Process development for electrocarboxylationof 2-acetyl-6-methoxynaphthalene

Electrochemical carboxylation of 2-acetyl-6-methoxynaphthalene to 2-hydroxy-2-(6-methoxy-2-naphthyl)propionic acid may be carried out in good yield (∼89% in the electrolysis; 75% as isolated dried product) in an undivided flow cell using lead as the cathode and aluminium as the dissolving anode. Dimethylformamide was found to be the best solvent for the reaction and low cost tetraethylammonium chloride hydrate is a good electrolyte for the system. The best conditions are those that increase carbon dioxide concentration although higher pressure seems to be more effective than low temperature. The reaction may be carried out with good yield at fairly high current density (1150Am−1) and higher current densities are likely attainable. The allowable payload is limited to around 10% because higher payloads (20%) resulted in solution too viscous to pump. Initially it was surmised that trace quantities of water would be detrimental to good yields in these reactions. However, it was found that small amounts of water (that associated with typical quaternary ammonium chloride salts) has the beneficial effect of eliminating the major byproduct which is formed in more nearly anhydrous solutions without resulting in formation of alternative byproducts. Process conditions were evaluated at 0.2L scale, then scaled up to 1L and finally 75L. The best results were attained in the 1L system, solvable operating problems limited the yield in the largest scale electrolysis.