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Custom Synthesis

Tailor-made manufacturing

We manufacture individual, innovative and sophisticated products, applying our kilo lab facilities to seamlessly transfer projects from research to pilot scale and exclusive synthesis at full production scale. This includes performing complex multi-step syntheses.

Kilo lab

We perform small-scale manufacturing of innovative intermediate products ranging from 100g – 10kg, seamlessly transferring the product to pilot scale via our kilo lab.

Initial quantities of expensive intermediates can be delivered flexibly and in less time compared to a pilot plant, shortening the customer’s time-to-market.

Pilot & Scale-up

By providing reliable scale-up from lab development to pilot production, we help achieve ambitious project deadlines. Our team‘s taking care of punctual delivery, based on state-of-the-art chemical and technical expertise, frees up customers‘ resources to be applied elsewhere.

Exclusive synthesis

At two production plants in the industrial park Frankfurt-Höchst, we perform complex, individual multi-step syntheses in more than 80 reactors in various materials ranging from 100 and 5,000 liters, delivering quantities of up to several metric tons.

The flexible design of our assets enables a broad variety of chemical transformations and unit operations, while the close proximity of development, scale-up and commercial manufacturing plants saves time and cost in delivering a project.

Markets

Organic Electronics

A long track record in the manufacturing of organic electronic materials for:

  • Organic LED (OLED) for displays 

  • Organic Photovoltaic (OPV) 

  • Organic Photodetector (OPD) 

  • Liquid crystal building blocks in high purity 

  • Materials for batteries 

Ligands and catalysts

  • Phosphorus-containing ligands and others (Large commercial and midsize scale) 

  • Metallocenes and homogeneous catalysts 

  • Pilot and midsize plants from 10 kg up to tons scale offering high flexibility 

  • Advanced technologies: Low-temperature, e.g. for boronic acids and high pressure reactions for e.g. chiral compounds 

  • Extended capacities for chemical process development at lab scale for contract research

  • Process development for applications of bio-based materials 

  • Applied technologies are hydrogenation, oxidation or purifications via rectification or crystallization 

Examples

  • Piloting of new products 

  • Manufacturing of test and tox quantities in a range of 100 kg up to tons per campaign 

  • Large scale manufacturing at sites within the WeylChem network 

Capabilities

Kilolab

  • Reactors from 10 to 100 liter constructed of glass, stainless steel and glass-lined steel and other materials as required 

  • Distillation units 

  • Thin film evaporators 

  • Range of filtration units 

  • Heating and cooling system 

  • Vacuum drying cabinets 

  • Option for direct connection to up and downstream units in the pilot plant at 300 to 500 liter 

Examples of key technologies used in large scale: 

  • Acylation 

  • Alkylation 

  • Amination 

  • Bromination 

  • Carbonylation 

  • Carboxylation 

  • Chlorination 

  • Chlorosulfonation 

  • Cross coupling 

  • Diazotization 

  • Diels-Alder reaction 

  • Friedel-Crafts reactions 

  • Grignard reaction 

  • Hartwig-Buchwald coupling 

  • Heck reaction 

  • Hydroformylation 

  • Hydrogenation 

  • Lithium alanate reduction 

  • Melt reactions at high temperatures 

  • Nitration 

  • Organometallic reactions, e. g. with BuLi or HexLi 

  • Organophosphorus chemistry 

  • Polymerization or polycondensation 

  • Reductive amination 

  • Sodium boro-hydride reduction 

  • Sulfonation (also with oleum) 

  • Suzuki coupling 

  • Ullmann reaction 

Capabilities 

  • Advanced reactors with capacities of 100 l, 500 l and 1000 l can be operated via a heating/cooling circuit with an inert heat-transfer medium in the range from -100 °C to +200 °C. 

  • Air-sensitive raw materials (e.g. Grignard-, butyl lithium-, lithium alanate-solutions, etc.) are metered from safety boxes. The reactors are DCS-controlled and equipped with on-site operator terminals. If required, they can quickly be linked to a number of conventional upstream and downstream reactors: 

Products 

  • Various specialty chemicals including  

  • Complex aldehydes 

  • Organic boronic acids 

  • Coupled aromatic ring systems  

  • Homogenous catalysts 

  • Building blocks for API-synthesis and materials for organic electronic 

Capabilities 

  • Reactions including hydroformylations, carbonylations and hydrogenations performed in the presence of catalysts under high pressure to achieve the required conversion, selectivity and yield. 

  • Special high-pressure autoclaves 

  • 26 lab autoclaves of 0.2 to 1 liter up to 750 bar, 300 °C in different materials for process development 

  • Piloting: 7 autoclaves from 5 to 300 liter up to 200 bar, 300 °C 

  • Hastelloy up to 1.6 m³ (up to 200 bar, 200 °C) 

  • Stainless steel up to 1.8 m³ (up to 100 bar) 

  • Compressors and gas-supply stations 

  • Carbon monoxide 

  • Ethylene and Hydrogen from pipeline 

  • Pre-formation and handling of air-sensitive homogenous catalysts 

Products 

  • Enantiomeric alcohols (e.g. based on ketones) 

  • Carboxylic acid esters and amides 

Examples

Flexible, variably connectable equipment for complex multi-stage synthesis 

  • Total stirred reactor capacity >50 m3 

  • 80 different reaction vessels from 0.1 up to 5.0 m3 

  • Stirred pressure filters up to 4 m2 

  • Thin film evaporators up to 1.0 m2 

  • Short path evaporators up to 0.3 m2 

  • Distillation columns up to 30 theoretical plates 

  • Materials: Stainless steel, glass-lined steel, Hastelloy, glass 

Related Topics

Analytical Services
Contract Development
Custom Manufacturing

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    Dr. Christoph Naumann

    HEAD OF MARKETING & SALES

    • +49 69 305 6247
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    WeylChem International GmbH