Manufacturing Process Development for Belzutifan, Part 6: Ensuring Scalability for a Deoxyfluorination Reaction

The development of a regio- and stereoselective deoxyfluorination process for the manufacture of belzutifan (MK-6482) was challenging because of a combination of particular reaction and engineering sensitivities. These aspects were addressed through a series of mechanistic, range-finding, and mixing studies that enabled a robust process to be established. In particular, mixing studies led to the discovery of a second phase of perfluoro-1-butanesulfonyl fluoride in the reaction at cryogenic temperature, requiring the liquid–liquid dispersion to be controlled sufficiently to minimize the formation of side products. The changes implemented as a result of these investigations culminated in a process executed successfully on the pilot and commercial scales.