The present invention concerns a process and intermediate compounds useful in the preparation of statins, particularly Rosuvastatin.

According to the present invention, there is provided a process for the preparation of a compound of formula (7):

[Image Omitted]

wherein

- R¹represents an alkyl group, such as a C_1-6alkyl group, and preferably an isopropyl group;
- R²represents an aryl group, preferably a 4-fluorophenyl group;
- R³represents hydrogen, a protecting group or an alkyl group, such as a C_1-6alkyl group, and preferably a methyl group; and
- R⁴represents hydrogen, a protecting group or a SO₂R⁵group where R⁵is an alkyl group, such as a C_1-6alkyl group, and preferably a methyl group,
  which comprises
a) hydroxylating a compound of formula (1):

[Image Omitted]

- wherein Y represents a halo group, preferably Cl or Br; P¹represents hydrogen or a protecting group, and W represents â• O or OP², in which P²represents hydrogen or a protecting group,
  to give a compound of formula (2):

[Image Omitted]

b) oxidising the compound of formula (2) to give a compound of formula (3):

[Image Omitted]

c) coupling the compound of formula (3) with a compound of formula (4):

[Image Omitted]

- wherein R³represents a protecting group or an alkyl group, such as a C_1-6alkyl group, and preferably a methyl group; R⁴represents a protecting group or a SO₂R⁵group where R⁸is an alkyl group, such as a C_1-6alkyl group, and preferably a methyl group; and R⁶represents (PR⁷R⁸)⁺X^âˆ’ or P(â• O)R⁷R⁸in which X is an anion and R⁷and R⁸each independently is an alkyl, aryl, alkoxy or aryloxy group, preferably a phenyl group,
  to give a compound of formula (5):

[Image Omitted]

- wherein R³represents a protecting group or an alkyl group, such as a C_1-6alkyl group, and preferably a methyl group; and R⁴represents a protecting group or a SO₂R⁶group where R⁵is an alkyl group, such as a C_1-6alkyl group, and preferably a methyl group,
d) when W represents â€”OP², removing any P²protecting group and oxidising the compound of formula (5) to give a compound of formula (6):

[Image Omitted]

and

e) subjecting the compound of formula (5) when W represents â• O, or compound of formula (6) to ring-opening, removal of any P¹protecting groups, and optionally removing any additional protecting groups to give a compound of formula (7).

In step (e), any P¹protecting groups and any additional protecting groups may be removed individually or together and prior to ring opening, during ring opening or after ring opening of the compounds of formula (5) or (6).

Preferably, in steps (a) to (c), W is OP²for the compounds of formula (1), (2), (3) and (5).

Protecting groups which may be represented by P¹and P²include alcohol protecting groups, examples of which are well known in the art. Particular examples include tetrahydropyranyl, benzyl and methyl groups, and optionally substituted variants thereof. Substituents may advantageously be used to modify the ease of introduction or removal of the protecting group. Preferred protecting groups are silyl groups, for example triaryl- and especially trialkylsilyl groups. Especially preferred examples are trimethylsilyl, t-butyldimethylsilyl and t-butyldiphenylsilyl groups.

Protecting groups which may be represented by P¹and P²may be the same or different. When the protecting groups P¹and P²are different, advantageously this may allow for the selective removal of only P¹or P². Preferably, when the protecting groups P¹and P²are different, P¹is a tetrahydropyranyl, benzyl, or silyl group and P²is a methyl group. More preferably, when the protecting groups P¹and P²are different, P¹is a benzyl, or silyl group and P²is a methyl group.

Protecting groups which may be represented by R³and R⁴include amine protecting groups, examples of which are well known in the art. Particular examples include benzyl groups, carbamates (such as CBZ, Boc, Fmoc), phosphate, thiophosphate, silyl groups and, when R³and R⁴together are a single protecting group, an imine group.

Hyrdoxylation of compounds of formula (1) can be achieved by methods known in the art for displacing a halo group with a hydroxide source. Preferably, the process comprises contacting the compound of formula (1) with a source of hydroxide. Hydroxide sources include hydroxide salts, especially ammonium or alkali metal hydroxides, particularly lithium, sodium or potassium hydroxide, and various aqueous media such as water in the presence of basic media such as N-methylpryrrolidinone, HMPA, Al₂O₃, CaCO₃, Na₂CO₃, K₂CO₃or KO₂/18-crown-6, silver salts such as AgNO₃or Ag₂O, or oxidants such perbenzioc acid. A particularly preferred process comprises contacting the compound of formula (1) with 5 molar equivalents of KOH in the presence of dimethylsulfoxide solvent at a temperature of, for example, about 50Â° C.

Alternatively, hydroxylation may be achieved by first displacing the halogen with a leaving group such as acetate, triflate or sulphate optionally in the presence of a silver salt, then displacing the leaving group with a hydroxide source. A particularly preferred process comprises contacting the compound of formula (1) with 3 molar equivalents of NaOAc in the presence of dimethylformamide solvent and tetra-n-butylammonium chloride at a temperature of, for example, about 100Â° C., isolating the acetyl compound and contacting with potassium carbonate in the presence of methanol solvent and at a temperature of, for example, about 0Â° C.

Oxidation of compounds of formula (2) can be achieved using oxidation systems known in the art for the oxidation of alcohols, especially those known in the art for the oxidation of primary alcohols. Examples include oxidation with Dess-Martin periodinane, bromine, Swern oxidation or various metal based oxidations such as Fetizon reagent, manganate based reagents, and chromate based reagents such as Collins reagent. Swern oxidation is preferred. When Swern oxidation is employed, preferred conditions comprise the use of dimethyl sulphoxide and oxalyl chloride or bromine in a solvent such as dichloromethane or dichlormethane/THF mixtures, at reduced temperature, such as from 0 to âˆ’100Â° C., preferably 50 to âˆ’80Â° C. Preferably, reagents are added at reduced temperature, such as 30 to âˆ’80Â° C., and then once all reagents are added, the reaction mixture is allowed to warm to 15 to 20Â° C.

Alternatively, the compound of formula (3) may be obtained directly from a compound of formula (1), for example by treatment with dimethysulphoxide and an acid acceptor.

The coupling of the compound of formula (3) with the compound of formula (4) may employ conditions analogous to those given in WO0185702 for the corresponding coupling of a compound of formula (4). Alternatively, conditions comprising refluxing the compounds of formula (3) and (4) in a hydrocarbon solvent, such as toluene or cyclohexane, or mixtures thereof, followed by contact with aqueous acid, such as aqueous HCl may be employed.

Alkyl, aryl, alkoxy or aryloxy groups which may be represented by R⁷and R⁸include C_1-6alkyl groups, such as methyl and ethyl groups, C_6-12aryl groups, such phenyl, tolyl or naphthyl, C_1-6alkoy groups, such as ethoxy groups, and C_6-12aryloxy groups such as phenoxy groups.

Anions which may be represented by X include halide.

R⁶preferably is P(â• O)R⁷R⁸where R⁷and R⁸each independently is an alkyl, aryl, alkoxy or aryloxy group, preferably a phenyl group.

When W represents OP², the protecting group may be removed to form a hydroxy group by methods known in the art for the removal of the given protecting group. For example, silyl protecting groups may be removed by contact with a source of fluoride ion, such as tetrabutylammonium fluoride.

Oxidation of compounds formed by deprotection of compounds wherein W represents OP²may employ conditions known in the art for the oxidation of pyranols to pyranones, and include those given in â€œComprehensive Organic Transformationsâ€ , R. C. Larock, 2^ndEd (1999) p 1670, published by Wiley VCM, incorporated herein by reference. Preferred oxidation systems include Ag₂CO₃Celite, especially Celite J2, bromine or Swern.

Ring opening of the compounds of formula (5), when W represent â• O or formula (6) may employ conditions known in the art for ring opening of a pyranone. Preferably, the ring is opened by contact with a base, such as sodium hydroxide or calcium oxide. Conveniently, polar solvents are employed, for example methanol, acetonitrile, tetrahydrofuran or mixtures thereof.

Remaining protecting groups may be removed by methods known in the art for the removal of the given protecting group. For example, silyl protecting groups may be removed by contact with a source of fluoride ion, such as tetrabutylammonium fluoride, and benzyl groups may be removed by treatment with TMSI or under selective hydrogenation conditions.

It will also be recognised that compounds of formulae (2), (3) and (5) may also be subjected to oxidation (when W represents â€”OH) or deprotection and oxidation (when W represents (â€”O-protecting group) to form the corresponding compound wherein W represents â• O.

Preferred compounds of formula (1) are compounds of formula:

[Image Omitted]

wherein W, P¹and Y are as previously described.

Preferred compounds of formula (2) are compounds of formula:

[Image Omitted]

wherein W and P¹are as previously described.

Preferred compounds of formula (3) are compounds of formula:

[Image Omitted]

wherein W and P¹are as previously described.

Preferred compounds of formula (5) are of formula:

[Image Omitted]

wherein R¹, R², W and P¹are as previously described.

Preferred compounds of formula (6) are of formula:

[Image Omitted]

wherein R¹and R²are as previously described.

Preferred compounds of formula (7) are of formula:

[Image Omitted]

wherein R¹and R²are as previously described.

Compounds of formula (7) are advantageously converted to pharmaceutically acceptable salts, especially their calcium salts (for example WO0160804).

Compounds of formula (4) are advantageously prepared by the methods given in WO0049014 and WO0185702. Particularly preferred compounds of formula (4) are compounds of formula:

[Image Omitted]

Compounds of formula (1) are advantageously prepared by enzyme catalysed condensation of acetaldehyde and 2-haloacetaldehyde, for example using the method given in U.S. Pat. No. 5,795,749.

Compounds of formulae (2) and (3) and, when W is OP², formula (5) form further aspects of the present invention.

The invention is illustrated by the following examples.

EXAMPLE 1Preparation of Chlorolactol methyl acetal ((2S,4R)-2-(chloromethyl)-6-methoxytetrahydro-2H-pyran-4-ol), a compound of Formula 1 where Yâ• Cl, â• H and Wâ• OP², in which P²=Me

Crude chlorolactol (15 g) was dissolved in methanol (150 ml) and heated to 40Â° C. for 2 hours in the presence of 0.1 ml sulphuric acid. The solvent was removed by rotary evaporation to afford the product as a dark brown flowing oil. The product was dissolved in DCM and washed with sodium bicarbonate solution. The solvent was removed by rotary evaporation to afford the product as a dark brown flowing cil, which was purified by column chromatography (16.1g) containing a mixture of anomers m/z 179, 149 and 113; ¹H nmr CDCl₃3.6-3.7 (m 2H), 4.1 (m 1H), 1.5-1.6 (m 2H), 4.0 (m 1H), 1.3-1.6 (m 2H), 4.9 (m 1H), 3.3 & 3.5 (s 3H); ¹³C nmr CDCl₃32, 36, 45, 55&56, 64, 65, 94.

EXAMPLE 2Preparation of O-benzyl-chlorolactol methyl acetal ((2S,4R)-4-(benzyloxy)-2-(chloromethyl)-6-methoxytetrahydro-2H-pyran), a compound of Formula 1 where Yâ• Cl, P¹=Bn and Wâ• OP², in which P²=Me

Chlorolactol methyl acetal (1 g) was dissolved in THF (5 ml) and charged to sodium hydride (0.33 g 60% in mineral oil) in THF (5 ml) at room temperature. Benzyl bromide (1.9 g) was added dropwise and the mass heated to 80Â° C. for 2 hours. Methanol (2 ml) was added and the mass was partitioned between DCM water, and was then washed with water. The organic phase was dried and the solvent was removed by rotary evaporation to afford an orange flowing oil (2.1 g), containing a mixture of anomers containing a mixture of anomers. m/z 270; 238; 203; 132; 91; ¹H nmr CDCl₃1.6-2.0 (m 4H), 3.4 & 3.5 (s 3H), 3.6 (m 2H), 3.8 (m 1H), 4.0 (m 1H), 4.5 (m 2H), 4.7 (m 1H), 7.3-7.5 (m 5H); ¹³C nmr CDCl₃32&33, 46, 55&56, 53, 66, 74, 96&98, 128-131.

EXAMPLE 3Preparation of Hydroxy-O-benzyl-lactol methyl acetal ([(2R,4R)-4-(benzyloxy)-6-methoxytetrahydro-2H-pyran-2-yl]methanol), a compound of Formula 2 where Pâ€²=Bn and Wâ• OP², in which P²=MePreparation of the Acetate Intermediate:

To a 3-litre three necked round bottomed flask flushed with thy nitrogen the O-benzyl-chlorolactcl methyl acetal (30 g) was charged into dry N-methyl pyrollidinone (756 mls). Anhydrous tetrabutylammonium acetate (102.57 g) was also charged to the solution. The reaction mixture was then heated at 100Â° C. for 24 hours. The reaction mixture was sampled at routine intervals and directly analysed by tlc and gc/ms.

The black solution was then diluted with water (150 mls) and extracted with ethyl acetate (3Ã—1500 mls). The combined upper organic layer was then washed with water (3Ã—1500mls). The aqueous portion showed no product content at this point. The layers were then separated, dried, (Na₂SO₄) and the solvent removed in vacuo to yield a black flowing oil (31 g, 95%) containing a mixture of anomers. ¹H nmr CDCl₃1.4-1.8 (m 4H), 2.0-2.1 (duplicate s, 3H), 3.4 & 3.5 (s 3H), 3.8 (m 1H), 4.0 (m 1H), 4.1 (m 2H), 4.5 (m, 2H), 4.7-4.9 (m 1H), 7.2-7.3 (m, 5H); ¹³C nmr CDCl₃20.8; 30-35; 55&56; 57&64; 66&68; 69&72; 70&71; 98&99; 127-128 & 138; 170.5; m/z 293, 262, 221, 203, 156, 91 and 43.

Preparation or the Alcohol from the Acetate Intermediate:

To a 5 mls three necked round bottomed flask flushed with dry nitrogen the O-benzyl-chlorolactol methyl acetal acetate (2 g) was charged into dry methanol (10 mls) containing anhydrous potassium carbonate (1 g). The resultant suspension was stirred at 20Â° C. for 30 minutes. G.C./M.S. showed complete conversion of acetate to alcohol. The solid was filtered off and the solvent removed in vacuo to yield a brown flowing oil containing a mixture of anomers (1.6 g, 93%). ¹H nmr CDCl₃1.4-1.8 (m 4H), 3.4 & 3.5 (s 3H), 3.8 (m 1H), 3.9 (m 1H), 4.0 (m 2H), 4.5 (m 2H), 4.7-4.9 (m 1H), 7.2-73 (m, 5H); ¹³C nmr CDCl₃30-38; 55&56; 65&66; 65&69; 70&71; 72&73; 99&100; 128 & 140; m/z 252, 221, 189, 163, 114 and 91.

EXAMPLE 4Preparation of formyl-O-benzyl-lactol methyl acetal (2S,4R)-4-(benzyloxy)-6-methoxytetrahydro-2H-pyran-2-carbaldehyde a compound of Formula 3 where P¹=Bn and Wâ• OP², in which P²=Me

Dess-Martin periodinane reagent (1.91 g) in dichloromethane (50 mls) was charged to a 1000 mls round bottomed flask purged with dry nitrogen. The hydroxy-O-benzyl-lactol methyl acetal (1.0 g,) was dissolved in dichloromethane (50 mls) and added to the Dess-Martin periodinane reagent at 20Â° C. The reaction mixture was then stirred at room temperature for 30 minutes. The reaction was monitored by tic. The reaction mixture was then diluted with diethyl ether (500 mls) to precipitate the excess reagent. The suspension was then washed with 10% aqueous sodium hydroxide (200 mls). The upper organic layer was then washed with water (250 mls). The upper organic layer was then separated, dried (Na₂SO₄) and the solvent removed in vacuo to yield a dark flowing oil as a mixture of anomers (0.8 g).

¹H nmr CDCl₃1.6-1.9 (m 4H), 3.3 & 3.5 (s 3H), 3.7 (m 1 H), 3.8 (m 1 H), 4.4 (m 2H), 4.7-4.9 (m 1H), 7.2-8.1 (m, 5H), 9.6-9.7 (2Ã—s, 1H).

¹³C nmr CDCl₃30-38; 55&56; 65&66; 65&69; 70&71; 99&100; 128 & 140; 201.

m/z 250, 221, 189, 163, 143, 117 and 91.

Alternatively, a Swern oxidation can be carried out as illustrated by the following example:

A stirred solution of oxaiyl chloride (0.037 cm³, 0.44 mmol) in dichloromethane (4 cm³) under nitrogen was cooled to âˆ’78 C and DMSO was added in one portion. A solution of the alcohol (100 mg, 0.40 mmol) in dichloromethane (1 cm³) was added to the reaction mixture and the reaction mixture stirred at 78 C for 5 min. Triethylamine (0.272 cm³, 19.8 mmol) was added and the resulting solution was stirred at 78 C for 25 min and used immediately without isolation or purification. Tlc r_f0.40 ethyl acetate:hexane (1:1) orange spot with 2,4-dinitrophenylhydrazine stain

EXAMPLE 5Preparation of Pyrimidyl-ethenyl-O-benzyl-lactol methyl acetal, a compound of Formula 5 where R¹=iPr, R²=4-FC₆H₄, R³=Me, R⁴â• SO₂Me, P¹=Bz and Wâ• OP², in which P²=Me.

Pyrimidyl-ethenyl-O-benzyl-lactol methyl acetal was obtained by first dissolving 0.21 g of the compound of formula 4 wherein R³=:Me, R⁴â• SO₂Me and R⁶â• PO(Ph)₂in 10 ml dry THF, cooling to âˆ’60Â° C. and then adding 0.2 ml of a 2M solution of sodium hexamethyldisilazide. After 20 min, a solution of 0.1g formyl-O-benzyl-lactol methyl acetal in 10 ml dry THF at âˆ’30Â° C. was added. The reaction mixture was then maintained at this temperature for 8 hours and monitored by tic. The reaction mixture was allowed to slowly warm up to 20Â° C. Glacial acetic (5 mls) acid was then charged to quench the reaction. Water (5 mls) was also charged to the mixture. The solvent was then removed in vacuo and reconstituted with toluene (15 mls) and water (15 mls). The upper organic layer was then separated and the aqueous layer was then washed with ethyl acetate (15 mls). The combined organics were then dried and the solvent removed in vacuo to yield an oil containing a mixture of isomers, that can be purified by chromatography. The desired product had the tentative NMR assignment

¹H nmr CDCl₃1.2 (d, 6H), 1.6-1.9 (m 4H), 3.3 (s, 3H), 3.4 (s, 3H), 3.2 & 3.5 (2Ã—s, 3H), 3.7 (m 1H), 3.8 (m 1H), 4.2 (m 1H), 4.4 (m 2H), 4.7-4.9 (m 1H), 5.35 (dd, 1H), 5.85-6.7 (d, 1H), 7.1-8.1 (m, 9H).

EXAMPLE 6Preparation of Pyrimidyl-ethenyl-OH-lactol methyl acetal (Rosuvastatin Lactol-OMe) a compound of Formula 5 where R¹=iPr, R²=4-FC₆H₄, R³=Me, R⁴â• SO₂Me, P¹â• H and Wâ• OP², in which P²=Me

Pyrimidyl-ethenyl-OH-1ol methyl acetal may be obtained by reaction of Pyrimidyl-ethenyl-O-benzyl-lactol methyl acetal with TMSI.

EXAMPLE 7Preparation of Pyrimidyl-ethenyl-OH-lactol (Rosuvastatin Lactol), a compound of Formula 5 where R¹=iPr, R²=4-FC₆H₄, R³=Me, R⁴â• SO₂Me, P¹â• H and Wâ• OP², in which P²â• H

Pyrimidyl-ethenyl-OH-lactol may be obtained by treatment of the Pyrimidyl-ethenyl-OH-lactol methyl acetal with 0.1N HCl in methanol.

EXAMPLE 8Preparation of Lactone, a compound of Formula 6 where R¹=iPr, R²=4-FC₆H₄, R³=Me, R⁴â• SO₂Me, P¹â• H

The pyrimidyl-ethenyl-OH-lactol (35 mg, 0.065 mmol) in dichloromethane (0.5 ml) was added to Dess-Martin periodinane (30 mg, 0.07 mmol) and stirred at room temperature for 2.5 hours, The reaction was partitioned between 1M sodium hydroxide and diethyl ether. The phases were then separated and the organic volume reduced in vaccuo to afford the crude product oil.

EXAMPLE 9Preparation of Rosuvastatin (hydrolysis of Lactone), a compound of Formula 7 where R¹iPr, R²=4-FC₆H₄, R=Me, R⁴â• SO₂Me

The lactone (1.1 g) was dissolved in ethanol (10 ml). Water (2 ml) and Ca(OH)₂(0.15 g) were added and the suspension warmed to 60Â° C. for 3 hours. A further 10 ml of warm water was added, then the mixture allowed to cool slowly to room temperature. The precipitate formed was filtered and dried to give Rosuvastatin calcium salt. The material was identical to an authentic sample by mixed melting point, NMR and mass spectrometry.