For a mixing sensitive complex reaction network, impinging jet mixer have shown to be an efficient reactor design due to the generation of high turbulent energy dissipation (>1 kW/kg) to provide intensive mixing. As a result, impinging jet provides reproducible mixing conditions and enables sensitive control of fast reactions. In this study, an impinging jet flow process was developed under GMP conditions to address the formation of a problematic dimer impurity in a mixing sensitive reaction network. Efficient process development of the robustness of the impinging jet required an intricate understanding of intrinsic kinetics, transport phenomena, and analysis of flow patterns within these jets. A computational fluid dynamics (CFD) model was developed to design the impinging jet mixer and mixing time was calculated and verified experimentally. Rational exploration of these factors enabled us to successfully scale-up this process to a multi-kilogram amount of API.
All authors are employees of AbbVie and may own AbbVie stock. AbbVie sponsored and funded the study; contributed to the design; participated in the collection, analysis, and interpretation of data, and in writing, reviewing, and approval of the final publication.