DEVELOPMENT OF FLOW PROCESSES FOR THE EFFICIENT AND SUSTAINABLE PREPARATION OF HIGH VALUE CHEMICALS

Sustainability in chemistry involves the development and implementation of chemical processes, materials, and technologies that fulfill present needs without compromising the ability of future generations to meet theirs. Growing concerns over global pollution and resource depletion have underscored the urgency of reducing the environmental and health impacts of chemical production. Within this context, enabling technologies such as flow chemistry offer considerable advantages by providing more efficient and environmentally friendly approaches to the synthesis of fine chemicals and active pharmaceutical ingredients (APIs). This doctoral research aimed to develop sustainable and efficient continuous flow protocols for the synthesis of high-value compounds, in line with the principles of green chemistry and the circular economy. The study leveraged continuous flow technology for both enzymatic and chemical catalysis, integrating in-line purification and work-up steps to reduce waste and downstream processing. Sustainable flow protocols were established for the synthesis of phenolic derivatives—particularly amides and esters—with potential antioxidant, antimicrobial, and radical-scavenging properties. Additionally, flow-biocatalysis was employed to synthesize riparin-inspired amides and hydroxycinnamic acid derivatives. The research also focused on the development of continuous flow methods for the synthesis of sugar-based surfactants, addressing limitations of traditional batch processes such as harsh conditions, low selectivity, and high energy consumption. Special attention was given to the valorization of dairy by-products (e.g., glucose and galactose) for the production of surfactants, supporting circular economy strategies. A six-month industrial placement at Olon S.p.A., a global pharmaceutical company, was undertaken to assess the feasibility of converting a batch process to a continuous one for the production of a key intermediate in the synthesis of an anti-cancer drug. The study evaluated the potential benefits of continuous manufacturing, including improved efficiency, reduced costs, and enhanced product quality, while also identifying challenges related to equipment, process control, and regulatory compliance. Overall, this work contributes to the advancement of sustainable chemical manufacturing by proposing innovative methodologies for the synthesis of bioactive compounds and surfactants. It also addresses issues of scalability and environmental impact, promoting the adoption of greener technologies in both academic and industrial sectors.