Development and characterization of “push–pull” sampling device with fast reaction quenching coupled to high-performance liquid chromatography for pharmaceutical process analytical technologies

A push–pull sampling system interfaced on-line to high-performance liquid chromatography (HPLC) was developed for micro-volume real-time monitoring of reaction mixtures. The device consists of concentric tubes wherein sample was continuously withdrawn through the outer tube and reaction quenchant continuously delivered through a recessed inner tube. The device allowed sampling rates of 0.1–6.0 μL/min from a reaction vessel and stopped the reaction by passive mixing with quenchant to preserve the conditions observed in the reaction vessel. A finite element model of the system showed that reaction mixtures could be completely mixed with quenchant within 4.3 s at a flow rate of 1.0 μL/min. The model also showed that an offset distance of 1 mm between the push capillary and sample capillary tips is sufficient to avoid leakage of quenchant/diluent into the bulk sample for push flow rates up to 95% of the pull flow rate. The maximum relative push flow rate was determined to be 90% of the pull flow rate experimentally. Delay between sampling and delivery to the HPLC was from 111 ± 3 s to 317 ± 9 s for pull flow rates from 1.0 to 3.0 μL/min in agreement with expected delays based on tubing volume. Response times were from 27 ± 1 s to 52 ± 6 s over the same flow rate range. The sampler was tested to determine the effects of sample viscosity. The sampler was also used to demonstrate periodic sampling capabilities. As a test of the system, it was used to monitor the base-catalyzed hydrolysis of aspirin for 1.5 h, demonstrating its utility for monitoring an ongoing reaction.