Patent Description:
<NUM>-Dehydrocholesterol is a key intermediate used in the synthesis for cholecalciferol (=vitamin D3).

A possible pathway of synthesis of <NUM>-dehydrocholesterol is disclosed in <CIT> starting from cholesteryl acetate and using an intermediate <NUM>-tosylhydrazone cholesterylacetate in an organic solvent and a base. Similar processes are also disclosed in <CIT> and <NPL>). It has been found that this procedure has significant drawbacks.

In a newly developed process for the synthesis of <NUM>-dehydrocholesterol, it has been observed that a higher molecular compound is formed as a byproduct.

It has been also found that this higher molecular compound when present in high amounts is deposited on the surface of the photoreactor in the photoreaction of <NUM>-dehydrocholesterol of at a later stage in the synthesis of vitamin D3. This is of course very disadvantageous. At lower concentrations, however, this is no longer the case.

It has now be found that the process according to claim <NUM> solves surprisingly this problem. A significant lower amount of the new higher molecular compound is formed. This process enables to reduce the amount of this higher molecular compound to the range of between <NUM>% and <NUM>%, particular between <NUM>% and <NUM>%, in relation to <NUM>-dehydrocholesterol.

Furthermore, it has been found that the new higher molecular species which has been identified and its structure characterized, is coloured and can be used as a new colorant. However, this does not form part of the present invention.

It has been also found that the sequence of steps is very crucial for the present invention. In a first step the salt of the intermediate OH-protected <NUM>-tosylhydrazone cholesterol (formula (II)) is added to an already hot solvent (> <NUM>) of formula (III). In comparing this process to a process in which a cold (< <NUM>, particularly room temperature) mixture of solvent and the intermediate OH-protected <NUM>-tosylhydrazone cholesterol (formula (II)), is heated up subsequently, we could show that the amount of the observed higher molecular compound is significantly lower and high conversion and yield can be obtained.

Further aspects of the invention are subject of further independent claims. Particularly preferred embodiments are subject of dependent claims.

In a first aspect the present invention relates to a process of manufacturing a compound of the formula (I)
<CHM>
comprising the step.

For sake of clarity, some terms as used in the present document are defined as follows:
In the present document, a "Cx-y-alkyl" group is an alkyl group comprising x to y carbon atoms, i.e., for example, a C<NUM>-<NUM>-alkyl group is an alkyl group comprising <NUM> to <NUM> carbon atoms. The alkyl group can be linear or branched. For example -CH(CH<NUM>)-CH<NUM>-CH<NUM> is considered as a C<NUM>-alkyl group. Hence, "propyl" can be "n-propyl" or "iso-propyl" (=isopropyl). Analogously, "butyl" can be "n-butyl" or "iso-butyl" or "sec-butyl" or "tert-butyl".

In the present document, "aralkyl" group is an alkyl group of which at least one H is substituted by an aryl group. Hence, for example, benzyl (=C<NUM>H<NUM>-CH<NUM>-) is a C<NUM>-aralkyl group.

In the present document, "alkylaryl" group is an aryl group of which at least one H of the aromatic ring is substituted by an alkyl group. Hence, for example, ethylphenyl (CH<NUM>-CH<NUM>-C<NUM>H<NUM>-) is a C<NUM>-alkylaryl group.

In case identical labels for symbols or groups are present in several formulae, in the present document, the definition of said group or symbol made in the context of one specific formula applies also to other formulae which comprises the same said label.

R' represents an OH-protecting group. An OH-protecting group is a group which protects a hydroxyl group and the protecting group can be easily removed, i.e. by state-of-the-art methods, resulting to the respective compound with the free alcoholic group again.

The OH-protecting group R' is introduced by a chemical reaction of the compound of the respective formula having H instead of the OH-protecting group with a protecting agent.

The protecting agents leading to the corresponding OH-protecting groups are known to the person skilled in the art, as well as the chemical process and conditions for this reaction. If, for example, the OH-protecting group forms with the rest of the molecule an ester, the suitable protecting agent is for example an acid, an anhydride, or an acyl halide.

The OH-protecting group R' is particularly selected from the groups consisting of
<CHM>.

If R' is represented by
<CHM>
the respective compound is an ester of a carboxylic acid or dicarboxylic acid, which can be formed by the reaction of the respective protecting agent with the hydroxyl group. In this case, the protecting agent may be for example an anhydride or halide of the respective carboxylic acid (<NUM>) or dicarboxylic acid (<NUM>). <CHM>
<CHM>.

If the compound of the respective formula is an ester of a carboxylic acid or dicarboxylic acid, it is preferred that R' is an C<NUM>-<NUM>-acyl, preferably acetyl, trifluoro acetyl, propionyl or benzoyl group, or a substituted benzoyl group.

Esters can be easily deprotected under the influence of an acid or a base.

If R' is
<CHM>
the respective compound is an acetal, which can be formed by the reaction of the respective protecting agent with the hydroxyl group. In this case, the protecting agent may be for example, a respective aldehyde, alkyl halide, e.g. MeO(CH<NUM>)<NUM>OCH<NUM>Cl, or an enol ether, e.g. <NUM>,<NUM>-dihydro-<NUM>H-pyran.

In this case, the substituent R' is preferably
<CHM>
with n=<NUM> or <NUM>.

In some instances, acetals are also called "ethers", particularly in the cases mentioned above: methoxymethyl ether (MOM-ether), β-methoxyethoxymethyl ether (MEM-ether) or tetrahydropyranyl ether (THP-ether).

Acetals can be easily deprotected under the influence of acids.

In another preferred embodiment, the respective compound is an ester of phosphoric acid, pyrophosphoric acid, phosphorous acid, sulphuric acid or sulphurous acid.

Depending on the reaction conditions, the esterification is either complete or partial, leaving some residual acid groups of the respective acid non-esterified.

It is most preferred that the protecting group R' is a benzoyl group or a C<NUM>-<NUM>-acyl group, particularly acetyl or trifluoro acetyl group, more particularly acetyl group. The molecules in which R' represents an acyl group, particularly an acetyl group, can be easily prepared from the corresponding unprotected molecule by esterification, and the unprotected alcohol can be obtained from the corresponding ester by ester hydrolysis, particular by strong bases such as NaOH or KOH.

It is preferred that the protecting group R' represents an acyl group, preferably an acetyl or benzoyl group, particularly an acetyl group:
<CHM>.

In one embodiment R represents a R', in other words, R represents an OH-protecting group.

In the other embodiment R represents H. In this case, the compound of formula (I-A) resulting from step a), having a protected OH group, needs to undergo in a further step z) a deprotection reaction to deprotect the protected OH group to form a free hydroxyl group, and, hence, compound of formula (I) having a free hydroxy group (R'=H).

The deprotection of the protected hydroxyl group is known by the person skilled in the art, and is particularly performed as mentioned above in the discussion of the specific protecting groups.

It is preferred that the compound of the formula (II) is prepared by salt formation of a compound of the formula (IV)
<CHM>
and a strong base comprising an alkali metal, particularly an alkali metal alcoholate, amide, hydride or complex hydride or a alkali metal alkyl, particularly butyllithium, preferably by NaNH<NUM> or LiNH<NUM>.

The compound of formula (IV) is readily available from tosylhydrazide and the compound of formula (IV-a) which itself can be obtained from compound (IV-b):
<CHM>.

The alkali metal amide is preferably obtained by in situ formation from a mixture of the respective alkali metal and ammonia, particularly in the presence of an iron catalyst.

The formation of a salt of the formula (II) is preferably made in a solvent of formula(III).

Preferably, the base is suspended in the solvent of formula (III) is mixed with compound of formula (IV) at a temperature preferably of lower than <NUM>, preferably between <NUM> and <NUM>, most preferably at around room temperature, forming the salt in a dispersion.

It is preferred that the amount of solvent of formula (III) in this dispersion is less than <NUM>%, preferably less than <NUM> % of the solvent of formula (III) used in step a).

Principally, the solvent can be removed and the salt can be isolated and added in step a) as solid salt or the salt can be added in step a) as said dispersion. The base is preferably used in a stoichiometric excess relative to compound of formula (IV). Typically the molar ratio of base/compound of formula (IV) is between <NUM>: <NUM> and <NUM>:<NUM>, more preferably between <NUM>:<NUM> and <NUM>:<NUM>.

In step a) the solvent of formula (III) is heated to a temperature of between <NUM> and the boiling point of said solvent. To said warm solvent the salt of formula (II) is then added, preferably under stirring. It has been found that it is preferably that the salt is added slowly.

Hence, the salt of formula (II) is preferably added over a time range of between <NUM> and <NUM> minutes, preferably between <NUM> and <NUM> minutes.

It is preferred that the multiplication product of temperature of the solvent (in K) and the time of adding (in min) is between <NUM>'<NUM> and <NUM>'<NUM> Kmin, preferably between <NUM>'<NUM> and <NUM>'<NUM> Kmin.

It is preferred that after the salt is completely added, the mixture is continued to be stirred for a time of preferably between <NUM> minutes and <NUM> hours, more preferably between <NUM> and <NUM> hours.

It is preferred that the salt of the formula (II) is added in step a) during a time period of between <NUM> and <NUM> minutes, preferably between <NUM> and <NUM> minutes.

The reaction of step a) is performed using a solvent of formula (III)
<CHM>.

R<NUM> represents an C<NUM>-<NUM>-alkyl group and n = <NUM> or <NUM> or <NUM> or <NUM>, preferably <NUM>.

Furthermore, X represents either a halogen atom, preferably Cl, or a C<NUM>-<NUM>-alkoxy group.

In a first embodiment, X represents a C<NUM>-<NUM>-alkoxy group. The methoxy group A is the preferred C<NUM>-<NUM> alkoxy group.

In this embodiment, the solvent of formula (III) is preferably selected from the group consisting of anisole, <NUM>-methylanisiole, <NUM>-methylanisole, and <NUM>-methylanisole, preferably anisole.

In another, and preferred, embodiment X represents a halogen atom, preferably Cl.

Hence, compound of formula (III) can have up to <NUM> C<NUM>-<NUM>-alkyl groups bound directly on the aromatic ring. The solvent of formula (III) is preferably selected from the group consisting of chlorobenzene, o-chlorotoluene, m-chlorotoluene, p-chlorotoluene. Most preferred, the solvent of formula (III) is chlorobenzene.

It has been found that when the reaction is performed at higher temperatures, the yield can be increased substantially.

It is preferred that the temperature in step a) is between <NUM>° and reflux temperature of said solvent at ambient pressure, preferably between <NUM> and <NUM>.

The reaction of step a) can be performed particularly at ambient pressure or under pressure.

In case the reaction of step a) is performed under pressure, it is preferred that the process is performed under a pressure of larger than <NUM> bar.

In this case, it is preferred that the temperature of the solvent is between <NUM>° and <NUM>.

In step a), compound of formula (V) is formed at very low amounts. Compound of formula (V) has a significantly higher molecular weight as compared to compound of formula (I) respectively (II).

The structure of the new compound of formula (V) has been fully identified and the compound is characterized particularly by <NUM>H-NMR, <NUM>C-NMR and MS.

The compounds having protected groups (such as acetate) could been identified accordingly as well.

Disclosed herein, but not forming part of the present invention, is the compound of formula (V)
<CHM>.

The residues R and R" represents either H or an OH-protecting group.

The OH-protecting group is as described already before for the compound of formula (I) or (II).

The OH-protecting group is preferably an acyl group, preferably an acetyl group.

The compound of formula (V) is yellow and can be used as a new colorant. However, this does not form part of the present invention.

As mentioned above the compound of formula (V) is formed at very low amounts parallel to the formation of compound (I).

It has been found that the process leads quantitatively, i.e. in high conversion and yield to the <NUM>-dehydrocholesterol or its OH-protected forms, respectively.

It has been further found by the process of the invention the amount of compound of the formula (V) can be even further reduced, particularly when working at higher dilution and at higher temperature of solvent of formula (III).

Therefore, disclosed herein, but not forming part of the present invention, is a composition comprising.

Details for the OH-group have already been given before.

The present invention is further illustrated by the following experiments.

<NUM> equivalents of LiNH<NUM> have been added to chlorobenzene (amount as to form a concentration, relative to <NUM>-tosylhydrazone cholesterylacetate, as given in table <NUM>) and stirred. Then <NUM> equivalent of <NUM>-tosylhydrazone cholesterylacetate (=Compound of formula (IV), R'=CH<NUM>COO) has been added at <NUM> under stirring during <NUM> minutes, forming a dispersion of the Li salt (=compound of formula (II), M=Li, R'=CH<NUM>COO)).

Then the dispersion has been stirred for the time (tr) at a temperature (TR) given in table <NUM>). Then the mixture has been filtered. The filtrate was extracted twice with water and once with saturated NaCl solution. After evaporation of the chlorobenzene the product has been isolated in the yield given in table <NUM>. The amount of the compound of formula (V) has been determined and is given in table <NUM>.

<NUM> equivalents of LiNH<NUM> have been added to <NUM>% or <NUM>%, respectively, of the total amount of chlorobenzene (for obtaining in process II a concentration of <NUM>-tosylhydrazone cholesterylacetate in chlorobenzene of <NUM> or <NUM>/ml, respectively)(see conc. in table <NUM>) and stirred. Then <NUM> equivalent of <NUM>-tosylhydrazone cholesterylacetate (=Compound of formula (IV), R'=CH<NUM>COO) has been added at <NUM> under stirring during <NUM> minutes, forming a dispersion of the Li salt (=compound of formula (II), M=Li, R'=CH<NUM>COO) (LiSalt).

The rest (i.e. <NUM>% or <NUM>%, respectively) of the total amount of chlorobenzene has been separately heated up to the temperature (TCB). The dispersion of the above Li salt (LiSalt) has been added under stirring for the time (tadd) given in table <NUM> to said hot chlorobenzene. The reaction mixture was stirred for the time (tr) at a temperature (TR) given in table <NUM>. Then the mixture has been filtered. The filtrate was extracted twice with water and once with saturated NaCl solution. After evaporation of the chlorobenzene the product has been isolated in the yield given in table <NUM>. The amount of the compound of formula (V) has been determined and is given in table <NUM>.

In both processes the identity of compound has been verified by NMR and MS (see before) and the amount of the individual compounds has been quantified by HPLC.

In process II the salt of the formula (II) is added to hot chlorobenzene compound whereas in the process (II) (comparison) the salt of the formula (II) is prepared in situ and directly to the reaction temperature. The comparison of examples Ref.<NUM> and <NUM> show that the process (I) leads to significant reduction of compound of formula (V) whereas conversion and yield remain the same. The comparison of examples <NUM> and <NUM> shows that it is beneficial to add the salt of formula (II) slowly, i.e. preferably within a time of more than <NUM> minutes. The comparison of example <NUM> and <NUM> shows that by working in a lower concentration the amount of compound of formula (V) is reduced, that the yield in compound of formula (I), however, slightly drops. Comparison of Example <NUM> with examples <NUM> respectively <NUM> finally shows that it is advantageous to increase the temperature of chlorobenzene higher, to its boiling boing (reflux conditions) increases the yield significantly and have even further reduction in the amount of compound of formula (V) and that the slight drop in yield found in working at lower concentration can be compensated.

Claim 1:
Process of manufacturing a compound of the formula (I)
<CHM>
comprising the step
a) adding a salt of the formula (II) to a solvent of the formula (III) at a temperature of between <NUM> and the boiling point of said solvent
<CHM>
<CHM>
characterized in that
R' represents an OH-protecting group;
R represents H or R';
M is an alkali metal atom, preferably Li;
X represents either a halogen atom, preferably Cl, or a C<NUM>-<NUM>-alkoxy group; R<NUM> represents an C<NUM>-<NUM>-alkyl group;
n = <NUM> or <NUM> or <NUM> or <NUM>, preferably <NUM>;
with the proviso, that if R represents H,
the process comprises further a step z) which takes place after step a) z) deprotecting the protected hydroxyl group of the compound of the formula (I-A)
<CHM>
to form the compound of the formula (I).