Modular systems for performing multistep chemical reactions, and methods of using same

A modular chemical reaction system comprising:

• a substrate layer having a substrate and a plurality of flow components positioned within the substrate, the substrate having an outer surface;
• a surface-mount layer having a plurality of flow modules selectively mounted to the outer surface of the substrate in overlying relation to the plurality of flow components, wherein each flow module of the plurality of flow modules is positioned in fluid communication with at least one flow component of the plurality of flow components at a respective interface;
• and
• a plurality of sealing elements configured to establish a fluid-tight seal at each interface between a flow module of the plurality of flow modules and a flow component of the plurality of flow components,
• wherein the plurality of flow modules and the plurality of flow components cooperate to establish a fluid flow pathway for performing at least one step of a chemical reaction, and
• wherein at least one flow module of the plurality of flow modules is a reactor or a separator.

A method comprising:

• introducing at least one reagent into a first fluid flow pathway of a modular chemical reaction system, the modular chemical reaction system comprising:
• a substrate layer having a substrate and a plurality of flow components positioned within the substrate, the substrate having an outer surface;
• a plurality of modules selectively mounted to the outer surface of the substrate in overlying relation to the plurality of flow components, wherein at least a portion of the plurality of modules cooperate with at least a portion of the plurality of flow components to produce the first fluid flow pathway, the plurality of modules comprising at least one monitoring module configured to produce at least one output indicative of at least one condition of the first chemical reaction;
• at least one analysis device, each analysis device being positioned in operative communication with the fluid flow pathway through at least one module of the plurality of modules and configured to produce at least one output indicative of at least one characteristic of the chemical reaction as the chemical reaction occurs;
• and
• processing circuitry communicatively coupled to the at least one monitoring module and the at least one analysis device, wherein the processing circuitry is configured to receive the outputs from the at least one monitoring module and the at least one analysis device to monitor the chemical reaction as the chemical reaction occurs;
• and
• performing at least one step of a chemical reaction using the at least one reagent.