Cover Page

Contents

Cover

Related Titles

Title Page

Copyright

Foreword 1

Foreword 2

Foreword 3

List of Contributors

Introduction

List of Abbreviations

Chapter 1: Copper-Catalyzed Coupling for a Green Process

1.1 Introduction

1.2 Synthesis of Amino Acid 14

1.3 Copper-Catalyzed Cyclization

1.4 Sustainability

1.5 Summary

Acknowledgments

References

Chapter 2: Experiences with Negishi Couplings on Technical Scale in Early Development

2.1 Introduction

2.2 Synthesis of LBT613 via Pd-Catalyzed Negishi Coupling

2.3 Elaboration of a Negishi Coupling in the Synthesis of PDE472

2.4 Ni-Catalyzed Negishi Coupling with Catalytic Amounts of ZnCl2

2.5 Conclusions

References

Chapter 3: Developing Palladium-Catalyzed Arylations of Carbonyl-Activated C–H Bonds

3.1 Introduction

3.2 Suzuki Approach to Side Chain Installation

3.3 Arylation of Carbonyl-Activated C–H Bonds

3.4 Pd Purging from API

3.5 Conclusions

References

Chapter 4: Development of a Practical Synthesis of Naphthyridone p38 MAP Kinase Inhibitor MK-0913

4.1 Introduction

4.2 Medicinal Chemistry Approach to 1

4.3 Results and Discussion

4.4 Conclusions

References

Chapter 5: Practical Synthesis of a Cathepsin S Inhibitor

5.1 Introduction

5.2 Synthetic Strategy

5.3 Syntheses of Building Blocks

5.4 Sonogashira Coupling and Initial Purification of 1

5.5 Salt Selection

5.6 Conclusions

Acknowledgments

References

Chapter 6: C–N Coupling Chemistry as a Means to Achieve a Complicated Molecular Architecture: the AR-A2 Case Story

6.1 A Novel Chemical Entity

6.2 Evaluation of Synthetic Pathways: Finding the Best Route

6.3 Enabling C–N Coupling by Defining the Reaction Space

6.4 From Synthesis to Process

6.5 Concluding Remarks

References

Chapter 7: Process Development and Scale-up of PF-03941275, a Novel Antibiotic

7.1 Introduction

7.2 Medicinal Chemistry Synthesis of PF-03941275

7.3 Synthesis of 5-Bromo-2,4-difluorobenzaldehyde (1)

7.4 Synthesis of Amine 3

7.5 Miyaura Borylation Reaction

7.6 Suzuki–Miyaura Coupling

7.7 Barbituric Acid Coupling

7.8 Chlorination and API Isolation

7.9 Conclusions

Acknowledgments

References

Chapter 8: Development of a Practical Negishi Coupling Process for the Manufacturing of BILB 1941, an HCV Polymerase Inhibitor

8.1 Introduction and Background

8.2 Stille Coupling

8.3 Suzuki Coupling

8.4 Negishi Coupling

8.5 Comparison of Three Coupling Processes

References

Chapter 9: Application of a Rhodium-Catalyzed, Asymmetric 1,4-Addition to the Kilogram-Scale Manufacture of a Pharmaceutical Intermediate

9.1 Introduction

9.2 Early Development

9.3 Process Optimization

9.4 Process Scale-up

9.5 Recent Developments

9.6 Conclusions

Acknowledgments

References

Chapter 10: Copper-Catalyzed C–N Coupling on Large Scale: An Industrial Case Study

10.1 Introduction

10.2 Process Development of the C–N Bond Formation

10.3 Choice of Catalytic System

10.4 Choice of Base: Inorganic versus Organic

10.5 Choice of Solvent

10.6 Optimized Conditions for C–N Bond Formation to 1

10.7 Purging Residual Copper from 1

10.8 Conclusions

References

Chapter 11: Development of a Highly Efficient Regio- and Stereoselective Heck Reaction for the Large-Scale Manufacture of an α4β2 NNR Agonist

11.1 Introduction

11.2 Process Optimization

11.3 Conclusions

Acknowledgments

References

Chapter 12: Commercial Development of Axitinib (AG-013736): Optimization of a Convergent Pd-Catalyzed Coupling Assembly and Solid Form Challenges

12.1 Introduction

12.2 First-Generation Synthesis of Axitinib

12.3 Early Process Research and Development

12.4 Commercial Route Development

12.5 Conclusions

Acknowledgments

References

Chapter 13: Large-Scale Sonogashira Coupling for the Synthesis of an mGluR5 Negative Allosteric Modulator

13.1 Introduction

13.2 Background

13.3 Process Development of the Sonogashira Coupling

13.4 Large-Scale Sonogashira Coupling and API Purification

13.5 Conclusions

Acknowledgments

References

Chapter 14: Palladium-Catalyzed Bisallylation of Erythromycin Derivatives

14.1 Introduction

14.2 Discovery of 6,11-O,O-Bisallylation of Erythromycin Derivatives

14.3 Process Development of 6,11-O,O -Bisallylation of Erythromycin Derivatives

14.4 Discovery and Optimization of 3,6-Bicyclolides

14.5 Conclusions

Acknowledgments

References

Chapter 15: Route Selection and Process Development for the Vanilloid Receptor-1 Antagonist AMG 517

15.1 Introduction

15.2 Retrosynthesis and Medicinal Chemistry Route

15.3 Optimization of Medicinal Chemistry Route

15.4 Identification of the Process Chemistry Route

15.5 Optimization of the Suzuki–Miyaura Reaction

15.6 Postcampaign Improvements

15.7 Summary

Acknowledgments

References

Chapter 16: Transition Metal-Catalyzed Coupling Reactions in the Synthesis of Taranabant: from Inception to Pilot Implementation

16.1 Introduction

16.2 Development of Pd-Catalyzed Cyanations

16.3 Development of Pd-Catalyzed Amidation Reactions

16.4 Conclusions

References

Chapter 17: Ring-Closing Metathesis in the Large-Scale Synthesis of SB-462795

17.1 Background

17.2 The RCM Disconnection

17.3 The RCM of Diene 5

Acknowledgments

References

Chapter 18: Development of Migita Couplings for the Manufacture of a 5-Lipoxygenase Inhibitor

18.1 Introduction

18.2 Evaluation of the Sulfur Source for Initial Migita Coupling

18.3 Selection of Metal Catalyst and Coupling Partners

18.4 Development of a One-Pot, Two-Migita Coupling Process

18.5 Crystallization of 1 with Polymorph Control

18.6 Final Commercial Process on Multikilogram Scale

18.7 Conclusions

Acknowledgments

References

Chapter 19: Preparation of 4-Allylisoindoline via a Kumada Coupling with Allylmagnesium Chloride

19.1 Introduction

19.2 Kumada Coupling of 4-Bromoisoindoline

19.3 Workup

19.4 Isolation

19.5 Conclusions

Acknowledgments

References

Chapter 20: Microwave Heating and Continuous-Flow Processing as Tools for Metal-Catalyzed Couplings: Palladium-Catalyzed Suzuki–Miyaura, Heck, and Alkoxycarbonylation Reactions

20.1 Introduction

20.2 Coupling Reactions Performed Using Microwave Heating or Continuous-Flow Processing

20.3 Conclusions

Acknowledgments

References

Chapter 21: Applying the Hydrophobic Effect to Transition Metal-Catalyzed Couplings in Water at Room Temperature

21.1 Introduction: the Hydrophobic Effect Under Homogeneous and Heterogeneous Conditions

21.2 Micellar Catalysis Using Designer Surfactants

21.3 First Generation: PTS

21.4 Heck Couplings in Water at rt

21.5 Olefin Metathesis Going Green

21.6 Adding Ammonia Equivalents onto Aromatic and Heteroaromatic Rings

21.7 Couplings with Moisture-Sensitive Organometallics in Water

21.8 A New, Third-Generation Surfactant: “Nok”

21.9 Summary, Conclusions, and a Look Forward

References

Chapter 22: Large-Scale Applications of Transition Metal Removal Techniques in the Manufacture of Pharmaceuticals

22.1 Introduction

22.2 Methods that Precipitate or Capture/Extract the Metal while Maintaining the Coupling Product in Solution

22.3 Methods that Precipitate the Coupling Product while Purging the Metal to the Filtrates

22.4 Miscellaneous Methods

22.5 Other Methods for Metal Removal

22.6 Conclusions

Acknowledgments

References

Index

Related Titles

de Meijere, A., Bräse, S., Oestreich, M. (eds.)

Metal Catalyzed Cross-Coupling Reactions and More

2014

ISBN: 978-3-527-33154-3

Zaragoza Dörwald, F.

Lead Optimization for Medicinal Chemists

Pharmacokinetic Properties of Functional Groups and Organic Compounds

2012

ISBN: 978-3-527-33226-7

Shioiri, T., Izawa, K., Konoike, T. (eds.)

Pharmaceutical Process Chemistry

2011

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Yudin, A. K. (ed.)

Catalyzed Carbon-Heteroatom Bond Formation

2011

ISBN: 978-3-527-32428-6

Hall, D. G. (ed.)

Boronic Acids

Preparation and Applications in Organic Synthesis, Medicine and Materials

Second, Completely Revised Edition

2011

ISBN: 978-3-527-32598-6

Blaser, H.-U., Federsel, H.-J. (eds.)

Asymmetric Catalysis on Industrial Scale

Challenges, Approaches and Solutions

Second Edition

2010

ISBN: 978-3-527-32489-7

Dunn, P., Wells, A., Williams, M. T. (eds.)

Green Chemistry in the Pharmaceutical Industry

2010

ISBN: 978-3-527-32418-7

Nugent, T. C. (ed.)

Chiral Amine Synthesis

Methods, Developments and Applications

2010

ISBN: 978-3-527-32509-2

Title Page

To Kari, Ana, and Sonia, for their love and support. And to my parents, for their gift of a good education.

– Javier Magano

For Cynthia, for Caitlin.

– Joshua R. Dunetz

Foreword 1

The ever-increasing impact of transition metal catalysis on organic synthesis can be seen in our day-to-day reading of the top chemistry journals. The Nobel Prizes to Sharpless, Noyori, and Knowles (2001), Schrock, Grubbs, and Chauvin (2005), and Heck, Suzuki, and Negishi (2010) further highlighted the importance of catalytic processes in everyday synthetic chemistry. As the methodology matures, its application on larger scale in the pharmaceutical industry is investigated at an increasing rate. Key to success in this endeavor is the development of reliable and cost-effective protocols. Each example of the use of a given technique demonstrated on a large scale gives industrial chemists increased confidence about employing it in their own work in pharmaceutical process chemistry and manufacturing settings.

Catalytic chemistry as practiced today offers synthetic chemists a wide array of different approaches to effect the same bond disconnection. As can be seen in many of the examples described in this book, the synthetic route is something that evolves over time. Beginning with the medicinal chemistry route, process chemists look for improvements in terms of safety, yield, robustness, and, ultimately, cost. Even when the identities of the basic steps that will be utilized become clear, a significant amount of work remains. This is a result of the tremendous number of different catalysts, ligands, and reaction conditions that have been developed to accomplish almost any important transformation. Thus, a standard aspect of the synthetic chemists approach has been to screen a series of different reaction parameters in order to arrive at the optimal reaction conditions. The calculus of deciding, for example, which catalyst to utilize in a carbon–carbon cross-coupling reaction can be quite complex. In addition to the efficiency of the catalyst (in terms of both yield and volumetric productivity), the cost and availability of the ligand need to be considered. Moreover, the use of less expensive metals such as nickel, iron, or copper, rather than palladium, is often explored. In addition, there may be a benefit to using a simpler ligand and an aryl bromide (typically more expensive), rather than a more complex one that allows one to use an aryl chloride coupling partner. Superimposed on this is whether patent considerations limit the use of any given technology and, if so, how onerous are the licensing terms.

From the perspective of one who develops new catalysts and synthetic methods, an examination of case studies, such as the ones in this book, is most enlightening. Issues that are often not considered in depth in academic circles (e.g., the need to employ cryogenic conditions, the concentration of reagents, particularly avoiding high dilution reactions, and problems with reaction workup on scale) may hold the key to whether a given process might be applicable in the final manufacturing route.

It is clear that catalytic methods will have an ever more important role in the manufacturing of fine chemicals. Both societal and economic pressures will place an increasing emphasis on greener processes. In order to achieve success, the advent of new and more efficient catalysts and synthetic methods will be required. The lessons presented in this book will be invaluable to synthetic chemists working to develop more efficient processes. Specifically, chemists should make an effort to test their new reactions on increasingly complex substrates, particularly on heterocycle-containing ones. For it is here where their methods will have the greatest impact on the “real-world” practice of synthetic chemistry.

Stephen L. Buchwald

Camille Dreyfus Professor of Chemistry

Massachusetts Institute of Technology

Foreword 2

Industrial process chemists often rely on academic discoveries of new chemical reactions, catalysts, or ligands when designing novel synthetic routes to complex target molecules such as pharmaceuticals. The best chemistry is quickly taken up by industry and used in manufacturing processes, none more so than transition metal-catalyzed coupling reactions, which have proved so versatile in synthetic chemistry over the past 20 years. Many of these reactions have been named after their inventors, some of whom have been awarded the Nobel Prize for their discoveries and for their outstanding work.

A negative aspect of transition metal-catalyzed couplings for the process chemist is that the catalysts and ligands can be expensive and have the potential to increase process costs. So, for efficient manufacture of pharmaceuticals, the process chemist not only has to focus on obtaining a high yield but also has to study the reaction conditions in detail and examine catalyst turnover number and frequency, and in some cases catalyst/ligand recycling and reuse. Understanding the complex mechanism of these reactions leads to better process control and batch-to-batch consistency as well as process robustness for large-scale operation.

Many transition metal-catalyzed couplings can be adversely affected by impurities in raw materials or solvents and lack of reproducibility can sometimes ensue. The temptation to abandon this chemistry and find something more reproducible should be avoided since a detailed and painstaking study of the effect of small amounts of process impurities on catalyst performance usually results in an efficient and robust process – perseverance pays off! Understanding the detailed interactions, mechanisms, side reactions, and so on is part of the fascination of process chemistry.

Process chemists are expert at examining the effect of changing reaction parameters on yield and product quality; these days statistical methods of optimization such as design of experiments and principal component analysis (still surprisingly not taught in many university chemistry departments) are widely used to maximize yield, minimize impurity formation, and optimize space–time yield (a useful measure of process throughput) to produce an efficient, scalable, and robust process.

Transition metal-catalyzed couplings can also present unusual difficulties for the process chemist with regard to product workup and isolation, since the often toxic and usually homogeneous catalyst needs to be removed from the pharmaceutical product to ppm levels. Transition metals are notorious for liking to complex with the type of molecules used in the pharmaceutical industry, and special technologies and/or novel reagents need to be used in the workup and isolation strategies. Detailed crystallization studies may also be required to produce products within specification.

In the case studies presented in this unique book, the chapter authors provide fascinating stories of the innovative process research and development needed to convert a transition metal-catalyzed coupling reaction into an economic and robust manufacturing process for the manufacture of kilograms or even tons of complex products in high purity. The trials and tribulations are described for all to see. The editors and chapter authors are to be congratulated on producing an outstanding work that should be of value not only to process chemists but also to those teaching industrial applications of academic discoveries.

Trevor Laird

Scientific Update LLP

Editor, Organic Process Research and Development

Foreword 3

Selecting metals and designing ligands for transformations in organic chemistry, mostly hydrogenations and couplings, were largely academic pursuits for several decades. As these reactions became increasingly popular, chemists in industry applied them to the synthesis of many drug candidates. The value of transition metal-catalyzed cross-couplings was evident in the pharmaceutical industry since the 1990s with the manufacturing of the family of sartans, antihypertensive agents.1 The power of transition metal-catalyzed couplings was recognized with the Nobel Prize awarded in 2010 to Professors Heck, Negishi, and Suzuki.

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Transition metal-catalyzed couplings are more complicated to optimize than many organic reactions, especially for researchers in industrial process R&D. On scale, the charges of expensive transition metals and ligands are minimized, as the benefits of any increased selectivity from the catalyst must be balanced with the overall contribution to the cost of goods and with any difficulties encountered during workup and isolation. On scale, the transition metals charged may be recovered and reused. The amount of water in a process often must be controlled, as water can activate or deactivate reactions and produce impurities such as those from protodeboronation in Suzuki couplings. Starting materials, for example, halides or sulfonates, may be chosen to promote reactivity and decrease excess charges needed; starting materials may also be selected to mitigate reactivity or minimize the formation of by-products, such as those from olefin migration. Processes must be well understood both to avoid the introduction of inhibitors and to control the generation of inhibitors, thus minimizing the charges of metal and ligands and making operations more rugged. Some transition metal-catalyzed reactions are driven by equilibrium, necessitating the development of practical workups to quench reactive conditions; simply pouring a reaction mixture onto a column of silica gel as is often done in the laboratory may be ineffective on scale. Last but not least, removing the metals to control the quality of the product can influence the workup and isolation of the product. These considerations are discussed in this book.

Many of the investigations in these chapters were oriented toward preparing tens to hundreds of kilograms of products from transition metal-catalyzed couplings. In the case studies, critical considerations ranged from selection of routes and starting materials to reducing cycle times on scale. Details of some manufacturing processes are also divulged. Routinely conducting processes on scale is the culmination of many efforts and demonstrates the thorough understanding of the process chemist and engineer.

In addition to the case studies in these chapters, two valuable chapters from academia are included. The chapter from Professor Leadbeater describes conditions using both microwave heating and continuous operations, which can be useful for making larger amounts of material with minimal process development. The chapter from Professor Lipshutz, recipient of a US Presidential Green Chemistry Award in 2011, describes the use of emulsions for running moisture-sensitive reactions in largely aqueous media. This area will also be fruitful for future transition metal-catalyzed scale-ups.

Cost considerations will become even more crucial to process development in industry. Environmental and toxicity considerations may make the selection of some solvents and transition metals less attractive, and these will affect the cost of goods and influence process development. The availability of some transition metals may be affected by international politics, resulting in increased costs. We will probably see the increased use of catalysts containing less expensive transition metals, perhaps doped with small amounts of other metals; examples might be iron catalysts containing palladium or copper [3,4]. With the use of different transition metals, different ligands will likely be designed. Extremely small charges of transition metals and ligands can be effective [5], making the recovery of metals no longer economical [6]. Thorough understanding will continue to be critical for developing rugged catalytic processes.

Javier Magano and Joshua Dunetz put a huge amount of work into their 2011 review “Large-scale applications of transition metal-catalyzed couplings for the synthesis of pharmaceuticals” [7]. Therein, they described details of the reaction sequences, workup conditions used to control the levels of residual metals, and critical analyses of the advantages and disadvantages of such processes run on scale. These considerations are evident in this book too, as Javier and Josh have extended the analyses for developing practical processes to scale up transition metal-catalyzed reactions. This book will also be important in the continuing evolution of chemical processes. I am sure that this valuable book will stimulate many thoughts for those involved in process R&D of transition metal-catalyzed processes.

Neal G. Anderson

Anderson's Process Solutions LLC

Author of “Practical Process Research & Development – A Guide for Organic Chemists”

Note

1. The “sartan” family of drugs is widely prescribed to treat hypertension. Losartan potassium was marketed in 1995, and at least five other antihypertensive agents with ortho -substituted, unsymmetrical biaryl moieties have been marketed since then [1]. Many of these APIs could be manufactured by reaction of amines with the commercially available 4′-(bromomethyl)biphenyl-2-carbonitrile, which can be derived by bromination of o -tolylbenzonitrile (OTBN). A group from Catalytica described Ni- and Pd-catalyzed preparations of OTBN using inexpensive components [2].

References

1. Yet, L. (2007) Chapter 9: Angiotensin AT1 antagonists for hypertension, in The Art of Drug Synthesis (eds D.S. Johnson and J.J. Li), John Wiley & Sons, Inc., New York, pp 129–141.

2. (a) Miller, J.A. and Farrell, R.P. (1998) Tetrahedron Lett., 39, 6441; (b) Miller, J.A. and Farrell, R.P. (2001) US Patent 6,194,599 (to Catalytica, Inc.).

3. Laird, T. (2009) Org. Process Res. Dev., 13, 823.

4. Buchwald, S.L. and Bolm, C. (2009) Angew. Chem., Int. Ed., 48, 5586.

5. Arvela, R.K., Leadbeater, N.E., Sangi, M.S., Williams, V.A., Granados, P., and Singer, R.D. (2005) J. Org. Chem., 70, 161.

6. For some examples, see Corbet, J.-P. and Mignani F G. (2006) Chem. Rev., 106, 2651.

7. Magano, J. and Dunetz, J.R. (2011) Chem. Rev., 111, 2177.

List of Contributors

Murat Acemoglu

Novartis Pharma

Chemical & Analytical Development

4002 Basel

Switzerland

David J. Ager

DSM Innovative Synthesis B.V.

950 Strickland Road, Suite 103

Raleigh, NC 27615

USA

Markus Baenziger

Novartis Pharma

Chemical & Analytical Development

4002 Basel

Switzerland

Carl A. Busacca

Boehringer Ingelheim Pharmaceuticals, Inc.

Chemical Development

900 Ridgebury Road

Ridgefield, CT 06877

USA

Weiling Cai

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Brian Chekal

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

John Y.L. Chung

Merck Research Laboratories

Global Process Chemistry

126 E. Lincoln Ave

Rahway, NJ 07065

USA

David Damon

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Xiaohu Deng

Janssen Research & Development LLC

3210 Merryfield Row

San Diego, CA 92121

USA

Johannes G. de Vries

DSM Innovative Synthesis B.V.

6160 MD Geleen

The Netherlands

Joshua R. Dunetz

Pfizer Worldwide Research & Development

Chemical Research & Development

Eastern Point Road

Groton, CT 06340

USA

Vittorio Farina

Boehringer Ingelheim Pharmaceuticals, Inc.

Chemical Development

900 Ridgebury Road

Ridgefield, CT 06877

USA

and

Janssen Pharmaceutica

Department of Pharmaceutical Development and Manufacturing Sciences

Turnhoutseweg 30

2340 Beerse

Belgium

Roger M. Farr

Wyeth Pharmaceuticals

Department of Chemical and Pharmaceutical Development

401 N. Middletown Rd.

Pearl River, NY 10965

USA

Hans-Jürgen Federsel

AstraZeneca

Pharmaceutical Development

Silk Road Business Park

Macclesfield Cheshire SK10 2NA

UK

Mousumi Ghosh

Wyeth Pharmaceuticals

Department of Chemical and Pharmaceutical Development

401 N. Middletown Rd.

Pearl River, NY 10965

USA

Martin Hedberg

SP Technical Research Institute of Sweden

SP Process Development AB

15121 Södertälje

Sweden

Kevin E. Henegar

Pfizer Worldwide Research & Development

Chemical Research & Development

Eastern Point Road

Groton, CT 06340

USA

Rolf Herter

Boehringer Ingelheim Pharmaceuticals, Inc.

Chemical Development

900 Ridgebury Road

Ridgefield, CT 06877

USA

Azad Hossain

Boehringer Ingelheim Pharmaceuticals, Inc.

Chemical Development

900 Ridgebury Road

Ridgefield, CT 06877

USA

Timothy A. Johnson

Pfizer Veterinary Medicine Research & Development

Medicinal Chemistry

333 Portage Street

Kalamazoo, MI 49007

USA

Christoph M. Krell

Novartis Pharma

Chemical & Analytical Development

4002 Basel

Switzerland

Danny LaFrance

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Nicholas E. Leadbeater

University of Connecticut

Department of Chemistry

55 North Eagleville Road

Storrs, CT 06269

USA

Kyle Leeman

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Guisheng Li

Boehringer Ingelheim Pharmaceuticals, Inc.

Chemical Development

900 Ridgebury Road

Ridgefield, CT 06877

USA

Jimmy Liang

Janssen Research & Development LLC

3210 Merryfield Row

San Diego, CA 92121

USA

Bruce H. Lipshutz

University of California

Department of Chemistry & Biochemistry

Santa Barbara, CA 93106

USA

Bruce Z. Lu

Boehringer Ingelheim Pharmaceuticals, Inc.

Chemical Development

900 Ridgebury Road

Ridgefield, CT 06877

USA

Javier Magano

Pfizer Worldwide Research & Development

Chemical Research & Development

Eastern Point Road

Groton, CT 06340

USA

Neelakandha S. Mani

Janssen Research & Development LLC

3210 Merryfield Row

San Diego, CA 92121

USA

Wolfgang Marterer

Novartis Pharma

Chemical & Analytical Development

4002 Basel

Switzerland

Carlos Mojica

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Andrew Palm

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Alexandra Parker

AstraZeneca

Pharmaceutical Development

Silk Road Business Park, Charter Way

Macclesfield, Cheshire SK10 2NA

UK

Xiaowen Peng

Enanta Pharmaceuticals, Inc.

Chemistry Department

500 Arsenal Street

Watertown, MA 02472

USA

Fredrik R. Qvarnström

AstraZeneca

Pharmaceutical Development

15185 Södertälje

Sweden

Arianna Ribecai

F.I.S. – Fabbrica Italiana Sintetici S.p.A.

Research & Development

Viale Milano 26

36075 Montecchio Maggiore (VI)

Italy

Frank Roschangar

Boehringer Ingelheim Pharmaceuticals, Inc.

Chemical Development

900 Ridgebury Road

Ridgefield, CT 06877

USA

Per Ryberg

AstraZeneca

Pharmaceutical Development

Chemical Science

Forskargatan 18

15185 Södertälje

Sweden

Chris H. Senanayake

Boehringer Ingelheim Pharmaceuticals, Inc.

Chemical Development

900 Ridgebury Road

Ridgefield, CT 06877

USA

Janice Sieser

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Robert A. Singer

Pfizer Global Research & Development

Chemical Research & Development

Eastern Point Road

Groton, CT 06340

USA

Jeffrey B. Sperry

Pfizer Worldwide Research & Development

Chemical Research & Development

Eastern Point Road

Groton, CT 06340

USA

Paolo Stabile

F.I.S. – Fabbrica Italiana Sintetici S.p.A.

Research & Development

Viale Milano 26

36075 Montecchio Maggiore (VI)

Italy

Michael St. Pierre

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Karen Sutherland

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Datong Tang

Enanta Pharmaceuticals, Inc.

Chemistry Department

500 Arsenal Street

Watertown, MA 02472

USA

Jason S. Tedrow

Amgen

Chemical Process Research and Development

One Amgen Center Drive

Thousand Oaks, CA 91320-1799

USA

Oliver R. Thiel

Amgen

Chemical Process Research and Development

One Amgen Center Drive

Thousand Oaks, CA 91320-1799

USA

Wei Tian

AstraZeneca

Pharmaceutical Development

15185 Södertälje

Sweden

Rajappa Vaidyanathan

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

John Van Alsten

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Brian Vanderplas

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Carrie Wager

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Debra J. Wallace

Merck Research Laboratories

Global Process Chemistry

Rahway, NJ 07065

USA

Guoqiang Wang

Enanta Pharmaceuticals, Inc.

Chemistry Department

500 Arsenal Street

Watertown, MA 02472

USA

Huan Wang

GlaxoSmithKline

API Chemistry & Analysis

709 Swedeland Road

King of Prussia, PA 19406

USA

Gerald Weisenburger

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Greg Withbroe

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Shu Yu

Pfizer Worldwide Research & Development

Chemical Research and Development

Eastern Point Road

Groton, CT 06340

USA

Michael J. Zacuto

Merck Research Laboratories

Global Process Chemistry

Rahway, NJ 07065

USA

Introduction

Joshua R. Dunetz and Javier Magano

When faced with life's common maladies, such as the occasional headache, muscle soreness, or fever, you may have reached for a pain reliever such as Advil, Motrin, or Nuprin. Ibuprofen, the active ingredient in these medicines, was discovered by the Boots Pure Drug Company and patented in the 1960s [1]. For several decades, the Boots synthesis would serve as the established method for the industrial manufacture of this pharmaceutical compound (Scheme I.1). This process, which has supplied millions of pounds of ibuprofen throughout the years, comprises six steps and has the disadvantage of generating substantial amounts of industrial waste. Much of the waste stems from an indirect approach to the carboxylic acid moiety through a series of functional group manipulations. From a process safety perspective, this route also suffers from intermediates and reagents containing potentially hazardous, high-energy functional groups such as epoxide 2, oxime 3, and hydroxylamine.

Scheme I.1 Original synthesis of ibuprofen by Boots Company.

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In light of the pending patent expiration for ibuprofen in the mid-1980s, the Boots Company teamed with Hoechst Celanese Corporation to develop an improved synthesis of ibuprofen that addresses the inefficiencies of the original route. This joint venture led to the BHC Company that patented a greener, three-step process for the industrial production of ibuprofen (Scheme I.2) [2]. Key to the improved synthesis is a Pd-catalyzed carbonylation as the final step. The reaction of alcohol 5 with carbon monoxide, Pd catalyst, and phosphine ligand in acidic aqueous media (e.g., aq HCl) directly installs the carboxylic acid and avoids the arduous sequence of functional group manipulations from the original synthesis. This innovative application of transition metal catalysis provides a more efficient manufacturing route to ibuprofen, and this achievement was recognized with the 1997 Presidential Green Chemistry Challenge Award [3].

Scheme I.2 Improved synthesis of ibuprofen via Pd-catalyzed carbonylation.

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This story of ibuprofen is not unique. The literature contains countless examples in which chemists have implemented transition metal-catalyzed couplings to streamline the synthesis of pharmaceuticals [4]. These coupling technologies are continuously evolving to accommodate the increasing structural complexities of APIs (active pharmaceutical ingredients). Large-scale applications of transition metal catalysis for the manufacture of drug ingredients require processes that are safe, efficient, and reliable. Process chemists are also tasked with developing synthetic routes that provide API with very high purity.

This book is not intended as a cursory overview of transition metal-catalyzed couplings. Rather, this book contains the personal accounts of process chemists describing their own development of robust coupling processes for the synthesis of pharmaceuticals. Each case study details the optimization of a coupling reaction while elaborating on issues such as design of experiments, scalability and throughput, product isolation, metal purging, process safety, cost efficiency, waste management, and overall environmental impact. The chapters span a wide range of named coupling reactions: Suzuki–Miyaura, Negishi, Heck, Buchwald–Hartwig, Sonogashira, Kumada–Corriu, Tsuji–Trost, Migita, and Hayashi–Miyaura. Other case studies discuss the process development of metal-catalyzed cyanations, borylations, enolate arylations, carbonylations, and ring-closing metathesis. Two of the three final chapters cover emerging technologies: the potential for large-scale catalysis using continuous-flow processing and microwave heating, and applications of designer surfactants for green catalysis in aqueous media. The final chapter reviews metal scavengers used for the removal of residual catalyst metals from coupling products on process scale.

In editing this book, we had the privilege of collaborating with talented process chemists from pharmaceutical companies throughout the world, as well as two innovative professors at the forefront of developing creative solutions to process chemistry challenges. The case studies we received are arranged alphabetically with respect to the corresponding author; grouping chapters by reaction would have been problematic as some chapters discuss more than one type of coupling.

We hope you learn as much from this book as we did.

References

1. Nicholson, J.S. and Adams, S.S. (1968) Phenyl propionic acids. US Patent 3,385,886.

2. (a) Elango, V., Murphy, M.A., Smith, B.L., Davenport, K.G., Mott, G.N., Zey, E.G., and Moss, G.L. (1991) Method for producing ibuprofen. US Patent 4,981,995; (b) Lindley, D.D., Curtis, T.A., Ryan, T.R., de la Garza, E.M., Hilton, C.B., and Kenesson, T.M. (1991) Process for the production of 4′-isobutylacetophenone. US Patent 5,068,448.

3. http://www.epa.gov/greenchemistry/pubs/pgcc/winners/gspa97.html.

4. (a) Crawley, M.L. and Trost, B.M. (eds) (2012) Applications of Transition Metal Catalysis in Drug Discovery and Development: An Industrial Perspective, John Wiley & Sons, Inc., Hoboken, NJ; (b) Busacca, C.A., Fandrick, D.R., Song, J.J., and Senanayake, C.H., (2011) Adv. Synth. Catal., 353, 1825; (c) Magano, J. and Dunetz, J.R. (2011) Chem. Rev., 111, 2177.

List of Abbreviations

Ac acetyl
acac acetylacetone
ADC acetonedicarboxylate
AIBN 2,2′-azobis(2-methylpropionitrile)
Am amyl
AmPhos di-t-butyl(4-dimethylaminophenyl)phosphine
API active pharmaceutical ingredient
9-BBN 9-borabicyclo[3.3.1]nonane
BINAP (1,1′-binaphthalene-2,2′-diyl)bis(diphenylphosphine)
Biphen 5,5′,6,6′-tetramethyl-3,3′-di-t-butyl-1,1′-biphenyl-2,2′-diol
BIPHEP 2,2′-bis(diphenylphosphino)-1,1′-biphenyl
Boc t-butyloxycarbonyl
BTPP t-butylimino-tri(pyrrolidino)phosphorane
Bu butyl
t-BuDavePhos 2-di-t-butylphosphino-2′-(N,N-dimethylamino)biphenyl
cBRIDP di-t-butyl(2,2-diphenyl-1-methyl-1-cyclopropyl)phosphine
Cbz carbobenzyloxy
CDI 1,1′-carbonyldiimidazole
(S,S)-ChiraPHOS (2S,3S)-(−)-bis(diphenylphosphino)butane
COD 1,5-cyclooctadiene
Cy cyclohexyl
trans-CyDA (1R,2R)-trans-cyclohexyldiamine
Cy-JohnPhos 2-(dicyclohexylphosphino)biphenyl
d day
1,2-DAP 1,2-diaminopropane
DavePhos 2-dicyclohexylphosphino-2′-(N,N-dimethylamino)biphenyl
dba dibenzylideneacetone
DBU 1,8-diazabicyclo[5.4.0]undec-7-ene
DCE 1,2-dichloroethane
dcpe 1,2-bis(dicyclohexylphosphino)ethane
dcpm bis(dicyclohexylphosphino)methane
DIAD diisopropyl azodicarboxylate
(S,S)-DIOP (4S,5S)-(+)-O-isopropylidene-2,3-dihydroxy-1,4-bis(diphenylphosphino)butane
(S,S)-DIPAMP (1S,2S)-(+)-bis[(2-methoxyphenyl)phenylphosphino]ethane
DIPHOS 1,2-bis(diphenylphosphino)ethane
dippf di-i-propylphosphinoferrocene
DIPT di-i-propyl tartrate
DKR dynamic kinetic resolution
DLS dynamic light scattering
DMAc N,N-dimethylacetamide
DMAP 4-dimethylaminopyridine
DMC dimethyl carbonate
trans-DMCyDA (1R,2R)-N,N′-dimethylcyclohexyldiamine
DME 1,2-dimethoxyethane
DMEDA N,N′-dimethylethylenediamine
DMF N,N-dimethylformamide
DMG N,N-dimethylglycine
DMSO dimethyl sulfoxide
DoE design of experiments
DPEPhos bis[(2-diphenylphosphino)phenyl]ether
dppb diphenylphosphinobutane
dppe diphenylphosphinoethane
dppf diphenylphosphinoferrocene
dppm diphenylphosphinomethane
dppp diphenylphosphinopropane
dtbpf di-t-butylphosphinoferrocene
EDTA ethylenediaminetetraacetic acid
ee enantiomeric excess
Et ethyl
FDA Food and Drug Administration
FT-IR Fourier transform infrared spectroscopy
fur 2-furfuryl
GC gas chromatography
GMP good manufacturing practice
h hour
HATU 1-[bis(dimethylamino)methylene]-1H-1,2,3-triazolo[4,5-b]pyridinium-3-oxid hexafluorophosphate
HCV hepatitis C virus
HDPE high-density polyethylene
Hex hexyl
HIV human immunodeficiency virus
HMBC heteronuclear multiple-bond correlation
HMDS hexamethyldisilazide
HOAt 1-hydroxy-7-azabenzotriazole
HPLC high-performance liquid chromatography
HRMS high-resolution mass spectrometry
HST hydroboration–Suzuki–Tamao
HTE high-throughput experimentation
IMes·HCl 1,3-bis(2,4,6-trimethylphenyl)imidazolium chloride
IMS industrial methylated spirits
INDAC (S)-2-indoline carboxylic acid
IPA 2-propanol
IR infrared
JohnPhos (2-biphenyl)di-t-butylphosphine
KF Karl Fischer
L ligand or liters
LC liquid chromatography
LOX lipoxygenase
MAP mitogen-activated protein
mCBA m-chlorobenzoic acid
mCPBA m-chloroperbenzoic acid
Me methyl
(R,R)-MeDuPhos (–)-1,2-bis[(2R,5R)-2,5-dimethylphospholano]benzene
MEK methyl ethyl ketone
MePhos dicyclohexylphosphino-2′-methylbiphenyl
Mes mesityl
2-MeTHF 2-methyltetrahydrofuran
(R,R)-Me-ULLUPHOS (–)-1,2-bis[(2R,5R)-2,5-dimethylphospholano]benzene
MIBK methyl isobutyl ketone
min minute
MP macroporous polystyrene
Ms methanesulfonyl
MS mass spectrometry
MSZL metastable zone limit
MTBE methyl t-butyl ether
mv mean volume
MVK methyl vinyl ketone
MW microwave
NAM negative allosteric modulator
NBS N-bromosuccinimide
NCE new chemical entity
NCS N-chlorosuccinimide
ND not detected
NIXANTPHOS 4,6-bis(diphenylphosphino)phenoxazine
nm nanometer
NMM N-methylmorpholine
NMP 1-methyl-2-pyrrolidone
NMR nuclear magnetic resonance
NNRTI non-nucleoside reverse transcription inhibitor
NOE nuclear Overhauser effect
Np neopentyl
Nu nucleophile
PAL phenylalanine ammonia lyase
PCA principal component analysis
PDE phosphodiesterase
PEEK polyether ether ketone
PEG polyethylene glycol
Peppsi pyridine-enhanced precatalyst preparation, stabilization, and initiation
Phen phenanthroline
PLS projection to latent structure
PMB p-methoxybenzyl
PMI process mass intensity
ppm parts per million
Pr propyl
PS polystyrene
PTFE polytetrafluoroethylene
PTS (polyoxoethanyl-α-tocopheryl)sebacate
PXRD powder X-ray diffraction
PyBOP (benzotriazol-1-yloxy)tripyrrolidinophosphonium hexafluorophosphate
QPhos 1,2,3,4,5-pentaphenyl-1′-(di-tert-butylphosphino)ferrocene
QPT quinoline pyrimidine trione
RA rheumatoid arthritis
RCC renal cell carcinoma
RCM ring-closing metathesis
RSM response surface methodology
rt room temperature
RuCl2[(S)-xylbinap][(S)-daipen] dichloro{(S)-(−)-2,2′-bis[di(3,5-xylyl)phosphino]-1,1′-binaphthyl}[(2S)-(+)-1,1-bis(4-methoxyphenyl)-3-methyl-1,2-butanediamine]ruthenium(II)
RuPhos 2-dicyclohexylphosphino-2′,6′-diisopropoxybiphenyl
SFC supercritical fluid chromatography
SPhos 2-dicyclohexylphosphino-2′,6′-dimethoxy-1,1′-biphenyl
TBAB tetra-n-butylammonium bromide
TBAC tetra-n-butylammonium chloride
TBS t-butyldimethylsilyl
TEM transmission electron microscopy
Tf trifluoromethylsulfonyl
TFA trifluoroacetic acid
THF tetrahydrofuran
THP tetrahydropyran
TIPS tri-i-propylsilyl
(R)-TMBTP 2,2′,5,5′-tetramethyl-4,4′-bis(diphenylphosphino)-3,3′-bithiophene
TMEDA tetramethylethylenediamine
TMG 1,1,3,3-tetramethylguanidine
TMHD 2,2′,6,6′-tetramethylheptane-2,5-dione
TMS trimethylsilyl
TMT trimercaptotriazine
tol tolyl
TrixiePhos (±)-2-di-t-butylphosphino-1,1′-binaphthyl
TRP transient receptor potential
Ts toluenesulfonyl
VEGF vascular endothelial growth factor
VR vanilloid receptor
wt weight
Xantphos 4,5-bis(diphenylphosphino)-9,9-dimethylxanthene
XPhos 2-dicyclohexylphosphino-2′,4′,6′-triisopropylbiphenyl
XRF X-ray fluorescence