Direct Mechanocatalytic Oxidation without Milling Media

Objective

The chemical and pharmaceutical industries rely heavily on oxidation reactions that typically require large volumes of toxic solvents and complex molecular catalysts. These processes generate enormous amounts of chemical waste and contribute significantly to CO2 emissions. Building on our ERC Starting Grant Mechanocat, which pioneered direct mechanocatalysis (DM), we propose a transformative alternative: performing catalytic oxidations without solvents and without added catalysts, using only the catalytic surface of a coated reaction vessel. In MechanOxidation we will validate this principle at significantly larger scale (100-fold increase), demonstrating oxidation reactions in a resonance acoustic mixer with gold-coated reactor surfaces. This approach offers multiple advantages: elimination of solvent waste, minimized catalyst use, simple catalyst recycling, and improved scalability through media-free operation. The project combines technical validation with sustainability and market analyses. We will (i) provide experimental proof that DM oxidation is scalable and robust, (ii) quantify ecological and economic benefits via life-cycle assessment and green metrics, (iii) protect intellectual property through new patent applications, and (iv) prepare a business plan for a spin-off company in mechanochemical manufacturing. By bridging the gap from academic discovery to industrial application, MechanOxidation has the potential to revolutionize catalytic processes in fine and pharmaceutical chemistry. It directly contributes to the EU Green Deal and the chemical industry’s commitment to carbon neutrality by providing a sustainable, electricity-driven alternative to conventional, resource-intensive oxidation chemistry.