Continuous flow gas-liquid thin film microreactors have been effectively used for the selective fluorination of a range of 1,3-dicarbonyl and aromatic substrates and, additionally, the conversion of aromatic disulfides to the corresponding sulfur pentafluorides. Scale-up was demonstrated by the application of a three channel microreactor device fabricated by replication of a single channel system.

Versatile and conveniently operated microreactor devices, suitable for long term chemical synthesis for both laboratory and industrial use, are described. Direct fluorination of ethyl acetoacetate by fluorine gas is used as a model reaction to illustrate the successful application of reactors having either 9, 18 or 30 microchannels, with all channels supplied from single reagent sources, to provide significant quantities of fluorinated products. Convenient reactor maintenance, simple design, versatility and the enhanced safety features of using such modular microreactor devices, make these systems appropriate for synthesis on the large scale.

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The design, fabrication, use and scale-out of versatile, multi-channel gas/liquid microreactors, which are suitable for both laboratory and industrial syntheses, are described. Direct fluorination reactions of diethyl malonate and Meldrum's acid using the new microreactor technology were studied to demonstrate the viability of the device for carrying out gas/liquid processes, particularly when using potentially hazardous materials.