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Continued emphasis in the pharmaceutical industry toward development of hybrid and continuous processes has led to a resurgence in process analytical technologies. The need to consistently and rapidly monitor the quality of material being made from these processes is a significant challenge that requires integrated, online analytics. Often the most challenging aspect of implementing real-time monitoring is ensuring that the analytical instrumentation is receiving a representative sample from the process. The Small Molecule Design and Development organization at Eli Lilly and Company has developed a highly adaptable process-to-analytics interface that has been broadly implemented across the development portfolio. The automated sample carts use only gravity and low-pressure nitrogen to obtain representative process samples, typically on the order of 0.3–6 mL. Subsequent sample preparation operations including quenching, derivatization, and most commonly dilution (10–250× is customary, but not restrictive) i...

This paper presents a case study in establishing the operation space of a Grignard reaction in a continuous stirred tank reactor (CSTR). The operation space is the multivariate space with the boundary defined by the proven acceptable range of every CSTR process parameter such as flow rates and temperature. The mapping of the operation space was conducted by a thorough understanding of reaction kinetics, magnesium (Mg) sequestration efficiency, equipment characterization, and the impact of process disturbances has on steady state. A fit-for-use reaction kinetics model was developed to parametrize the kinetics and mass transfer rates of the batch Grignard reaction across different scales from 250 mL to 500 gallons. The reaction kinetics model was applied to design the Mg recharge frequency accounting operational variability to ensure a state of control can be maintained. Furthermore, reactor temperature was determined to be suitable to detect process failures to ensure process safety and product quality at ...

A fully continuous process including an asymmetric hydrogenation reaction operating at 70 bar hydrogen, aqueous extraction, and crystallization was designed, developed, and demonstrated at pilot scale. This paper highlights safety, quality, and throughput advantages of the continuous reaction and separations unit operations. Production of 144 kg of product was accomplished in laboratory fume hoods and a laboratory hydrogenation bunker over two continuous campaigns. Maximum continuous flow vessel size in the lab hoods was 22 L glassware, and maximum plug flow tube reactor (PFR) size in the bunker was 73 L. The main safety advantages of running the hydrogenation reaction continuous rather than batch were that the flow reactor was smaller for the same throughput and, more importantly, the tubular hydrogenation reactor ran 95% liquid filled at steady state. Therefore, the amount of hydrogen in the reactor at any one time was less than that of batch. A two-stage mixed suspension–mixed product removal (MSMPR) c...

The [3,3] Claisen rearrangement is a well-known reaction that has been very useful for the synthesis of o-allyl phenols. The thermally induced rearrangement could present safety and operational issues at large batch scale. Herein, we report a process that utilized a tube reactor to make 80 g of an early phase intermediate in a short time while mitigating the potential chemistry hazards. Thus, both project material demands and flow chemistry proof of concept were achieved.