NOVEL PROCESS FOR PREPARATION OF KEY INTERMEDIATE OF PINOXADEN

Abstract

A novel process for preparation of compounds of formula (I) used in the synthesis of Pinoxaden. The intermediate is a substituted phenyl malonic esters of formula (I), where R is C.sub.1-C.sub.4 alkyl, straight or branched chain.

Claims

1. A process for preparation of compound of formula-I, through novel route comprising the steps of: A. Reacting Grignard salts of formula Il with oxomalanoic acid esters of formula Ill, where R is C1-C4 alkyl, straight or branched chain, to form compound of formula IV. B. Halogenation of compound of formula IV in a solvent along with halogenating agent to obtain compound of formula V C. Hydrodehalogenation of compound of formula V to obtain compound of formula I. ##STR00011## wherein Formula-1, R is C.sub.1-C.sub.4 alkyl, straight or branched chain.

2. The process of claim 1, where in step A is carried out in tetrahydrofuran solvent at temperatures between −30° C. to +10° C.

3. The process of claim 1, where in step B is carried out between −10° C. to +10° C.

4. The process of claim 1, where in step B is carried out in one of a solvent such as Chlorobenzene, Toluene, Dichloromethane, Dichloroethane.

5. The process of claim 1, where in halogenating agent in step B is POCl.sub.3, PCl.sub.5, POBr.sub.3, PBr.sub.5, or SOCl.sub.2

6. The process of claim 1, where in step C is carried out in presence of catalyst selected from a group consisting of Platinum, Palladium, Nickel or Copper.

7. The process of claim 1, where in step C is carried out in one of the alcohols based solvent such as methanol, ethanol, n-propanol, isopropanol, n-butanol, and t-butanol.

8. The process of claim 1, where in step C is carried out at temperature between 35° C. to 70° C.

9. The Process of claim 1, where Step C is carried under hydrogen pressure between 2 to 10 kg/cm2 g.

Description

DETAILED DESCRIPTION

[0014] The present invention relates to the process of preparation of substituted phenyl malonic esters of formula (I), where R is C.sub.1-C.sub.4 alkyl, straight or branched chain, which is a key intermediate in the synthesis of Pinoxaden.

[0015] Grignard salts of formula II can be prepared from corresponding aryl haldides of formula IIa, where halide is preferably a bromide.

##STR00004##

[0016] The reaction of arylbromide is carried out in Tetrahydrofuran (THF) at temperature between 0 and 100 deg C., preferably at room temperature. Ethylbromide is used as Grignard initiator. Dialkyloxomalonates can be prepared in a manner which is known from the literature (J. Org. Chem., 1981, 46, 2598). Compound of formula IV is formed by the reaction of Grignard salt with Dialkyloxomalonates. The reaction is carried out in THF at temperature between −80 to +30 deg C., preferably between −30 to 10 deg C.

[0017] Compound of formula IV which formed from the reaction of Grignard salt with oxomalonates, is further halogenated in suitable solvent such as chlorobenzene, toluene, dichloromethane, dichloroethane etc with a suitable halogenating agent like POCl.sub.3, PCI.sub.5, POBr.sub.3, PBr.sub.5, SOCl.sub.2, in particular SOCl.sub.2 to obtain compound of formula V. The reaction may be conducted at temperature between −20 deg C. to +40 deg C., preferably between −10 to +10 deg C.

[0018] Hydrodehalogenation of compound of formula V in carried out in suitable solvents like THF, toluene, xylene, alcohols such as methanol, ethanol, n-propanol, isopropanol, n-butanol, t-butanol, more preferably in methanol and ethanol to obtain compound of formula I. The reaction is preferably carried out in presence of catalyst selected from a group consisting of Platinum, Palladium, Nickel or Copper, preferably Pd/C, Pt/C, Raney-Ni. The reaction is carried out at temperature between 0 to 100 deg C., preferably between 35 to 70 deg C. The reaction is carried under hydrogen pressure between 1 kg/cm2 g to 20 kg/cm2 g, preferably between 2 to 10 kg/cm2 g.

[0019] Below are some examples for best understanding the process.

Example

Preparation diethyl-2-(2,6-diethyl 4-methyl phenyl) malonate

Step A: Preparation of diethyl 2-hydroxy-2-(2,6-diethyl-4-methylphenyl)malonate

[0020] ##STR00005## ##STR00006##

[0021] In a 2 liter 4-neck round bottom flask equipped with stirrer, thermometer, heater/cooling thermostat, nitrogen purging, charge 600 ml of tetrahydrofuran, 20 gm of magnesium turnings, 0.5 gm of ethyl bromide at room temperature. Add 106 gm of 2,6-diethyl-4-methyl bromobenzene at 35-40 deg C. over a period of 2 hr and maintain the reaction mixture till end of completion of 2,6-diethyl-4-methyl bromobenzene on GC. Separate the excess magnesium turnings from the reaction mass by decantation. Cool the reaction mixture to −15 deg C. and add 308 gm of diethyl oxomalonate in 2 hr while maintain the temperature of reaction mass. Maintain the reaction at −15 deg C. for 6 hr. Add 53 gm of 1N hydrochloric acid at 0 deg C. and stir the reaction mass for 60 min and separate the aqueous layer. Distill the solvent and excess oxomalonate from the organic layer under vacuum to obtain residue of 150 gm containing 125.1 gm of product corresponding to a yield of 84%.

Step B: Preparation of diethyl 2-chloro-2-(2,6-diethyl-4-methylphenyl)malonate

[0022] ##STR00007##

[0023] In a 2 liter 4-neck round bottom flask equipped with stirrer, thermometer, heater/cooling thermostat with nitrogen purging, charge 150 gm of diethyl 2-hydroxy-2-(2,6-diethyl-4-methylphenyl)malonate crude obtained from the previous step. Add 900 gm of dichloromethane and cool to 0 deg C. Add 35 gm of dimethyl formamide followed by 63 gm of thionyl chloride while maintaining the reaction mass at 0 deg C. Maintain the reaction mass till completion of starting material. At the end of reaction wash the organic layer with 2×400 ml of water and recover the solvent under rotavapor resulting in residue of 141 gm containing 125.8 gm of product corresponding to yield of 95%.

Step C: Preparation of diethyl-2-(2,6-diethyl-4-methylphenyl)malonate

[0024] ##STR00008##

[0025] In a 2 liter autoclave charge 127 gm of diethyl 2-chloro-2-(2,6-diethyl 4-methylphenyl)malonate, 800 gm ethanol, 44 gm of triethylamine and 1 gm 5% palladium carbon at room temperature. Heat the reaction mass to 50 deg C. and maintain the autoclave at 5 kg/cm2 g hydrogen pressure till completion of the reaction. Cool to room temperature and filter to separate palladium carbon. Remove ethyl alcohol in a rotavapour and charge 500 gm of xylene. Filter triethylamine hydrochloride salt. Organic layer contains 107 gm of diethyl-2-(2,6-diethyl 4-methyl phenyl) malonate corresponding to yield of 95% of theory.

Preparatory Example: Preparation of 8-(2,6-diethyl 4-methyl phenyl)-tetrahydro-pyrazolo[1,2-d][1,4,5]oxadiazepine-7,9-dione

[0026] ##STR00009##

[0027] In a 2 liter 4-neck round bottom flask equipped with stirrer, thermometer, heater/cooling thermostat with nitrogen purging, charge xylene layer from previous contains 107 gm of diethyl (2,6-diethyl 4-methyl phenyl) malonate, 67 gm of 1,4,5-oxadiazepane dihydrochloride at room temperature. Then add 78 gm of triethylamine and heat to reflux, maintain the reaction at reflux temperature for 6 hr, cool to room temperature and filter the triethylamine hydrochloride. Xylene is recovered and the product is purified by re-precipitation of its sodium salt with aq HCl and dried to obtain 102 gm of white powder, yield 90% and purity is 98%.

Preparatory Example: Preparation of Pinoxaden

[0028] ##STR00010##

[0029] In a 2 liter 4-neck round bottom flask equipped with stirrer, thermometer, heater/cooling thermostat with nitrogen purging charge tetrahydrofuran 600 ml, 100 gm of 8-(2,6-diethyl 4-methyl phenyl)-tetrahydro-pyrazolo[1,2-d][1,4,5]oxadiazepine-7,9-dione and cool to 20° C. and charge 67 gm of triethyl amine and 1 gm of 4-dimethyl amino pyridine and add 50 gm pivaloyl chloride. Maintain the reaction at 20-25° C. till completion of the reaction and wash the reaction mass with 20% brine solution. Organic layer is concentrated and the product is recrystallized in methyl tertbutyl ether and dried to obtain 97 gm of Pinoxaden of purity 98.1% corresponding to yield 75%.