Abstract
The decarbonization of pharmaceutical manufacturing is critical for achieving the industry's net-zero targets, and electrochemistry is emerging as a promising green technology that could play a key role in this transition. This work evaluates a continuous-flow electrochemical route for ibuprofen synthesis through electrochemical carboxylation of 1-chloro-(4-isobutylphenyl) ethane as a low-carbon alternative that can be directly coupled with renewable electricity. Experimental studies have demonstrated the selective formation of ibuprofen using a silver cathode in the ionic liquid N-methyl-N-propylpiperidinium bis(trifluoromethanesulfonyl)imide (PP13 TFSI). While the reaction mechanism is based on laboratory-scale, batch experiments, this study develops a conceptual design and scale-up methodology for the continuous route to provide an evaluation of the industrial feasibility of this electrochemical pathway through a rigorous plant-wide simulation in AVEVA® Process Simulation. Global sensitivity analysis is employed to identify key operating variables and evaluate their impact on reactor and process performance, energy consumption, and ionic liquid recovery. These insights provide a robust foundation for informed decision-making in process intensification, demonstrating the technical viability and scalability of continuous flow electrosynthesis as a sustainable alternative to conventional API manufacturing.