An optimized route to an iodo-imidazole intermediate in the synthesis of 4-ethynyl-2,5-dimethyl-1-aryl-1H-imidazoles (6) was devised. Important data for the optimization work was obtained by carrying out a DOE study to gain understanding of the parameters that affect the key intramolecular cyclization to build the imidazole ring. Additional information on the reaction mechanism of this step was obtained by carrying out a flow NMR experiment. In order to complete the proof of concept, the iodo-imidazole intermediate was converted to two ethynyl imidazoles (6a, b) using metal-catalyzed reactions.

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An exothermic decomposition was observed during a metalation/acylation of 3,4-difluoroanisole (5), resulting in a significant thermal hazard. The lithiated anion 6 was found to decompose exothermically at temperatures above −47 °C showing an adiabatic temperature rise at a peak rate of 120 °C/min. A literature search revealed similar observations for metalation/acylation in analogous aromatic difluoro compounds. This sequence of reactions was evaluated thermochemically. Control experiments at −55 °C over 2 h indicated anion 6 was stable at temperatures below −55 °C under dilute reaction concentrations. This runaway hazard could be addressed using MgCl2 to stabilize the reactive species and thereby decrease its decomposition rate. Thermochemical experiments suggested MgCl2 forms a weak interaction with lithiated species 6, rather than via complete lithium−magnesium exchange. The process was successfully piloted on a multikilo scale by use of MgCl2 as an additive.