Continuous
flow processing presents a solution for the safe and
effective formation of 1,5-tetrazoles due to the small reactive inventory
and absence of a reactor headspace. This has been exemplified using
a model amide, 2-chloro-N-methylacetamide, activated
using POCl3 to its corresponding imidoyl chloride, which
reacts with trimethylsilyl azide. Initial scoping revealed that an
excess of azide is vital to facilitate a clean reaction but also that
a high concentration would dramatically accelerate the reaction without
the need for greatly elevated temperature. In a short residence time
of 10 min, complete conversion was achieved, resulting in 77–86%
yield of the desired product in high purity (>99.7%) after recrystallization,
omitting any chromatographic purification. The developed process reached
an excellent space–time yield (1.16 kg L–1 h–1) due to its high concentration and short residence
time. Successful technology transfer included development of a continuous
workup, with pH-controlled quench in a CSTR, followed by extraction.
During flow optimization, two orthogonal PAT methods were separately
employed, NMR and FTIR, enabling real-time starting material and product
quantification. Finally, the developed reaction protocol was demonstrated
on a number of other substrates, achieving high yields in most cases,
up to quantitative.