24 L. Cyclohexane (48 L) was added to the reaction vessel,
and distillation was again repeated at an internal temperature
of 45-50 °C under vacuum until the volume of solution in
the vessel was reduced to 24 L. A second portion of
cyclohexane (48 L) was added to the reaction vessel, and
distillation was again repeated at an internal temperature of
45-50 °C under vacuum until the volume of solution in the
vessel was reduced to 24 L. While the temperature was held
at 50 °C, the solution was seeded with 24 and allowed to
granulate while stirring 2 h. The solution was then cooled
slowly (over 1.5 h) to room temperature and allowed to
granulate while stirring for 15 h. The mixture was filtered.
The resulting solids were rinsed with cyclohexane (10 L)
and dried under vacuum at 40 °C to afford 7504 g of solids
that contained 7 wt % of residual cyclohexane; further drying
was not necessary for continuation of the process. This
provided a theoretical recovery of 6979 g (94%) of 24;
analytical data is presented for a solvent-free sample: mp
142.3-142.4. 1H NMR (400 MHz, d6-acetone) δ 0.96 (t, 3,
J ) 7.4), 1.55-1.75 (m, 2), 2.86 (dd, 1, J ) 6.6, 16.2), 2.96
(dd, 1, J ) 6.2, 16.2), 3.69 (s, 3), 3.92-3.99 (m, 1), 5.49
(br d, 1, J ) 8.7), 6.76 (d, 2, J ) 8.7), 7.37 (d, 2, J ) 8.7),
9.42 (br s, 1). 13C NMR (100 MHz, CDCl3) δ 10.6, 28.1,
40.2, 51.5, 53.4, 112.5, 119.0 (q, J ) 32.70), 125.2 (q, J )
270.2), 126.9 (q, J ) 3.8), 150.1, 152.7, 173.4. Anal. Calcd
for C14H17F3N2O3: C, 52.83; H, 5.38; N, 8.80. Found: C,
52.71; H, 5.37; N, 8.80.
(2R,4S)-(2-Ethyl-6-trifluoromethyl-1,2,3,4-tetrahydro-
quinolin-4-yl)carbamic Acid Methyl Ester (25). To a clean,
dry 100-L glass reactor was charged 24 (7474 g of a lot that
contains 7% solvent, theoretical 6951 g, 21.84 mol) followed
by EtOH (46 L, denatured with 0.5% toluene) and water
(2.35 L). NaBH4 (620 g, 11-mm pellets, 16.4 mol) was added
to the solution in one portion. Some off-gassing of hydrogen
occurred; nitrogen gas purging was maintained. The mixture
was stirred at room temperature for 20 min and then cooled
to -10 °C. A solution of 3.3 M aq MgCl2 solution (4.68 kg
of MgCl2‚6H2O, 23.0 mol in 7 L of water) was added at
such a rate that the internal temperature did not exceed -5
°C. Once addition was complete, the reaction solution was
warmed to 0 °C for 45 min. The reaction was quenched by
transferring the reaction mixture to a 200-L reactor containing
methylene chloride (70 L), and 1 M HCl/citric acid solution
(5.8 L of concentrated HCl, 64 L of water, and 10.5 kg of
citric acid). The headspace of the reactor was purged with
nitrogen gas since the quench liberates some H2. This bilayer
was stirred at room temperature for 2 h. The phases were
separated, and the lower organic product layer was removed.
After aqueous layer removal, the organic phase was returned
to the reaction vessel and extracted with an aqueous citric
acid solution (6.3 kg of citric acid, 34 L of water). The
mixture was stirred for 1 h and allowed to settle overnight.
The layers were separated, and to the organic phase was
added Darco activated carbon (G-60 grade, 700 g), and the
solution was stirred for 30 min. The mixture was filtered
through Celite, and the carbon was rinsed twice with
methylene chloride (14 and 8 L). The filtrate was distilled
while periodically adding hexanes so as to displace the
methylene chloride with hexanes to a total final volume of
70 L (the internal volume was kept at approximately 65-
70 L, total hexanes used ) 112 L). Product crystallized
during the displacement. Once a stable distillation temper-
ature was reached, the solution was cooled and granulated
at room temperature for 10 h. The solids were filtered off,
rinsed with hexanes (14 L), and dried at 40 °C under vacuum
to provide 5291 g (80%) of 25: mp 139.0-140.5. 1H NMR
(400 MHz, d6-acetone) δ 1.00 (t, 3, J ) 7.5), 1.51-1.67
(m, 3), 2.19 (ddd, 1, J ) 2.9, 5.4, 12.4), 3.44-3.53 (m, 1),
3.67 (s, 3), 4.89-4.96 (m, 1), 5.66 (br s, 1), 6.56 (br d, 1, J
) 8.7), 6.65 (d, 1, J ) 8.7), 7.20 (d, 1, J ) 8.7), 7.30 (br s,
1). 13C NMR (100 MHz, CDCl3) δ 9.9, 29.2, 35.5, 48.1,
52.4, 52.6, 113.7, 118.9 (q, J ) 33.1), 121.4, 124.1 (q, J )
3.8), 125.1 (q, J ) 270.6), 125.7 (q, J ) 3.8), 147.7, 157.3.
Anal. Calcd for C14H17F3N2O2: C, 55.62; H, 5.67; N, 9.27.
Found: C, 55.68; H, 5.78; N, 9.31.
(2R,4S)-2-Ethyl-4-methoxycarbonylamino-6-trifluoro-
methyl-3,4-dihydro-2H-quinoline-1-carboxylic Acid Ethyl
Ester (26). To a clean, dry 100-L glass reactor was charged
25 (5191 g, 17.17 mol), methylene chloride (21 L), and
pyridine (4.16 L, 51.4 mol). The reaction vessel was cooled
to -10 °C. Ethyl chloroformate (4.10 L, 42.9 mol) was
slowly added at such a rate that the internal temperature did
not exceed -5 °C (jacket temperature was set at -25 °C to
absorb exotherm). The reaction solution was brought to 0
°C and held for 20 h. The reaction was quenched by adding
to a mixture of IPE (36 L), CH2Cl2 (6.2 L), and 1.5 M HCl
solution (52 L). The resulting phases were separated, and
the organic layer was extracted with 1 M NaOH solution
(15 L). The resulting phases were separated, and the organic
layer was extracted with a sat. aq NaCl solution (15 L). The
resulting phases were separated, and the organic layer was
concentrated by distillation to a volume of 40 L. Crystal-
lization initiated at the lower volume. The CH2Cl2 was
displaced with IPE by distilling the mixture and periodically
adding IPE to maintain a constant volume at ∼40 L until a
distillation temperature of 68 °C was maintained (46 L total
IPE used). The mixture was cooled and allowed to granulate
with stirring at room temperature for 19 h. The solids were
filtered, rinsed with IPE (8 L), and dried under vacuum at
40 °C to provide 5668 g (88%) of 26: mp 157.3-157.6. 1H
NMR (400 MHz, d6-acetone) δ 0.84 (t, 3, J ) 7.5), 1.26 (t,
3, J ) 7.0), 1.44-1.73 (m, 3), 2.59 (ddd, 1, J ) 4.6, 8.3,
12.9), 3.67 (s, 3), 4.14-4.28 (m, 2), 4.46-4.54 (m, 1), 4.66-
4.74 (m, 1), 6.82 (br d, 1, J ) 9.1), 7.53 (s, 1), 7.58 (d, 1,
J ) 8.3), 7.69 (d, 1, J ) 8.3). 13C NMR (100 MHz, CDCl3)
δ 9.9, 14.6, 28.5, 38.1, 46.9, 52.6, 53.7, 62.4, 120.8 (q, J )
3.4), 124.32 (q, J ) 271.7), 124.36 (q, J ) 3.4), 126.38,
126.46 (q, J ) 32.7), 134.7, 139.7, 154.7, 156.9. Anal. Calcd
for C17H21F3N2O4: C, 54.54; H, 5.65; N, 7.48. Found: C,
54.50; H, 5.68; N, 7.55.
(2R,4S)-4-[(3,5-Bis(trifluoromethyl)benzyl)methoxy-
carbonylamino]-2-ethyl-6-trifluoromethyl-3,4-dihydro-2H-
quinoline-1-carboxylic Acid Ethyl Ester (1). To a clean,
dry 100-L glass reactor was charged 26 (5175 g, 13.82 mol),
CH2Cl2 (20 L), and potassium tert-butoxide (1551 g, 13.82
mol) at room temperature. The mixture was stirred for 5 min.
Vol. 10, No. 3, 2006 / Organic Process Research & Development
•
479