Continuous Flow N‐methylation of Morpholine and Aniline Catalyzed by Mesoporous Al‐SBA‐15

Abstract A continuous flow alkylation process is disclosed to synthesize N‐methylated derivatives of aniline and morpholine, compounds vital to the pharmaceutical, agrochemical, and polymer industries, using a mesoporous Al‐SBA‐15 catalyst. Conversions reached up to 99 % with almost complete selectivity for monoalkylated products under optimized temperature, pressure, and flow conditions. Compared to traditional batch methods, the continuous flow system enabled precise control of reaction parameters, significantly enhancing efficiency, reducing solvent use, and minimizing by‐product formation. The results demonstrate the process‘s feasibility for industrial applications, emphasizing its potential for more sustainable, cost‐effective large‐scale production and the role of continuous flow systems in developing safer, scalable, and environmentally friendly chemical processes.