A Continuous Process of the Direct Mechanocatalytic Suzuki Coupling

Introduction

The major contribution to chemical waste accumulating in the chemical industry is made by solvents, often organic solvents, which are potentially toxic or harmful to the environment. My ERC-StG Mechanocat targeted this challenge by removing solvents entirely from chemical processes using a concept called mechanochemistry.

Mechanocat Overview

In Mechanocat, I applied mechanochemistry and targeted the famous Suzuki-coupling reaction, which is one of the most popular catalyses in chemistry. The breakthrough of the project was the utilization of a principle for this reaction that we denoted as direct mechanocatalysis (DM).

Direct Mechanocatalysis

Applying DM, the catalyst neither must be added as a molecule or complex as in homogeneous catalysis nor as solid powder as in heterogeneous catalysis. The milling ball itself served as the catalyst because it was made from the catalytic material. This allowed for the easiest ever-possible way of catalyst separation and reutilization—simply taking the milling ball out of the milling vessel.

Current Limitations

Despite its great economic and ecological advantages, our principle has only been demonstrated on the scale of milligrams using conventional laboratory mills running in batch mode.

MechanoExtrusion Project

To advance DM from lab curiosity to true innovation, the ERC-PoC project MechanoExtrusion will thus transfer DM to a continuous process at a larger scale by providing experimental evidence that one of the most popular reactions in pharmaceutical/medical chemistry—the Suzuki coupling—can be conducted in a Pd-coated extruder applying 100 times upscaled substrate quantities.

Future Goals

In order to show that DM can become a true alternative to conventional catalysis, MechanoExtrusion will:

1. Quantify the economic and ecological metrics using life-cycle assessment and market analysis.
2. Target IP protection.
3. Create industrial partnerships to establish a first joint project.
4. Elaborate a business plan for potential spin-off foundation.