New process for the preparation of dronedarone

The present invention relates to-a novel process for the preparation of A^-[2-butyl-3-{4-[(3-dibutylamino)propoxy]benzoyl}-l-benzofuran-5-yl]methane-sulfonamide (dronedarone) of formula I.
and its pharmaceutically acceptable salts, and to the new intermediates of. the preparation process.
Dronedarone of formula I is used in the treatment of certain pathological changes of the cardiovascular system, especially in the treatment of angina pectoris, high blood pressure, arrhythmia and insufficient cerebral blood circulation (EP 0471609 Bl).

There are several known methods for the preparation of dronedarone of formula I. Patent application of publication number-WO 02/48132 discloses the following super-convergent method: The 5-amino-2-butyl-benzofuran of formula IV is mesylated and the resulting 2-butyl-5-methanesulfonamido-benzofuran of formula II is reacted under Friedel-Crafts conditions with the 4-[3-(dibutylamino)propoxy]-benzoyl chloride hydrochloride salt of formula III to obtain the.dronedarone hydrochloride salt of formula I.

This method is very simple and economical as regards the number of the reaction steps. Its drawback is however, that in the last step the hydrochloride salt of dronedarone is obtained in a substantially contaminated form. This can be explained by the presence of the dibutylamino-propyl group in the FriedelrCrafts reaction. In the published examples.the yield is 90%, during the purification steps first the raw dronedarone hydrochloride salt, then following treatment with hydrogen chloride solution in isopropanpl, the purified dronedarone hydrochloride salt is obtained (90%).

Another drawback of the method is that the reacitants used in the Friedel-Crafts reaction arid the obtained by-products are insoluble in water, thus they cannot be removed from the system by aqueous washing.
A further drawback of the method is that during the mesylation of the 5-amino-2-butyl-benzofuran IV a double mesylated derivative always appears as a by-product of the reaction. Purification is solved by recrystallisation, its yield is 78.5%:

Our aim was to work out a hovel method for the preparation of dronedarone arid its pharmaceutically acceptable salts, which method avoids the above mentioned disadvantages, and is economical and industrially applicable.

We have found that if in the course of the process, instead of the 2-butyl-5-methanesulfonamido-benzofuran II, its alkali- or alkali earth metal salt is reacted with the 4-[3-(dibutylamino)propoxy]benzoyl chloride hydrochloride salt of formula III

under Friedel-Crafts conditions, then the above mentioned disadvantages can be avoided.
According to our invention the 5-amino-2-butyl-benzofuran of formula IV is mesylated by a method known from the literature (WO 02/48132) and the resulting 2-butyl-5-methanesulfonamido-benzofuran of formula II is reacted with an appropriate alkali- or alkali earth metal salt to give the respective alkali-or alkali earth metal salt of the compound of formula II,

which is then reacted as described above, with the 4-[3-(dibutylamino)propoxy]-penzoyl chloride hydrochloride salt of formula III underFriedel-Crafts conditions, to obtain the Ar-[2-butyl-3-{4-[(3-
dibutylamino)propoxy]benzoyl}-l-benzofuran-5-yl]-methanesulfonamide of formula I, which is optionally transformed into its salt, or liberated from its salt.

The advantage of the process according to the invention is that the by-product which is formed during the mesylation of the compound of formula IV will not disturb me further reaction steps, because to the obtained reaction mixture the alkali- or alkali earth metal salt solution is added, and the alkali- or alkali earth metal salt of the desired compound of formula II will dissolve and remain in the aqueous phase.

By choosing suitable reaction conditions the compound of formula I is obtained in the required purity and yield, the by-product is not formed, only a few percent of unreacted starting material may remain in the reaction mixture, which can easily be removed by aqueous washing and may be re-used.

According to one embodiment of the invention ail alkali metal salt of the compound of formula II is reacted with the compound of formula III. The term alkali metal includes lithium, sodium or potassium,

The lithium, sodium or potassium salt of the compound of formula II is prepared by reacting the 2-butyl-5-methanesulfonylamido-benzofuran of formula II with the appropriate alkali metal hydroxide (lithium hydroxide, sodium hydroxide, potassium hydroxide).

According to another embodiment of the invention an alkali earth metal salt of the compound of formula II is reacted with the compound of formula III. The term alkali earth metal includes magnesium or calcium.

The magnesium or calcium salt of the 2-butyl-5 -methanesulfonylamido-benzofuran of formula II is prepared by reacting the 2-butyl-5-methanesulfonylamido-benzofuran of formula II first with an alkali metal hydroxide (lithium hydroxide or potassium hydroxide) and..then with the appropriate alkali earth metal halogenide (calcium chloride, calcium bromide, magnesium chloride, magnesium bromide).

According to a preferred version of our invention the reaction of the alkali metal or alkali earth metal salt of the compound of formula II and the compound of formula III is performed in an inert organic solvent, or in the mixture of inert organic solvents. As inert organic solvent, halogenated hydrocarbons (dichloromethane, dichloroethane, chlorobenzene) or the mixture of them can be used.

According to a preferred version of our invention the reaction of the alkali metal or alkali earth metal salt of the compound of formula II with the compound of formula III is carried out in the presence of a Friedel-Crafls catalyst (iron(III) chloride, aluminum chloride).

According to a preferred version of our invention the reaction of the alkali metal or alkali earth metal salt of the compound of formula II with the compound of formula IILis carried out at a temperature between 10-100 °C.

The 2-b.utyl-5-methanesulfonylamido-benzofuran of formula II
and its preparation by mesylation of the 5-amino-2-butyl-benzofuran of formula IV is known from the literature (WO 02/48132).

The 4-[3-(dibutylamino)propoxy]benzoyl chloride hydrochloride of formula III which is used in the process, and its preparation is known from the literature (WO 02/48078).

The lithium salt IIa, sodium salt IIb, potassium salt IIC, magnesium salt IId and calcium salt IIe of the compound of formula II are new compounds, not known from the literature.

Further details of the invention are demonstrated by the following examples - without limiting the claims to the examples. .

EXAMPLES
Example 1.

JV-r2-butvI-3- {4-[(3-dibutvlamino)propoxv1benzovl} -1 -benzofuran-5-vll-methanesulfonamide I
To the suspension made of 5.2 g 2-butyl-5-methanesulfonamido-benzofuran sodium salt IIb and 20 ml dichloromethane,. the solution of 6.29 g 4-{3-(dibutylamino)-propoxy}benzoyl chloride hydrochloride salt III in 25 ml dichloromethane is added. The reaction mixture is stirred for 30 minutes. In 15 minutes at 5-10°C 3.57 g iron(III) chloride is added and the. reaction mixture is stirred at 20-25°C for 2 hours: At 40°C in 10 minutes 20 ml water is added to the mixture and the phases are separated. The dichloromethane phase is washed by stirring with 15 ml water, then with 15 ml 5% sodium hydrogen carbonate solution.

The dichloromethane phase is evaporated.
9.8 g (98.0%) yellow oil is obtained;
Purity by HPLC: 98:6%
1H NMR (DMSO): 0.8-0.9ppm (m, 9H);,1.2-1.5ppm. (m,10H); 1.67ppm (5',2H);
1.87ppm (5', 2H); 2.38ppm (t, J= 7.2Hz, 4H); 2.57ppm (m, 2H); 2.81ppm (t, J=
7.5Hz, 2H); 2.91ppm (S, 3H); 9.51ppm (t, J= 6.2Hz, 2H); 7.09ppm (d, J= 8.8Hz,
2H); 7.24ppm (dd, J= 8.9, 2.2Hz, 1H); 7,38ppm (d, J= 2,1Hz, 1H); 7.65ppm (d,
J=8.8Hz,lH);7.81ppm(d,J= 8.8Hz, 2H) . .

Example 2,
Ar2-butvl-3-(4-r(3-dibutvlamino')propoxv1benzovl}-l-benzofuran-5-vll- methanesulfonamide I ,

The procedure as described in Example 1. was followed, but chlorobenzene was used, instead of dichloromethane.

Yield: 97.8%.
Purity by HPLC: 98.4%

Example 3.
N- r2-butvl-3 - f 4-|Y3 -dibutvlamino)propoxvlbenzoyl) -1 -benzofuran-5-y 11-methanesulfonamide I
The procedure as described in Example 1. was followed, with the difference that instead of 2-butyl-5-methanesulfpnamido-benzofuran sodium salt lib, equivalent amount of 2-butyl-5-methanesulfonamido-benzofuran potassium salt lie was used. The resulting material is identical with the product of Example 1.
Yield: 99.1%.
Purity by HPLC: 98.4%

Example 4.
N-r2-butyl-344-[(3-dibu1ylammo)propoxv1benzoyU-l-benzofuran-5-yl]-methanesulfonamide I
The procedure as described in Example 1. Was followed, with the difference that instead of 2-butyl-5-methanesulfonamido-benzofuran sodium salt IIb, equivalent amount of 2-butyl-5-methanesulfonamido-benzofuran lithium salt Ila was used. The resulting material is identical with the product of Example 1.

Yield: 98.1%. , Purity by HPLC: 98.7%

Example 5.
iV-r2-butvl-3-(4-rn-dibutvlamino')propoxv1benzo'vn-l-benzofiiran-5-vl1-methanesulfonamide I

The procedure as described in Example 1. was followed, with the difference that instead of 2-butyl-5-methanesulfonamido-benzofuran sodium salt IIb, equivalent amount of 2-butyl-5-methanesulfonamido-benzofuran magnesium salt IIe was used. The resulting material is identical with the product of Example 1.

Yield: 97.8%.
Purity by HPLC: 99.0%

Example 6.
ALr2-butvl-3-(4'("(3-dibutvlammo)propoxv1benzovl}^i-benzofuran-5-yl]-methanesulfonamide I
The procedure as described in Example 1. was followed, with the difference that instead of 2Tbutyl-5-methanesulfonamido-benzofuran sodium salt lib, equivalent amount of 2-butyl-5-methanesulfonamido-benzofuran calcium salt lid was used. The resulting material is identical with the product of Example 1.
Yield: 97.7%. . .
purity by HPLC: 97.6% .

Example?.
N-[2-butvl-3-(4-[3-dibutvlamino)propoxvlbenzoyl-l-benzofufan-5-yl]-methanesulfonamide I

The procedure as described in Example 1. was followed, but 2.93 g aluminum chloride was used, instead of iron(III) chloride.

The resulting material is identical with the product of Example 1.
Yield: 89.9%. . Purity by HPLC:.96.1%

Example 8.
2-butyl-5-methanesulfonamido-benzofuran lithium salt IIa
2.23 g 2-butyl-5-methanesulfonamido-benzofuran II is added under stirring to the solution of 0.20 g lithium hydroxide in 5 ml water. The reaction mixture is stirred at room temperature for 1 hour and then kept at 0-5°C for 8 hours. The precipitated white material was collected, washed with 1 ml 5°C water and dried at 70°C.

Mass of the product: 1.7 g (74.5%)
Melting point: 252.1-253.7°C
Elemental .analysis: C:51.98%, H:5.79%,.N:4.61%, S.10.44%, Li:2.41%
(Calculated values: C:57.1%, H:5.86%, N:5.13%, S:11.7%,Li:2.56%)

Example 9.
2-butvl-5'methanesulfonamido-benzofuran sodium salt IIb
2.12 g 2-butyl-5-methanesulfonamido-benzofuran II was added to the solution of lg sodium hydroxide in 75 ml water. The resulting suspension was warmed to 70°C, then allowed to cool to 20°C and stirred at 5-10°C for I hour. The product was filtered off, dried in vacuum.

Mass of the product: 2.04 g (89.0%)
Melting point: 226.3-228.9°C
Elemental analysis: C: 59.9%; H: 5.63%; N: 5.16%; S: 11.14%; Na: 7.2%;.

(Calculated values: C: 59.98%; H:5.54%; N: 4.84%; S: 1L07%; Na: 7.94%)

Example 10.
2-butyl-5-methanesulfonamido-benzofuran sodium salt IIb
The procedure as described in Example 9. was followed, but 40 ml water was used
in the reaction. The resulting material is identical with the product of Example 9.

Yield: 95.0%.
Example 11.

2-butvl-5-methanesulfonamido-benzofuran potassium salt IIe
2.12 g 2-butyl-5-methanesulfonamido-benzofuran II was added to the solution of lg of 85% potassium hydroxide in 25 ml water. The reaction mixture was stirred at room temperature for 1 hour, and then at 5°C for 2 hours. The product was filtered off, dried in vacuum.

Mass of the product: 2.0 g (82.0%)
Melting point: 103.2-105.7°C

Elemental analysis: C: 50.37%; H: 5.16%; N: 4.54%; S: 9.53%; K: 12.0%
(Calculated values: C: 51.07%; H: 5.24%; N: 4.58%; S; 10.47%; K: 12.8%)

Example 12.
2-butvl-5-methanesulfonamido-benzofuran potassium salt IIe
The procedure as described in Example 11- was followed, but 10 ml water was used in the reaction. The resulting material is identical with the product of Example 11. Yield: 94.0%.

Example 13.
2-butvl-5-memanesulfonamido-benzofuran calcium salt He 2.0 g 2-butyi-5-methanesulfonamido-benzofuran II was added to the solution of 0.5 g 85% potassium hydroxide in 20 ml water. The reaction mixture was,, stirred for 30 minutes. To the obtained solution 0.89 g calcium chloride dissolved in 5 ml water was added in 10 minutes, the resulting suspension was stirred at 20-25°C for 1 hour and then at 5°C for 2 hours. The product was filtered off and dried.

Mass of the product: 1.8 g (86.1%)
Melting point: 103.4-105.7°C
Elemental analysis: C: 51.74%; H: 5.50%; N: 4.55%; S: 10.29%; Ca:5.8%
(Calculated values: C: 54.47%; H: 5.58%; N: 4.89%; S: 11.17%; Ca:6.99%)

Example 14.
2-butyl-5-methanesulfonamido-benzofuran calcium salt IIe
The procedure as described in Example 13. was followed, but 15 ml water was used in the reaction, instead of 20 ml. The resulting material is identical with the product of Example 13.
Yield: 92.0%.

Example 15.
2-butvl-5-methanesulfonamido-benzofuran magnesium salt IId
1.6 g 2-butyl-5-methanesulforiamido-benzpfuran II was added to the solution of 0.28 g 85% potassium hydroxide in 16 ml water. The reaction mixture was stirred for 30 minutes. To the obtained solution 0.76 g magnesium chloride dissolved in 5 ml water was added in 1.0.minutes, the resulting suspension was stirred at 20-25°C for 1 hour and then at 5°C for 2 hours, The product was filtered off and dried.

Yield: 1.4 g (83.8%)
Melting point: above 270°C
Elemental analysis: C: 51.74%; H: 5.50%; N: 4.55%; S: 10.29%; Mg: 4.8%;
(Calculated values: C: 56.0%; H: 5.74%; N: 5.03%; S: 11.49; Mg: 4.36%)

Example 16.
2-butyl-5-methanesulfonamido-benz6furan magnesium salt lid

The procedure as described in Example 15. was followed, but 10 ml water was used in the reaction, instead of 16 ml. The resulting material is identical with the product of Example 15.
Yield: 93.7%

Claims :

1. Process for the preparation of N-[2-butyi-3-{4-[(3-dibutylamino)propoxy]-behzoyl}-l-benzofuran-5-yl]methanesulfonamide of formula I and its pharmaceutically acceptable salts, characterized in that ' an alkali- or alkali earth metal salt of the compound of formula II is reacted with the 4-[3-(dibutylamino)prqpoxy]benzoyl chloride hydrochloride of formula III in the presence of a catalyst, and optionally, the compound of formula I is transformed into its salt, or liberated from its salt.

2. The process as defined in claim .1., characterized in that the term alkali metal includes lithium, sodium or potassium, and the term alkali earth metal includes magnesium or calcium.

3. The process as defined in any of claims 1-2., c h a r a c t e r i z e d in t h a t the reaction of the compound of formula II and the compound of formula III is carried out in an inert solvent or in the mixture of them.

4. The process as defined in claim 3.,characterized in that, as . for inert solvent, halogenated hydrocarbons are applied.

5. The process as defined in claim 4., characterized in t h a t, as for halogenated hydrocarbons, dichloromethane, dichloroethane, chlorobenzene or the mixtures of them are used.

6. The process as defined in any of claims 1-5., characterized in t h a t, as for catalyst, iron(III) chloride or aluminum chloride is used.

7. - The process as defined in any of claims 1-6., characterized in t h a t the reaction is carried out at a temperature between 10-100 °C.

8. The alkali metal- and alkali earth metal salts of the 2-butyl-5-methanesulfonamido-benzofuran of formula II.

9. Of the compounds according to claim 8., the lithium salt IIa, sodium-salt IIb, potassium salt He, magnesium,salt IId and calcium salt IIe of the compound of formula II.

10. Process for the preparation of the alkali metal salts of compound II according to any of claims 8-
9., characterized in that the compound of formula II is reacted with the appropriate alkali metal hydroxide.

11. The process according to claim 10. c h a r a c t e r i z e d in that me term alkali metal hydroxide comprises lithium hydroxide, sodium hydroxide or potassium hydroxide.

12. Process for the preparation of the alkali earth metal salts of compound II according to any of claims 8-9., c haracterized in that the compound of formula II is first reacted with lithium hydroxide or potassium hydroxide, and then with the appropriate alkali earth metal halogenide.

13. The process according to claim 12-. characterized in that the term alkali earth metal halpgenide comprises magnesium chloride, magnesium bromide, calcium chloride or calcium bromide.