Continuous Synthesis Systems Engineering Research Group

1. Advanced telescoped flow processes for highly efficient continuous synthesis of specialty chemicals

We have developed a telescoped flow process consisting of two flow reaction systems and two multistage continuous extraction-separation systems, and successfully demonstrated the continuous synthesis of vanillin, a widely used flavoring compound. Compared with conventional batch processes, this flow-based process achieved a 42-fold increase in production efficiency and an 87% reduction in waste generation, clearly demonstrating the advantages of flow chemistry.

Schematic of the developed continuous vanillin synthesis process

2. Development of enabling technologies for continuous flow process construction

We have successfully developed a range of enabling technologies, including devices that allow flexible control of slug length in slug flow with large liquid–liquid interfacial areas for extraction applications; machine-learning models capable of predicting partition coefficients; liquid-liquid separating devices without the need for extraction discharge valves or liquid–liquid interface monitoring; and compact continuous distillation and separation units.

（From left: generation of slug flow with varying slug lengths; continuous liquid-liquid separator; schematic of continuouous distillation unit）