Scalable chemistry involving diazonium salts

Herein an alternative approach aimed at reducing the cost of numbering up technique as a scale up strategy for chemical processes from the laboratory bench top to the industry is explored. The effect of increasing channel size on the reaction conversion of the synthesis of azo compounds is investigated. This was achieved via a systematic investigative understanding of the synthesis in microreactors where a proof of concept study was performed to determine the optimum reaction parameters in azo coupling reactions involving couplers with aminated or hydroxylated groups in Little Things Factory-MS microreactors (Channel diameter: 1.0 mm) It was found that at slightly alkaline conditions (pH 8.55) and at a temperature of 25 °C, excellent conversions were attained in the azo coupling reaction of the diazonium salt solution of 2,4-dimethylaniline to 2-naphthol. On the other hand, the azo coupling reaction of the diazonium salt solution of p-nitroaniline to diphenylamine was found to thrive at a pH of 5.71 and at a temperature of 25 °C. Using, these optimized reaction parameters, the in-situ and reactive quench of diazonium salts in LTF-MS microreactors was investigated where it was found that at a flow rate of 0.2 ml/min, 0.03 ml/min and 0.07 ml/min of diazotizable amine & HCl, sodium nitrite and coupler solutions respectively, a conversion of 98% is achieved in approximately 2.4 minutes. A library of azo compounds was thus generated under these reaction conditions from couplers with aminated or hydroxylated aromatic aromatic systems. The scaled up synthesis of these compounds in a homemade PTFE tubing (ID 1.5 mm) reactor system was thereafter investigated and comparable conversions were observed. Capitalizing on the benefits of a large surface area and the short molecular diffusion distances observed in microreactors, in-situ phase transfer catalyzed azo coupling reaction of diphenylamine to p-nitroaniline was also explored. In this investigation a rapid and easy optimization protocol that yielded a 99%, 22% and 33% conversion of diphenylamine, carbazole and triphenylamine respectively in approximately 2.4 minutes using Chemtrix microreactors was established. On increasing the microreactor channel internal diameter in the scaled up synthesis approach, it was found that a 0.5 mm increase in channel internal diameter does result in lower reaction conversions