Continuous total spontaneous resolution

We achieved chiral symmetry breaking through continuous crystallizations, which enables the continuous industrial production of chirally pure crystals. For this, a novel recycling platform that mimics a continuous cooling crystallization process with a hot concentrated feed and an outflow of cold suspension was developed and tested. A virtually enantiopure steady-state was realized by seeding a clear supersaturated achiral solution with enantiopure seed crystals at the start of the experiment. Seeding with the enantiopure form ensured that fragments of the seeded form were continuously created through secondary nucleation. Below the metastable zone limit, the product continued to consist of crystals of the same handedness as the seeded form provided that long residence times were applied in combination with sufficiently high feed concentrations. Short residence times in combination with low feed concentrations led to fouling-induced formation of both chiral forms and a decrease in the product's enantiomeric excess. Overall these results demonstrate the feasibility of continuous total spontaneous resolution of chiral pharmaceutical products in an industrial setting. This continuous manufacturing approach provides many benefits including ease of operation, consistent product quality, and a high degree of process control

Scaling up temperature cycling-induced deracemization by suppressing nonstereoselective processes

The scale-up of Temperature Cycling-Induced Deracemization (TCID) of sodium bromate is feasible provided that two nonstereoselective processes are suppressed. Both nonstereoselective processes occur as a result of insufficient crystal breakage or attrition. In the absence of crystal breakage or attrition during the temperature cycles, large crystals emerge and the resulting small total crystal surface area is unable to sufficiently consume the supersaturation during cooling, resulting in nonstereoselective nucleation. This nonstereoselective process can be avoided by applying small temperature cycles involving small dissolving solid fractions. However, this leads to a slow deracemization rate. In addition, crystals undergo nonstereoselective agglomeration, which leads to the formation of large racemic agglomerates constructed of both chiral forms. To counteract their formation, secondary nucleation through crystal breakage was found to be a key requirement. At a large scale, a homogenizer was used to induce crystal breakage which, in combination with temperature cycles, led to the removal of racemic agglomerates as well as a significant increase in the deracemization rate. Overusing the homogenizer, however, caused the enantiomeric excess increase to stop. Our experiments show the importance of secondary nucleation in TCID of sodium bromate. However, secondary nucleation is currently not incorporated in the TCID process models. In the presence of a large amount of crystals which facilitates a sufficiently large crystal surface area at the highest temperature and careful use of the homogenizer, TCID leads to complete deracemization in volumes up to 1 L, demonstrating the potential to extend TCID to industrial applications

Assessing crystallisation kinetics of Zr metal-organic frameworks through turbidity measurements to inform rapid microwave-assisted synthesis

Controlling the crystallisation of metal‐organic frameworks (MOFs), network solids of metal ions or clusters connected by organic ligands, is often hindered by the significant number of synthetic variables inherent to their synthesis. Coordination modulation, the addition of monotopic competing ligands to solvothermal syntheses, can allow tuning of physical properties (particle size, porosity, surface chemistry), enhance crystallinity, and select desired phases, by modifying the kinetics of self‐assembly, but its mechanism(s) are poorly understood. Herein, we use turbidity measurements to assess the effects of modulation on the solvothermal synthesis of the prototypical Zr terephthalate MOF UiO‐66 and apply the knowledge gained to its rapid microwave synthesis. The studied experimental parameters ‐ temperature, reagent concentration, reagent aging, metal precursor, water content, and modulator addition ‐ all influence the time taken for onset of nucleation, and subsequently allow microwave synthesis of UiO‐66 in as little as one minute. The simple, low cost turbidity measurements align closely with previously reported in situ synchrotron X‐ray diffraction studies, proving their simplicity and utility for probing the nucleation of complex materials while offering significant insights to the synthetic chemist

Prenucleation self-assembly and chiral discrimination mechanisms during solution crystallisation of racemic diprophylline

The crystallisation behaviour of (RS)-diprophylline (DPL) in two different solvents is investigated to assess the incidence of solvated pre-associations on nucleation, crystal growth and chiral discrimination. In the solvated state, Raman spectroscopy shows that dimeric associations similar to those depicted in the crystalline solid solution (ssRII) predominate in isopropanol (IPA), which may account for the systematic spontaneous nucleation of this crystal form from this solvent. By contrast, spontaneous nucleation in DMF yields the stable racemic compound RI, consistently with the distinct features of the Raman spectrum collected in this solvent. A crystal growth study of ssRII in IPA reveals that the crystal habitus is impacted by the solution enantiomeric excess; this is explained by increased competition between homo- and heterochiral pre-associations. This is supported by a molecular modelling study on the enantiomeric selectivity of the DPL crystal lattices. The combination of assessment methods on solution chemistry, nucleation and chiral discrimination provides methodological tools from which the occurrence of solid solutions can be rationalised

Development of 3D printed rapid tooling for micro-injection moulding

The use of additive manufacturing techniques in conjunction with injection moulding is becoming increasingly popular, with financial and time benefits to coupling the techniques. This study demonstrates a systematic development process of 3D printed rapid tooled moulds using stereolithography. A high flexural modulus and elongation were found to increase the likelihood of success of a mould material in the injection moulding process. Success is defined as the mould surviving the process and being capable of producing the desired object successfully. Stereolithography was found to produce high quality moulds when a diagonal print orientation and a scaling factor of 109.3% is employed. The presented technique and systematic workflow is highly suitable for the production of moulds with detailed micro-features. This is of particular interest for rapid tooling for micro-injection moulding for the manufacture of pharmaceuticals and medical devices, where the microstructure directly impacts the performance of the products

Self-association during heterogeneous nucleation onto well-defined templates

We investigated the interplay between self-associates in solution and surface templating by studying the crystallization behavior of isonicotinamide (INA) and 2,6-dihydroxybenzoic acid (DHB) in the presence of self-assembled monolayers (SAM). The end group of the SAM as well as the hydrogen-bonding capabilities of the solvent and self-association of INA and DHB were found to be important in polymorph crystallization on SAMs. In the case of INA in ethanol, both chain and dimer self-associates are present in the solution. In the absence of SAMs the polymorph form II (dimer structure) is the crystallization outcome. In ethanol the 4-mercaptopyridine and 4-mercaptobenzoic acid SAMs organize INA chain associates at the template surface and enable the crystallization of form I while the 16-mercaptohexadecanoic acid SAM results in the crystallization of form II. Raman spectroscopy suggests that molecular interactions between INA and the SAM are responsible for the formation of specific polymorphs. XRPD results in the identification of the orientation of the crystal on the surface that further verified the results obtained by Raman spectroscopy. In nitrobenzene and nitromethane INA associates in solution only as chains and crystallization results in the formation of form IV and form I, respectively (both chain forms). The crystals formed in the bulk solution and on SAMs were the same, which seems to indicate that the self-association in nitrobenzene and nitromethane is not influenced by the presence of templates. In the case of DHB in toluene and chloroform, all three SAMs nucleated only one type of polymorph (stable form 2). In the case of toluene the polymorphic outcome was stable form 2 instead of metastable form 1, which is favored in toluene in the absence of the SAMs. Again, Raman spectroscopy and XRPD suggest that DHB-SAM molecular interactions may be responsible for the formation of form 2

Measuring secondary nucleation through single crystal seeding

This article presents a novel assessment method for secondary nucleation rates using a well-controlled, small scale seeding procedure. The procedure comprises the seeding of a well-monitored, stirred, supersaturated solution by a carefully selected single crystal under conditions at which spontaneous nucleation does not occur. The determined number of particles in time were translated to a suspension density using a calibration performed with monodisperse polymer spheres. The increasing crystal suspension density in time subsequently allowed the determination of the secondary nucleation rate under very specific conditions of supersaturation and temperature. The secondary nucleation rate was measured as a function of seed crystal size and supersaturation. It was observed that the time elapsed between the moment a single seed crystal is added and the moment the suspension density started to increase is larger when the seeded crystals are smaller and the supersaturation is lower. A systematic study of secondary nucleation at different supersaturations led to the determination of a supersaturation threshold for secondary nucleation, which could be used in industrial crystallization process design to identify process conditions with the right secondary nucleation rate behavior

Solubility determination from clear points upon solvent addition

A method is described for determining the solubility of multicomponent crystalline compounds from clear points upon sample dilution at a constant temperature. Clear points are established by continuously adding a solvent mixture to a suspension of known composition until a clear solution appears. For validation, this solvent addition method is compared to the traditional equilibrium concentration method at constant temperature and the more recent temperature variation method with which clear point temperatures are determined upon increasing the sample temperature. Solubility data of binary systems (1 solute, 1 solvent) measured using the solvent addition method are obtained relatively quickly compared to the equilibrium concentration method. These solubility data are consistent with those of the temperature variation and the equilibrium concentration method. For the temperature variation method, the results are dependent on the heating rate. Likewise, for the solvent addition method, they are dependent on the addition rate. Additionally, for ternary systems involving antisolvent or cocrystals, solubilities are determined at a constant temperature using the solvent addition method. The use of the solvent addition method is especially valuable in the case of solvent mixtures and other complex multicomponent systems, in which the temperature variation method cannot be applied easily

Effect of chirality on the compression of 2-(2-Oxo-1-pyrrolidinyl)butyramide : a tale of two crystals

Understanding polymorphism in chiral systems for drug manufacturing is essential to avoid undesired therapeutic effects. Generally, polymorphism is studied through changes in temperature and solution concentration. A less common approach is the application of pressure. The goal of this work is to investigate the effect of pressure on levetiracetam (pure enantiomer) and etiracetam (racemic compound). Anisotropic compressions of levetiracetam and etiracetam are observed to 5.26 and 6.29 GPa, respectively. The most compressible direction for both was identified to be perpendicular to the layers of the structure. Raman spectroscopy and an analysis of intermolecular interactions suggest subtle phase transitions in levetiracetam (∼2 GPa) and etiracetam (∼1.5 GPa). The stability of etiracetam increases with respect to levetiracetam on compression; hence, the chiral resolution of this system is unfavorable using pressure. This work contributes to the ongoing efforts in understanding the stability of chiral systems