Patent Application
20210238138
The present invention is related to a method for improving nucleation step in a crystallisation process.
Many products in the pharmaceutical and high value chemical industries go through multiple crystallization steps during their development and manufacture. Crystallisation is commonly used in purification of chemicals and controls size, shape and polymorphism of the obtained chemicals.
In the pharmaceutical industry, precisely controlling the size, polymorphism and shape of the particles is also of key importance, as it has an influence on pharmacokinetics and mixing behaviour of active molecules. Usually, size of particles in powders is obtained by a grinding step, also referred to as micronization, which can be problematic, as heating may be introduced in the process by friction effects.
Nowadays, continuous flow synthesis of organic molecules is becoming an area of upmost interest for the pharmaceutical industry and more generally in engineering and chemistry. Continuous phase synthesis and crystallization of high value Active Pharmaceutical Ingredients (API) have been successfully reported for molecules such as artemisinin, imatinib, efavirenz and others (for example Cogoni G.; de Souza B. P.; Frawley P. J., Chem. Eng. Sci. 2015, 138, 592-599). Several continuous crystallization methods have been described and developed commercially, like e.g. mixed suspension, mixed product removal setups (MSMPR, see Alvarez A. J. Singh A.; Myerson A. S., Cryst. Growth Des. 2011, 11, 4392-4400.), and impinging jet crystallizers (see Metzger L.; Kind M., Chem. Eng. Sci., 2015, 133, 91-105).
Many organic molecules exhibit polymorphism and pseudo-polymorphism, where a compound can adopt more than one crystal form without or with solvent molecules incorporated in the crystal lattice. Selective crystallization of metastable crystals becomes then mandatory to retain the requested end-product polymorph. The approach for selective crystallization is based on seeding locations or spontaneous nucleation of the targeted form in these domains and controlling the cooling or antisolvent addition rate, or both, so that the combined effects only promote the nucleation of the desired (meta)stable crystalline form. Many approaches are described in literature using single and mixed solvents, supercritical crystallization, seeding strategies, capillary crystallization, polymer- and substrate-induced heteronucleation, and others.
Therefore, there is a need to develop a continuous and seedless process to crystallise chemicals from solution wherein the obtained crystalline structure is well defined, and wherein the size and shape of the particles is controlled, so that a grinding (or micronization) step can be avoided.
The present invention discloses a method for nucleating crystals from a solution comprising the steps of:
The supersaturation a is defined as σ=(C−C*)/C* where C is the actual concentration and C* the solubility value at the crystallization temperature.
Preferred embodiments of the present invention disclose at least one, or an appropriate combination of the following features:
The invention is also related to a method for crystallising a compound from an under saturated solution comprising the steps of nucleating crystals of the compound by the method according to any of the previous claims and growing the obtained nuclei in a metastable supersaturated solution.
Another aspect of the invention is related to a method of seeding a supersaturated solution by injecting nuclei obtained by the method for nucleating crystals from a supersaturated solution according to the invention.
The device and method of the invention is related to the controlled crystallisation of crystallisable soluble organic molecules such as active pharmaceutical ingredients. The device and method of the invention is particularly suitable for molecules where the crystallisation is mainly limited by the nucleation process. Preferred molecules are pharmaceutical ingredients and more general small organic molecules selected from the group consisting of acetylsalicylic acid, paracetamol, etiracetam, piracetam, brivaracetam, lamivudine, ketamine, lactic acid, lactate esters, antiretroviral drugs (like abacavir, atazanavir, darunavir, didanosine, efavirenz, emtricitabine, tenofovir, . . . ), ibuprofen, artesunate, entecavir, zanamivir and artemether, and others.
The device and method of the invention is used to continuously nucleate and grow crystals of organic molecules (solute) in solution inside capillaries with inner diameter equal or less than 1 millimeter for industrial production. The very small size of the capillary ensures that saturation conditions can be varied very fast, getting in less than 1 second from under saturated conditions or metastable conditions (i.e. supersaturated conditions, but without spontaneous nucleation) to strongly supersaturated solutions, above the spontaneous nucleation threshold. For instance, surface to volume ratio in such system permits very fast and efficient cooling on one side, and the very small volume inside the capillary permits high concentration gradient improving antisolvent mixing on the other side.
Nucleation can be obtained by either cooling and/or antisolvent injection. Fast cooling rates are achieved by flowing concentrated solutions into these capillaries. The tubular crystallizer is positioned at low temperatures generating highly supersaturated conditions. An example of such device is represented in
Depending on the molecule to be crystallised, suitable solvent can be a polar solvent selected from the group consisting of water, alcohol, (methanol, ethanol, propanol, isopropanol, hexanol) acetate (, ethyl acetate, isopropyl acetate,) Ketone (methyl isobutyl ketone, methyl isopropyl ketone) organic acid (acetic acid), acetone, acetonitrile, dimethyl formamide, dimethyl sulfoxide and their mixture or can be apolar solvent such as pentane, hexane, cyclohexane, tetrahydrofuran, benzene, toluene, diethyl ether or others.
Typically, the antisolvent is another liquid selected from the same group consisting of water, alcohol, (methanol, ethanol, propanol, isopropanol, hexanol) acetate (, ethyl acetate, isopropyl acetate,) Ketone (methyl isobutyl ketone, methyl isopropyl ketone) organic acid (acetic acid), acetone, acetonitrile, dimethyl formamide, dimethyl sulfoxide and their mixture or can be apolar solvent such as pentane, hexane, cyclohexane, tetrahydrofuran, benzene, toluene, diethyl ether or others.
Advantageously, cooled antisolvent can be added by a side feed, preferably at constant flow rates. In that case, both the side feed and the main feed are of capillary dimensions, so that fast mixing is obtained, ensuring fast spontaneous nucleation.
Preferably, static mixers, such as restrictions of variable lengths and diameters, included in the flow path prior to cooling, help increasing and controlling the overall nucleation rate; hence, by parameter selection, predefined crystal sizes can easily be obtained with a micrometric dimension (typically between 5 μm and 500 μm) and a narrow size distribution, both ensuring appropriate biodisponibility and controllable pharmacokinetics.
By restriction, it is meant a change in diameter over a certain distance as opposed to the normal inner diameter of the tubing. Such a restriction can have an inner diameter of 250 to 750 μm, over a length of 1 mm to 50 cm. The purpose of these restrictions is to induce recirculation zones at the end of the restriction in the flow path of the liquid and thus increasing cooling rates further downstream due to convection as well as increasing overall shear rates of the liquid over the full length of the crystallizer. Appropriate positioning of the restrictions renders a full control of crystal nucleation rate and therefore final crystal size.
The dimensions of the capillary ensure fast cooling rates of all the liquid (10-50° C./s) at set flow rate. Length may vary between 15 cm and 10 m: shorter lengths (15 cm to 1 m) are used when antisolvent is added to the crystallizing liquid, longer lengths (between 1 and 10 m) when only cooling crystallization is applied.
Supersaturation is the driving force for nucleation. The fast cooling rates and/or antisolvent gradients obtained inside the apparatus provide high supersaturation values resulting in high enough nucleation rates in order to have a continuous stream of small crystals at the outlet of the apparatus. Preferred values between 2 and 18 as maximum supersaturation is defined as σ=(C−C*)/C* with C is the actual concentration and C* the solubility value at the crystallization temperature. More preferably, the maximum supersaturation is comprised between 4 and 16.
Preferably, the time to get from the undersaturated conditions to the maximum supersaturation is less than 1 s.
For example, following tests were made on Brivaracetam/IPAc (IsoPropylAcetate) at different concentrations. Induction time (appearance of crystals) is shown in table 1 for different increasing concentrations at a crystallization temperature of 20° C. after flowing through the tube at 30 mL/min in a 7 m long tubing.
The combination of flow rates and tube length determines the residence time of the molecules inside the tubing. Moreover, the flow rate impacts the recirculation zones after the restrictions in flow. Therefore, the ideal combination of flow rates and supersaturation time gradient has to be found for each different molecule.
Table 2 shows the change in crystal size for Brivaracetam/IPAc solutions for different flow rates Q at a crystallization temperature Tc of 0° C. (so same overall supersaturation). The variation in crystal size is shown without and with a 5 cm long 500 μm restriction. “Needles and rods” indicate appearance of concurring crystallizations of the two possible crystal types of Brivaracetam. Therefore the method also influences selectivity for one single crystal form. In the case of Brivaracetam, rods are preferred.
Decreasing flow rate results in longer residence times and therefore more nucleation, so smaller crystals are observed (tests 2, 3 and 4 in table 2). Introducing one single restriction, an optimum is reached for 32 mL/min. Nucleation rates J drastically increased when using one restriction as opposed to none (tests 6, 7, 8 compared to 2, 3, 4 in table 2).
The advantage of using restriction(s) has already been indicated in previous tables. A series of tests was also performed using identical conditions and only changing the number of identical restrictions. In table 3, the tests were performed with restrictions of 1 mm in length and having an inner diameter of 500 μm. Crystal length decreases drastically when placing more restrictions in series in the tubing line.
Also different geometries of restriction were tested on Brivaracetam/IPAc mixtures: different lengths and different inner diameters. All result in fast crystallization and different obtained crystal lengths and sizes, as shown in table 4.
The length of the capillary tube has also been varied. In the following tests, antisolvent hexane at 4° C. was added to a solution of Brivaracetam/IPAc. The varying parameters are listed in table 5. It became clear that for these cases different lengths of tubing are to be investigated, as too long tube results into blockage of the tubes due to too high solid content in suspension in the solution, as reported in table 6. In all cases, the preferred rods form was observed.
Tubing length should also be adapted when no antisolvent is added to the molecule/solvent solution. For example in the crystallization of acetylsalicylic acid in Ethanol/water mixtures, it is observed that in tubes longer than 3 m, the solid content in suspension in the solution becomes so high that blockage of the tubing occurs as reported in table 7.
As can be seen from the reported results, depending on the crystallisation system to be treated, different parameters can be varied, and optimal setup depends on the solvent/solute combination and composition.
The crystallization temperature is controlled by a water bath containing about 5 L of water, temperature is monitored at all times by a thermocouple. This water is cooled by a 1 m long cupper serpentine plunged into the bath with cooling liquid flowing from and to a cryothermostat, the water bath itself is agitated with a magnetic bar stirrer. The internal volume of a 7 m long tubing of 1 mm inner diameter is about 22 mL. As this volume is 220 times smaller than the volume of the present water it is assumed that the water temperature remains within a 0.5° C. or smaller margin of the set temperature value.
Especially since the wall thickness of the used tubing is 0.3 mm—PTFE—which enhances temperature exchange between crystallizing liquid and the water bath. Temperature simulations using COMSOL Multiphysics, above mentioned conditions, and—measured and documented—physicochemical values of the solute/solvent solution for heat capacity, heat conductivity and density have pointed out that temperature variation inside the tubing when flowing at different flow rates is fast and that the crystallization temperature of the water bath is reached for flow rates 20 to 50 mL/min, starting from a tube length of 7 m long tubing. Simulated temperature variation as a function of tubing length is shown in
Solvents and solvent mixtures can have an increased viscosity, as is the case for ethanol/water mixtures: viscosity goes through a maximum of when mixed in a 50/50 volumetric ratio. Hence, it is expected that the inner diameter of the restrictions have to be reduced for a mixture of solvent and acetylsalicylic acid to have a positive effect on nucleation rate as opposed to Brivaracetam/Isopropyl acetate solutions.
This reduction in size has to be performed in order to increase the reigning Reynolds number inside the restriction at set flow rates and concentrations. Indeed, in table 8, the average crystal lengths, Sphere Equivalent Diameter (SED) and nucleation rates are shown for 10 repeated tests of several conditions with varying inner diameter and number of restrictions for an acetylsalicylic acid/ethanol/water mixture of 200 mg acetylsalicylic acid/mL solvent in a 50/50 volumetric ratio of ethanol and water.
The use of two restrictions with an inner diameter of 500 μm has some effect on the average size. It is however mostly the use of 250 μm inner diameter restrictions that have a drastic impact: not only is the average crystal length reduced; also the crystal aspect has changed: instead of rectangular rods with an observed equal width and depth for tests 37 to 40, this depth is reduced to about ⅕ of the width in tests 43 and 44.
Therefore, the use of these restrictions has also a large impact on crystal appearance, pinpointing again to the influence of shear stresses on the nucleation behavior of small organic molecules. Next to this, the use of 2 restrictions increases drastically the nucleation rate by 2 orders of magnitude, as was also shown for Brivaracetam. It is expected that any molecule undergoing cooling crystallization in this setup will be influenced by the use and position of proposed flow path restrictions.
Using the proposed setup of claim 1, the crystals will have attained a certain size and shape at the end of the tubular crystallizer, which corresponds to their nucleation rate attained inside the tubing. Obtaining different crystal sizes as end-product then depends on the time that is given to the crystals to mature further.
Tests reported in table 9 were performed on acetylsalicylic acid/ethanol/water solutions of 200 mg acetylsalicylic acid/mL solvent in a 50/50 volumetric ratio of ethanol/water, using a flow rate of 30 mL/min and a bath temperature of 10° C. Crystal growth treatments varied between growth in suspension up to equilibrium followed by filtration and drying (test 45); filtration after 60 seconds (test 46); filtration after 90 seconds (test 47); addition of 250 mL of the mother liquor to 250 mL of a saturated 70 mg/mL acetylsalicylic acid/ethanol/water solution under gentle stirring followed by filtration and drying (test 48).
When the product is filtered after 1 minute, the final product is indeed smaller than the product found at equilibrium. After 90 seconds this effect is already absent, meaning that equilibrium conditions are met very fast inside the liquor. The fact that average crystal length of test 47 is larger than test 45 as to be found in small variations in nucleation rate as a function of time. When the same product is added to a saturated solution, overall concentration drops and therefore the system is more diluted after the nucleation step. Therefore, the number of nuclei formed inside the tubular crystallizer will undergo less growth and hence, reduced crystal sizes are obtained.
To further proof the effect of early filtration (see table 10), the liquor of tests 43 and 44 were also directly filtered after exiting the tubing (test 49 and 50, respectively); the product of test 44 was also collected for 2 minutes and filtered afterwards (test 51). As a result, a very fine crystalline powder is obtained which does not require any further processing to be incorporated into tablets.
Two different capillaries of dimensions 1000 and 1500 μm inner diameter ID were used for a test using the setup of
The transition time is defined as the time necessary to reach crystallization conditions in the used setup (i.e. time for a fluid particle flowing in the liquid to get from undersaturated conditions to nucleation conditions). Therefore, this time is at a given concentration dominated by the difference in temperature between the solubility temperature and the metastable zone width or MSZW. At temperatures below this MSZW the solute in solution starts to nucleate spontaneously. For example, a concentration of 200 mg/mL aspirin in a 50/50 vol % ethanol/water solution has a solubility temperature of 40° C. and spontaneous nucleation starts at 20° C. (both measured). The transition time is then defined as the time needed to overcome this 20° C. difference in temperature. In a process according to the invention, this time is a short as possible.
The total tubing length and hence residence time of setup shown in
For example, in a series of tests, an identical total residence time inside the tubing of 5.3 s was respected. A solution of 200 mg/mL aspirin in 50 vol % ethanol/water was used; at different flow rates. This means that the total length of the tubing inside the water bath was varied according to the set flow rate in order to retain the 5.3 s residence time. As expected, none of the several repeated tests showed any crystallization when using the 1500 μm ID tubing, since in no case 5.3 s total residence time is sufficient to cool the liquid down to solubility, overcome the transition time and nucleate inside the tubing. Using a 750 and 1000 μm ID tubing, 5.3 s is indeed sufficient for the total residence time and crystals are retrieved. Note that the nucleation rate is a function of imposed flow rate at fixed thermodynamics: neither the temperature, concentration and residence time were changed for these tests.
| Number | Date | Country | Kind |
|---|---|---|---|
| 18171018.7 | May 2018 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2019/061347 | 5/3/2019 | WO | 00 |
