Herein, we describe the development of two continuous
manufacturing
processes for the synthesis of 6-chloro-1H-pyrazolo[3,4-b]pyrazine, which is a key intermediate en route to the
SHP2 inhibitor GDC-1971 (migoprotafib). The reaction sequence starts with a plug-flow metalation/formylation
of readily available 2,6-dichloropyrazine using i-Pr2NMgCl·LiCl (MgDA) as the base, whereupon the
resulting unstable heteroaryl aldehyde intermediate is isolated as
its easier-to-handle and bench-stable bisulfite adduct. The ensuing
cyclization step to the pyrazolopyrazine product necessitates the
use of excess amounts of hydrazine reagent, and involves the accumulation
of highly energetic, nitrogen-rich intermediates. A continuous stirred-tank
reactor (CSTR) process was engineered to address the associated safety
concerns while accommodating for the heterogeneity of the reaction
mixture. These two safe and robust continuous processes have been
demonstrated on multikilogram scale, and serve as enabling contributions
toward large-scale manufacturing of GDC-1971.