Continuous, scalable, safe hydrogenation for pharmaceutical manufacturing

The National Center for Advancing Translational Sciences, National Institutes of Health awarded Zaiput Flow Technologies LLC $306,301 on August 15, 2026, under the NCATS program (CFDA 93.350) to develop a continuous, scalable, safe hydrogenation solution for pharmaceutical manufacturing.

Zaiput will design and test an advanced gas-liquid distribution module and demonstrate scalable reaction results in Phase I. The work combines Zaiput's layered modular reactor design with W.L. Gore's advanced catalyst immobilization technique to address current hydrogenation challenges in batch-based pharmaceutical synthesis, including safety risks from hydrogen's explosive nature, scalability limitations, and high costs of precious metal catalysts. Phase II will involve designing and building larger-scale devices, conducting real-world testing with pharmaceutical manufacturers, and initiating commercialization.

The recipient is Zaiput Flow Technologies LLC, a small business based in Waltham, Massachusetts. Work is performed in Waltham, MA. The award period runs through May 14, 2027.

Abstract

Domestic pharmaceutical manufacturing is currently struggling to meet growing demands. To address this challenge, IT is crucial to develop tools that can significantly enhance the productivity of existing production facilities. Pharmaceutical production today relies heavily on batch-based chemical synthesis, where chemical reactions occur in several separate steps within large reactors. Among these steps, hydrogenation stands out as a very frequent and important chemical transformation unfortunately plagued by significant technical challenges, including scalability issues and safety risks due to the explosive nature of hydrogen. Additionally, the process requires expensive precious metal catalysts, further complicating production. We propose the development of a safe, scalable, and continuous hydrogenation solution for pharmaceutical applications. This innovative approach will combine W.L. Gore's advanced catalyst immobilization technique with a layered modular reactor design designed by zaiput. Our goal is to overcome the current challenges associated with hydrogenation, such as safety concerns, scalability limitations, and the inefficiencies inherent in traditional batch-based chemical synthesis. In phase i of this sbir project, we will focus on key technological innovations necessary to demonstrate the scalability of the layered reactor concept. Specifically, we will: 1) develop an advanced gas-liquid distribution module that ensures uniform distribution across various reactor sizes, and 2) demonstrate the system's effectiveness by achieving scalable reaction results. In phase II, we will design and build larger-scale devices, conduct real-world testing in partnership with pharmaceutical manufacturers to validate the technology in a manufacturing setting, and initiate the commercialization process. If successful, this project will produce a tool capable of immediately addressing hydrogenation challenges and contribute to the reshoring of pharmaceutical manufacturing to the U.S. This aligns with government priorities by offering safer, more efficient, cost-effective, and environmentally friendly hydrogenation processes.