A Scalable Two-Step Continuous Flow Synthesis of Nabumetone and Related 4-Aryl-2-butanones

Organic synthesis in flow mode by selective liquid-phase hydrogenation over heterogeneous non-noble metal catalysts

Flow hydrogenation performed over heterogeneous catalysts makes organic synthesis more economical, safe and environmentally friendly. Over the past two decades, a significant amount of research with a major focus on noble metal catalysts has been carried out in this area. However, catalysts based on non-noble metals (Ni, Cu, Co, etc.) are more promising for practical use due to their low cost and high availability. This review article discusses the use of supported and bulk non-noble metal catalysts for the liquid-phase hydrogenation of bi- and polyfunctional organic compounds in flow mode. The main attention is paid to the selective reduction of one functional group (NO2, CC, CN, CO, and CN) in the presence of other substituents. In addition, cascade synthetic protocols involving hydrogenation are presented.

Tetraethylammonium Salts as Solid, Easy to Handle Ethylene Precursors and Their Application in Mizoroki-Heck Coupling

In this study, we introduce a convenient Heck vinylation protocol that eliminates the requirement for ethylene gas as a coupling partner. In contrast to traditional methodologies, quaternary ammonium salts can serve as solid olefin precursors under ambient atmosphere conditions. The practicality of this method, distinguished by its convenience and safety in a one-pot reaction, renders it appealing for applications in research and discovery context.

Advances and Challenges in Development of Transition Metal Catalysts for Heterogeneous Hydrogenation of Organic Compounds

Actual problems of development of catalysts for hydrogenation of heterocyclic compounds by hydrogen are summarized and discussed. The scope of review covers composites of nanoparticles of platinum group metals and 3d metals for heterogeneous catalytic processes. Such problems include increase of catalyst activity, which is important for reduction of precious metals content; development of new catalytic systems which do not contain metals of platinum group or contain cheaper analogues of Pd; control of factors which make influence on the selectivity of the catalysts; achievement of high reproducibility of the catalyst's performance and quality control of the catalysts. Own results of the authors are also summarized and described. The catalysts were prepared by decomposition of Pd0 and Ni0 complexes, pyrolysis of Ni2+ and Co2+ complexes deposited on aerosil and reduction of Ni2+ in pores of porous support in situ. The developed catalysts were used for hydrogenation of multigram batches of heterocyclic compounds.

Continuous-flow Heck coupling reactions catalyzed by Pd complexes of amidoxime fibers

Improving production efficiency and developing green catalytic systems are key issues for applying Heck coupling reactions in the chemical industry. In this study, an amidoxime-fiber-supported Pd catalyst is prepared from polyacrylonitrile fiber, hydroxylamine hydrochloride, and PdCl2. The morphology and structure of amidoxime-fiber-supported Pd are characterized by scanning electron microscopy, energy-dispersive spectroscopy, X-ray photoelectron spectrometer, X-ray diffraction, and inductively coupled plasma-optical emission spectrometer. A packed-bed flow reactor is designed and employed for catalysis of the Heck reaction of iodobenzene and styrene based on the amidoxime-fiber-supported Pd catalyst. The effects of reaction temperature, flow rate, cycle time, and reactant concentration on the conversion and yield are investigated. The results show that the optimal conditions for the continuous-flow single reactor are 70 °C, iodobenzene concentration of 30 mmol L−1 in a solution of N,N-dimethylformamide (100 mL) under continuous flow at a flow rate of 2 mL min−1. The catalyst showed good activity and stability after a continuous operation time of 50 h, with catalytic activity 2.21 times higher than that obtained with traditional batch reaction. Furthermore, we have established a new flow reaction system based on the numbering-up of reactors with a parallel connection. The catalytic efficiency of four parallel reactors is four times higher than that of a single reactor. Kinetic studies reveal that the reaction has low activation energy (8.8771 kJ mol−1), indicating that amidoxime-fiber-supported Pd has good catalytic activity. This research provides an alternative pathway for highly efficient Heck coupling in continuous flow.

Wittig and Wittig-Horner Reactions under Sonication Conditions

Carbonyl olefinations are among the most important organic syntheses that form C=C bonds, as they usually have high yields and in addition offer excellent stereoselectivity. Due to these advantages, carbonyl olefinations have important pharmaceutical and industrial applications. These reactions contain an additional step of an α-functionalized carbanion to an aldehyde or ketone to produce alkenes, but syntheses performed using metal carbene complexes are also known. The Wittig reaction is an example of carbonyl olefination, one of the best ways to synthesize alkenes. This involves the chemical reaction between an aldehyde or ketone with a so-called Wittig reagent, for instance phosphonium ylide. Triphenylphosphine-derived ylides and trialkylphosphine-derived ylides are the most common phosphorous compounds used as Wittig reagents. The Wittig reaction is commonly involved in the synthesis of novel anti-cancer and anti-viral compounds. In recent decades, the use of ultrasound on the Wittig reaction (and on different modified Wittig syntheses, such as the Wittig-Horner reaction or the aza-Wittig method) has been studied as a green synthesis. In addition to the advantage of green synthesis, the use of ultrasounds in general also improved the yield and reduced the reaction time. All of these chemical syntheses conducted under ultrasound will be described further in the present review.

Synthesis of odorants in flow and their applications in perfumery

Continuous flow technology is a key technology for sustainable manufacturing with numerous applications for the synthesis of fine chemicals. In recent years, the preparation of odorants utilizing the advantages of flow reactors received growing attention. In this review, we give an overview of selected methods for the synthesis of odorants in flow, including heterogeneously catalyzed reactions, gas reactions, and photochemical C–H functionalization processes. After a brief introduction on types of odorants, the presented odorant syntheses are ordered according to the main odor families “fruity”, “green”, “marine”, “floral”, “spicy”, “woody”, “ambery”, and “musky” and their use and importance for perfumery is briefly discussed.

Modeling Temperature and Species Concentration Profiles on a Continuous-Flow Reactor Applied to Aldol Condensation

This paper presents the modeling of a continuous-flow reactor used for the synthesis of organic products. The finite element method software, COMSOL Multiphysics, was used to model transport phenomena and reaction kinetics. The temperature is one of the most important kinetic factors that may modify the reaction. A rise in temperature can generate a positive reaction but also secondary side reactions. The design of our system and of many other continuous systems makes it impossible, however, to measure the temperature throughout the reactor. In this paper, we modeled the temperature profile within the reactors as a function of the flow rate, temperature set point, and type of reactor material. The results demonstrated that although it is not a good thermal conductor, polytetrafluoroethylene can be used like other materials. The desired temperature was not reached for any of the reactor material likely to affect the product yield. The model gave the residence time required to reach the stabilized temperature. The comparison of calculated and experimental values of outlet temperature showed good agreement, with a maximum relative difference of only 5%. Knowledge of the temperature profile made it possible to control the concentration distribution of the chemical species in the reactor. The aldol condensation was chosen to determine the kinetic parameters of this reaction as the products of this reaction are found in many natural molecules and drugs. To integrate the chemical model, the kinetic parameters were determined by using experimental data. An equilibrium concentration of 0.2 mol/L was found with initial reactant concentrations of 0.45 mol/L. The chemical modeling gave the species concentrations throughout the reactor. Calculated concentrations were in good agreement with experimental data, with a maximum relative difference of less than 9%. By modeling this reaction, the reaction yield as a function of reactant concentration, temperature, and residence times was estimated.

Reductive Aldol-type Reactions in the Synthesis of Pharmaceuticals

The efficient chemo-, regio- and stereoselective formation of saturated carbon-carbon fragment is the critical challenge of organic synthesis; therefore, developing new methods for formation of these bonds is paramount. The rising interest for reductive aldol-type reactions is conditioned by its versatile applications, allowing the efficient formation of carbon-carbon bonds. The review aims to highlight the advantages and disadvantage of reductive aldol-type reactions to total synthesis of pharmaceutical substances in order to summarize knowledge and encourage further investigation of the field.

A comprehensive review of flow chemistry techniques tailored to the flavours and fragrances industries

Due to their intrinsic physical properties, which includes being able to perform as volatile liquids at room and biological temperatures, fragrance ingredients/intermediates make ideal candidates for continuous-flow manufacturing. This review highlights the potential crossover between a multibillion dollar industry and the flourishing sub-field of flow chemistry evolving within the discipline of organic synthesis. This is illustrated through selected examples of industrially important transformations specific to the fragrances and flavours industry and by highlighting the advantages of conducting these transformations by using a flow approach. This review is designed to be a compendium of techniques and apparatus already published in the chemical and engineering literature which would constitute a known solution or inspiration for commonly encountered procedures in the manufacture of fragrance and flavour chemicals.

How to approach flow chemistry

Flow chemistry is a widely explored technology whose intrinsic features both facilitate and provide reproducible access to a broad range of chemical processes that are otherwise inefficient or problematic. At its core, a flow chemistry module is a stable set of conditions - traditionally thought of as an externally applied means of activation/control (e.g. heat or light) - through which reagents are passed. In an attempt to simplify the teaching and dissemination of this field, we envisioned that the key advantages of the technique, such as reproducibility and the correlation between reaction time and position within the reactor, allow for the redefinition of a flow module to a more synthetically relevant one based on the overall induced effect. We suggest a rethinking of the approach to flow modules, distributing them in two subclasses: transformers and generators, which can be described respectively as a set of conditions for either performing a specific transformation or for generating a reactive intermediate. The chemistry achieved by transformers and generators is (ideally) independent of the substrate introduced, meaning that they must be robust to small adjustments necessary for the adaptation to different starting materials and reagents while ensuring the same chemical outcome. These redefined modules can be used for single-step reactions or in multistep processes, where modules can be connected to each other in reconfigurable combinations to create chemical assembly systems (CAS) targeting compounds and libraries sharing structural cores. With this tutorial review, we provide a guide to the overall approach to flow chemistry, discussing the key parameters for the design of transformers and generators as well as the development of chemical assembly systems.

Synthesis of Spiroisoxazolines via TEMPO/NaNO2-Catalyzed Aerobic Oxidative Dearomatization

A catalytic, aerobic oxidative dearomatization protocol has been developed for the preparation of spiroisoxazline scaffolds from oximes using TEMPO and NaNO₂ as the catalyst and O₂ as the sole oxidant. This dearomatization methodology features its mild reaction conditions, good functional group tolerance, and an unprecedented broad substrate scope, encompassing phenols, aryl ethers, thiophenols, aryl sulfides, etc.

The Role of Support Hydrophobicity in the Selective Hydrogenation of Enones and Unsaturated Sulfones over Cu/SiO2 Catalysts

The substitution of complex hydrides and Ni- and noble metal-based catalysts in the synthesis of pharma and fragrance products is a relevant topic in the green chemistry scenario. Here, we report that non-toxic, non-noble metal-based Cu/SiO2 catalysts are effective and very selective in the hydrogenation of α,β-unsaturated ketones, esters and sulfones under very mild conditions. Vanillyl acetone can be obtained in quantitative yield in 1 h at 90 °C and 1 bar of H2. High dispersion of the metallic phase and support wettability play a significant role in determining catalytic performance.

Continuous Manufacturing in Pharmaceutical Process Development and Manufacturing

The pharmaceutical industry has found new applications for the use of continuous processing for the manufacture of new therapies currently in development. The transformation has been encouraged by regulatory bodies as well as driven by cost reduction, decreased development cycles, access to new chemistries not practical in batch, improved safety, flexible manufacturing platforms, and improved product quality assurance. The transformation from batch to continuous manufacturing processing is the focus of this review. The review is limited to small, chemically synthesized organic molecules and encompasses the manufacture of both active pharmaceutical ingredients (APIs) and the subsequent drug product. Continuous drug product is currently used in approved processes. A few examples of production of APIs under current good manufacturing practice conditions using continuous processing steps have been published in the past five years, but they are lagging behind continuous drug product with respect to regulatory filings.

Oxidative Asymmetric Formal Aza-Diels⁻Alder Reactions of Tetrahydro-β-carboline with Enones in the Synthesis of Indoloquinolizidine-2-ones

Ru-catalyzed tandem amine oxidative dehydrogenation/formal aza-Diels⁻Alder reaction for enantio- and diastereoselective synthesis of indoloquinolizidine-2-ones from tetrahydro-β-carbolines and α,β-unsaturated ketones is described. The reaction proceeds via tandem ruthenium-catalyzed amine dehydrogenation using tert-butyl hydroperoxide (TBHP) as the oxidant and a chiral thiourea-catalyzed formal aza-[4 + 2] cycloaddition, providing a step-economical strategy for the synthesis of these valuable heterocyclic products.

Synthesis and Antioxidant Activity of Caffeic Acid Derivatives

A series of caffeic acid derivatives were synthesized via a modified Wittig reaction which is a very important tool in organic chemistry for the construction of unsaturated carbon⁻carbon bonds. All reactions were performed in water medium at 90 °C. The aqueous Wittig reaction worked best when one unprotected hydroxyl group was present in the phenyl ring. The olefinations in the aqueous conditions were also conducted with good yields in the presence of two unprotected hydroxyl groups. When the number of the hydroxyl groups was increased to three, the reaction yields were worse, and the derivatives 12, 13, and 18 were obtained with 74%, 37%, and 70% yields, respectively. Nevertheless, the Wittig reaction using water as the essential medium is an elegant one-pot synthesis and a greener method, which can be a safe alternative for implementation in organic chemistry. The obtained compounds were tested for their antioxidant activity, and 12, 13, and 18 showed the highest activities. Moreover, all synthesized compounds displayed no cytotoxicity, and can therefore be used in the pharmaceutical or cosmetic industry.

Application of Silicon-Initiated Water Splitting for the Reduction of Organic Substrates

The use of water as a donor for hydrogen suitable for the reduction of several important classes of organic compounds is described. It is found that the reductive water splitting can be promoted by several metalloids among which silicon shows the best efficiency. The developed methodologies were applied for the reduction of nitro compounds, N-oxides, sulfoxides, alkenes, alkynes, hydrodehalogenation as well as for the gram-scale synthesis of several substrates of industrial importance.

Advanced Continuous Flow Platform for On-Demand Pharmaceutical Manufacturing

As a demonstration of an alternative to the challenges faced with batch pharmaceutical manufacturing including the large production footprint and lengthy time-scale, we previously reported a refrigerator-sized continuous flow system for the on-demand production of essential medicines. Building on this technology, herein we report a second-generation, reconfigurable and 25 % smaller (by volume) continuous flow pharmaceutical manufacturing platform featuring advances in reaction and purification equipment. Consisting of two compact [0.7 (L)×0.5 (D)×1.3 m (H)] stand-alone units for synthesis and purification/formulation processes, the capabilities of this automated system are demonstrated with the synthesis of nicardipine hydrochloride and the production of concentrated liquid doses of ciprofloxacin hydrochloride, neostigmine methylsulfate and rufinamide that meet US Pharmacopeia standards.

Design and Scaling Up of Microchemical Systems: A Review

The past two decades have witnessed a rapid development of microreactors. A substantial number of reactions have been tested in microchemical systems, revealing the advantages of controlled residence time, enhanced transport efficiency, high product yield, and inherent safety. This review defines the microchemical system and describes its components and applications as well as the basic structures of micromixers. We focus on mixing, flow dynamics, and mass and heat transfer in microreactors along with three strategies for scaling up microreactors: parallel numbering-up, consecutive numbering-up, and scale-out. We also propose a possible methodology to design microchemical systems. Finally, we provide a summary and future prospects.

Engineering Porous Polymer Hollow Fiber Microfluidic Reactors for Sustainable C-H Functionalization

Highly hydrophilic and solvent-stable porous polyamide-imide (PAI) hollow fibers were created by cross-linking of bare PAI hollow fibers with 3-aminopropyl trimethoxysilane (APS). The APS-grafted PAI hollow fibers were then functionalized with salicylic aldehyde for binding catalytically active Pd(II) ions through a covalent postmodification method. The catalytic activity of the composite hollow fiber microfluidic reactors (Pd(II) immobilized APS-grafted PAI hollow fibers) was tested via heterogeneous Heck coupling reaction of aryl halides under both batch and continuous-flow reactions in polar aprotic solvents at high temperature (120 °C) and low operating pressure. X-ray photoelectron spectroscopy (XPS) and inductively coupled plasma (ICP) analyses of the starting and recycled composite hollow fibers indicated that the fibers contain very similar loadings of Pd(II), implying no degree of catalyst leaching from the hollow fibers during reaction. The composite hollow fiber microfluidic reactors showed long-term stability and strong control over the leaching of Pd species.

An efficient and selective microwave-assisted Claisen-Schmidt reaction for the synthesis of functionalized benzalacetones

A simple and direct method for the Claisen-Schmidt reaction to prepare functionalized α,β-unsaturated ketones has been developed. Microwave irradiation of aldehydes with acetone produces benzalacetones selectively without self-condensation product in very short reaction times and good yields. Graphical AbstractGraphics for use in the Table of Contents.

Highly efficient synthesis of HIV NNRTI doravirine

The development of an efficient and robust process for the production of HIV NNRTI doravirine is described. The synthesis features a continuous aldol reaction as part of a de novo synthesis of the key pyridone fragment. Conditions for the continuous flow aldol reaction were derived using microbatch snapshots of the flow process.

Continuous and convergent access to vicinyl amino alcohols

A four module convergent chemical assembly system delivers two classes of vicinyl amino alcohol and five APIs.

The expanding utility of continuous flow hydrogenation

There has been an increasing body of evidence that flow hydrogenation enhances reduction outcomes across a wide range of synthetic transformations.

Carbon-carbon bond cleavage in activation of the prodrug nabumetone

Carbon-carbon bond cleavage reactions are catalyzed by, among others, lanosterol 14-demethylase (CYP51), cholesterol side-chain cleavage enzyme (CYP11), sterol 17β-lyase (CYP17), and aromatase (CYP19). Because of the high substrate specificities of these enzymes and the complex nature of their substrates, these reactions have been difficult to characterize. A CYP1A2-catalyzed carbon-carbon bond cleavage reaction is required for conversion of the prodrug nabumetone to its active form, 6-methoxy-2-naphthylacetic acid (6-MNA). Despite worldwide use of nabumetone as an anti-inflammatory agent, the mechanism of its carbon-carbon bond cleavage reaction remains obscure. With the help of authentic synthetic standards, we report here that the reaction involves 3-hydroxylation, carbon-carbon cleavage to the aldehyde, and oxidation of the aldehyde to the acid, all catalyzed by CYP1A2 or, less effectively, by other P450 enzymes. The data indicate that the carbon-carbon bond cleavage is mediated by the ferric peroxo anion rather than the ferryl species in the P450 catalytic cycle. CYP1A2 also catalyzes O-demethylation and alcohol to ketone transformations of nabumetone and its analogs.

Continuous synthesis of artemisinin-derived medicines

Continuous, convergent/divergent synthesis of four anti-malarial APIs.