Organic Process Research & Development
Article
3
2
catalytic systems. Addition of 20 mol % of potassium
benzoate showed no deleterious effect on conversion.
No issues with exotherms or formation of emulsions took place
during the workup while achieving a similar Process Mass
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Based on the previous observations, the following scheme
depicts the proposed fate of the ester substrate (Scheme 2).
Intensity (PMI). Furthermore, the composition of the
resulting waste streams was more favorable. In addition to
the desired product, hydrolysis side product (3) and desbromo
side product (4) were observed by HPLC as low-level
impurities (Scheme 4).
Scheme 2. Fate of Ester
Scheme 4. Isolated Side Products from Reduction of Methyl
6
-Bromo-2-naphthoate
The hydrolysis side product (3) formed while affecting the
yield was readily removed by performing a basic wash. The
desbromo side product (4), thought to form as a result of trace
palladium present in the vessel, was not readily purged.
Following on from this, we investigated transferring the
hydrogenation of methyl 6-bromo-2-naphthoate to a con-
tinuous flow reactor. The potential benefits of this would be to
allow access to higher temperatures/pressures in a safer
manner, should this be necessary as a means of intensifying the
process. The key challenge to overcome based on previous
batch observations was the issue of solids being generated over
the course of the reaction, which would likely block
conventional tubing or capillaries. As such, a bespoke CSTR
flow reactor available from Autichem Ltd. was examined with
the following setup (Figure 7).
The two inputs into the reactor are hydrogen gas and the
reaction mixture consisting of methyl 6-bromo-2-naphthoate,
KOt-Bu, Ru(PNP) (I), and 2-MeTHF, which were made up in
a feed tank. As the liquid phase enters the reactor, the rotating
agitator ensured efficient gas−liquid contact. The rate at which
the mixture was pumped gave control over the residence time.
In addition to giving a plug-flow-like behavior, this setup has
the added benefit of having a greater tolerance for solids as the
agitator helped mobilize slurries. Initial runs resulted in no
conversion, as KOt-Bu had settled within the feed tank in
which the reaction mixture was made up and thus did not enter
the reactor. This issue was resolved by replacing solid KOt-Bu
with KOt-Bu as a solution in THF to give a homogeneous feed
solution. The results from the runs following this are
summarized below (Table 4).
During the induction period, hydrolysis and transesterification
with the base take place. Upon formation of the active catalytic
species, reduction of either ester takes place. This initially
forms an aldehyde, possibly as a short-lived intermediate or
masked as a hemiacetal or hydrate, and then is further reduced
to the product alcohol. The product may then undergo
transesterification with the starting material to give a
homocoupled ester; this too, given enough time may reduce
to the product alcohol. With the exception of the hydrolysis
side product, all other substrates eventually react to give the
product.
With this knowledge in hand, two of the previously
identified pharmaceutically relevant intermediates were con-
sidered for further examination. First, the reduction of methyl
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6
-bromo-2-naphthoate was performed on a 10 g scale
(Scheme 3).
Scheme 3. Reduction of Methyl 6-bromo-2-naphthaote
The setup was operationally straightforward and worked
with minimal complications to afford a suspension of the
product. Long residence times were required to achieve high
conversions. The longest residence time (54 min) would allow
5
0 g of substrate to be reduced in ∼17 h. While the reactor
The reaction was run in a 500 mL glass-jacketed vessel.
Solids were observed to precipitate out of the solution as the
reaction proceeded, presumably due to the product alcohol
being less soluble in the reaction solvent, 2-MeTHF, than the
starting material. The reaction was left overnight, after which
the rate of gas consumption had plateaued. At this stage, the
reaction mixture was sampled, and complete consumption of
starting material was indicated. Isolation of the product was
performed by aqueous extraction, followed by a put-and-take
distillation with addition of isooctane. Compared to the
existing process in which the reduction was performed with
DIBAL-H, the isolation procedure was significantly simplified.
itself was rated to higher temperatures and pressures, other
components in this particular setup were rated to a maximum
of 7 bar of pressure. Throughput could in principle be
increased by applying higher temperatures and pressures.
Furthermore, larger variants of these reactors are commercially
available.
Following on from this, we focused our attention on the
large-scale reduction of methyl 6-methylnicotinate, another
pharmaceutically relevant intermediate (Scheme 5). The
reaction was performed in a 5 L Hastelloy pressure reactor
equipped with a gas entrainment impeller. A lower catalyst
loading (0.1 mol %) was used without loss of activity.
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Org. Process Res. Dev. XXXX, XXX, XXX−XXX