Additively manufactured small-volume continuous manufacturing reactor system for C–C cross-coupling reactions

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dc.contributor.authorKhabiyev, Alibek
dc.contributor.authorSavas, Dilibal
dc.contributor.authorAssel, Mussulmanbekova
dc.contributor.authorRafikova Kh.S.
dc.contributor.authorKanapiya, Magzhan
dc.contributor.authorMedet, Dyussembayev
dc.contributor.authorIskender, Aidana
dc.date.accessioned2025-12-05T10:29:56Z
dc.date.available2025-12-05T10:29:56Z
dc.date.issued2026
dc.departmentFakülteler, Mühendislik Fakültesi, Mekatronik Mühendisliği Bölümü
dc.description.abstractContinuous manufacturing (CM) is increasingly recognized as a transformative approach in pharmaceutical and chemical production, offering enhanced efficiency, reproducibility, and sustainability compared to conventional batch processing. This study presents the development and application of an additively manufactured PEEK-based small-volume continuous reactor system for the three-stage Suzuki–Miyaura synthesis of biphenyl. The process integrated ligand synthesis, catalyst precursor formation, and the cross-coupling reaction within modular reactors, achieving high product selectivity and reproducibility. Comparative analysis with traditional batch synthesis revealed superior performance for the continuous system, including faster kinetics, shorter residence times, improved yields (up to ~100% for catalyst C within 10 minutes at 100 °C), and reduced waste generation. Additive manufacturing enabled the rapid prototyping of reactors with optimized geometries featuring integrated mixing and heat exchange, ensuring precise control of flow rates and thermal conditions. Beyond pharmaceutical applications, the system demonstrated significant potential for hydrometallurgical processes such as leaching, solvent extraction, and electrochemical metal recovery, where continuous flow operation offers substantial advantages in efficiency and sustainability. These findings underscore the synergy of CM, additive manufacturing, and process analytical technology as a flexible and environmentally responsible platform. The developed reactor system provides a pathway for scalable, modular, and on-demand chemical manufacturing, with broad implications for both high-value drug synthesis and sustainable resource management.
dc.description.sponsorshipMinistry of Education and Science of the Republic of Kazakhstan: AP22783377
dc.identifier.doi10.21608/ejchem.2025.413353.12176
dc.identifier.endpage52
dc.identifier.issn0449-2285
dc.identifier.issue1
dc.identifier.scopus2-s2.0-105022893178
dc.identifier.scopusqualityQ3
dc.identifier.startpage45
dc.identifier.urihttps://doi.org/10.21608/ejchem.2025.413353.12176
dc.identifier.urihttps://hdl.handle.net/11501/2524
dc.identifier.volume69
dc.indekslendigikaynakScopus
dc.institutionauthorDilibal, Savaş
dc.institutionauthorid0000-0003-4777-7995
dc.language.isoen
dc.publisherNational Information and Documentation Centre
dc.relation.ispartofEgyptian Journal of Chemistry
dc.relation.publicationcategoryMakale - Uluslararası Hakemli Dergi - Kurum Öğretim Elemanı
dc.rightsinfo:eu-repo/semantics/closedAccess
dc.subjectAdditive Manufacturing
dc.subjectBiphenyl Synthesis
dc.subjectC–C Cross-Coupling Reaction
dc.subjectReactor System
dc.subjectSuzuki–Miyaura Reaction
dc.titleAdditively manufactured small-volume continuous manufacturing reactor system for C–C cross-coupling reactions
dc.typeArticle

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