Pyridone 1, a key intermediate in the preparation
of ERK inhibitor GDC-0994, was synthesized via a cross-coupling/hydrolysis
sequence from commercially available starting materials. C–C
bond formation was achieved via an efficient palladium catalyzed Kumada–Corriu
cross-coupling reaction. However, the 4-pyridylmagnesium halide reagent
generated in situ was found to be unstable at the
reaction temperature, leading to inconsistent results on scale. In
order to address process robustness issues associated with the cross-coupling
reaction, we investigated both flow chemistry and a low temperature
Kumada–Corriu coupling reaction. Finally, a basic hydrolysis
process of 2-fluoropyridine was developed to avoid formation of toxic
and corrosive hydrofluoric acid, resulting in a safe and scalable
process toward 1.