The rise of continuous flow chemistry in fine chemicals and pharmaceutical production environments has shown immediate advantages in selected cases. The systematic roll-out of this technique requires, however, a structured approach to define specific options for applying flow syntheses in complex synthetic pathways.The first step is including flow options into �route scouting� activities to define the best synthetic pathway. Classical retrosynthesis aims at dissecting a complex molecule into simpler units while having well known synthetic steps in mind. Taking into account further options for offered by flow chemistry will add synthetic options, and it will also allow judging the consequences and implications of implementing a given process on larger scale. This enlarges �route scouting� to �process scouting�.After this exercise, suitable flow equipment has to be defined: which features are required? Which capacity? Which unit operations should proceed in flow, and at which point in processing are �batches� of processed material collected? The decision for a certain reactor concept depends on various factors: Which construction material is suitable? Which size of internal structures is required, and how are these structures generated? How is the equaling up or parallelization done to reach the desired capacity? Should it be a dedicated (single use, probably even disposable) or a specially configured modular reactor or work-up unit?Finally a suitable concept of integrating a certain device into existing infrastructure has to be defined. Hardly ever will a new device completely replace existing hardware, it will rather be added to the existing plant to host certain critical unit operations.DSM has a track record of developing flow processes and integrating them into existing production equipment. Examples of such processes are given and merits and pitfalls are discussed.

Right reactions in right reactors:  How to successfully implement flow syntheses into production environments

246th National Meeting (2013)

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