Etched silicon powder-supported Pd is developed as a durable and efficient catalyst for continuous flow hydrogenation and reductive alkylation.

This study develops a novel heterogeneous palladium catalyst immobilized on etched silicon powder, demonstrating high efficiency and long-term stability under continuous flow conditions. Characterization reveals that the Pd⁰ species are generated via in situ reduction of the Pd^II precursor by terminal hydrogens preloaded on the etched silicon surface. The catalyst readily integrates into packed-bed column reactors, facilitating efficient hydrogenation and reductive alkylation. The practical applicability of this system is demonstrated through the continuous synthesis of several valuable chemical compounds, including key fragrance and pharmaceuticals. A long-term durability test confirms sustained catalytic performance over 30 days without noticeable deactivation. Remarkably, the catalyst retains its activity even after 2 years of storage without protective measures. The system enables the flexible synthesis of diverse products by changing the starting materials, all within the same reactor setup. This study represents a significant advancement in green and sustainable chemistry, offering a robust and adaptable catalytic platform for scalable and resource-efficient chemical production.