Preparation of 4-Bromo-1-naphthalenecarboxylic Acid
(27). To a solution of 1,4-dibromonaphthalene (25 kg, 87 mol)
at 0 °C in THF (175 L) was added a solution of iPrMgCl:LiCl
(1.35 M in THF, 100 L, 135 mol) under a nitrogen atmosphere.
The mixture was stirred at 0 °C for 30 min, warmed to 20 °C,
and stirred at that temperature until complete formation of the
Grignard intermediate (level of dibromonaphthalene <2% by
HPLC). The mixture was cooled to -10 °C and sparged with
CO2 gas for ∼1 h until there was no more consumption of the
Grignard intermediate (typical level of Grignard intermediate
in solution at the end of the reaction is 7%). The reaction
mixture was warmed to 20 °C and added to water (200 L), and
then THF was distilled off at atmospheric pressure (65 °C). At
the end of the distillation, the mixture was cooled to 45 °C;
ethyl acetate (325 L) was added followed by aqueous HCl (5
M, 75 L). The biphasic mixture was stirred at 45 °C for 20
min and allowed to settle. The aqueous phase was removed.
Water (175 L) was added, the biphasic mixture was stirred at
45 °C for 10 min, and the aqueous phase was removed. Heptane
(175 L) was added and the mixture concentrated down to 175
L at atmospheric pressure. The mixture was then cooled to 55
°C, and heptane (75 L) added. The mixture was then seeded
with an authentic sample of 27 (25 g) if required, cooled to 50
°C, and stirred for 1 h. It was then cooled to 20 °C over 2 h
and stirred at 20 °C for 1 h. It was finally cooled to 5 °C over
30 min and stirred at that temperature for 1 h, and then the
solid was filtered off and the cake washed with heptane (50 L)
and dried at 50 °C under vacuum to give a white solid (18.15
kg, 83%). 1H NMR (DMSO-d6, 400 MHz) δ 7.73-7.80 (m, 2
H), 7.98-8.05 (m, 2 H), 8.25-8.32 (m, 1 H), 8.89-8.97 (m,
1 H), 13.40 (s, 1 H); MS: MH+ ) 251-253.
Preparation of 4-{(1E)-3-Oxo-3-[(phenylmethyl)oxy]-1-
propen-1-yl}-1-naphthalenecarboxylic Acid (7). To a solution
of 27 (29 kg, 116 mol) at 20 °C in toluene (174 L) and
triethylamine (80 L, 574 mol) was added palladium acetate (0.78
kg, 3.5 mol), triphenylphosphine (1.5 kg, 5.7 mol), and benzyl
acrylate (26 L) under a nitrogen atmosphere. The mixture was
heated to 90 ( 3 °C and stirred for at least 11 h. The reaction
mixture was cooled to 70 °C and then sampled and analysed
by HPLC. The reaction was deemed complete when 25 was
<2%. After completion of the reaction the solution was cooled
to 20 ( 5 °C. The reaction mixture was filtered through a 5
µm cloth. The precipitate was washed with toluene (58 L), and
the washes were combined with the previous filtrate. HCl (1
M, 57 L) was added to the toluene solution, and the mixture
was stirred for at least 5 min and then allowed to settle. The
organic phase was removed. 2-Methyltetrahydrofuran (435 L)
was added to the aqueous phase followed by 1 M HCl (174 L)
over at least 5 min. The mixture was stirred for at least 5 min
and then allowed to settle. The pH of the aqueous phase was
controlled to <3, and the aqueous phase was removed. The
contents were concentrated to ∼145 L by atmospheric distil-
lation. The solution was cooled to 20 ( 3 °C over at least 3 h,
and n-heptane was (145 L) added over at least 2 h, maintaining
the contents at 20 ( 3 °C. The slurry was aged at 20 ( 3 °C
for at least 5 h before being filtered. The solid was then washed
with n-heptane (58 L) and dried in a vacuum oven at 40 °C to
constant probe temperature to give a white solid (32.1 kg, 84%).
1H NMR (DMSO-d6, 400 MHz) δ 5.30 (s, 2 H), 6.82 (d, J )
16 Hz, 1 H), 7.36 (t, J ) 7 Hz, 1 H), 7.42 (t, J ) 7 Hz, 2 H),
7.46-7.50 (m, 2 H), 7.67-7.74 (m, 2 H), 8.02 (d, J ) 8 Hz,
1 H), 8.11 (d, J ) 8 Hz, 1 H), 8.25-8.33 (m, 1 H), 8.51 (d, J
) 16 Hz, 1 H), 8.85-8.92 (m, 1 H), 13.34 (s, 1 H); MS: MH+
) 333.
Preparation of Phenylmethyl (2E)-3-(4-{[4-(4-{[3-(3,3-
dimethyl-1-piperidinyl)propyl]oxy}phenyl)-1-piperidinyl]-
carbonyl}-1-naphthalenyl)-2-propenoate fumarate (33). 7 (20
kg, 60 mol) was slurried in isopropyl acetate (200 L) and heated
to 79 ( 3 °C. Thionyl chloride (5.26 L, 72 mol) was added;
once a solution was obtained, the reaction was heated to reflux;
heating continued until there was less than 5% a/a 7 by HPLC
analysis (typically <1.0 h) and the solution cooled to 55 ( 3
°C. 25a (32 kg, 51 mol) was slurried in isopropyl acetate (160
L) and aqueous potassium carbonate (20% w/w, 160 L) added.
The biphasic solution was heated to 55 ( 3 °C. The biphasic
mixture was stirred for 10 min, and the layers were separated,
and the aqueous phase was discarded. Aqueous potassium
carbonate (20% w/w, 160 L) was added to the isopropyl acetate
layer, the biphasic mixture was stirred for 10 min at 55 ( 3
°C, and the layers were separated, the aqueous phase discarded.
Aqueous potassium carbonate (20% w/w, 160 L) was added to
the solution and the biphasic mixture heated to 55 ( 3 °C. The
acid chloride solution was added, maintaining the internal
temperature at 55 ( 5 °C; the biphasic mixture was heated until
there was less than 0.25% a/a 25 by HPLC analysis (typically
<0.25 h). The layers were separated, and the isopropyl acetate
layer was washed with water (160 L) at 55 ( 3 °C. The
isopropyl acetate layer was distilled to 320 L, isopropyl alcohol
(320 L) was added and the solution distilled to 320 L. Further
isopropyl alcohol (320 L) was added, and the solution was
distilled to 480 L and cooled to 70 ( 3 °C. Fumaric acid (7
kg, 60 mol) was added, and the mixture was stirred at 70 ( 3
°C to obtain a solution and cooled to 50 °C over 1 h. The
solution was aged for 4 h to form a slurry; the slurry was cooled
to 25 °C over 2 h and aged for 15 min. The slurry was filtered,
and the cake was washed with isopropyl acetate/isopropyl
alcohol (3× 40 L) and dried in a vacuum oven at 65 °C to
yield 33 as a white solid (36.6 kg, 81%). 1H NMR (500 MHz,
DMSO-d6) δ 0.91 (s, 6 H), 1.17-1.25 (m, 2 H), 1.51-1.60
(m, 2 H), 1.63-1.79 (m, 2 H), 1.84-1.92 (m, 4 H), 2.15 (br s,
2 H), 2.35-2.43 (m, 2 H), 2.70-2.79 (m, 1 H), 2.91-3.17 (m,
3 H), 3.26-3.30 (m, 1 H), 3.95-3.99 (m, 2 H), 4.79-4.85 (m,
2 H), 5.30 (s, 2 H), 6.61 (s, 2 H), 6.79-6.86 (m, 3 H),
7.13-7.20 (dd, J ) 21 Hz, 9 Hz, 2 H), 7.35-7.97 (m, 9 H),
8.02-8.04 (m, 1 H), 8.29 (d, J ) 5 Hz, 1 H), 8.51 (d, J ) 15
Hz, 1 H); MS: MH+ ) 645.
Preparation of 3-(4-{[4-(4-{[3-(3,3-Dimethyl-1-piperidinyl)-
propyl]oxy}phenyl)-1-piperidinyl]carbonyl}-1-naphthalenyl)-
propanoic Acid Hydrochloride (10). 33 (23.5 kg) was slurried
in butanone (235 L) and aqueous potassium carbonate (20%
w/w, 118 L) added. The biphasic solution was stirred at 25 (
3 °C for 15 min, the layers were separated, and the aqueous
phase was discarded. Aqueous potassium carbonate (20% w/w,
118 L) was added to the butanone layer, the biphasic mixture
was stirred for 15 min at 25 ( 3 °C, and the layers were
separated, the aqueous phase discarded. The butanone layer was
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