Luis G.
Encarnación-Gómez
,
Andreas S.
Bommarius
and
Ronald W.
Rousseau
*
School of Chemical and Biomolecular Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0100, USA. E-mail: rwr@gatech.edu
First published on 1st March 2016
Seeded reactive crystallization in the manufacture of semi-synthetic β-lactam antibiotics is described and the beneficial effects on yield are discussed. Conventional enzymatic synthesis of β-lactam is limited by secondary hydrolysis reactions that consume the desired product as it is being produced. Recent work in this area has pointed to the potential advantage of performing reactions at conditions that allow product crystallization to reduce the rate of secondary hydrolysis by protecting ampicillin in the solid phase. However, these approaches led to crystallization of both D-phenylglycine and ampicillin, which will greatly increase downstream processing. In the work described here, seeded crystallization is used to promote secondary nucleation of the desired ampicillin while it is being produced by the synthesis reaction, thereby selectively crystallizing ampicillin. Quantification of the solid phase confirmed selective crystallization of ampicillin with purities greater than 95% wt in all runs.
An alternative route for the manufacture of β-lactam antibiotics is the enzymatic synthesis catalyzed by penicillin G acylase (PGA). This enzyme can catalyze the acyl transfer from an activated side-chain donor to the nucleophilic β-lactam to form the desired antibiotic. As for example, enzymatic synthesis of ampicillin can be achieved by reacting 6-aminopenicillanic acid (6-APA) with D-phenylglycine methyl ester (D-PGME) in the presence of PGA. Similarly, other β-lactam products can be synthesized by simply changing the initial reactants.
The overall reaction scheme is presented in Fig. 1, which also shows that in addition to PGA catalyzing the synthesis of ampicillin it also catalyzes the hydrolysis of D-PGME to D-phenylglycine (primary hydrolysis) and the hydrolysis of ampicillin to D-phenylglycine and 6-APA (secondary hydrolysis). In addition, production of the 6-APA starting material can be achieved through hydrolysis of penicillin G by PGA.3
The multiple reaction-engineering strategies that have been used to improve the conversion of 6-APA to ampicillin can be classified into thermodynamically controlled reactions or kinetically controlled reactions. The first relies on optimization of the reaction medium to shift the reversibility of the enzymatic reaction towards the synthesis reaction. Based on the fact that the undesired reaction is an hydrolysis reaction,3–5 used organic co-solvents to shift equilibrium towards synthesis, thereby improving the equilibrium constants, but, unfortunately, reducing the kinetics of reaction drastically. However, the synthesis of ampicillin illustrated in Fig. 1 is kinetically controlled, i.e. an activated carboxylic acid electrophile forms an acyl–enzyme complex before the nucleophile, here 6-APA, replaces the active site serine and forms ampicillin.
Reaction optimization is enabled by acquiring information about the three main reactions: (1) synthesis of ampicillin, (2) primary hydrolysis, and (3) secondary hydrolysis. Significant work has been done in this area, including building kinetic models, optimization of pH and temperature of the reaction, heterogeneous reactions, and complex reactor design.6–9 Among these, reaction with product crystallization seems to be a promising option due to the advantage of obtaining high concentrations of product and its recovery in the solid phase. Several authors have reported the possibility of precipitating ampicillin while it is being produced in solution.9,10 However, ampicillin precipitation was accompanied by precipitation of D-phenylglycine, which has downstream disadvantages: namely, it will be necessary to design a strategy for separation of the two crystallized species.11
In the present work we have developed a reaction–crystallization protocol in which ampicillin is the only product crystallized. To achieve this goal, we have obtained and combined information about solution thermodynamics as well as reaction and crystallization kinetics. The experimental results led to a protocol to ensure high product recovery and purity with a reactive seeded crystallization. In the following sections we demonstrate the process by showing reaction data and the effect on the concentration profile of adding seed crystals to the system.
Calibration curves were obtained at pH values of 6.00 and 7.00 to ensure that the absorbance of the components was independent of pH value. Some peaks split when the pH of solution was changed as charged species had a different retention time than zwitterions; however, charged and neutral species exhibit the same UV absorbance as a function of concentration.
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Fig. 3 Solubility of ampicillin (left axis), D-phenylglycine (left axis), and 6-APA (right axis) as a function of pH at 298 K. Data from Santana et al. 2010. |
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Fig. 4 Synthesis of ampicillin at 25 °C and pH of 7. Initial concentration of 0.20 M 6-APA and 0.10–0.30 M D-PGME. |
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Fig. 5 Accumulation of D-phenylglycine at 25 °C and pH of 7.00. Initial concentration of 0.2 M 6-APA and D-PGME 0.10 to 0.30 M. |
Youshko et al. developed a model that predicts reaction kinetics for this complex reaction.7 The results are shown in eqn (1), which indicates that an increase in D-PGME concentration at constant concentration of [6-APA] will decrease the selectivity of the reaction towards ampicillin (Amp) because a significant amount of substrate is lost through primary hydrolysis.
![]() | (1) |
As observed in Fig. 4, the concentration of ampicillin did not decrease at any point during the runs. This indicates that crystallization did not occur even though supersaturations (S = [Amp]/[Amp*]) in the range of 2 to 5 were reached.
Since product crystallization occurred in none of the previous examples, the initial concentration of 6-APA was raised to 0.50 M and that of D-PGME to 0.75 M. Concentration profiles of ampicillin and D-phenylglycine for subsequent reactions are given in Fig. 6, which shows the concentration of ampicillin reached 0.30 M before showing a slight decrease in concentration, but that D-phenylglycine concentration started to decrease after 100 mM, and crystals were observed in the system after 100 minutes. This means that D-phenylglycine precipitation was taking place. Analysis of the solid phase indicated a purity of only 4.85 wt% ampicillin. Hence, we attribute a significant portion of the decay in ampicillin concentration to secondary hydrolysis because high concentrations of ampicillin favor that reaction. In the next section, we will discuss why ampicillin crystallization was not possible at considerable levels of supersaturation.
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Fig. 6 Concentration profiles of ampicillin and D-phenylglycine, substrate composition 0.50 M 6-APA and 0.75 M D-PGME. |
tind = tN + tG | (2) |
In most cases it is acceptable to assume that nucleation is the limiting step (i.e. tN ≫ tG), so that induction periods can be related to the rate of primary nucleation.
tind = B1−1 | (3) |
![]() | (4) |
Substitution of eqn (4) into eqn (3) leads to an expression that can be used to relate induction time to primary nucleation.
![]() | (5) |
Linearization of eqn (5) yields an expression whose slope represents the exponential primary nucleation constant, B0. This constant controls the onset of primary nucleation and can be used to obtain relationships between supersaturation and induction periods.
![]() | (6) |
More details on induction periods and the physical meaning embodied in the constants can be found elsewhere.16
Ottens et al. reported on induction-time experiments performed to estimate the primary nucleation rate constant B0.17 In a later work by the same group, the effect of multiple impurities on ampicillin crystallization was reported.18 According to their results, reaction substrates and by-products inhibit ampicillin crystallization. This behavior is illustrated for three different initial concentrations of 6-APA in Fig. 7, which shows induction periods as a function of initial supersaturation based on the functional form of eqn (6). Clearly, as 6-APA concentration increases the slope of the semi-logarithmic plot also increases, meaning that a higher supersaturation was necessary to induce nucleation.
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Fig. 7 Log of induction time against log of inverse of initial substrate concentration squared. Data obtained from Ottens et al., 2004. |
The slope of each plot represents the primary nucleation constant B0 for the given 6-APA concentration. As shown in Fig. 8, the slopes follow a linear relationship over the experimental range of 6-APA concentrations.
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Fig. 8 Nucleation rate constant Bo as a function of 6-APA concentration. Data obtained from Ottens et al., 2004. |
For qualitative purposes we extrapolated the nucleation rate constant to higher concentrations of 6-APA (up to 150 mM) to estimate the expected induction time as a function of the concentration of 6-APA. As shown in Fig. 9, 6-APA concentration strongly affects induction periods, which can explain why ampicillin crystallization did not occur in our experiments at a supersaturations of 5. In fact, at the experimental conditions, our calculations show that a supersaturation of approximately 10 is necessary for primary nucleation.
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Fig. 9 Extrapolation of induction time against 6-APA concentration at multiple supersaturation levels. |
Extremely high supersaturations generally are undesirable in crystallization processes because they induce uncontrolled nucleation leading to small crystals and incorporation of impurities. Additionally, as mentioned in the previous section, increasing the concentration of the substrates led to D-phenylglycine precipitation as this by-product has a low solubility. Hence, to reduce the required initial supersaturation for crystallization and thereby improve solid-phase purity, addition of seed crystals was explored and is described in the next section.
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Fig. 10 Generation of ampicillin at 25 °C and pH 7.00. Initial concentration of 0.20 M 6-APA and 0.20 M or 0.30 M D-PGME, and 0.05 g of seed crystals added after 2 hours of starting the reaction. |
In contrast to the results for unseeded crystallization, Fig. 11 shows that the D-phenylglycine concentration profiles for the same experiments increased continuously, suggesting that crystallization of D-phenylglycine did not occur during the process. The data demonstrate one of the potential advantages of seeded reactive crystallization: i.e. the desired product is selectively recovered in the solid phase as it is synthesized and, therefore, subsequent product recovery and purification is not necessary.
The effect of the specific time at which the seed crystals were added was determined by maintaining the amount of seed crystals constant and varying the time at which they were added to the system. Fig. 12 and 13 show the concentration profiles of ampicillin and D-phenylglycine when the seed crystals were added at 30 min, 60 min, and 120 min. Fig. 12 shows that adding seed crystals at 30 min maintained lower ampicillin concentration as ampicillin crystallization was promoted earlier in the process. Fig. 13 shows there was an insignificant effect on the concentration of D-phenylglycine, providing further evidence that the seed crystals promoted only secondary nucleation of ampicillin.
Fig. 14 shows the effects of adding different amounts of seed crystals to the reaction system after 2 hours of operation. Consistent with expectations, larger amounts of seed crystals enhanced crystallization rates and maintained lower concentrations of ampicillin in solution. While the addition of ampicillin seed crystal had an impact on the way ampicillin concentration evolved during the reaction, Fig. 15 shows that the crystallization resulting from addition of seed crystals also reduced the production of D-phenylglycine. Such behavior is consistent with a reduction in secondary hydrolysis.
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Fig. 14 Concentration of ampicillin in solution at 25 °C and pH 7.00. Initial concentrations of 0.200 M 6-APA and 0.30 M D-PGME using 0.01 g, 0.05 g, and 0.10 g of seed crystals. |
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Fig. 15 Generation of D-phenylglycine at 25 °C and pH 7.00. Initial concentrations of 0.200 M 6-APA and 0.30 M D-PGME using 0.01 g, 0.05 g, and 0.10 g of seed crystals. |
The solutions described in the preceding runs were filtered after 6 h of run time to recover product crystals, which were then dried at room temperature and their purity determined through HPLC analysis. The results in Table 1 show that greater than 90% purity and in most cases greater than 99% purity was obtained from runs in which seed crystals were employed. In fact, the mole fractions of D-phenylglycine in the solid phase were similar to those of 6-APA and D-PGME, which implies that the impurities in the solid phase resulted from entrapment or adherence of the filtered solution to the recovered crystals. It is worth noting that the recovered crystals were not washed, which undoubtedly would have increased their purity still further.
Run | [6-APA]0 (M) | [D-PGME]0 (M) | Seed mass (mg) | Seeding time (min) | Crystal purity (wt%) |
---|---|---|---|---|---|
1 | 0.20 | 0.30 | 0.00 | — | — |
2 | 0.20 | 0.30 | 50.0 | 30 | 98.4 |
3 | 0.20 | 0.30 | 50.0 | 60 | 99.1 |
4 | 0.20 | 0.30 | 10.0 | 120 | 99.4 |
5 | 0.20 | 0.30 | 50.0 | 120 | 95.2 |
6 | 0.20 | 0.30 | 100.0 | 120 | 92.3 |
7 | 0.20 | 0.20 | 50.0 | 120 | 99.8 |
8 | 0.50 | 0.75 | 0.00 | — | 4.85 |
The previous experiments were performed with a total volume of 5 mL. Additionally, during the experiments aliquots of approximately 0.5 mL were withdrawn every time a sample was prepared, meaning roughly 60% of the material was lost through sampling. This does not consider all the material lost during transferring and filtration; thus, the total material recovered is certainly less than that produced by the process. Hence, the total amount of crystalline product was approximated from the following equation:
Crystal mass = ([Amp]Run 1 − [Amp])·V·MWAmp | (7) |
The equation assumes that the concentration at the end of run would correspond to that exhibited by unseeded Run 1. We then attribute differences in concentration between Run 1 and subsequent runs to crystallization of ampicillin, leading to the results in Table 2 for generated crystal mass after 6 h or reaction and crystallization. Typical progress of two runs is shown in Fig. 16 as the initially clear solutions progressed to cloudy mixtures after addition of seed crystals and then to nearly completely white as the population of ampicillin crystals increased.
Run | [6-APA]0 (M) | [D-PGME]0 (M) | Crystals mass (mg) |
---|---|---|---|
1 | 0.20 | 0.30 | 0.0 |
2 | 0.20 | 0.30 | 84.7 |
3 | 0.20 | 0.30 | 75.3 |
4 | 0.20 | 0.30 | 34.3 |
5 | 0.20 | 0.30 | 67.7 |
6 | 0.20 | 0.30 | 72.73 |
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Fig. 16 Reactive-crystallization Runs 4 and 5 when reaction started (left), after seeding (center), and after 6 hours (right). |
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Fig. 17 Reactive crystallization scaled-up to 250 mL (6-APA 0.20 M, D-PGME 0.30 M, 25 °C, and pH 7.00). |
Fig. 18 and 19 show FBRM data for the run described in the preceding paragraph. The increase in chord counts at around 200 minutes in Fig. 18 is thought to result from secondary nucleation, which is consistent with the nearly simultaneous decrease in ampicillin concentration shown in Fig. 18. Additionally, we note that 30 to 60 minutes after such nucleation, the number of small crystals (assumed to be characterized by chord lengths of 0 to 50 μm) started to decay while the number of larger crystals (chord lengths 50 to 300 μm) continued to increase. We hypothesize that after nucleation a depletion of supersaturation is caused predominantly by crystal growth rate rather than additional nucleation. Evolution of the chord length distributions, as shown in Fig. 19, is thought to reflect growth of ampicillin crystals.
Finally, 8.5 g of crystals were obtained from the run by filtration and drying process similar to that followed in earlier experiments. The recovered mass included 2.5 g of seed crystals, so that 6.0 g of ampicillin were produced in the process representing a total yield of 67% ampicillin, based on the 6-APA fed to the reactor. Additionally, crystal purity was determined by HPLC to be 99.05 wt% ampicillin. Even with the care taken, we recognize that ampicillin yield is likely to be slightly higher as some material was lost during downstream processing and unrecoverable material remaining in the reactor.
Moreover, as do other reactive crystallization processes, the operation shown in this work has the advantage of reducing the rates of secondary hydrolysis because ampicillin is protected from the enzyme whenever it is in the solid phase. We also showed that primary hydrolysis could be reduced by adjusting the ratio of substrates fed to the reactor.
[Amp] | Ampicillin concentration (mM) |
[PG] | D-Phenylglycine concentration (mM) |
[PGME] | D-Phenylglycine methyl ester concentration (mM) |
[APA] | 6-Aminopenicillanic acid concentration (mM) |
t ind | Induction period (s) |
t N | Induction period (s) |
t G | Growth period (s) |
B o | Primary nucleation exponential constant |
B 1 | Rate of primary nucleation (# per s m3) |
k B 1 | Primary nucleation constant (# per s m3) |
S o | Initial supersaturation (mM mM−1) |
α | Synthesis vs. hydrolysis kinetic constant (dimensionless) |
β 0 | Synthesis vs. hydrolysis kinetic saturation constant (M−1) |
γ | Synthesis vs. hydrolysis kinetic constant (dimensionless) |
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