Organic Process Research & Development 2009, 13, 1094–1099
A Scalable Zinc Activation Procedure Using DIBAL-H in a Reformatsky Reaction
Michael J. Girgis,* Jessica K. Liang, Zhengming Du, Joel Slade, and Kapa Prasad*
Chemical and Analytical DeVelopment, NoVartis Pharmaceuticals Corporation, East HanoVer, New Jersey 07936, U.S.A.
Abstract:
or highly exothermic decomposition reactions can occur. A
temperature runaway, possibly accompanied by an explosion,
can ultimately result.
In the synthesis of multikilogram quantities of an intermedi-
ate for a developmental drug,6 it was necessary to introduce a
chiral center by reaction of imine 1, substituted with chiral
auxiliary tert-butylsulfinamide, with ethyl bromoacetate 2 to
make amine intermediate 3 (Scheme 1).
The highly exothermic nature of Reformatsky reagent formation
and the reported unpredictability of the induction time for its
formation pose challenging problems for scaling up Reformatsky
reactions. A zinc-activation procedure using DIBAL-H was de-
veloped and investigated using reaction calorimetry along with
subsequent parts of the process. This procedure was shown to have
important advantages for scale-up relative to previous zinc
activation methods, including an immediate start of Reformatsky
reagent formation with addition-controlled reaction. Calorimetric
analysis was especially useful in specifying quickly a suitable
temperature for Reformatsky reagent formation. The process was
scaled up successfully.
A suitable process for scale-up of the zinc activation as well
as for formation of the Reformatsky reagent was thus essential.
For such exothermic reactions, a well-defined, detectable start
of reaction on large scale is ideal, since it is then possible to
continue the process safely. Preferably, the reaction should start
when a reagent is added to a vessel and terminate when reagent
addition stops. Such reactions are termed “addition-controlled”.
Processes involving induction periods during addition should
be especially avoided, as reactions that initiate suddenly after
significant amounts of reagent have been added will lead to
large and sudden heat releases (i.e., heat accumulation) and
hazardous conditions.
Because the reaction between the Reformatsky reagent and
1 required a temperature below -5 °C to obtain 3 with high
optical purity, the zinc activation, typically carried at or above
room temperature, had to be performed separately from the
coupling. Thus, procedures similar to the one devised by
Schekenbeek and Siegel,5 involving the addition of a haloester
to a mixture containing the electrophile and activated zinc above
40 °C, though giving an addition-controlled reaction, could not
be applied here. Compound 3 was not isolated, but was
converted to the corresponding amino ester hydrochloride (4)
for characterization purposes (see Experimental Section).
Introduction
The classic Reformatsky reaction comprises the zinc-
mediated formation of a ꢀ-hydroxyester from an R-haloester
and an aldehyde or ketone. Its scope has been broadened to
other electrophiles such as imines.1 The reaction is typically
carried out by first activating zinc using a chemical treatment
to remove the zinc oxide layer from the metal surface and/or
to obtain a high specific surface area of zinc metal. Various
zinc activation methods have been reported,1-3 including
treatment with ultrasound, iodine, chlorotrimethylsilane, sodium
bis(2-methoxyethoxy)aluminumhydride (Red-Al), 1,2-dibro-
moethane, and cuprous chloride, with the latter two reagents
having been used in large-scale reactions.4,5 Reaction between
the activated zinc and the R-haloester to form a zinc enolate
(i.e., the Reformatsky reagent) then occurs. The latter reacts
with the electrophile, with subsequent hydrolysis affording the
product. The electrophile may also be present during Refor-
matsky reagent formation.5
The formation of the Reformatsky reagent is highly exo-
thermic with unpredictable induction times reported in some
cases.5 The unpredictable start of a highly exothermic reaction
poses severe problems on large scale, as a sudden heat release
will lead to a large batch-temperature excursion if cooling
cannot be applied quickly. If the temperature rise is sufficiently
large, pressure buildup (due to rapid solvent vaporization) and/
In this paper, we report on an effective and scalable zinc
activation procedure utilizing diisobutylaluminum hydride
(DIBAL-H). This reagent has been used previously for activa-
tion of magnesium in Grignard reactions.7 All reactions in the
process, especially zinc activation and Reformatsky reagent
* To whom correspondence may be sent. E-mail: michael.girgis@
novartis.com; prasad.kapa@novartis.com.
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Vol. 13, No. 6, 2009 / Organic Process Research & Development
10.1021/op900192m CCC: $40.75 2009 American Chemical Society
Published on Web 09/23/2009