# Patent

## Title
Process to prepare treprostinil, the active ingredient in remodulin

## Abstract

This present invention relates to an improved process to prepare prostacyclin derivatives. One embodiment provides for an improved process to convert benzindene triol to treprostinil via salts of treprostinil and to purify treprostinil.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Patent Application 61/014,232, filed Dec. 17, 2007, the entire contents of which are incorporated herein by reference.


BACKGROUND
The present invention relates to a process for producing prostacyclin derivatives and novel intermediate compounds useful in the process.
Prostacyclin derivatives are useful pharmaceutical compounds possessing activities such as platelet aggregation inhibition, gastric secretion reduction, lesion inhibition, and bronchodilation.
Treprostinil, the active ingredient in Remodulin®, was first described in U.S. Pat. No. 4,306,075. Treprostinil, and other prostacyclin derivatives have been prepared as described in Moriarty, et al in J. Org. Chem. 2004, 69, 1890-1902, Drug of the Future, 2001, 26(4), 364-374, U.S. Pat. Nos. 6,441,245, 6,528,688, 6,765,117 and 6,809,223. Their teachings are incorporated by reference to show how to practice the embodiments of the present invention.
U.S. Pat. No. 5,153,222 describes use of treprostinil for treatment of pulmonary hypertension. Treprostinil is approved for the intravenous as well as subcutaneous route, the latter avoiding septic events associated with continuous intravenous catheters. U.S. Pat. Nos. 6,521,212 and 6,756,033 describe administration of treprostinil by inhalation for treatment of pulmonary hypertension, peripheral vascular disease and other diseases and conditions. U.S. Pat. No. 6,803,386 discloses administration of treprostinil for treating cancer such as lung, liver, brain, pancreatic, kidney, prostate, breast, colon and head-neck cancer. U.S. patent application publication No. 2005/0165111 discloses treprostinil treatment of ischemic lesions. U.S. Pat. No. 7,199,157 discloses that treprostinil treatment improves kidney functions. U.S. patent application publication No. 2005/0282903 discloses treprostinil treatment of neuropathic foot ulcers. U.S. application Ser. No. 12/028,471 filed Feb. 8, 2008, discloses treprostinil treatment of pulmonary fibrosis. U.S. Pat. No. 6,054,486 discloses treatment of peripheral vascular disease with treprostinil. U.S. patent application Ser. No. 11/873,645 filed Oct. 17, 2007 discloses combination therapies comprising treprostinil. U.S. publication No. 2008/0200449 discloses delivery of treprostinil using a metered dose inhaler. U.S. publication No. 2008/0280986 discloses treatment of interstitial lung disease with treprostinil. U.S. application Ser. No. 12/028,471 filed Feb. 8, 2008 discloses treatment of asthma with treprostinil. U.S. Pat. Nos. 7,417,070, 7,384,978 and U.S. publication Nos. 2007/0078095, 2005/0282901, and 2008/0249167 describe oral formulations of treprostinil and other prostacyclin analogs.
Because Treprostinil, and other prostacyclin derivatives are of great importance from a medicinal point of view, a need exists for an efficient process to synthesize these compounds on a large scale suitable for commercial production.
SUMMARY
The present invention provides in one embodiment a process for the preparation of a compound of formula I, hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof.




The process comprises the following steps:
(a) alkylating a compound of structure II with an alkylating agent to produce a compound of formula III,




wherein

    
    
        w=1, 2, or 3;
        Y1 is trans-CH═CH—, cis-CH═CH—, —CH2(CH2)m—, or —C≡C—; m is 1, 2, or 3;
        R7 is
        (1) —CpH2p—CH3, wherein p is an integer from 1 to 5, inclusive,
        (2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C1-C3) alkyl, or (C1-C3)alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R7 is phenoxy or substituted phenoxy, only when R3 and R4 are hydrogen or methyl, being the same or different,
        (3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C1-C3)alkyl, or (C1-C3)alkoxy, with the proviso that not more than two substituents are other than alkyl,
        (4) cis-CH═CH—CH2—CH3,
        (5) —(CH2)2—CH(OH)—CH3, or
        (6) —(CH2)3—CH═C(CH3)2;
        wherein —C(L1)-R7 taken together is
        (1) (C4-C7)cycloalkyl optionally substituted by 1 to 3 (C1-C5)alkyl;
        (2) 2-(2-furyl)ethyl,
        (3) 2-(3-thienyl)ethoxy, or
        (4) 3-thienyloxymethyl;
        M1 is α-OH:β-R5 or α-R5:β-OH or α-OR1:β-R5 or α-R5:β-OR2, wherein R5 is hydrogen or methyl, R2 is an alcohol protecting group, and
        L1 is α-R3:β-R4, α-R4:β-R3, or a mixture of α-R3:β-R4 and α-R4:β-R3, wherein R3 and R4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R3 and R4 is fluoro only when the other is hydrogen or fluoro.
    
    


(b) hydrolyzing the product of step (a) with a base,
(c) contacting the product of step (b) with a base B to for a salt of formula Is




(d) reacting the salt from step (c) with an acid to form the compound of formula I.
The present invention provides in another embodiment a process for the preparation of a compound of formula IV.




The process comprises the following steps:
(a) alkylating a compound of structure V with an alkylating agent to produce a compound of formula VI,




(b) hydrolyzing the product of step (a) with a base,
(c) contacting the product of step (b) with a base B to for a salt of formula IVs, and




(d) reacting the salt from step (b) with an acid to form the compound of formula IV.


DETAILED DESCRIPTION
The various terms used, separately and in combinations, in the processes herein described are defined below.
The expression “comprising” means “including but not limited to.” Thus, other non-mentioned substances, additives, carriers, or steps may be present. Unless otherwise specified, “a” or “an” means one or more.
C1-3-alkyl is a straight or branched alkyl group containing 1-3 carbon atoms. Exemplary alkyl groups include methyl, ethyl, n-propyl, and isopropyl.
C1-3-alkoxy is a straight or branched alkoxy group containing 1-3 carbon atoms. Exemplary alkoxy groups include methoxy, ethoxy, propoxy, and isopropoxy.
C4-7-cycloalkyl is an optionally substituted monocyclic, bicyclic or tricyclic alkyl group containing between 4-7 carbon atoms. Exemplary cycloalkyl groups include but not limited to cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl.
Combinations of substituents and variables envisioned by this invention are only those that result in the formation of stable compounds. The term “stable”, as used herein, refers to compounds which possess stability sufficient to allow manufacture and which maintains the integrity of the compound for a sufficient period of time to be useful for the purposes detailed herein.
As used herein, the term “prodrug” means a derivative of a compound that can hydrolyze, oxidize, or otherwise react under biological conditions (in vitro or in vivo) to provide an active compound. Examples of prodrugs include, but are not limited to, derivatives of a compound that include biohydrolyzable groups such as biohydrolyzable amides, biohydrolyzable esters, biohydrolyzable carbamates, biohydrolyzable carbonates, biohydrolyzable ureides, and biohydrolyzable phosphate analogues (e.g., monophosphate, diphosphate or triphosphate).
As used herein, “hydrate” is a form of a compound wherein water molecules are combined in a certain ratio as an integral part of the structure complex of the compound.
As used herein, “solvate” is a form of a compound where solvent molecules are combined in a certain ratio as an integral part of the structure complex of the compound.
“Pharmaceutically acceptable” means in the present description being useful in preparing a pharmaceutical composition that is generally safe, non-toxic and neither biologically nor otherwise undesirable and includes being useful for veterinary use as well as human pharmaceutical use.
“Pharmaceutically acceptable salts” mean salts which are pharmaceutically acceptable, as defined above, and which possess the desired pharmacological activity. Such salts include acid addition salts formed with organic and inorganic acids, such as hydrogen chloride, hydrogen bromide, hydrogen iodide, sulfuric acid, phosphoric acid, acetic acid, glycolic acid, maleic acid, malonic acid, oxalic acid, methanesulfonic acid, trifluoroacetic acid, fumaric acid, succinic acid, tartaric acid, citric acid, benzoic acid, ascorbic acid and the like. Base addition salts may be formed with organic and inorganic bases, such as sodium, ammonia, potassium, calcium, ethanolamine, diethanolamine, N-methylglucamine, choline and the like. Included in the invention are pharmaceutically acceptable salts or compounds of any of the formulae herein.
Depending on its structure, the phrase “pharmaceutically acceptable salt,” as used herein, refers to a pharmaceutically acceptable organic or inorganic acid or base salt of a compound. Representative pharmaceutically acceptable salts include, e.g., alkali metal salts, alkali earth salts, ammonium salts, water-soluble and water-insoluble salts, such as the acetate, amsonate (4,4-diaminostilbene-2,2-disulfonate), benzenesulfonate, benzonate, bicarbonate, bisulfate, bitartrate, borate, bromide, butyrate, calcium, calcium edetate, camsylate, carbonate, chloride, citrate, clavulariate, dihydrochloride, edetate, edisylate, estolate, esylate, fumarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexafluorophosphate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate, N-methylglucamine ammonium salt, 3-hydroxy-2-naphthoate, oleate, oxalate, palmitate, pamoate (1,1-methene-bis-2-hydroxy-3-naphthoate, einbonate), pantothenate, phosphate/diphosphate, picrate, polygalacturonate, propionate, p-toluenesulfonate, salicylate, stearate, subacetate, succinate, sulfate, sulfosalicylate, suramate, tannate, tartrate, teoclate, tosylate, triethiodide, and valerate salts.
The present invention provides for a process for producing treprostinil and other prostacyclin derivatives and novel intermediate compounds useful in the process. The process according to the present invention provides advantages on large-scale synthesis over the existing method. For example, the purification by column chromatography is eliminated, thus the required amount of flammable solvents and waste generated are greatly reduced. Furthermore, the salt formation is a much easier operation than column chromatography. Moreover, it was found that the product of the process according to the present invention has higher purity. Therefore the present invention provides for a process that is more economical, safer, faster, greener, easier to operate, and provides higher purity.
One embodiment of the present invention is a process for the preparation of a compound of formula I, or a hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof.




The process comprises the following steps:
(a) alkylating a compound of formula II with an alkylating agent to produce a compound of formula III,




wherein

    
    
        w=1, 2, or 3;
        Y1 is trans-CH═CH—, cis-CH═CH—, —CH2(CH2)m—, or —C≡C—; m is 1, 2, or 3;
        R7 is
        (1) —CpH2p—CH3, wherein p is an integer from 1 to 5, inclusive,
    
    


(2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C1-C3) alkyl, or (C1-C3)alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R7 is phenoxy or substituted phenoxy, only when R3 and R4 are hydrogen or methyl, being the same or different,

    
    
        (3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C1-C3)alkyl, or (C1-C3)alkoxy, with the proviso that not more than two substituents are other than alkyl,
        (4) cis-CH═CH—CH2—CH3,
        (5) —(CH2)2—CH(OH)—CH3, or
        (6) —(CH2)3—CH═C(CH3)2;
        wherein —C(L1)-R7 taken together is
        (1) (C4-C7)cycloalkyl optionally substituted by 1 to 3 (C1-C5)alkyl;
        (2) 2-(2-furyl)ethyl,
        (3) 2-(3-thienyl)ethoxy, or
        (4) 3-thienyloxymethyl;
        M1 is x-OH:β-R5 or α-R5:β-OH or α-OR1:β-R5 or α-R5:β-OR2, wherein R5 is hydrogen or methyl, R2 is an alcohol protecting group, and
        L1 is α-R3:β-R4, α-R4:β-R3, or a mixture of α-R3:β-R4 and α-R4:β-R3, wherein R3 and R4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R3 and R4 is fluoro only when the other is hydrogen or fluoro.
    
    


(b) hydrolyzing the product of step (a) with a base,
(c) contacting the product of step (b) with a base B to for a salt of formula Is




(d) reacting the salt from step (c) with an acid to form the compound of formula I.
In one embodiment, the compound of formula I is at least 90.0%, 95.0%, 99.0%.
The compound of formula II can be prepared from a compound of formula XI, which is a cyclization product of a compound of formula X as described in U.S. Pat. No. 6,441,245.




Wherein n is 0, 1, 2, or 3.

The compound of formula II can be prepared alternatively from a compound of formula XIII, which is a cyclization product of a compound of formula XII as described in U.S. Pat. No. 6,700,025.




One embodiment of the present invention is a process for the preparation of a compound having formula IV, or a hydrate, solvate, or pharmaceutically acceptable salt thereof.




The process comprises
(a) alkylating a compound of structure V with an alkylating agent such as ClCH2CN to produce a compound of formula VI,




(b) hydrolyzing the product of step (a) with a base such as KOH,
(c) contacting the product of step (b) with a base B such as diethanolamine to for a salt of the following structure, and




(d) reacting the salt from step (b) with an acid such as HCl to form the compound of formula IV.
In one embodiment, the purity of compound of formula IV is at least 90.0%, 95.0%, 99.0%, 99.5%.
In one embodiment, the process further comprises a step of isolating the salt of formula IVs.
In one embodiment, the base B in step (c) may be ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, or triethanolamine.
The following abbreviations are used in the description and/or appended claims, and they have the following meanings:
“MW” means molecular weight.
“Eq.” means equivalent.
“TLC” means thin layer chromatography.
“HPLC” means high performance liquid chromatography.
“PMA” means phosphomolybdic acid.
“AUC” means area under curve.
In view of the foregoing considerations, and specific examples below, those who are skilled in the art will appreciate that how to select necessary reagents and solvents in practicing the present invention.
The invention will now be described in reference to the following Examples. These examples are not to be regarded as limiting the scope of the present invention, but shall only serve in an illustrative manner.
EXAMPLES
Example 1
Alkylation of Benzindene Triol























 








 













Name
MW
Amount
Mol.
Eq.
















Benzindene Triol
332.48
1250
g
3.76
1.00


K2CO3 (powder)
138.20
1296
g
9.38
2.50


CICH2CN
75.50
567
g
7.51
2.0


Bu4NBr
322.37
36
g
0.11
0.03


Acetone
—
29
L
—
—


Celite ® 545
—
115
g
—
—









A 50-L, three-neck, round-bottom flask equipped with a mechanical stirrer and a thermocouple was charged with benzindene triol (1250 g), acetone (19 L) and K2CO3 (powdered) (1296 g), chloroacetonitrile (567 g), tetrabutylammonium bromide (36 g). The reaction mixture was stirred vigorously at room temperature (23±2° C.) for 16-72 h. The progress of the reaction was monitored by TLC. (methanol/CH2Cl2; 1:9 and developed by 10% ethanolic solution of PMA). After completion of reaction, the reaction mixture was filtered with/without Celite pad. The filter cake was washed with acetone (10 L). The filtrate was concentrated in vacuo at 50-55° C. to give a light-brown, viscous liquid benzindene nitrile. The crude benzindene nitrile was used as such in the next step without further purification.
Example 2
Hydrolysis of Benzindene Nitrile























 








 













Name
MW
Amount
Mol.
Eq.


















Benzindene Nitrile
371.52
1397
g*
3.76
1.0



KOH
56.11
844
g
15.04
4.0



Methanol
—
12
L
—
—



Water
—
4.25
L
—
—







*Note:



This weight is based on 100% yield from the previous step. This is not isolated yield.






A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with a solution of benzindene nitrile in methanol (12 L) and a solution of KOH (844 g of KOH dissolved in 4.25 L of water). The reaction mixture was stirred and heated to reflux (temperature 72.2° C.). The progress of the reaction was monitored by TLC (for TLC purpose, 1-2 mL of reaction mixture was acidified with 3M HCl to pH 1-2 and extracted with ethyl acetate. The ethyl acetate extract was used for TLC; Eluent: methanol/CH2Cl2; 1:9, and developed by 10% ethanolic solution of PMA). After completion of the reaction ( ̃5 h), the reaction mixture was cooled to −5 to 10° C. and quenched with a solution of hydrochloric acid (3M, 3.1 L) while stirring. The reaction mixture was concentrated in vacuo at 50-55° C. to obtain approximately 12-14 L of condensate. The condensate was discarded.
The aqueous layer was diluted with water (7-8 L) and extracted with ethyl acetate (2×6 L) to remove impurities soluble in ethyl acetate. To aqueous layer, ethyl acetate (22 L) was added and the pH of reaction mixture was adjusted to 1-2 by adding 3M HCl (1.7 L) with stirring. The organic layer was separated and the aqueous layer was extracted with ethyl acetate (2×11 L). The combined organic layers were washed with water (3×10 L) and followed by washing with a solution of NaHCO3 (30 g of NaHCO3 dissolved in 12 L of water). The organic layer was further washed with saturated solution of NaCl (3372 g of NaCl dissolved in water (12 L)) and dried over anhydrous Na2SO4 (950-1000 g), once filtered.
The filtrate was transferred into a 72-L reactor equipped with mechanical stirrer, a condenser, and a thermocouple. To the solution of treprostinil in reactor was added activated carbon (110-130 g). The suspension was heated to reflux (temperature 68-70° C.) for at least one hour. For filtration, a pad of Celite® 545 (300-600 g) was prepared in sintered glass funnel using ethyl acetate. The hot suspension was filtered through the pad of Celite® 545. The Celite® 545 was washed with ethyl acetate until no compound was seen on TLC of the washings.
The filtrate (pale-yellow) was reduced to volume of 35-40 L by evaporation in vacuo at 50-55° C. for direct use in next step.
Example 3
Conversion of Treprostinil to Treprostinil Diethanolamine Salt (1:1)























 








 











Name
MW
Amount
Mol
Eq















Treprostinil
390.52
1464
g*
3.75
1.0


Diethanolamine
105.14
435
g
4.14
1.1


Ethanol
—
5.1
L
—
—


Ethyl acetate
—
35
L**
—
—


Treprostinil Diethanolamine
—
12
g
—
—


Salt (seed)





*Note:


This weight is based on 100% yield from benzindene triol. It is not isolated yield. The treprostinil was carried from previous step in ethyl acetate solution and used as such for this step.


**Note:


The total volume of ethyl acetate should be in range 35-36 L (it should be 7 times the volume of ethanol used). Approximately 35 L of ethyl acetate was carried over from previous step and additional 1.0 L of ethyl acetate was used for rinsing the flask.






A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with a solution of treprostinil in ethyl acetate (35-40 L from the previous step), anhydrous ethanol (5.1 L) and diethanolamine (435 g). While stirring, the reaction mixture was heated to 60-75° C., for 0.5-1.0 h to obtain a clear solution. The clear solution was cooled to 55±5° C. At this temperature, the seed of polymorph B of treprostinil diethanolamine salt ( ̃12 g) was added to the clear solution. The suspension of polymorph B was stirred at this temperature for 1 h. The suspension was cooled to 20±2° C. overnight (over a period of 16-24 h). The treprostinil diethanolamine salt was collected by filtration using Aurora filter equipped with filter cloth, and the solid was washed with ethyl acetate (2×8 L). The treprostinil diethanolamine salt was transferred to a HDPE/glass container for air-drying in hood, followed by drying in a vacuum oven at 50±5° C. under high vacuum.
At this stage, if melting point of the treprostinil diethanolamine salt is more than 104° C., it was considered polymorph B. There is no need of recrystallization. If it is less than 104° C., it is recrystallized in EtOH-EtOAc to increase the melting point.
Data on Treprostinil Diethanolamine Salt (1:1)















Wt. of
Wt. of Treprostinil




Batch
Benzindene Triol
Diethanolamine Salt
Yield
Melting point


No.
(g)
(1:1) (g)
(%)
(° C.)



















1
1250
1640
88.00
104.3-106.3


2
1250
1528
82.00*
105.5-107.2


3
1250
1499
80.42**
104.7-106.6


4
1236
1572
85.34
105-108





*Note:


In this batch, approximately 1200 mL of ethyl acetate solution of treprostinil before carbon treatment was removed for R&D carbon treatment experiments.


**Note:


This batch was recrystallized, for this reason yield was lower.






Example 4
Heptane Slurry of Treprostinil Diethanolamine Salt (1:1)
















Name
Batch No.
Amount
Ratio





















Treprostinil
1
3168 g
1



Diethanolamine Salt



Heptane
—
37.5 L
12



Treprostinil
2
3071 g
1



Diethanolamine Salt



Heptane
—
36.0 L
12










A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with slurry of treprostinil diethanolamine salt in heptane (35-40 L). The suspension was heated to 70-80° C. for 16-24 h. The suspension was cooled to 22±2° C. over a period of 1-2 h. The salt was collected by filtration using Aurora filter. The cake was washed with heptane (15-30 L) and the material was dried in Aurora filter for 1 h. The salt was transferred to trays for air-drying overnight in hood until a constant weight of treprostinil diethanolamine salt was obtained. The material was dried in oven under high vacuum for 2-4 h at 50-55° C.
Analytical Data on and Treprostinil Diethanolamine Salt (1:1)












Test
Batch 1
Batch 2







IR
Conforms
Conforms


Residue on Ignition (ROI)
<0.1% w/w
 <0.1% w/w


Water content
 0.1% w/w
 0.0% w/w


Melting point
105.0-106.5° C.
104.5-105.5° C.


Specific rotation [α]25589
+34.6°
+35°







Organic volatile impurities









Ethanol
Not detected
Not detected


Ethyl acetate
Not detected
<0.05% w/w


Heptane
<0.05% w/w 
<0.05% w/w


HPLC (Assay)
100.4%
99.8%


Diethanolamine
Positive
Positive









Example 5
Conversion of Treprostinil Diethanolamine Salt (1:1) to Treprostinil




A 250-mL, round-bottom flask equipped with magnetic stirrer was charged with treprostinil diethanolamine salt (4 g) and water (40 mL). The mixture was stirred to obtain a clear solution. To the clear solution, ethyl acetate (100 mL) was added. While stirring, 3M HCl (3.2 mL) was added slowly until pH 1 was attained. The mixture was stirred for 10 minutes and organic layer was separated. The aqueous layer was extracted with ethyl acetate (2×100 mL). The combined organic layers was washed with water (2×100 mL), brine (1×50 mL) and dried over anhydrous Na2SO4. The ethyl acetate solution of treprostinil was filtered and the filtrate was concentrated under vacuum at 50° C. to give off-white solid. The crude treprostinil was recrystallized from 50% ethanol in water (70 mL). The pure treprostinil was collected in a Buchner funnel by filtration and cake was washed with cold 20% ethanolic solution in water. The cake of treprostinil was air-dried overnight and further dried in a vacuum oven at 50° C. under high vacuum to afford 2.9 g of treprostinil (Yield 91.4%, purity (HPLC, AUC, 99.8%).
Analytical Data on Treprostinil from Treprostinil Diethanolamine Salt (1:1) to Treprostinil












Batch No.
Yield
Purity (HPLC)







1
91.0%
99.8% (AUC)


2
92.0%
99.9% (AUC)


3
93.1%
99.7% (AUC)


4
93.3%
99.7% (AUC)


5
99.0%
99.8% (AUC)


6
94.6%
99.8% (AUC)









Example 6
Comparison of the Former Process and a Working Example of the Process According to the Present Invention
















Working example of the





Process according to the


Step

Former Process
present invention


No.
Steps
(Batch size: 500 g)
(Batch size: 5 kg)















Nitrile










1
Triol weight
500 g
5,000 g


2
Acetone
20 L (1:40 wt/wt)
75 L (1:15 wt/wt)


3
Potassium
1,300 g (6.4 eq)
5,200 g (2.5 eq)



carbonate


4
Chloroacetonitrile
470 g (4.2 eq)
2,270 g (2 eq)


5
Tetrabutylammonium
42 g (0.08 eq)
145 g (0.03 eq)



bromide


6
Reactor size
72-Liter
50- gallon


7
Reflux time
8 hours
No heating,





Room temperature (r.t.) 45 h


8
Hexanes addition
Yes (10 L)
No



before filtration


9
Filter
Celite
Celite


10
Washing
Ethyl acetate (10 L)
Acetone (50 L)


11
Evaporation
Yes
Yes


12
Purification
Silica gel column
No column




Dichloromethane: 0.5 L




Ethyl acetate: 45 L




Hexane: 60 L


13
Evaporation after
Yes
No



column


14
Yield of nitrite
109-112%
Not checked







Treprostinil (intermediate)










15
Methanol
7.6 L (50-L reactor)
50 L (50-gal reactor)


16
Potassium hydroxide
650 g (8 eq)
3,375 g (4 eq)


17
Water
2.2 L
17 L


18
% of KOH
30%
20%


19
Reflux time
3-3.5 h
4-5 h


20
Acid used
2.6 L (3 M)
12 L (3 M)


21
Removal of
3 × 3 L Ethyl acetate
2 × 20 L Ethyl acetate



impurities


22
Acidification
0.7 L
6.5 L


23
Ethyl acetate
5 × 17 L = 35 L
90 + 45 + 45 = 180 L



extraction


24
Water washing
2 × 8 L
3 × 40 L


25
Sodium bicarbonate
Not done
120 g in 30 L water + 15 L



washing

brine


26
Brine washing
Not done
1 × 40 L


27
Sodium sulfate
1 kg
Not done


28
Sodium sulfate
Before charcoal, 6 L
N/A



filtration
ethyl acetate


29
Charcoal
170 g, reflux for 1.5 h,
Pass hot solution (75° C.)




filter over Celite, 11 L
through charcoal cartridge




ethyl acetate
and clean filter, 70 L ethyl





acetate


30
Evaporation
Yes, to get solid
Yes, adjust to 150 L




intermediate treprostinil
solution







Treprostinil Diethanolamine Salt










31
Salt formation
Not done
1,744 g diethanolamine,





20 L ethanol at 60-75° C.


32
Cooling
N/A
To 20° C. over weekend;





add 40 L ethyl acetate;





cooled to 10° C.


33
Filtration
N/A
Wash with 70 L ethyl





acetate


34
Drying
N/A
Air-dried to constant wt.,





2 days







Treprostinil (from 1.5 kg Treprostinil diethanolamine salt)










35
Hydrolysis
N/A
15 L water + 25 L ethyl





acetate + HCl


36
Extraction
N/A
2 × 10 L ethyl acetate


37
Water wash
N/A
3 × 10 L


38
Brine wash
N/A
1 × 10 L


39
Sodium sulfate
N/A
1 kg, stir


40
Filter
N/A
Wash with 6 L ethyl





acetate


41
Evaporation
N/A
To get solid, intermediate





Treprostinil


42
Crude drying on tray
1 or 3 days
Same


43
Ethanol & water for
5.1 L + 5.1 L
10.2 L + 10.2 L (same %)



cryst.


44
Crystallization in
20-L rotavap flask
50-L jacketed reactor


45
Temperature of
2 h r.t., fridge −0° C. 24 h
50° C. to 0° C. ramp, 0° C.



crystallization

overnight


46
Filtration
Buchner funnel
Aurora filter


47
Washing
20% (10 L) cooled
20% (20 L) cooled




ethanol-water
ethanol-water


48
Drying before oven
Buchner funnel (20 h)
Aurora filter (2.5 h)




Tray (no)
Tray (4 days)


49
Oven drying
15 hours, 55° C.
6-15 hours, 55° C.


50
Vacuum
<−0.095 mPA
<5 Torr


51
UT-15 yield weight
~535 g
~1,100 g


52
% yield from triol)
~91%
~89%


53
Purity
~99.0%
99.9%









The quality of treprostinil produced according to this invention is excellent. The purification of benzindene nitrile by column chromatography is eliminated. The impurities carried over from intermediate steps (i.e. alkylation of triol and hydrolysis of benzindene nitrile) are removed during the carbon treatment and the salt formation step. Additional advantages of this process are: (a) crude treprostinil salts can be stored as raw material at ambient temperature and can be converted to treprostinil by simple acidification with diluted hydrochloric acid, and (b) the treprostinil salts can be synthesized from the solution of treprostinil without isolation. This process provides better quality of final product as well as saves significant amount of solvents and manpower in purification of intermediates.
Although the foregoing refers to particular preferred embodiments, it will be understood that the present invention is not so limited. It will occur to those of ordinary skill in the art that various modifications may be made to the disclosed embodiments and that such modifications are intended to be within the scope of the present invention.
All of the publications, patent applications and patents cited in this specification are incorporated herein by reference in their entirety.

## Claims

1. A process for the preparation of a compound of formula I



comprising
(a) alkylating a compound of structure II with an alkylating agent to produce a compound of formula III,







wherein


w=1, 2, or 3;
Y1 is trans-CH═CH—, cis-CH═CH—, —CH2(CH2)m—, or —C≡C—; m is 1, 2, or 3;
R7 is
(1) —CpH2p—CH3, wherein p is an integer from 1 to 5, inclusive,
(2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C1-C3) alkyl, or (C1-C3)alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R7 is phenoxy or substituted phenoxy, only when R3 and R4 are hydrogen or methyl, being the same or different,
(3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C1-C3)alkyl, or (C1-C3)alkoxy, with the proviso that not more than two substituents are other than alkyl,
(4) cis-CH═CH—CH2—CH3,
(5) —(CH2)2—CH(OH)—CH3, or
(6) —(CH2)3—CH═C(CH3)2;
—C(L1)-R7 taken together is

(1) (C4-C7)cycloalkyl optionally substituted by 1 to 3 (C1-C5)alkyl;
(2) 2-(2-furyl)ethyl,
(3) 2-(3-thienyl)ethoxy, or
(4) 3-thienyloxymethyl;
M1 is α-OH:β-R5 or α-R5:β-OH or α-OR1:β-R5 or α-R5:β-OR2, wherein R5 is hydrogen or methyl, R2 is an alcohol protecting group, and
L1 is α-R3:β-R4, α-R4:β-R3, or a mixture of α-R3:β-R4 and α-R4:β-R3, wherein R3 and R4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R3 and
R4 is fluoro only when the other is hydrogen or fluoro,
(b) hydrolyzing the product of formula III of step (a) with a base,
(c) contacting the product of step (b) with a base B to form a salt of formula Is,






(d) reacting the salt formed in step (c) with an acid to form the compound of formula I.

2. The process of claim 1, which does not include purifying the compound of formula (III) produced in step (a).

3. The process according to claim 2, wherein the product of step (d) has the purity of compound of formula I of at least 90.0%.

4. The process according to claim 1, further comprising a step of isolating the salt of formula Is.

5. The process according to claim 1, wherein the alkylating agent is Cl(CH2)wCN, Br(CH2)wCN, or I(CH2)wCN.

6. The process according to claim 1, wherein the base in step (b) is KOH or NaOH.

7. The process according to claim 1, wherein the base B in step (c) is selected from the group consisting of ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, triethanolamine, and diethanolamine.

8. The process according to claim 1, wherein the acid in step (d) is HCl or H2SO4.

9. The process according to claim 1, wherein Y1 is —CH2CH2—; M1 is α-OH:β-H or α-H:β-OH; —C(L1)-R7 taken together is —(CH2)4CH3; and w is 1.

10. The process according to claim 1, wherein the compound of formula I is a compound of formula IV,

11. A process for the preparation of a compound having formula IV



comprising
(a) alkylating a compound of formula V with an alkylating agent to produce a compound of formula VI,






(b) hydrolyzing the product of formula VI of step (a) with a base,
(c) contacting the product of step (b) with a base B to form a salt of formula IVs, and






(d) reacting the salt formed in step (c) with an acid to form the compound of formula IV.

12. The process of claim 11, which does not include purifying the compound of formula (VI) produced in step (a).

13. The process according to claim 12, wherein the product of step (d) has the purity of the compound of formula IV of at least 90.0%.

14. The process according to claim 11, further comprising a step of isolating the salt of formula IVs.

15. The process according to claim 11, wherein the alkylating agent is ClCH2CN.

16. The process according to claim 11, wherein the base in step (b) is KOH.

17. The process according to claim 11, wherein the base B in step (c) is selected from a group consisting of ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, triethanolamine, and diethanolamine.

18. The process according to claim 17, wherein the base B is diethanolamine.

19. The process according to claim 11, wherein the acid in step (d) is HCl.

20. The process of claim 2, wherein the product of step (d) has the purity of compound of formula I of at least 95%.

21. The process of claim 12, wherein the product of step (d) has the purity of compound of formula I of at least 95%.

22. The process of claim 12, wherein the base B in step (c) is selected from a group consisting of ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, triethanolamine, and diethanolamine.

23. The process of claim 22, wherein the base B is diethanolamine.

24. A process for the preparation of a compound having formula IV, or pharmaceutically acceptable salt thereof



comprising
(a) alkylating a compound of formula V with an alkylating agent to produce a compound of formula VI,






(b) hydrolyzing the product of formula VI of step (a) with a base, and
(c) contacting the product of step (b) with a base B to form a salt of formula IVs






 wherein the process does not comprise purifying the compound of formula (VI) produced in step (a).

25. The process according to claim 24, wherein the base B in step (c) is selected from a group consisting of ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, triethanolamine, and diethanolamine and wherein the compound produced is a compound of the formula IVs,



wherein the base B is selected from a group consisting of ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, triethanolamine, and diethanolamine.

26. The process according to claim 25, wherein the base B is diethanolamine and wherein the compound produced is a compound of the following formula:

27. The process according to claim 1, wherein the base in step (b) is KOH or NaOH and wherein the base B in step (c) is selected from the group consisting of ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, triethanolamine, and diethanolamine.

28. The process according to claim 11, wherein the base in step (b) is KOH or NaOH and wherein the base B in step (c) is selected from the group consisting of ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, triethanolamine, and diethanolamine.