At Hemshoolin, we believe that chemistry is not just about reactions it is about control, precision, and safety. Over the years, our team has successfully transitioned several complex and hazardous batch reactions to continuous flow systems, enabling safer, greener, and more efficient manufacturing at commercial scale.

Below are some highlights of our journey and achievements:

1. Nitration – From Risk to Reliability

Traditional nitration often faces the risk of over-nitration and thermal runaways. By implementing continuous flow nitration with real-time temperature and pressure control, we transformed this process into a stable and predictable operation.

Outcome:

  • Safer operating environment
  • Controlled mono-nitration

Reduced effluent and cleaner process

 

2. Bromination – Safety Without Compromise

Handling elemental bromine in batch mode can cause exposure and safety challenges. We shifted to inline bromine generation combined with precise real-time dosing in a flow reactor.

Outcome:

  • Significantly reduced operator exposure
  • Higher yield and improved selectivity

Enhanced workplace safety

3. Photo-Chlorination – Light With Precision

Batch photo-chlorination carries risks of UV overexposure and reaction runaway. We developed a flow-based photo-reactor system using UV LED technology and continuous substrate feed.

Outcome:

  • Safer control of energy input
  • Stable reaction conditions
  • Overall enhanced process reliability

4. Hydrolysis – Pushing Yield Boundaries

Incomplete hydrolysis in batch systems often limits productivity. Our continuous flow hydrolysis with real-time pH and temperature monitoring led to consistent reaction completion.

Outcome:

  • Yield improved by 18%
  • Better reproducibility and scalability

5. Coupling Reaction – Protecting Sensitive Chemistry

Moisture-sensitive chloro-amine coupling typically demands stringent controls. Using in-line microreactors under an inert atmosphere, we ensured smooth and selective reaction conditions.

Outcome:

  • Higher selectivity

Reduced impurity formation

6. Reduction – Taming Exothermic Reactions

Reductions using Hydrazine Hydrate can pose serious exothermic hazards. Our controlled flow addition with integrated inline cooling enabled safe and stable reaction progression.

Outcome:

  • Controlled exotherm

Safe and scalable process

7. Acid-Amine Coupling – Stability Through Smart Timing

Acid chlorides are highly reactive and unstable if stored. We optimized the process by generating acid chloride in-situ and reacting it immediately with the amine under flow conditions.

Outcome:

  • Smooth processing

Improved yield and operational convenience

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