well for preparative chemistry and for the oxidative destruction of chemical warfare agents. Such applications rely on the synergistic combination of light, an organic photosensitizer and ground state molecular oxygen. 

• #7: Stepping into Corning® Advanced-Flow™ Reactors: Application in Material Sciences via Nanoparticles Synthesis

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  Presenter: Dr. Philippe Roth

  Emerging as a mega-trend and shaping the world in a new way, nanoparticles are everywhere. The ability to synthesize them remains challenging and requires extreme precision. As flow chemistry is a powerful tool for synthesis, it can offer a different way of thinking and synthesizing nanoparticles. This talk shows through different examples the impact flow chemistry can have on the field.

• #8: Optimization and Seamless Scale-up in Corning® Advanced-Flow™ Reactors

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  Presenter: Mr. Marc Winter

  Corning AFR Technology has been designed to help the chemical and pharma industries optimize their processes and speed up their time to market. The great R&D work performed by Corning experts leads to a flow chemistry technology which is not only scalable but enables seamless scale-up.
  
  This webinar presents some of the innovation developed and how this enables customers from around the world to move to production inherently safer and quicker while keeping high quality standards. Through examples and case studies we discuss how achieving production scale is possible as well as process design optimization.

• #9: Considerations in Scaling Photochemistry – Case Studies from the CC FLOW Labs

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  Presenter: Dr. Jason Williams

  Photochemistry holds significant promise in organic synthesis, with the dissemination of a large number of new methodologies. As a result, there will be increasing pressure on process development chemists in coming years, to scale up photochemistry-containing routes developed on smaller scale. Continuous flow processing has a key role to play as an enabling technology, but comes with additional complexities. This webinar shows case studies from the CC FLOW labs, discussing the scale-up considerations for a range of photochemical processes.

• #10: Corning® Advanced-Flow™ Reactors Portfolio and Services – focused on customer-driven innovation

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  Presenter: Dr. Guillaume Gauron

  Corning has a long track-record of innovation spanning our 170-year history, with materials science at our core. For more than 17 years, Corning has developed and evolved its AFR technology to help meet customer requirements. From the lab to multi-ton production scale, to reactors and auxiliaries; from academic collaboration to customer training and technical support, Corning AFR is committed to delivering high quality products and unparalleled support to our customers. This webinar gives more insight into our portfolio of equipment and related services.

• #11: Corning AFR Qualified Lab work – Citos: Handling toxic and unstable intermediates. The optimum chemistry with the right technology.

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  Presenters:
  Dr. Andrea Adamo, Zaiput Flow Technologies
  Trevor Murray, Zaiput Flow Technologies
  Dr. Jean-Christophe Monbaliu, University of Liège
  Dr. Guillaume Gauron, Corning Reactor Technologies

  Flow chemistry provides a rather broad set of advantages that range from process robustness, ease of scale up, to access otherwise very challenging reaction conditions. Harvesting the full benefits of flow chemistry requires in-line work-up capabilities integrated within the flow process. In this talk, we highlight how in-line continuous and scalable liquid-liquid extraction provided by the Zaiput’s line of separators aids in a full continuous process integration which provides safe operation in a compact foot print. Specifically, the minimal internal volume, lack of head space and inherently safe continuous operation of the separators, provide a valuable tool to process hazardous materials. Further, the  scalability of the technology provides a straightforward path to the production of larger quantities of material. Among different examples, we will highlight a recently published case where flow reactions and workups are utilized to manage the reactivity and toxicity of α-chloronitroso derivatives in various conditions.

• #12: Continuous Manufacturing of Nanostructured Materials in a Corning® Advanced-Flow™ Reactor

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  Guest Presenter: Dr. Kejun Wu, Zhejiang University 

  A lot of promising nanostructured materials (NM) technologies never reach the market due to issues with the scaling-up process required to produce large quantities. Microreactor-based processes offer considerable advantages, including excellent control of mixing, heat and mass transfer, reproducibility, and seamless transition from lab-scale to large production. This webinar showcases studies from Dr. Wu's group, discussing the hydrodynamics and mixing behaviour and Ag NM continuous production in Corning Advanced-Flow Reactors.

• #13: Continuous flow case study: Efficiency in API manufacturing through continuous flow

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  Presenters: 
  Dr. Dirk Hütten, Raybow PharmaScience
  Alessandra Vizza, Corning Reactor Technologies

  This webinar focuses on reaction design and scale-up for larger production. Attendees will explore the benefits of continuous flow reactions in pharmaceutical API & Intermediate manufacturing. Raybow Pharmaceutical has a long history in the field with experience in R&D as well as manufacturing with multiple continuous flow reactors, the largest one of which produces more than 140 tons API per year.

• #14: Corning AFR Qualified Lab work - CiTOS: Upgrading of biobased polyols to high value-added chemicals with Corning AFR

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  Presenter:
  Dr. Jean-Christophe M. Monbaliu, Associate Professor, University of Liège

  This webinar illustrates our recent efforts for the upgrading of biobased polyols towards value-added chemicals. The combination of novel chemistry and unique process conditions opens up new possibilities in the area of green and sustainable development. In particular, we will discuss the preparation of organic carbonates, glycidyl ethers and derivatives, as well as cyclic phosphates from biobased polyols featuring Corning Advanced-Flow Reactor Technology.

• #15: Introducing a new flow chemistry educational platform, Corning Nebula™ Education Kits

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  Presenter:
  Dr. Xinjun (Eric) Wu, Manager, Corning Reactor Technology Center (China)

  Corning AFR is committed to helping the next generation of scientists and chemists build a foundation in and fundamental understanding of flow chemistry and flow reactor operation. We introduced our Corning Nebula™ Education Kits to provide students a hands-on learning experience and exposure to a new technology that is inherently safer than batch reactors. This webinar gives more insight into our Corning Nebula education platform and Corning’s efforts and investment in developing talent for the pharmaceutical, fine chemical, specialty chemical, and new material industries.

• #16: Ozonolysis in Flow under pressure: Case study on Beta-pinene

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  Presenter:
  Dr. Philippe Roth, Application Engineer, Corning Reactor Technologies

  With ongoing scientific research, the number of ways to assemble molecules keeps increasing. Despite being widely known, some reactions remain underused, such as ozonolysis. While even all undergraduate students are aware of its potential, the dangerous nature of ozone and its intermediates is a deterrent for widespread use. The present webinar describes how flow chemistry can be combined with ozone under pressure to maximize efficiency while mitigating risks by using an inherently safer technology.

• #17: AFR Qualified Lab work – Nalas: Impact of Process Intensification on Process Safety

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  Presenter:
  Jerry Salan, Chief Executive Officer, Nalas Engineering

  For decades chemical engineers have explored various methods of process intensification to develop more robust and economical solutions. Over time new tools have been developed with the support of breakthrough technologies. As these new technologies are developed and transitioned towards commercial manufacturing the chemical engineer must reassess process safety. Today's chemical engineer must have expertise in all aspects of process development including safety implications. Sometimes this requires in-depth knowledge of the chemical mechanism. Nalas has the expertise and equipment to monitor chemical reactions and adapt manufacturing equipment to produce high-quality materials without compromising safety. The AFR provides an economical and safe solution for today's chemical engineer through enhanced mass and heat transfer. This brief webinar showcases some of the tools available at Nalas.

• #18: Flow Processes in Pharmaceutical Industry: From lab scale to pilot plant manufacturing

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  Presenter:
  Dr. Julien Freudenreich, Research Scientist, Oril Industrie

  Flow chemistry is a great technology to support industrial chemists: it opens chemical windows, handling toxic and unstable intermediates, productivity… Flow reactions are developed and optimized first at lab scale to become more effective, productive and selective. Nevertheless, from the proof of concept to the pilot manufacturing, how does it work? In this Webinar, we will see not only some real cases of flow processes to illustrate flow synthesis applied to pharmaceutical industry but also their transposition from small scale to the pilot production and their limitations.

• #19: The “FlowChem Revolution” in Pharma R&D

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  Presenter:
  Jacopo Buzzanca, Custom Synthesis Manager, Angelini Pharma S.p.A.

  Responding to the rising number of new APIs / HPAPIs that require specialized and niche chemistry, today there is an immense pressure on process chemists to select and develop scalable, cost-effective and sustainable process chemistry routes for scale-up and industrialization. Flow Chemistry is playing an increasingly important role in process chemistry R&D area in the modern pharmaceutical industry. The small size of the microreactor offers high surface-to-volume ratio which translates into high controllability of all process parameters (such as mixing, temperature, pressure, flow rate and residence time) and opening new opportunities to develop of new chemical reactions under conditions that are considered difficult ("forbidden chemistry") or even impossible ("forgotten chemistry") in batch reactors. Many of these new routes lead to access of novel chemical spaces on large-scale, filling a current gap in Pharma R&D between Medicinal Chemistry and Process Chemistry.

• #20: Achieving selectivity in photoredox direct arylations by the combined use of aqueous reaction medium and photoreactors

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  Presenter:
  Sara Mattiello, Senior Post-Doc Researcher, UNIMIB
  

  Photoredox direct arylation is rapidly gaining attention as a promising approach enabling direct C–H activation under UV-Vis light irradiation. The method is efficient but lacks selectivity, as the formation of the hydrodehalogenation product competes with the arylation reaction. This webinar showcases how the combined use of an aqueous reaction medium and of a microfluidic photoreactor allows to achieve unprecedented selectivity and improved reaction time without eroding yields.

• #21: High Energy Photochemical Processes Tamed by a Microfluidic Reactor: Selective Syntheses and Post-modifications of Bioactive Molecules

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  Presenter:
  Joshua Barham, Sofja Kovalevskaja Group Leader, University of Regensburg, Germany

  Flow chemistry allows photochemical processes involving high energy intermediates to be tamed in a controlled and safe fashion, especially by back pressure regulation and enhanced mixing of reactions that evolve or consume gases, safety and desired conversion that can be enhanced while minimizing the reacting volume (hazard) per time. This webinar presents recent examples from our labs at the University of Regensburg. The first example showcases how the productivity, selectivity, and safety profiles of an N2-evolving catalyst-free photochemical synthesis of heterocyclic bicycles was improved by the combined uses of a microfluidic flow platform, a biodegradable ‘green’ solvent and a Design of Experiments optimization approach. The second example shows how continuous photoflow reactors bolstered the conversion, productivity, and mechanistic understanding of an N-CH3-selective oxidative post-modification of alkaloids to N-formamides involving molecular O2.

• #22: Corning® Advanced-Flow™ Reactors Industrial Adoptions in China: Scaling up from lab to 10000 mt/yr/unit seamlessly

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  Presenter:
  Dr. Yi Jiang, President & General Manager, Corning^® Advanced-Flow^™ Reactor Technology

  As environmental and safety regulations become more stringent, the pharma and chemical industries are increasingly looking to continuous flow manufacturing as an inherently safer, more efficient, and less costly alternative to traditional batch processing.
  
  The chemical plant blast in eastern China on March 21, 2019 has led to acceleration of inherently safer technology (IST) adoption such as advanced-flow reactors (AFR) based continuous manufacturing with integrated process automation and downstream continuous separation operations.

  Corning has been promoting AFR continuous flow process applications globally and launched a portfolio of reactor products and auxiliary systems, covering lab development and industrial production. By integrating “seamless scale-up” design of “heart” channels, “sandwich type” modules and “hybrid type” reactor configurations with robust materials (glass, SiC and stainless-steel), we have achieved excellent mass and thermal transfers, strong resistances to thermal shocks, leading single unit 100 times flow scale up while keeping the same reaction performance.

  This presentation will talk through two installed plant projects in China with nitration, diazotization, and hydrolysis involved, respectively. Both plants have been continuously running 24/7 for more than 25000, and 35000 hours with improved yield, reduced waste, as well as ROI less than 30 months. We will explain why Corning AFR has been able to ensure seamless scale up from the lab to 10000 my/yr/unit even with multiphases.

   

• #23: Challenges, experience, and solutions scaling up flow chemistry

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  Guest Presenters:
  Irene Prat, thermal analysis and calorimetric studies at Medichem
  Manel Vázquez, pilot plant manager, Medichem

  Medichem is a Spanish pharmaceutical company that specializes in the development and manufacture of active pharmaceutical ingredients and medicines for the global generics industry. Medichem approached flow chemistry processes in 2011, when a market opportunity was detected. An API intermediate based on an organometallic reaction synthesized under cryogenic conditions was developed. After building up a homemade flow system to optimize the reaction at laboratory scale, the process was transferred to Corning® Advanced-Flow™ Reactors to scale it up. It took less than one year to bring the process from the laboratory to full GMP production obtaining double yield than in batch.

  Since then, flow technology has been essential to develop processes that involve hazard reagents and high exothermic reactions to become inherently safer.

  • 2016: A nitration reaction was optimized using homemade equipment and consecutively scaled up in Corning reactor in less than one year.

  • 2017: A Corning® Low-Flow reactor was acquired to improve the development steps and move more rapidly from lab to plant. With this equipment, a diazotization reaction was developed increasing the yield 14% compared with the batch.

  • 2021: Nitration reaction has been optimized allowing to reduce the use of nitration reagent.

  Those industrial case studies constitute a very successful example of process intensification.