Ep 0673941 A2

Europaisches Patentamt J European Patent Office © Publication number: 0 673 941 A2 Office europeen des brevets

EUROPEAN PATENT APPLICATION

@ Date of filing: 29.03.88

This application was filed on 03 - 06 - 1995 as a © Applicant: LITHIUM CORPORATION OF divisional application to the application AMERICA mentioned under INID code 60. 449 North Cox Road Gastonia NC 28054 (US) © Priority: 30.03.87 US 31639 @ Inventor: Rathman, Terry Lee © Date of publication of application: 3843 Gardner Park Drive 27.09.95 Bulletin 95/39 Gastonia, North Carolina 28054 (US) © Publication number of the earlier application in Inventor: Morrison, Robert Charles accordance with Art.76 EPC: 0 285 374 1946 Elmwood Drive Gastonia, © Designated Contracting States: North Carolina 28054 (US) AT BE CH DE ES FR GB GR IT LI LU NL SE

Oi 00 CO

Rank Xerox (UK) Business Services (3. 10/3.09/3.3.4) EP 0 673 941 A2

This invention concerns a high-yield, economical Process for producing novel , hydrocarbon soluble organo metallic compositions such as, for example, alkyllithium compounds, in a hydrocarbon solvent containing a limited amount of tetrahydrofuran (THF) other ethereal compounds or Lewis bases. Alkyllithium compounds, particularly methyllithium (MeLi), are used as reagents in the preparation of 5 pharmaceuticals and special chemicals. MeLi has been available commercially in diethyl ether solutions in the presence of an equivalent of lithium bromide (LiBr) formed as a by-product and remaining in solution as a complex with the methyllithium. A principal deficiency of this product is its high flammability due in part to the diethyl ether which is highly flammable and explosive in combination with oxygen and which contributes highly to the pyrophoric nature of the contained methyllithium. Although the presence of lithium bromide io reduces the pyrophoric nature of methyllithium itself, the presence of lithium bromide interferes with certain applications of the methyllithium. There is evidence that the presence of lithium bromide may influence significantly the stereochemistry during the addition of methyllithium to carbonyl compounds. For these reasons it is often desirable to use a substantially halide-free methyllithium. However, the MeLi* LiBr complex has found in the past, and will in the future, many uses in organic syntheses, especially for those 75 applications where stereochemistry is unimportant. The pyrophoric nature of methyllithium taken together with the presence of diethyl ether has resulted in limited use of MeLi in diethyl ether. Moreover, other chemical routes or methyl Grignards are used. Attempts were made in the 1970's to commercially market ethereal solutions of halide-free methyllithium prepared from methyl chloride and lithium shot. This resulted in the desired product containing not 20 more than 5 mole percent lithium chloride based on contained methyllithium because the lithium chloride by-product has low solubility in diethyl ether. The slow reaction of methyl chloride with lithium shot resulted in incomplete reaction before filtration which resulted in poor product shelf life due to the post reaction Wurtz coupling of methyllithium and residual methyl chloride to form ethane and lithium chloride (LiCI). These diethyl ether solutions of methyllithium are marketed commercially even though they often degrade 25 badly before use. Gilman and Gaj in Journal of Organic Chemistry 22, 1164 (1957) disclose preparing methyllithium from methyl chloride and lithium metal in THF. The THF/Li mole ratio was 9.8 indicating use of a large excess of THF. Thermal stability of these products was found to be poor even at 0°C. So in view of the thermal decomposition and the high cost of THF these products are not commercially feasible. There remains a need for a halide-free, thermally stable methyllithium solution in a relatively non-volatile solvent 30 system and a process for producing such a product. Using proton and lithium NMR analysis House, H.O. et al., J. Org. Chem., 32, 2481 (1967) and L.M. Seitz et al., J. Amer. Chem. Soc, 88, 4140 (1966) found that in diethyl ether methyllithium (MeLi) and dimethylmagnesium (Me2Mg) form Li2MgMe4 and Li3MgMe5 complexes. L.M. Seitz et al. J. Organometallic Chem., 18, 227 (1969) disclose that in tetrahydrofuran only the 2:1 (Li:Mg) complex was observed. These 35 workers prepared halide-free dimethylmagnesium via two methods: (1) the long, tedious Schlenk reaction which involves first the synthesis of methylmagnesiumbromide, the addition of dioxane to precipitate magnesium bromide followed by vacuum removal of the dioxane; (2) the process in which highly toxic and expensive dimethylmercury was stirred with excess magnesium to generate dimethylmagnesium. Kamienski and Eastham in J. Organometallic Chem., 8, 542 (1967) disclose the reaction of an 40 alkyllithium with a special activated magnesium chloride in diethyl ether which was not and is not commercially available as a route to dimethylmagnesium. Kamienski and Eastham in J. Org. Chem., 34 1116 (1969) disclose reaction of RLi with RMgX in diethyl ether to prepare dialkylmagnesium. Most of the processes of the prior art are expensive, require handling of highly toxic reagents, employ commercially unavailable reagents and use highly flammable diethyl ether and thus are not commercially 45 feasible processes. Unfortunately diethyl ether solutions of halide-free methyllithium are undesirably pyrophoric. The need remains for an inexpensive, commercial synthesis of halide-free dimethylmagnesium and halide-free, stable alkyllithium compositions. The present invention provides stable hydrocarbon solvent-Lewis base, such as hydrocarbon- tetrahydrofuran, solutions of alkali metal alkyls and a method for producing stable hydrocarbon Lewis Base 50 compositions of alkali metal alkyls containing not more than 5 mole percent lithium chloride based on the alkali metal alkyl content in which compositions the ratio of tetrahydrofuran to alkali metal alkyl is within the range of 0.05:1 and 2:1 and the hydrocarbon is a liquid aliphatic, alicyclic or aromatic hydrocarbon. The preferred methyl halide, methyl chloride (MeCI) when reacted with an alkali metal produces a by- product, lithium chloride, which is essentially insoluble. When organic bromides or organic iodides such as 55 methyl bromide (MeBr) or methyl iodide (Mel) are employed, higher levels of by-product inorganic halide go into solution and actually improve the thermal stability of the complexed organometallic which is dissolved in a limited amount of Lewis Base and an aromatic solvent. For example, a MeLh.o* LiBr069 complex dissolved in a limited amount of THF (THF/MeLi = 1.65 mole ratio) and toluene was found

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significantly more thermally stable (about 8 times) at 40 °C than a comparable halide-free methyllithium solution in limited THF/toluene. As the number of carbon atoms in the alkyl group increases the amount of THF required to solubilize the organometallic compounds decreases. The solubility of methyllithium, even when stablized with an inorganic halide is such that at least some of the solvent must be an aromatic 5 solvent. The process of the invention when producing alkali metal alkyls reacts an alkali metal preferably lithium metal, most preferably containing some sodium with an alkyl halide in a hydrocarbon solvent containing a small amount of a Lewis Base such as THF. The alkali metal is preferably finely divided and dispersed or slurried in an aromatic hydrocarbon containing tetrahydrofuran. The alkyl halide, preferably methyl or ethyl io halide is added to the slurried lithium metal while the temperature is maintained below about 50 °C; preferably the temperature is maintained between 30 °C and 35 °C. Typically the alkyl halide is added slowly to alkali lithium metal slurry with agitation as this facilitates control of the reaction temperature. The reactions involving an alkali lithium metal are done under an inert atmosphere, preferably argon. The product is a tetrahydrofuran complex of alkyllithium, in a hydrocarbon solvent. is A method or process variable having a great influence on yield is the amount of tetrahydrofuran present during the reaction. While the ratio of tetrahydrofuran to methyl halide may vary between 0.05 and 2.0 moles of tetrahydrofuran per mole of methyl halide, the preferred range is about 1.2 to 1.5 moles of tetrahydrofuran per mole of methyl halide when there is no magnesium present in the reaction. Surprisingly higher and lower levels of tetrahydrofuran (THF) tend to result in lower yields. 20 Organic halides useful in practicing this invention may be represented by the formula RX in which X is selected from the group of chloride, bromide and iodide and R is selected from the group of alkyl, cycloalkyl, a,a-alkylene, alkenyl and aryl groups. More specifically, R can be selected from the group of methyl, ethyl, n-butyl, sec-butyl, 2-ethylhexyl n-octyl, cyclohexyl, 1 ,4-butylene, phenyl, cumyl, benzyl, tolyl, vinyl and crotyl groups. When desired mixtures of different organohalides can be employed to produce 25 mixed organic groups in the products of this invention. The liquid hydrocarbon solvents used in practicing this invention are typically selected from aliphatic hydrocarbons containing five to ten carbon atoms, alicyclics containing six to ten carbon atoms and aromatic hydrocarbons such as benzene, toluene, ethylbenzene, cumene and so forth. Products of this invention of particular interest include solutions of lower alkyllithium compounds which 30 if desired can contain stabilizing amounts of inorganic halides such as lithium bromide or lithium iodide. These compounds are useful as alkylating agents in the synthesis of pharmaceuticals and in other complex organic synthesis reaction sequences. The dialkylmagnesium/alkylmagnesium halides compositions of this invention have characteristics similar to the corresponding dialkylmagnesium compounds and are used for similar purposes such as 35 alkylations and the like where Grinard agents are often used. In this respect these compounds such as Me2Mg/MeMgCI, react more completely than Me2Mg as the presence of the chloride is believed to promote reaction of the alkyl groups and so, more completely reacting such alkyl groups in the Me2Mg/MeMgCI compounds. Methyllithium and dimethylmagnesium (Me2Mg) are not hydrocarbon soluble. While the use of a limited 40 amount of a Lewis Base, such as THF, solubilizes these organometallic compounds in hydrocarbon solvents, preferably aromatic solvents, the solutions containing only methyllithium tend to be unstable; methyllithium precipitates in certain cases, such as when cumene is the aromatic solvent, upon storage at low or elevated temperatures and metallates aromatic solvents under some storage conditions such as, at elevated temperatures. 45 The present process employs a hydrocarbon solvent containing a limited amount of tetrahydrofuran (THF), other ethereal compound or Lewis Base. The novel organometallic products of the process are dissolved in these hydrocarbon solvents containing a limited amount of a Lewis Base such as tetrahydrofuran, methyltetrahydrofuran and so forth. The amount of THF varies from 0.05 to 2.0 depending on the alkyl group selected. Slightly more than one (1) equivalent of THF per alkyl group is used when the 50 alkyl group is methyl with 1.2 to 1.5 THF equivalents being preferred. However, as the carbon content of the alkyl group increases less THF is required to solubilize the organometallic compound; when the alkyl group is ethyl only 0.5 to 0.7 equivalents of THF are required to solubilize ethyllithium and it is known that diamylmagnesium is hydrocarbon soluble without THF. Moreover n-propyllithium is known to be hydrocarbon soluble. Compositions of particular interest in pharmaceutical synthesis work are solutions of methyl- 55 lithium A particular advantage of the present invention is that the compounds of the invention have been synthesized in high yield by way of a novel reaction sequence in a single reactor which involves gradual addition of an organic halide to a metal selected from magnesium, calcium barium, aluminium and zinc in a

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hydrocarbon solvent containing a limited amount of tetrahydrofuran. The final product is obtained by filtration to remove unreacted metal and inorganic metal halide. The most important novel composition synthesized via this general process is dimethylmagnesium. The reactivity of the finely divided lithium in producing mono-metallic compositions is increased by the 5 presence of a small amount of sodium. H.O. House and M. Call in Organic Synthesis (1972), 52, 39 showed that a minimum 0.7 wt % preferably 1 to 2 weight percent sodium in the finely divided lithium is necessary for efficient and complete reaction with methyl chloride in diethyl ether. Dialkylmagnesium/alkylmagnesium halides of various compositions are synthesized via the process of this invention. This aspect of this invention can be represented by the following equation: 10 xLi + yMg + (1/2x + y) RX --> 1/2x R2Mg + (y - 1/2x)RMgX + xLiX (1)

wherein R is lower alkyl such as methyl (Me), x is less than 2 and y is 1 , and X is selected from chlorine, bromine and iodine. is The following examples further illustrate the invention. Unless indicated otherwise temperatures are in degrees C, percentages of reactants are in weight percent. All glassware was baked in an oven (150°C) over-night, assembled, and purged until cool with argon. An inert argon atmosphere was maintained throughout reaction, filtration, and packaging. The chloride content of solution was determined by Mohr titration. All lithium metal used contained 20 0.7% to 1.25% sodium. The analytical data in some examples reports values for "MeM" wherein M represents a mixture of magnesium and lithium metals and Me represents methyl.

A - ALKALI METAL EXPERIMENTS

25 The following series of experiments prepared methyllithiun by reacting methyl iodide with n-butyllithium. The methyllithium so produced was used for solubility and stability studies. The procedure in all such experiments: was substantially the same except that different solvent solutions were employed. The following Experiment 2 is exemplary of the various experiments conducted: Methyl iodide (0.1 mole) and hexane (50 ml) were added by syringe via a rubber septum to a reaction 30 flask. The flask and contents were cooled to -20 °C with a cooling bath. n-Butyllithium (0.1 mole) was then added, also by syringe, dropwise over a period of 30 minutes while maintaining the reaction between -40 and 0°C. A white precipitate immediately formed and increased in amount throughout the reaction. The resultant slurry was stirred an additional hour to ensure the completeness of reaction. The white slurry was then transferred to the filter funnel. A rapid filtration (15 minutes) resulted in solid methyllithium (MeLi) being 35 collected on the filter plate. The solid MeLi was then washed with 50 ml hexane and 50 ml toluene to remove impurities. The filtrate (hexane, toluene, and n-butyliodide) were removed by syringe, and a pre- mixture of 14.7 ml tetrahydrofuran (THF) and 33.8 ml toluene was added to the filter funnel. Stirring the contents of the filtration funnel resulted in complete dissolution of the MeLi. A light yellow clear solution of MeLi was obtained by filtration (88.4% recovered yield). 40 Analyses: Total base = 1 .50 M Watson Eastham Titration = 1 .47 M NMR analysis = 1.40 M = 2.23 THF/MeLi mole ratio

Data from additional experiments preparing methyllithium by the method of Experiment 2 are contained in Table 1 . The data in the tables was obtained by two titration methods and proton NMR. The total base (alkalinity/content) titration determines the equivalents of water soluble basic lithium hydroxide which forms when a methyllithium sample is hydrolyzed. The active lithium was determined by a modified Watson-Eastham method (Watson, S.C.; Eastham, J.F.; J. Organomet. Chem. (1967), 9, 165). This method not only titrates methyllithium but also any other strongly basic species such as metallated THF or toluene which may be contained in thermally degraded samples. Proton (NMR) analysis was used for assaying methyllithium samples regardless of the extent of the amount of decomposition. The modified Watson-Eastham titration did not distinguish between methyllithium

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and any other carbon lithium species present in a decomposed sample. Visually, decomposed samples were readily identified by their dark red color. Non-degraded samples were a light yellow color. The Watson-Eastham and NMR analyses were in excellent agreement for freshly prepared, non-degraded methyllithium samples. 5 In one experiment (see Table I - Exp. No. 1), an attempt to dissolve solid methyllithium with one equivalent of THF in toluene resulted in initial solubility; however, a precipitate formed overnight. Filtration resulted in about 50% of the total methyllithium being soluble (0.60M) and the soluble product being composed of a 2.08 THF:MeLi complex. The remaining MeLi was dissolved with additional THF/toluene solution in order to determine yield (76.6%). In another experiment (see Table I - Exp. No. 2), essentially all io the solid methyllithium was dissolved in a solution of toluene containing two equivalents of THF (MeLi = 1.40M - yield 88.4% - THF/MeLi by NMR - 2.23 mole ratio). This solution remained clear (no pptn.) after 47 days in the refrigerator (0 to 6°C) indicating good solution stability in cold weather. The above MeLi solutions were subjected to thermal stability testing at 0 ° C and room temperature. In a further experiment (see Table I - Exp. No. 3), an attempt to dissolve solid methyllithium with is cyclohexane containing two equivalents of THF resulted in a sparingly soluble product (MeLi = 0.20M - THF/MeLi = 18.5 mole ratio) which precipitated (clear solution = 0.1 3M) overnight in the refrigerator at 0°C. In the final experiment (see Table I - Exp. No. 4) an attempt to dissolve solid methyllithium with toluene containing two equivalents of diethyl ether (Et2 0) also resulted in a slightly soluble product. (MeLi = 0.1 4M - THF/MeLi = 22.2 mole ratio.) 20 The process of preparing methyllithium exemplified in Experiment 2 and detailed in Table I while suitable for laboratory investigations does not appear to be a suitable commercial process because of the cost of n-butyllithium and methyl iodide. The general method of these experiments was to use an argon atmosphere and feed gaseous methyl chloride slowly over one to two hours into a slurry of lithium metal dispersed in an aromatic hydrocar- 25 bon/THF medium maintained at 30 to 35 °C. Rapid addition of methyl chloride (MeCI) can result in coupling (MeLi + MeCI --> Ethane + LiCI) which reduces yield. Also, limiting the THF at the start of reaction and adding the THF incrementally throughout the reaction apparently prevents cleavage of the ether and coupling, resulting in a higher recovered yield. Before filtration the reaction mass was stirred overnight to ensure complete reaction and thus limit occurrence of post-reaction coupling (PRC) after filtration. As noted 30 above, PRC lowers yield and results in ethane gas pressure and a hazy (cloudy) MeLi solution due to the resultant very fine lithium chloride precipitate. Filtration yielded a light yellow solution of MeLhTHF in toluene. The MeLi content of solution was determined by total base and active carbon-lithium analysis and the mole ratio of THF/MeLi by proton NMR. Solutions of methyllithium containing two or less equivalents of THF were found to be stable at room temperature (16 to 22 °C) for at least 30 days and indefinitely stable 35 under mild refrigeration (0 to 6 ° C). At higher temperatures degradation occurs via metallation of toluene to form benzyllithium and methane. The analytical methods are discussed above. The lithium metal used throughout these examples, unless noted otherwise, was a dispersion containing 18.2 weight percent finely divided lithium metal (containing 1.36 weight % sodium based on lithium content) dispersed in mineral oil. A second series of experiments (5 to 11) prepared methyllithium by reacting methyl chloride with 40 lithium dispersion under an argon atmosphere. The following Example 10 (Table II) is exemplary of this series of experiments: Lithium dispersion (59.4 g) was pre-washed in a filter funnel with 100 ml toluene. The wash toluene and oil was removed by filtration and the lithium dispersion slurried with 250 ml toluene. The slurry was transferred to the reaction flask along with 5 ml MeLi in limited THF/toluene (1.55M). The resultant mixture was stirred for 30 minutes in order to condition the surface (increase reactivity) of the 45 lithium particles. Tetrahydrofuran (0.56 moles) was added to the contents of the flask prior to reaction with methyl chloride. An additional 0.28 moles of THF was added after 67% of the methyl chloride had been added. The reaction was initiated by the addition of 1.5 g MeCI. The temperature rose from 22 to 35 °C in eight minutes indicating a rapid initiation. The remaining MeCI (31.5 g) was slowly added over a period of one hour and 50 minutes, while maintaining the reaction temperature between 30 and 35 °C. The reaction 50 mass was allowed to slowly stir overnight. Filtration resulted in a light yellow solution of MeLi (recovered yield = 87.5% based on MeCI used). Analyses: Total Base = 1.55M; Active Lithium (W.E. Titration) = 1.55M; NMR Analysis = 1.65M and 1.36 mole ratio THF/MeLi. 55 The first experiment in this series (see Table II, Exp. No. 5), used an extruded lithium rod (0.7% Na) cut into small 1/4" pieces and slurried with toluene/THF which, when contacted with gaseous MeCI, resulted in a very slow reaction and low yield (34.7%).

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Reactivity was increased by using finely divided lithium dispersion containing 1.36 wt. % sodium; this dispersion was used for the next six experiments (see Exp. 6-11, Table II for details). In another experiment (see Table II, Exp. No. 6), gaseous MeCI was fed to a lithium dispersion slurry in THF/toluene for one hour. The reaction produced a slightly yellow solution of MeLi (1.59M or 4.0 wt. %) in an excellent 87.2% 5 recovered yield. NMR analysis verified the yield and indicated the product to have a 1.73 THF:MeLi mole ratio. The next five experiments involved preliminary reaction variable studies necessary for ascertaining the most efficient way to synthesize MeLi while maintaining a quality product, solubility, and high yields. The most critical yield reducing variable was determined to be the amount of THF present during the reaction (expressed in Table II as THF/MeCI mole ratio). When this mole ratio increased beyond about 1.5, yields of io MeLi dropped drastically and gassing occurred indicating Wurtz coupling. Additional experiments were conducted using various THF/MeCI mole ratios to further study the effect of the THF/MeCI ratio of methyllithium yield. Data from these additional experiments, together with selected data from Table II and from the literature are set forth in Table IX. These data show maximum yield occurs when the Lewis Base (THF) is limited to 1.1 to 1.42 moles of Lewis Base per mole of MeCI. Experiments 8 is and 9 illustrate the detrimental effect of too much THF. Gilman, even at 0°C, got low yields (see Table IX) when reacting methyl-chloride and lithium in THF solvent alone. Experiment 6 was repeated substituting gaseous methyl bromide for methyl chloride (see Table II, Example 12). The reaction of methyl bromide with lithium dispersion in toluene containing a limited amount of THF (THF/MeBr = 1.22 mole ratio), unexpectedly resulted in the formation of a highly soluble 20 MeLh.o* LiBr0.69 complex. After filtration, the solution contained 1.43 moles MeLi and 0.99 moles of LiBr per liter of solution. This sample was subjected to thermal stability testing and was found to be significantly more stable than "halide-free" methyllithium solutions in limited THF/toluene.

THERMAL STABILITY 25 The thermal stability of the methyllithium complexed with various amounts of THF and dissolved in toluene was investigated. The thermal stability of the complexes was monitored by NMR analyses. The modified Watson-Eastham method gave erroneous results on degraded samples but closely agreed with the NMR analyses of non-degraded samples. The thermal stability data in Tables III and IV illustrate the stability of 30 MeLi solutions containing 2 equivalents and 4 equivalents of THF per equivalent of methyllithium in toluene of samples stored at room temperature over a number of days. Atmospheric contamination was likely due to the repetitive sampling of a single container of each solution (Method A). Clearly, limiting the amount of THF has a profound effect on the thermal stability of methyllithium/THF complexes in solution in toluene. Additional thermal stability studies were conducted using multiple sample bottles which were sampled 35 once and discarded (Method B). Samples containing various amounts of THF were prepared according to the procedure of Experiment 6, tested at 40 °C, room temperature and 0°C, and assayed by NMR at various times for methyllithium content (loss). A MeLi:4.26 THF complex degraded very rapidly at 40 °C and at room temperature (see Table VI) losing 93.7 and 71 .9% activity after six and 27 days, respectively. The solutions turned dark red, contained high methane gas pressure, but contained no precipitation, all of which 40 are indicative of toluene metallation. After 28 days at 0°C, the MeLi:4.26 THF was relatively stable showing 4% loss. However, the color of the solution did change from light yellow to orange-yellow, but was clear, again indicating slight metallation. Samples of a MeLi:3.06 THF complex in toluene respectively lost 95 and 35% MeLi after eleven days at 40 ° C and 26 days at room temperature (see Table V). The solutions both turned dark red (metallation), 45 contained methane gas, but no precipitate. After 27 days at 0°C, NMR indicated no loss of MeLi. However, the MeLi:3.06 THF solution had turned orange, contained slight methane gas pressure which may indicate a slight amount of decomposition. Reducing the amount of THF resulted in even slower decomposition (metallation). After 27 days at 40 °C, a MeLi:1.36 THF solution in toluene lost 64.5% MeLi (see Table VII). This solution also turned dark 50 red, contained no precipitate, but heavy methane gas pressure. At room temperature the MeLi:1.36 THF solution remained yellow (no pptn.), contained slight methane gas pressure, and lost only 5.7% methyllithium after 27 days. After 27 days at 0°C this solution (MeLi:1.36 THF) exhibited no loss of MeLi, contained no gas, and remained yellow (see Table VII). The thermal stability data of methyllithium in various Lewis bases and co-solvents and the MeLh.o* LiBr069 complex in limited THF/toluene are summarized in 55 Table XI. The data presented in Table XI demonstrates that "halide-free" methyllithium solutions in toluene are significantly more thermally stable if the THF content is limited to 2 or less moles of THF per mole of methyllithium in solution, preferably 1.2 to 1.5 moles of THF per mole MeLi. (See Experiments 1-A, 1-B, 8,

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9 and 10.) Also, in limited THF/toluene, a methyllithium solution containing 0.69 molar equivalents of lithium bromide (MeLh.o* LiBr069 complex) was, unexpectedly found to be about eight times more stable than the "halide-free" methyllithium experiments shown in Table XI. (See Experiment 12.) Table XI also shows that methyllithium dissolved n limited THF (THF/MeLi = 1.3 to 1.8 mole ratio) and in aromatic solvents having 5 fewer metallable hydrogens than toluene also results in improved thermal stability. Substituting benzene, cumene or ethylbenzene for toluene resulted in improved thermal stability which was about 8, 5 and 3 times, respectively, more stable over the comparable methyllithium solutions in limited THF/toluene (see Table XI, Experiments Nos. 20, 13, 14 and 10).

w SOLUBILITY

Solution stability testing (or product solubility) was done to determine the resistance to product precipitation due to cold weather. Samples of varying methyllithium concentration containing varying amounts of THF were placed in a refrigerator at 3 ± 3°C and visually monitored for product precipitation 75 with time (see Table VIII). All samples tested remained in solution indicating good solution stability including the MeLi sample containing the least amount of THF. (See Table VIII, Experiment No. 10). MeLi was found to have virtually no solubility in hydrocarbon solvents (Table X, Exps. 2-A in toluene and 2-B in n-hexane). The solubility of MeLi in THF alone was not determined because this composition has no commercial value in terms of storage and shipping due to thermal instability (cleavage). Attempts to 20 prepare MeLi in limited diethylether/toluene (Table X, Exp. No. 4), in limited triethylamine (TEA)/toluene (Exp. No. 19-A) and in TEA alone (Exp. No. 19-B) resulted in quite insoluble products. MeLi was also found virtually insoluble in limited t-butylmethylether/toluene (Exp. No. 21 -A) and in t-butylmethylether alone (Exp. No. 21 -B). In limited dimethylether/toluene (Exp. No. 22) MeLi was initially soluble (Total Base = 0.87M), but partially precipitated overnight (Total Base = 0.42M of the clear supernatant solution) as the dietherate. 25 These results virtually eliminate the possibility of achieving solubility in longer chain, less polar dialkylethers or tertiary amines. The necessity for an aromatic solvent in combination with a limited amount of THF for reasonable solubility was demonstrated in Experiment 3 (Table X). Substituting cyclohexane for toluene yields a highly insoluble MeLi complex. Also, employing a mixed aromatic/cyclic hydrocarbon co-solvent (toluene = 2.0 30 eq/MeLi and cyclohexane = 3.0 eq/MeLi) in combination with a limited amount of THF also resulted in low solubility (0.46M - Exp. No. 15). These data strongly indicate that a strong Lewis Base, such as THF, and an aromatic solvent, such as toluene, provide a novel solvent composition for MeLi. Table X also presents solubility data for MeLi in limited THF or 2-methyltetrahydrofuran (MTHF) and other aromatic solvents. Methylchloride and lithium dispersion were employed for these preps and 35 solubilities were purposely exceeded in order to establish limits. In each synthesis more than 7% of the total MeLi formed was left on the filter plate, verifying that the solubility limit was approached. The best solvent combination found for MeLi was limited THF and benzene (Table X, Exp. No. 20) even exceeding the solubility limit of "halide free" MeLi in diethylether alone by about 10%. In substituted aromatic solvents containing limited THF solubility limits decreased according to the size of aliphatic hydrocarbon substituent 40 attached to the benzene ring (benzene > toluene > ethylbenzene > isopropylbenzene > t-butylbenzene). In terms of solubility benzene (Exp. No. 20) and toluene (Exp. No. 10) were determined to be the best aromatic co-solvents for MeLi. Ethylbenzene (Exp. No. 13) and isopropylbenzene (Exp. No. 14) were also acceptable co-solvents for MeLi. t-Butylbenzene (Exp. No. 16) was deemed unacceptable, not only because of low solubility (0.86M), but also because in combination with limited THF a metastable solution was 45 formed which precipitated MeLi when subjected to either cold or hot temperatures. In Table X, Exp. Nos. 17 and 18, demonstrated that a soluble MeLi composition can be generated from methylchloride and lithium in aromatic solvents and a limited amount of Lewis Base similar to, but other than, THF. The fact that 2-methyltetrahydrofuran (MTHF) was alkyl substituted and, thus, slightly less polar than THF was reflected in the solubility data. In limited MTHF/toluene MeLi was determined acceptably 50 soluble (1.37M). MeLi in limited MTHF/isopropylbenzene was found to be not only marginally soluble (1.01M) but also metastable in terms of product precipitation. The above data stress the necessity of an aromatic or substituted aromatic co-solvent to generate a soluble MeLhlimited THF complex. Other Lewis bases similar to THF (MTHF) also solvate, but weaker Lewis bases (Et2 0, TEA, DME, TBME, etc.) in limited amounts with aromatic co-solvents were not effective. 55 Solubility data are summarized in Table X.

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Synthesis of Dimethylmagnesium

Examples 23 & 24

5 Lithium dispersion (0.78 moles dispersed in mineral oil) was washed in a filter funnel twice with -100 ml of toluene. The toluene wash and oil were removed by filtration, and then the fine lithium particles were slurried with 190 ml of toluene. The slurry was transferred to a one liter reaction flask along with 17 ml of methyllithium in THF/cumene (0.02 moles). Next, magnesium metal powder (0.39 moles) was added to the contents of the flask. Residual magnesium on the weighing vessel was washed in with 28 ml of toluene. The io resultant slurry was then stirred for four hours in order to condition (activate) the metals for reaction. Next, THF (0.81 moles) was added and the reaction initiated by the addition of 1 gram of MeCI. The temperature rose from 20 °C to 31 °C in two minutes, indicating rapid initiation. The remaining MeCI (35 g) was added as a gas over a period of 67 minutes. The reaction temperature was controlled (30 ° to 40 ° C) by means of a cooling bath. The reaction temperature began to drop immediately after the halide addition. is Stirring of the reaction mass was continued overnight. NMR analysis of a clear sample taken the next morning indicated no residual MeCI. Filtration yielded 276 ml of a clear, water white, non-viscous clear solution of dimethylmagnesium. Example 23 was repeated to produce a saturated solution of dimethylmagnesium in toluene and labeled Example 24. The preparative and analytical details of Examples 23 and 24 are shown in Table XII and the 20 thermal stability results of Example 24 in Table XIV.

Synthesis of Me2Mg/MeMgCI Compositions

Examples 25 & 26 25 Lithium dispersion (0.52 mole dispersed in mineral oil) was prewashed (twice) in a filter funnel with 100 ml aliquots of toluene. The toluene and oil were removed by filtration, and the lithium reslurried in toluene (190 ml). The lithium slurry was transferred to a one liter reaction flask. Then, magnesium (0.52 mole) and the metal conditioner (0.01 mole Me2Mg in toluene) were added. This mixture was stirred (four hours) in 30 order to condition (activate) the metals prior to initiation. Next, THF (0.84 moles) was added, and the reaction initiated with MeCI (~1 g). The temperature rose from 26° to 39 °C in about four minutes indicating a rapid initiation. The remaining MeCI (34.6 g) was fed continuously over a period of 70 minutes while maintaining the reaction temperature at -35 ° C. The reaction mixture was allowed to stir overnight. Filtration was slow (~ five hours), yielding a clear light yellow solution. Only 179 ml of product solution (60.2% yield) 35 was obtained, indicating insoluble product and/or incomplete filtration. A THF wash (100 ml) resulted in recovery of additional product (83.9% total yield). This experiment was repeated and given number 26. The preparative and analytical details for Examples 25 and 35 are contained in Table XIII. Compositions of this invention also include a monometallic hydrocarbon solvent-Lewis base composition 40 comprising either (1) a monoorganometallic compound of the formula RM in which R is selected from methyl, ethyl and propyl and M the metal is an alkali metal selected from lithium, sodium and potassium or (2) a diorganometallic compound of the formula R1R2M1 in which R1 and R2 are independently selected from methyl, ethyl and propyl and M1 the metal is selected from magnesium, barium, calcium, aluminium and zinc; and (3) a hydrocarbon solvent; (4) 0.05 to 2 mole equivalents of a Lewis Base per mole of 45 organometallic compound; and (5) 1 to 100 mole percent of lithium halide, LiX, based on the organometallic compound. The examples demonstrate a method of preparing a stable methyllithium solution comprising adding a methyl halide to a mixture of lithium metal and an aromatic hydrocarbon containing tetrahydrofuran in an amount not exceeding 2 moles of tetrahydrofuran per mole of methyl halide while maintaining the mixture at 50 a temperature not exceeding 50 °C to thereby react in an inert atmosphere the lithium metal and methyl halide to produce methyllithium and by-product lithium halide.

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