Patent Application
20210017024
The present invention relates to a method for making brominating agents in flow starting from a bromide source.
In organic synthesis, halogen atoms, such as for example fluorine, bromine, chlorine or iodine atoms, are often introduced at various positions in chemical compounds in order to alter the properties of these compounds in a desirable manner. Brominated compounds are widely used for example as biocides, flame retardants, dyes and pharmaceuticals.
General synthetic methods for introducing bromine atoms into organic compounds involve reaction of organic compounds with a bromine source or brominating agent such as for example elemental bromine (Br2), hypobromite (BrO−), monobromomalonitrile and/or N-bromosuccinimide (NBS). In a typical procedure, the compound to be brominated and the bromine source are mixed in a suitable solvent. Via a bromination reaction, the brominating agent will brominate the starting material to yield the desired brominated end product.
Monobromomalonitrile and/or N-bromosuccinimide (NBS) are solid reagents and are relatively easy and safe to handle, but the atom efficiency of these compounds per kilogram of reagent is relatively low which makes them less interesting from an economical point of view.
Hypobromite is typically generated by reacting elemental bromine with an aqueous base. Such a hypobromite solution has a limited stability and needs to be prepared shortly before use. In addition, use of elemental bromine is prefereably avoided as described below.
Elemental bromine is often used as brominating agent as it has an intrinsic high atom efficiency. However, a major disadvantage of bromination reactions using elemental bromine is the very high intrinsic safety risk of handling and/or transporting liquid elemental bromine. Bromine is very toxic, it has an occupational exposure limit of 0.1 ppm and is very volatile (229 mbar vapour pressure at 20° C.). Therefore bromine is considered to be a chemical with an extremely high exposure risk through inhalation. As a result, the use of liquid bromine at industrial scale is critical and requires the use of dedicated and expensive installations equipped with extra safety provisions.
In an alternative procedure, bromide salts are used as bromine source. Bromide salts such as sodium bromide, potassium bromide or tetrabutylammonium bromide are commercially available and represent an abundant and harmless source of bromine atoms. The compound to be brominated and a bromide salt are mixed in a suitable solvent, often water, and an appropriate oxidizing reagent is added. First, the bromide salts react with the oxidizing reagent whereby they are converted by an oxidation reaction into elemental bromine. Such a preparation of the elemental bromine has only been described in the art by means of so-called batch processes. As the elemental bromine is formed in situ, disadvantages such as handling and transport of Br2 are avoided. Although this reaction procedure may work well in a number of cases, it has major drawbacks. Firstly, this reaction procedure is not suited for compounds having functional groups that are prone to oxidation because at least part of the oxidizing reagent will react with these functional groups leading to oxidised side products instead of the desired brominated compound. Secondly, elemental bromine may catalyse decomposition of the oxidizing agent, for example hydrogen peroxide, and as a result an excess of oxidizing agent is needed. Thirdly, as both the oxidation reaction and the bromination reaction are very exothermic and generate heat simultaneously, the heat being generated in these processes is difficult to control. Finally, such a reaction set-up does not allow a different reaction temperature between the oxidation reaction and the bromination reaction.
US 2005/0049420 discloses a process for the N-halogenation of a compound having a N-halogenatable amido or imido nitrogen atom in the molecule, comprising the steps of feeding the compound to be halogenated, an inorganic base, elemental bromine and water with a pH in the range of 5.5 to 8.
There is an urgent need in the market for brominating agents which have a high atom efficiency, which involve limited safety risks and which are widely applicable at a low cost.
It is an object of the present invention, to provide a cost efficient and safe method for preparing brominating agents.
This object is realized by the method below describing the generation of a brominating agent using flow chemistry. The method avoids handling of elemental bromine and the above mentioned problems related to batch reactions. The method involves two streams of reagents which are brought together in a continuous flow reactor, one flow comprising a bromide source and the other flow comprising at least one oxidizing agent. The obtained brominating agent may in a further step be added to a compound to be brominated. The major advantages of this new method using flow methodology are not only that the temperature applied for the formation of the brominating reagent inside the continuous flow reactor is independent from the temperature which is required for the bromination reaction; but also that possible unwanted reactions of the oxidizing agent with the compound to be brominated are practically avoided. Furthermore, the reaction in flow provides a high yield, is less labour-intensive compared to batch reactions and is beneficial from a health and safety point of view as no elemental bromine is used as starting reagent.
Other features, elements, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention. Specific embodiments of the invention are also defined below.
Substrate: chemical compound to be brominated
Target compound: brominated compound
Reaction in flow: a chemical reaction carried out in a continuous flow reactor wherein the reagents are fed by means of continuous streams
Continuous flow reactor: reactor were the reagents in flow meet and the chemical reaction takes place
Flow chemistry is a well-established technique for use at a large scale when manufacturing large quantities of a given material as well as for production of smaller quantities of specialized products.
In flow chemistry, a chemical reaction is run in a continuously flowing stream. Pumps move reagents via tubes into a continuous flow reactor where the chemical reaction takes place. The reagents are preferably fluids but may be solid or gaseous. Pumps used to initiate flow of the reagents are well-known in the art.
Continuous flow reactors allow a good control over reaction conditions such as heat transfer and reaction time. Continuous flow reactors are for example tube reactors, plate reactors, coil reactors, microreactors or continuously stirred tank reactors (CSTR). The reactivity of the reagents and/or the scale of the specific reaction determine the optimal flow rate of the reagents and/or the preferred size (length, diameter) of the continuous flow reactor. The flow rate may be changed in time but is preferably constant throughout the reaction. The residence time of the reagents in the continuous flow reactor may be calculated from the volume of the reactor and the flow rate through it:
Residence time=Reactor Volume/Flow Rate
Therefore, to achieve a longer residence time, reagents can be pumped more slowly and/or a larger volume continuous flow reactor may be used. In order to obtain an optimal reaction, it is up to the person skilled in the art to adapt these above mentioned variables.
Because the heat-exchange area to volume ratio is large, endothermal and exothermal reactions can easily be thermostated. Moreover, flow reactions can be relatively easy automated and allow for unattended operation and experimental planning. Multi step reactions can be arranged in a continuous sequence which can be especially beneficial if intermediate compounds are unstable, toxic, or sensitive to air, since they will exist only momentarily and in very small quantities.
According to the present invention, there is provided a method whereby a brominating reagent is formed inside a continuous flow reactor. The method involves at least two streams which are brought together in the continuous flow reactor. One flow comprises a bromide source and the other flow comprises an oxidizing agent. The bromide source and the oxidizing agent may be in liquid form—i.e. neat or in a solution in an appropriate solvent such as for example water, alcohols (e.g. MeOH, EtOH, i-propanol), aceton, ethylacetate, acetonitrile, MEK, DMF, THF, N-methyl-2-pyrrolidon, N,N-dimethylaceetamide, DMSO, and/or mixtures thereof—, solid or in gaseous form; preferably the bromide source and the oxidizing agent are aqueous solutions. The brominating agent which is formed may then be added to the substrate for the bromination reaction. This second reaction may be carried out via a flow reaction or, alternatively, the reaction may be carried out in a batch reaction.
The concurrent feeds in the process of this invention are continuous feeds and are preferably two feeds. However, tri-feeds or other multi-feeds reactions are possible. Product formation occurs when the reagents come into contact with each other in the continuous flow reactor. This contact of the reagents is preferably rapid and intimate and therefore it is preferred to provide sufficient mixing to cause such rapid intimate contact between the reagents.
The reagents are preferably mixed before they enter the continuous flow reactor and/or inside the continuous flow reactor. For example SMV™ or SMX™ static mixers (commercially available from Sulzer) and/or a T-mixer may be provided before the flow streams enter the continuous flow reactor while structured channels may be used inside the continuous flow reactor. Suitable continuous flow reactors are e.g. Plantrix™ or Protrix™ reactors (commercially available from Chemtrix), Flowplate™ reactors (commercially available from Lonza), Coil reactors preferably including a static mixer, and Spinning Disc reactors. Alternatively, a periodic flow may be applied in order to obtain appropriate mixing of the reagents. A periodic flow means that an oscillation is superimposed over a steady linear flow, preferably by means of a pulsation device (“pulsator”). If the amplitude of the oscillation is larger than the linear flow component, the direction of flow will be reversed during a certain period of time of the cycle. This is referred to as oscillatory flow. If the amplitude of the oscillation is smaller than the linear flow component, the net flow velocity remains positive at all times. This is referred to in the art as pulsatile flow.
The bromide source is preferably selected from hydrogen bromide, an organic bromide salt or an inorganic bromide salt. The inorganic bromide salt is preferably selected from an alkali metal bromide salt or an earth alkali metal bromide salt. Preferred alkali metal bromide salts are for example LiBr, NaBr, KBr, RbBr and CsBr; preferred earth alkali metal bromide salts are fro example BeBr2, MgBr2, CaBr2, SrBr2 and BaBr2. The organic bromide salts are preferably selected from primary, secondary, tertiary ammonium salts such as for example triethyl ammonium bromide or diethyl ammonium bromide. Quaternairy ammonium salts, also called quaternairy amines, are highly preferred and may be represented by NR1R2R3R4+ wherein R1 to R4 independently represent an optionally substituted alkyl, aryl or heteroaryl group. Examples of such compounds are tetrabutyl ammonium bromide, benzyl triethyl ammonium bromide, dodecyl trimethyl ammonium bromide, aryl triethyl ammonium bromide, etc. The bromide source is preferably an aqueous solution of a bromide salt.
The solution of the oxidizing agent is preferably an aqueous solution. Suitable oxidising reagents have a standard reduction potential with respect to the potential of the standard hydrogen electrode of preferably greater than 0.5 V, more preferably greater than 0.8 V and most preferably greater than 1.0 V. The oxidizing agent is preferably selected from, nitric acid, oxygen, chlorine, fluorine, ozone, peracids such as an optionally substituted peroxy benzoic acid, osmium tetroxide, potassium permanganate or potassium peroxomonosulfate. More preferably, the oxidizing agent is selected from hydrogen peroxide or hypochlorite. The concentration of a suitable aqueous solution containing the oxidizing agent mainly depends on the solubility of the oxidizing agent in the solvent and/or the kind of substrate and is preferably as high as possible.
The optional substituents on the peroxy benzoic acid may represent a halogen such as a fluorine, chlorine, bromine or iodine atom, a hydroxy group, an alkoxy group such as a methoxy or ethoxy group or an alkyl group such as a methyl, ethyl, propyl or isopropyl group.
The amount of bromide solution fed into the continuous flow reactor is preferably in excess such as 1 to 100% higher, more preferably 5 to 50% higher and most preferably 10 to 20% higher than the amount of oxidizing agent. As a result, oxidation—by for example unreacted oxidizing agent—of the substrate and/or target compound at a later stage can be avoided.
The brominating agent which is formed via the flow reaction is preferably elemental bromine (Br2) or hypobromite (BrO−) salt.
In a preferred embodiment of the present invention, hydrogen peroxide is used as oxidizing agent. The reaction between the bromide source and hydrogen peroxide results in formation of elemental bromine. Hydrogen peroxide is preferably an aqueous solution containing 1 to 50% wt of hydrogen peroxide, more preferably 5 to 40% wt of hydrogen peroxide and most preferably 10 to 30% wt of hydrogen peroxide.
In a further preferred embodiment of the present invention, a hypochlorite salt such as lithium, sodium or potassium hypochlorite, is used as oxidizing agent. The reaction between the bromide source and the hypochlorite salt results in formation of hypobromite salt. Hypochlorite salt is preferably an aqueous solution with a concentration of 5 to 50% wt, more preferably of 10 to 40% wt and most preferably of 15 to 20% wt.
The process of this invention is conducted so that the at least two separate flow streams occur continuously during the reaction. Once the continuous flows have been initiated, the flow rate of each separate flow may be adjusted as to establish and maintain the desired processing conditions for a steady-state reaction. Also, other reaction parameters such as temperature may be adjusted. Thus, once steady-state conditions have been achieved in the continuous flow reactor, the separate flows can be fed in appropriate proportions on a continuous basis whereby the reactor content maintains stable for virtually unlimited periods of time.
The reaction is preferably conducted without temperature control; i.e. at room temperature, typically 15 to 25° C., and at atmospheric pressure. If desired, however, the processes of this invention can be conducted using heating or cooling. For example, a flow of water or other heat exchange liquid for indirect heat exchange with the continuous flow reactor provides maintenance of steady-state temperature conditions in the reaction mixture. It is preferred that the temperature of the reaction mixture at any stage of the reaction preferably does not exceed about 90° C. and more preferably does not exceed about 70° C. Preferably, in order to obtain a high yield, a temperature within the range of about 30 to about 70° C. is used, more preferably a temperature between about 40 to about 60° C. is used and most preferably a temperature between 45° C. and 55° C.
The pressure at which the continuous flow reaction is conducted can be regulated by pressure regulator devices such as for example a backpressure regulator or a pressure reducing regulator. A high pressure can for example be obtained by adjusting the backpressure regulator whereby the pressure in the reactor may increase upto 100 bar. As a result, reaction temperatures above the normal boiling point of the reaction mixture can be achieved, for example upto 200° C.
Bromination is a particularly important reaction in organic synthetic chemistry covering a whole spectrum of substrates, both as end product and as reactive intermediate for further derivatisation. Preferred brominations are selected from bromine addition to the double and triple carbon-carbon bonds in alkenes and alkynes, the bromination of the α-position of aldehydes, ketones, esters, amides, carboxylic acids, sulfones, and nitriles, having at least one α-proton on an aliphatic group and the bromination of the active methylene groups having at least one proton on the active methylene position preferably selected from the group consisting of 1,3-diketones, 1,3-dialdehydes, β-ketoaldehydes, β-keto-esters, β-keto-amides, 1,3-dicarboxylic acids, 1,3-diesters, 1,3-diamides, β-carboxysulfones and esters thereof. Further preferred brominations are ring brominations of aromatic or heteroaromatic components, preferably electron rich aromatic compounds or electron rich heteroaromatic compounds. Phenoles, aryl ethers and anilines are preferred electron rich aromatic compounds. Preferred electron rich heteroaromatic rings are selected from thiophenes, furanes, pyrroles and indoles. Brominating agents such as hypobromite or bromine are also of importance in certain rearrangements and similar reactions, exemplified by a Hofmann rearrangement converting an amide into an amine and haloform reactions converting methyl ketones into carboxylic acid salts. Also these types of substrates are within the scope of the invention. Further brominations can be found in “Advanced Organic Chemistry: Reactions, Mechanisms and Structure, Fourth Edition, Jerry March (Wiley Interscience Publications, ISBN 0-471-60180-2)”, herein incorporated as reference. Further bromination agents of interests and bromination reactions and substrates can be found in Methoden der Organischen Chemie (Houben-Weyl), Teil 5/4, Halogen Verbindungen, Brom and Jod, β-516 (Vierte Auflage, Georg Thieme Verlag Stuttgart) and in Reactionen der Organischen Synthese (Cesare Ferri, Georg Thieme Verlag Stuttgart, ISBN 3-13-487401-6), also herein incorporated as reference.
Especially preferred substrates include optionally substituted acetophenone, diphenylethene, bisphenol A, malonic acid or any other organic substrate that is prone to bromination reactions. The bromination reaction is preferably carried out on a carbon atom. Highly preferred is the bromination reaction of compounds including a sulfone group such as optionally substituted dialkyl sulfone or aryl alkyl sulfone compounds.
In a preferred embodiment, the obtained brominating agent reacts subsequently with a substrate in a batch process. In this process, the obtained brominating agent is added in a continuous flow to the substrate. The substrate may be neat but is preferably in the form of an aqueous solution or a solution containing an appropriate solvent such as for example example water, alcohols (e.g. MeOH, EtOH, i-propanol), aceton, ethylacetate, acetonitrile, MEK, DMF, THF, N-methyl-2-pyrrolidon, N,N-dimethylaceetamide, DMSO, and/or mixtures thereof. It is preferred to operate with a slight excess of the brominating agent relative to the amount of bromine atoms to be inserted in the substrate—i.e. in the range of about 1 to about 8 atoms of bromine, more preferably 1 to 4 atoms of bromine and most preferably 1 to 2 atoms of bromine—relative to the amount of bromine atoms to be inserted in the substrate—which ensures full bromination without loss of substrate.
Examples of suitable alkyl groups are methyl, ethyl, n-propyl, isopropyl, n-butyl, 1-isobutyl, 2-isobutyl and tertiary-butyl, n-pentyl, n-hexyl, chloromethyl, trichloromethyl, iso-propyl, iso-butyl, iso-pentyl, neo-pentyl, 1-methylbutyl and iso-hexyl, 1,1-dimethyl-propyl, 2,2-dimethylpropyl and 2-methyl-butyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and methylcyclohexyl groups.
Examples of suitable aryl groups may be represented by for example an optionally substituted phenyl, benzyl, tolyl or an ortho- meta- or para-xylyl group, an optionally substituted naphtyl, anthracenyl, phenanthrenyl, and/or combinations thereof. Unless otherwise defined, the heteroaryl group herein is preferably a monocyclic or polycyclic aromatic ring comprising carbon atoms and one or more heteroatoms in the ring structure, preferably, 1 to 4 heteroatoms, independently selected from nitrogen, oxygen, selenium and sulphur. Preferred examples thereof include an optionally substituted furyl, pyridinyl, pyrimidyl, pyrazoyl, imidazoyl, oxazoyl, isoxazoyl, thienyl, tetrazoyl, thiazoyl, (1,2,3)triazoyl, (1,2,4)triazoyl, thiadiazoyl, thiofenyl group and/or combinations thereof.
The optional substituents on the alkyl, aryl, heteroaryl groups are preferably selected from hydroxy, —Cl, —Br, —I, —OH, —SH, —CN, —NO2, an alkyl group such as a methyl or ethyl group, an alkoxy group such as a methoxy or an ethoxy group, an aryloxy group, a carboxylic acid group or an alkyl ester thereof, a sulphonic acid group or an alkyl ester thereof, a phosphonic acid group or an alkyl ester thereof, a phosphoric acid group or an an ester such as an alkyl ester such as methyl ester or ethyl ester, a thioalkyl group, a thioaryl group, thioheteroaryl, —SH, a thioether such as a thioalkyl or thioaryl, ketone, aldehyde, sulfoxide, sulfone, sulfonate ester, sulphonamide, an amino, an amido, ethenyl, alkenyl, alkynyl, cycloalkyl, alkaryl, aralkyl, aryl, heteroaryl or heteroalicyclic group and/or combinations thereof.
Monitoring the level of bromide present in the reaction mixture can be performed by use of pH meters, chemical pH indicators, and/or the like. When conducting the bromination reaction at temperatures above the boiling temperature of the brominating reagent, it is desirable to feed the brominating agent subsurface to the liquid phase of the aqueous reaction mixture including the substrate.
Alternatively, the obtained brominating agent may be fed to a second continuous flow reactor to which the substrate is added in flow. The substrate is preferably fed in flow in the form of a solution containing a solvent such as for example water, alcohols (e.g. MeOH, EtOH, i-propanol), aceton, ethylacetate, acetonitrile, MEK, DMF, THF, N-methyl-2-pyrrolidon, N,N-dimethylaceetamide, DMSO, and/or mixtures thereof. An aqueous solution is preferred. As in the batch process discussed above, also here it is preferred to operate with a slight excess of the brominating agent relative to the amount of bromine atoms to be inserted in the substrate—i.e. in the range of about 1 to about 8 atoms of bromine, more preferably 1 to 4 atoms of bromine and most preferably 1 to 2 atoms of bromine—relative to the amount of bromine atoms to be inserted in the substrate—which ensures full bromination without loss of substrate. The flow rates of both the solution containing the substrate and the solution containing the brominating agent should be adapted to the specific bromination reaction. The skilled person can depending on the specific reaction, adapt the reaction conditions such as temperature, residence time and/or flow rate in order to obtain a high yield reaction.
Other compounds that may be included in the reaction mixture, provided they have no adverse effect upon the conduct of the process, are for example acids or bases, catalysts or organic solvents e.g. N, N-dimethylformamide, dimethylsulfoxide, alkanols, toluene, tetrahydrofuran or other saturated ethers, or the like.
The following Examples are presented to illustrate the practice of, and advantages made possible by, this invention. These Examples are not intended to limit, and should not be construed as limiting, the scope of this invention to the particular operations or conditions described therein.
All materials used in the following examples were readily available from standard sources such as Sigma-Aldrich (Belgium) and Acros (Belgium) unless otherwise specified. The target compounds used in the Examples are only illustrative to the invention.
1. Bromination with hypobromite
Reaction Scheme:
NaBr+NaOCl→NaOBr+NaCl
Reaction procedure:
Reaction Scheme:
Synthesis of Elemental Bromine in Flow
Bromination Reaction: Bromination of Bisphenol-A
Bromination Reaction: Bromination of E-Stilbene
Bromination Reaction: Acetophenone
Bromination Reaction: Malonic Acid
| Number | Date | Country | Kind |
|---|---|---|---|
| 16184675.3 | Aug 2016 | EP | regional |
This application is a 371 National Stage Application of PCT/EP2017/070554, filed Aug. 14, 2017. This application claims the benefit of European Application No. 16184675.3, filed Aug. 18, 2016, which is incorporated by reference herein in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/070554 | 8/14/2017 | WO | 00 |
