(380d) Process Development and Scale-up of a Photochemical Reaction for Drug Substance Manufacturing
AIChE Annual Meeting
2022 Annual Meeting
Catalysis and Reaction Engineering Division
In Honor of the 2021 CRE Practice Award Winner (Invited Talks)
Tuesday, November 15, 2022 - 4:45pm to 5:10pm
This presentation will discuss various strategies that have been used to develop and scale up a photochemical bromination. Small, benchtop experiments were used to identify the reaction mechanism and understand reaction sensitivities. By establishing photon equivalence as the scaling factor, the bromination was scaled up to larger batch reactors and tech transferred to continuous flow reactors. The process was scaled up to the kilo-scale with two different flow reactor configurations to understand the impact of reactor design on photochemical reaction performance before selecting a plug flow reactor for manufacturing. To further understand the bromination reaction in a production environment, the process was explored at various residence times, irradiation levels, and temperatures in the pilot plant. This data, along with kilo-scale process characterization investigations, enabled successful tech transfer of the process to manufacturing to produce metric tons of drug substance intermediate.