WO2007039287A1

WO2007039287A1 - PROCESS FOR THE SYNTHESIS OF HMG-CoA REDUCTASE INHIBITORS

Info

Publication number: WO2007039287A1
Application number: PCT/EP2006/009599
Authority: WO
Inventors: Zdenko Casar
Original assignee: Lek Pharmaceuticals dd
Current assignee: Lek Pharmaceuticals dd
Priority date: 2005-10-05
Filing date: 2006-10-04
Publication date: 2007-04-12
Anticipated expiration: 2008-04-05
Also published as: SI1937696T1; CN101277966A; BRPI0616977A2; AU2006299018B2; US8269001B2; EP1937696B1; EP2341054A1; EP1937696A1; EA014449B1; EP2341054B1; EP1775299A1; JP5150501B2; US20080300406A1; SI2341054T1; AU2006299018A1; JP2009510151A; EA200800916A1; CN101277966B; CA2624471C; CA2624471A1

Abstract

A novel synthesis of statins uses Wittig reaction of a heterocyclic core of statin with a lactonized side chain already possessing needed stereochemistry. Any separation of diastereoisomers is preformed early in the course of synthesis.

Description

Process for the Synthesis of HMG-CoA Reductase inhibitors

Field of the Invention

The present invention relates to a process for the preparation of HMG-CoA reductase inhibitors, known also as statins, particularly to rosuvastatin. Specifically this invention relates to common intermediates which can be used for preparation of all statins.

Background of the Invention

It is believed that the prerequisite for the biological activity of statins, of which the representative examples may be selected from rosuvastatin, cerivastatin, atorvastatin, fluvastatin, pravastatin, bervastatin or their analogs or pravastatin, simvastatin, lovastatin or their analogs, is their structure, consisting of respectively a heptenoic or heptanoic acid moiety (free acid, salt or lactone) connected to the aromatic core and especially their stereochemistry, especially configuration at the chiral atoms as depicted in following formula of their representative example rosuvastatin anion:

Synthetic approaches to statins are for example known from US 4625039 and WO 05/047276. Description of the invention

In this invention a novel synthesis of statins is proposed wherein one center of chirality is present already in the readily available starting compound while the other is introduced early in the course of synthesis. We have thus developed a highly controlled process where the moiety IX possessing the desired stereochemistry:

, where R₁ is a protecting group; is reacted with an appropriate phosphonium salt or phosphite of the skeleton of statin. It was important to synthesize this moiety from an (S) precursor in a stereoselective manner. This was achieved by reaction via new intermediate VII:

where R₄ is an (optionally substituted) alkyl. So the only enantiomer separation step takes place when separating compounds:

and , where X" is halo or alkyl- or arylsulfonyl; which is early in the course of synthesis. Furthermore we have been directing the synthesis of those precursor compounds in a manner to give high yield of the desired (4f?,6S)-diastereoisomer.

The general synthetic route is depicted in following Scheme 1 and the specific example using silyl protection and exemplified on the synthesis of rosuvastatin Ca in Scheme 2.

II III

VTb

VII VIII IX

XI

Scheme 1

MgCI

=/ /CuI THF, -35°C (EtO)₃P/DMPU

6a 6b

993 % d e

6a

U 10 Scheme 2

In accordance with our invention we react a compound IX:

(where Ri is a protecting group) under condition of Wittig coupling with a heterocylic derivatives of following formula:

O

PAR_xAR_y

where A can be a bond or O and wherein R_x, R_y, and R₂, are the same or different and are selected from optionally substituted Ci - C₈ alkyl or C₃-C₆ cycloalkyl or Ci - C₈ alkenyl or C₅-C₆ cycloalkenyl or aryl and X is an anion, preferably halogen or RCOO^" anion, more preferably chloro, bromo or trifluoroacetate; and Het is selected so that it forms a heterocyclic skeleton of a statin, and is preferably selected from:

whereupon after the workup, which comprises removal of the protecting group and optional hydrolysis of the lactone and conversion into free acid or salt thereof, and may comprise before hydrolysis (if needed) introduction of hydrogen atoms to a double bond, the rosuvastatin, cerivastatin, fluvastatin, pravastatin, bervastatin, atorvastatin or their analogs or salt thereof are formed.

The intermediate compound IX is the same regardless which statin is being prepared. It is peculiar that this compound may exist in two tautomeric forms:

of which later does not undergo Wittig reaction thus diminishing yield and/or increasing side products. In non-polar solvents in equilibrium we can observe only one form of IX which corresponds to an aldehyde. The forms may be observed in different solvent system using ¹³C NMR by carefully examining spectra between 150 in 110 ppm for olefine signals. Moreover, only keto form is present after conditioning (letting dissolved for up to 1 week) of the solid IX in toluene, chloroform or dichloromethane or hexane, preferably toluene, which is therefore also preferred and advantageous solvent for Wittig reaction.

Moreover the compound IX is also prone to hydration into its hydrate,

which is also not suitable for Wittig reaction. We have studied the aldehyde-hydrate equilibrium in order to increase the yield of Wittig reaction. Studying this reaction we discovered that toluene is a solvent which significantly increases the yield compared to THF, where equilibrium forms at around half of the compound as aldehyde and half as hydrate, thus THF, which is commonly used as the solvent for Wittig reaction is not suitable and we have discovered that in chlorinated solvents such as (chloroform, dichloromethane) hexane and preferably toluene the equilibrium is shifted towards aldehyde.

The invention provides a simple process for preparation of in intermediate IX from IVa, which is in turn prepared in only 5 steps from commercially available (S)-ethyl-3- hydroxy-4-chloro butyrate. Specifically (4R,6S)-4-(teAf-butyldimethylsilyloxy)-6- (iodomethyl)-tetrahydropyran-2-one (6a) with overall yield 23-31% of the desired stereoisomer, which is considerably higher than the known methods.

The intermediate compound IX used in the process of our invention is prepared from compound Via (4f?,6S)-4-(protected hydroxy)-6-(halomethyl)-tetrahydropyran-2-one or its derivative (X" = alkylsulfonyl or arylsulfonyl) by converting via compound of Formula VII (an ester such as pivaloate, chloroacetate, dichloroacetate, trichloroacetate, trifluoroacetate, methoxyacetate, triphenylmethoxyacetate, phenoxyacetate and its derivatives, phenylacetate and its derivatives, diphenylacetate, 3-phenylpropionate, pentenoate, 4-oxopentanoate, pentenoate, preferably acetate) into compound of Formula VIII₁ and oxidizing into compound of Formula IX.

This conversion into compound VII, where R4 is an optionally substituted alkyl is necessary because the attempted direct conversion of halo derivative into hydroxyl derivative either yielded only degradation products or caused the opening of lactone ring.

The needed stereochemistry is achieved in the last step of synthesis of intermediate compound Vl, which is prepared by halogen-mediated cyclization of compound V using molecular halogens such as iodine, bromine or chlorine as a source of halogen electrophiles. Alternative sources of halogens can also be applied for this reaction. Most commonly used are alkali or earth alkali halides or oxohalides such as Kl, Kl₃, Ca(OCI)₂, interhalogens such as iodine monochloride (1-Cl), iodine monobromide (I- Br) which have higher reactivity than elemental iodine and halogen(l) reagents such as iodonium acetate (1-OAc), N-iodosuccinimide (NIS), N-bromosuccinimide (NBS), bispyridine iodonium tetrafluoroborate (Py₂IBF₄). Hypervalent halogen electrophiles such as diacetoxy iodobenzene, bis(trifluoroacetoxy) iodobenzene, hydroxy(tosyloxy) iodobenzene (Koser's reagent) are also applicable for halocyclization reaction. However, molecular iodine is preferably used for conversion of V into mixture of (R₁S) and (f?,R)-diastereoisomers of lactone Via and VIb. Conveniently the reaction is performed in such matter that (f?,S)-diastereoisomer is formed in excess of (R,R)- diastereoisomer and if desired the (f?,S)-diastereoisomer is separated from the mixture giving optically pure compound Via. X" can be further substituted so that X" is thus a suitable substituent, preferably halo, cyano, alkylsulfonyl or arylsulfonyl, most preferably iodo.

Compound V can be prepared from compound of formula III by reaction with an appropriate Grignard reagent (vinyl magnesium halide)

MgX^*

where X' is a halogen, preferably chloride preferably in the presence of ortophosphite derivative and copper(l) halide, giving compound of formula IV which is hydrolyzed into compound of Formula V.

A suitable starting compound for an overall synthesis is an alkyl 3(S)-hydroxy-4- chlorobutyrate I wherein R₂ is preferably Ci - C₈ alkyl or C₅ - C₇ cycloalkyl which may be optionally substituted, preferably by an alkyl or aryl, alternatively a starting compound may be a derivative of I, wherein for example -COOR₂ may also be an amide of formula -CONR₃Rb, where R₃ and R_b may independently be H, an optionally substituted Ci - C₈ alkyl or C₅ - C₇ cycloalkyl, aryl or can together with N form a heterocycle. Substituted in this specification means that the substituted moiety bears one or more substituents, which are preferably selected from acyl, alkyl, alkenyl, cycloalkyl, cycloalkenyl, aryl, heteroaryl, halo, nitro, amino, alkoxy. Unless otherwise stated alkyl and aryl in this specification will preferably mean alkyl having up to 12 carbon atoms, preferably having 1 , 2, 3, 4, 5, 6 or 7 carbon atoms and aryl having up to 3 condensated aromatic rings, which may contain one or more heteroatoms, more preferably a phenyl which may be additionally substituted.

I

However any halo derivative or similar compound may be used. It is preferred to use iodo derivative or that said compound is converted to its iodo derivative of Formula II, where X is I and R₂ as defined above.

In subsequent step OH group of compound of Formual Il is protected by any suitable protecting agent giving compound of Formula III where Ri is suitable protecting group, preferably silyl, more preferably Ci - C₈ trialkylsilyl, Ci - Ce dialkylarylsilyl, Ci - C₈ alkyldiarylsilyl, where alkyls may be same or different, preferably aryl is phenyl and alkyls have 1 to 4 C atoms.

The process as described above provides statins selected from the group comprising rosuvastatin, cerivastatin, fluvastatin, pitavastatin, bervastatin, atorvastatin or analogs thereof which may be incorporated into pharmaceutical composition. Those statins are advantageous to those produced in alternative processes where the separation of stereoisomers is achived in later stages. It is known that stereoisomers are hard to remove, however purification processes following the early separation of compound Via and VIb still provide chance to remove part of the undesired stereoisomers. Thus the patients being administered said compositions will achieve lower loading of undesired stereoisomers r which causes reduced level of side effects In one embodiment of the invention a compound (4R,6S)-4-(tert- butyldimethylsilyloxy)-6-(iodomethyl)-tetrahydropyran-2-one (6a) corresponding to general formula Via where R₁ is tert-butyldimethylsilyl is prepared and converted into suitable precursor for a statin. For example (6a) may be converted to (2S,4/?)-4-(te/f- butyldimethylsilyloxy)-6-oxo-tetrahydro-2H-pyran-2-carbaldehyde (9) corresponding to general formula IX where Ri is te/t-butyldimethylsilyl, which can be further coupled to appropriate heterocyclic system, in the specific embodiment pyrimidine system, whereupon after the removal of protecting group and lactone ring opening and conversion into salt, in the specific embodiment rosuvastatin is formed.

One way to prepare (6a) is known from J. Chem. Soc, Perkin Trans. 1, 1991 , 133- 140 starting from methyl 2-cyanoacetate. Chloro analogue (compound of formula Via where X" is Cl) can be made enzymaticaly. 3(f?)-(tert-butyldimethylsilyloxy)-5- hexenoate (4) as described in J. Antibiot. 2002, 55, 147-154, can be converted to (f?)-3-(terf-butyldimethylsilyloxy)-5-hexenoic acid (5) according to Tetrahedron Lett. (43) 2002, 4381-4384.

In the first synthetic step (S)-ethyl 3-hydroxy-4-iodobutyrate (2) is prepared from ethyl 3(S)-hydroxy-chlorobutyrate (1) by reaction with NaI. Suitable solvents are selected from amides, preferably selected from: Λ/,Λ/-dimethylformamide - (DMF)₁ N,N- dimetylacetamide (DMA), hexamethylphosphortriamide - (HMPTA); N- methylpyrrolidone (NMP); /V,/V'-dimethylpropyleneurea (DMPU); Λ/.Λ/./V.Λ/¹- tetramethylurea (TMU); dimethylsulfoxide (DMSO); acetonitrile; lower alcohols; ketones, preferably acetone. The reaction can be performed at temperatures between 58 ⁰C to 90 ⁰C. Preferably at 60 ⁰C and is accomplished in period from half a day up to more days, preferably in 41 hours (at 90 ⁰C) to 120 hours (at 60 ⁰C).

In second step a protecting group is introduced, thus (S)-ethyl 3-(tert- butyldimethylsilyloxy)-4-iodobutyrate (3) is prepared from ethyl 3(S)-hydroxy-4- iodobutyrate and terf-butyl(chloro)dimethylsilane (TBSCI). The molar amount of later may be less than 1 ,5 mol per mol of butyrate. The reaction is conveniently done in presence of a base, selected from amines, imidazoles and pyridines, preferably imidazole in solvents such as amides (DMF, DMA, HMPTA, NMP, DMPU, TMU), DMSO, nitriles (acetonitrile), chlorinated hydrocarbons (dichloromethane, chloroform), aromatic hydrocarbons (toluene), preferably in DMF. The reaction can be performed at temperatures between 0 ⁰C to 10 ⁰C and it is preferably performed in presence of NaI. Preferably at 0 ⁰C. The reaction is accomplished in period from one hour up to a day, preferably in 12 to 17 hours.

In the third step ethyl 3(/?)-(ferf-butyldimethylsilyloxy)-5-hexenoate (4) is prepared from vinylmagnesium halide and (S)-ethyl 3-(terf-butyldimethylsilyloxy)-4- iodobutyrate, solvents such as amides (DMF, DMA, HMPTA, NMP, DMPU, TMU) or DMSO are used, preferably Λ/,Λ/'-dimethylpropyleneurea (DMPU) preferably in presence of copper halide, preferably CuI and ortophosphite derivative with formula,

where each of R', R", and R'" are same or different CrC₄ alkyl, C₅-C₇ cycloalkyl, or aryl which may be optionally substituted, preferably Ci-C₄ alkyl, phenyl, benzyl, most preferably P(OEt)₃. The reaction can be performed at temperatures between -45 ⁰C to -25 ⁰C. Preferably at -40 ⁰C. The reaction can be performed with vinylmagnesium chloride, bromide or iodide, preferably with vinylmagnesium chloride. The reaction is accomplished within up to a day, preferably within 3 hours to 5 hours whereupon it is quenched by addition of saturated aqueous NH₄CI solution at -10 ^CC to 0 ⁰C. The crude product is extracted with a water immiscible solvent and the organic solution is washed with diluted acids such as H₂SO₄, HCI, H₃PO₄ etc.

In each of those three steps the products are conveniently isolated by extraction with water immiscible solvents like ethers such as: Et₂O (diethyl ether), /-Pr₂O (diisopropyl ether), J-BuMeO (terf-butylmethyl ether) or alkanes such as: pentane, hexane, heptane or chlorinated hydrocarbons such as methylene chloride, preferably with t- BuMeO. Product can be purified by vacuum distillation at suitable temperature (i.e. 70 - 90 ⁰C for first step, 70 - 95 ⁰C for second step, and 55 - 80 °C for third step) and 0.100 - 0.500 mbar. In fourth step until now not yet isolated compound (R)-3-(terf-butyldimethylsilyloxy)-5- hexenoic acid (5) is prepared by hydrolysis of ethyl 3(R)-(te/f-butyldimethylsilyloxy)-5- hexenoate with an alkali in a solvent such as MeOH. The reaction can be performed at temperatures between 0 ⁰C to 80 ⁰C. Preferably at 40 ⁰C. The reaction can be performed in alcohols, THF, amide solvents or a mixture of these solvents with water. Preferably in alcohols. The reaction is accomplished in matter of minutes or hours, preferably in 0.5 hours to 3 hours. The hydrolysis of the ester can be performed with NaOH, KOH, LiOH, CsOH, Ca(OH)₂ or Ba(OH)₂ as a base. Preferably with KOH. Following the hydrolysis acidification to pH 2 can be performed with diluted acids such as: HCI, H₂SO₄, H₃PO₄ etc. Preferably with HCI. Again extraction with ethers and alkanes as described above, preferably with f-BuMeO, is a feasible isolation method.

In the fifth step the (R)-3-(terf-butyldimethylsιϊyloxy)-5-hexenoic acid (5) is converted by iodine to a mixture of (4f?,6S)-4-(terf-butyldimethylsilyloxy)-6-(iodomethyl)- tetrahydropyran-2-one and (4f?,6f?)-4-(teAf-butyl-dimethyl-silyloxy)-6-(iodomethyl)- tetrahydropyran-2-one (6a and 6b) as pale yellow solid. This solid is recrystallized preferably several times from n-pentane to afford {4R,6S)-4-(tert- butyldimethylsilyloxy)-6-(iodomethyl)-tetrahydropyran-2-one (d.e. 99.3 %) (6a) as colourless needles in 43 % yield. This simple step introduces the needed chirality into molecules. The reaction can be performed at temperatures between -10 ⁰C to 10 ⁰C. Preferably at 0 ⁰C. Again extraction with ethers and alkanes as above, preferably with f-BuMeO may be used. The optically pure compound (4R,6S)-4-(tert- butyldimethylsilyloxy)-6-(iodomethyl)-tetrahydropyran-2-one can be isolated by industrial scale HPLC.

Diastereoisomeres (in particular embodiment starting with ration 6a : 6b = 4:1) can be separated at room temperature on normal phase silica column (PHENOMENEX 4.6x150 mm, d_p = 5 μm) using different compositions of hexane and /-BuMeO as a mobile phase. Optically pure compound will mean diastereoisomeric excess (d.e.) above 96 %, preferably above 99 %, more preferably above 99.7 % (d.e. 99 % will mean 99.5 %/0.5 % ratio) as determined by HPLC.

The optically pure compound (4f?,6S)-4-(te/f-butyldimethylsilyloxy)-6-(iodomethyl)- tetrahydropyran-2-one is also alternatively prepared from (4R,6S)-4-(tert- butyldimethylsilyloxy)-6-(chloromethyl)-tetrahydropyran-2-one (Via, X"=CI) which can be obtained from unprotected (4R,6S)-6-(chloromethyl)-4-hydroxy-tetrahydropyran-2- one. (4ft,6S)-6-(Chloromethyl)-4-hydroxy-tetrahydropyran-2-one can be prepared enzymaticly by one-pot tandem aldol reaction catalyzed by a deoxyribose-5- phosphate aldolase (DERA) followed by chemical oxidation step as described in Proc. Natl. Acad. Sci. USA 2004, 101, 5788 - 5793. Analogous procedure can be applied if R₁ is a protecting group different from exemplified terf-butyldimethylsilyl.

In sixth reaction step ((2S,4/?)-4-(fert-butyldimethylsilyloxy)-6-oxo-tetrahydro-2H- pyran-2-yl)methyl acetate (7) is prepared from (4fi,6S)-4-(te/f-butyldimethylsιϊyloxy)- 6-(iodomethyl)-tetrahydropyran-2-one. The reaction can be performed at temperatures between 0 ⁰C to 130 ⁰C. Preferably at 120 ⁰C. The reaction can be performed in amide solvents selected from Λ/,Λ/-dimethylformamide (DMF), N₁N- dimetylacetamide (DMA), Λ/-methylpyrrolidone (NMP), Λ/./V-dimethylpropyleneurea (DMPU) or hexamethylphosphortriamide (HMPA); dimethylsulfoxide (DMSO) or acetic acid (AcOH). Preferably in AcOH. The reaction is accomplished in up to one day, preferably in 1 hour to 17 hours. The acylation (iodine substitution) can be performed with an acylating reagent selected from the group consisting of NaOAc, KOAc, LiOAc₁ CsOAc, AgOAc₁ CuOAc₁ Ca(OAc)₂, Mg(OAc)₂ or R₄NOAc as a nucleophilic reagent. Preferably with LiOAc or AgOAc. Isolation of the crude product with extraction can be preformed with AcOEt₁ ethers and alkanes as above, preferably with f-BuMeO.

In seventh reaction step ((2S,4f?)-4-(terf-butyldimethylsilyloxy)-6-oxo-tetrahydro-2/-/- pyran-2-yl)methyl acetate (7) is deacylated to (4R,6S)-4-(terf-butyldimethylsilyloxy)-6- (hydroxymethyl)-tetrahydropyran-2-one (8). Reaction may proceed with alkali hydroxides, but the most selective reagent is preferred. Deacylation can be performed also with enzymes: Porcine Pancreatic Lipase, Lipase MY₁ Lipase PS, Lipase Al, Candida Lipase and Alcalase, or reagents selected from group consisting of guanidine and guanidine/guanidinium nitrate, HBF₄*Et₂O/MeOH and BF₃ ^χEt₂0/MeCN, DBU/MeOH, hydrazine/MeOH and hydrazine hydrate/THF, cyanide/MeOH, l₂/Me0H or tin catalysts like dialkylchlorostanyl hydroxide dimers such as [NBu₂SnOH(CI)J₂. Dialkylchlorostanyl hydroxide dimers are preferred and [t- Bu₂SnOH(CI)J₂ is most prefered. The reaction using [f-Bu₂Sn0H(CI)]₂ can be performed at temperatures between 0 ⁰C to 40 ⁰C. Preferably at 25 ⁰C. The reaction can be performed in alcohols such as: MeOH, EtOH, /-PrOH or in mixtures of these alcohols with ethers such as: THF, Et₂O, /-Pr₂O, f-BuMeO. The 5-15 mol % of tin catalyst can be used for the deacetylation reaction. The reaction is accomplished in up to one day, preferably 4 - 17 hours. Isolation of the product can be preformed with crystallization. For this purpose alkanes or ethers as above, preferably hexane, may be used.

In eighth reaction step (2S,4f?)-4-(te/f-butyldimethylsilyloxy)-6-oxo-tetrahydro-2H- pyran-2-carbaldehyde (9) is formed from (4/?,6S)-4-(terf-butyldimethylsilyloxy)-6- (hydroxymethyl)-tetrahydropyran-2-one (8) by a suitable oxidation such as dimethylsulfoxide-mediated oxidations (Swern oxidation: DMSO-(COCI)₂ couple, Pfitzner-Moffatt procedure: DMSO-dicyclohexylcarbodiimide (DCC) couple, Parikh- Doering procedure: DMSO-SO₃*Py couple), Λ/-oxoammonium-mediated oxidations (2,2,6,6-tetramethyl-1-piperidinyloxyl (TEMPO)-oxidant couple), oxidations with organic hypervalent iodine compound such as Dess-Martin periodinane (DMP) or o- iodoxybenzoic acid (IBX or SIBX), oxidations with chromium (Vl) oxidants such as Collins reagent (CrO₃ ^χPy₂), pyridinum dichromate (PDC) (couple PDC-activated molecular sieves 4A), pyridinum chlorochromate (PCC), oxidations with manganese derivatives such as MnO₂ and BaMnO₄ or oxidations with tetra-n-propylammonium perruthenate: Pr₄N⁺RuO₄ ^' (TPAP). The reactions can be performed at temperatures between O to 40 ⁰C (Dess-Martin periodinane and couple PDC-activated molecular sieves 4A) and - 80 ⁰C to - 40 ⁰C (Swern). The reaction can be performed in CHCI₃, CH₂CI₂, ionic liquid (IL) like 1-butyl-3-methylimidazolium tetrafluoroborate (BMIMBF₄) or DMSO. The reaction is accomplished in 1- 24 hours. Isolation of the crude product with extraction can be preformed with AcOEt, ethers or alkanes as above. Preferably with PhMe, MTBE or AcOEt.

The analogous reaction conditions may be applied also to processes within the scope of this invention where Ri is different then herein used f-butyldimethylsilyl and R₂ is different than herein used Et. The reaction times of herein described reactions may thus be modified and in general depend on reaction conditions, especially temperature, solvents used and presence of any catalysts.

The formed compound of general formula IX may be used to synthesize statins. The subsequent reaction steps will differ depending on which final compound is synthesized.

Wittig coupling of compound of formula IX is performed in the presence of a strong base, preferably metal amide or silazane, most preferably selected from sodium hexametydisilazane, potassium hexametydisilazane, lithium hexametydisilazane, lithium diisopropylamide, sodium hydride, butyllithium or Grignard reagents at temperatures between - 80 ⁰C and 40 ⁰C in an organic solvent or a mixture of organic solvents, preferably in toluene or a mixture of another organic solvent and toluene or tetrahydrofuran and a process may further comprise a treatment of the reaction mixture, comprising steps: (optionally) concentrating a reaction mixture; acidifying a reaction mixture in the presence of water and extracting a product into water immiscible organic solvent; (optionally) washing an organic solvent solution of a product with water, water solution of an alkali salt or ammonium salt, and/or water solution of mineral acid; (optionally) washing an organic solvent solution of a product with a mixture water/polar aprotic organic solvent; (optionally) drying a solution with a drying agent; concentrating a solution to obtain residue, preferably by evaporation; and purifying a residue by column chromatography on silica.

In the specific embodiment related to rosuvastatin in the subsequent reaction step (2S,4f?)-4-(teAt-butyldimethylsilyloxy)-6-oxo-tetrahydro-2H-pyran-2-carbaldehyde (9) is reacted under condition of Wittig coupling (in the presence of base) with a ((4-(4- fluorophenyl)-6-isopropyl-2-(Λ/-methylmethylsulfonamido)pyrimidin-5- yl)methyl)triphenylphosphonium halide or any other ((4-(4-fluorophenyl)-6-isopropyl- 2-(/V-methylmethylsulfon-amido)pyrimidin-5-yl)methyl)phosphonium salt or alternatively di-i-propyl ({4-(4-fluorophenyl)-6-isopropyl-2-

[methyl(methylsulfonyl)amino]-5-pyrimidinyl}methylphosphonate or any other ({4-(4- fluorophenyl)-6-isopropyl-2-[methyl(methylsulfonyl)amino]-5- pyrimidinyljmethylphosphonate ester to give Λ/-(5-((E)-2-((2S,4R)-4-(teAf- butyldimethylsilyloxy)-6-oxo-tetrahydro-2/-/-pyran-2-yl)vinyl)-4-(4-fluorophenyl)-6- isopropylpyrimidin-2-yl)-Λ/-methylmethanesulfonamide (10). As a base lithium hexamethyldisilazane (LiHMDS), potassium hexamethyldisilazane (KHMDS), sodium hexamethyldisilazane (NaHMDS)₁ lithium diisopropylamide (LDA)₁ sodium hydride, butyllithium or Grignard reagents, preferably sodium hexamethyldisilazane may be used and the reaction can be performed in ethers selected from THF, Et₂O, /- Pr₂O, f-BuMeO; alkanes selected from: pentane, hexane, heptane, toluene or in mixtures of these solvents. The prefered solvents are anhydrous toluene and tetrahydrofuran. The reaction can be performed at temperatures between - 80 ⁰C to 40 ⁰C. Preferably at 0 to 30 ⁰C. The reaction is accomplished in 1- 12 hours. Isolation of the crude product with extraction can be preformed with AcOEt, ethers or alkanes as above. Preferably with /-BuMeO.

The silyl protecting group may be removed and lactone opened to produce a rosuvastatin free acid or its salt, optionally an amine, which may be converted to hemicalcium salt.

The deprotection can be performed at temperatures between 0 ⁰C to 80 ⁰C. Preferably at 25 or 60 ⁰C in suitable solvent, preferably a solvent selected from alcohols, THF, acetonitrile, methyltetrahydrofuran, dioxane, CH₂CI₂, more preferably in alcohols and THF. The usual deprotecting reagents may be used such as ammonium fluoride, FeCI₃, TMSCI/HF-2H₂O, chloroethylchloroformate (CEC), Ph₃PCH₂COMeBr. Opening of lactone takes places in preferably 4:1 to 2:1 mixture of THF/H₂O as well as a pure THF at temperatures between 20 ⁰C to 60 ⁰C with suitable alkali such as NaOH, KOH, ammonia or amines. The hydrolysis is accomplished in 30 minutes (at 60 ⁰C) to 2 hours (at 20 ⁰C). After that evaporation of solvents under the reduced pressure. can be conducted at temperatures between 10 °C to 50 °C and conversion to calcium salt, preferably by addition of Ca(OAc)2^χH₂O can be performed at temperatures between 0 ⁰C to 40 °C which can be added in one portion or dropwise in 5 to 60 minutes. After the addition of Ca(OAc)₂ ^χH₂O suspension can be stirred at temperatures between 0 °C to 40 ⁰C from 30 minutes to 2 hours.

To produce other statins the (2S,4f?)-4-(ferf-butyldimethylsilyloxy)-6-oxo-tetrahydro- 2H-pyran-2-carbaldehyde (9) is reacted under analogous condition of Wittig coupling with an appropriate reagent followed by hydrogenation when needed.

Statin containing nitrogen, such as atorvastatin, can be prepared in analogous manner by using a compound of formula Via wherein X" is cyano by conversion into an amine and cyclization with an appropriate derivative to give an intermediate, which can be upon workup converted into said statin containing nitrogen. Thus (6a) may be converted in the presence of a cyanide to 2-((2f?,4f?)-4-(terf- butyldimethylsilyloxy)-6-oxo-tetrahydro-2H-pyran-2-yl)acetonitrile followed by reduction of the cyano group and subsequent cyclization condensation of the amino group with appropriate precursor to afford the statin containing nitrogen, preferably atorvastatin derivative

Summary of the aspects of the invention is as follows:

The first main aspect of our invention is process for preparing the compound of formula Via

wherein X" is halo, preferably iodo; and Ri is a protecting group, preferably silyl or benzyl, [more preferably selected from optionally substituted Ci - C₈ trialkylsilyl, Ci - C₈ dialkylarylsilyl, Ci - C₈ alkyldiarylsilyl, where alkyls may be same or different], comprising steps:

(optionally) reacting alkyl 3(S)-hydroxy-4-chlorobutyrate of formula I₁

OH O Cl

wherein R₂ is an optionally substituted Ci - Ce alkyl or C₅ - C₇ cycloalkyl, or, alternatively -COOR₂ may also form an amide of formula -CONR_aR_b, where R_a and R_b may independently be H, an optionally substituted Ci - C₈ alkyl or C₅ - C₇ cycloalkyl, aryl or can together with N form a heterocycle with an iodide to give a alkyl 3(S)-hydroxy-4-iodobutyrate of formula Il

wherein R₂ is as above; protecting the compound of Formula Il to give a protected derivative of formula III,

wherein R₁ and R₂ are as above; reacting the compound of formula III with vinylmagnesium halide [preferably vinyl magnesium chloride] in presence of copper(l) halide and phosphite derivative with formula:

where each of R', R", and R'" are same or different Ci-C₄ alkyl, C₅-C₇ cycloalkyl, or aryl which may be optionally substituted to give an alkene of formula IV,

, wherein R₁ and R₂ are as above hydrolyzing [preferably with an alkali followed by acidification] the compound of formula IV to give compound of formula V

reacting compound of formula V, wherein Ri is as above, with a source of halogen [preferably selected from the group consisting of: iodine, bromine, chlorine, alkali metal and earthalkali metal halides or oxohalides, interhalogens, haloacetates, N-iodosuccinimide (NIS), N-bromosuccinimide (NBS), bispyridine iodonium tetrafluoroborate and hypervalent halogen electrophiles] in the presence of NaHCOs; and (optionally) separating the mixture of diastereoisomers obtained in previous step.

In an aspect the compound of the Formula Via is isolated in optical purity higher than 99 % d.e. as determined by HPLC.

Another aspect of the invention is use of a solvent selected from the group consisting of f-BuMeO, /-Pr₂O, pentane, hexane, heptane, cyclopentane, cyclohexane, AcOEt, methylene chloride, chloroform and mixture(s) thereof in any of the processes as described above and use of vacuum distillation in the process of purification of the compounds obtained in any of the processes as claimed above.

Additionally to above described process to compound Vl, a second main aspect of our invention further comprises preparing the compound of formula IX

where Ri is as defined above from compound of formula Via

where X" is a halogen, alkylsulfonyl, or arylsulfonyl, and where those sulfonyl derivatives may be prepared from halo compounds by conventional methods.

More specifically in the just described process the compound of formula IX

wherein Ri is as defined above, is prepared by process comprising one or more steps selected from g) converting the compound of formula Via

where X" is halo, alkylsulfonyl, or arylsulfonyl into compound of formula VII

wherein R₄ is (optionally halo, alkyl, aryl, alkyl oxy or aryl oxy substituted) CrC₄ alkyl; h) converting compound of formula VII in compound of formula VIII

; and i) converting the compound of formula VIII by oxidation into compound of formula IX,

Specific aspects of respective steps are that g) is performed with an acylation reagent selected from the group consisting of NaOAc₁ LiOAc, KOAc, CsOAc, AgOAc, CuOAc, Mg(OAc)₂, Ca(OAc)₂, R₄NOAc; h) is performed by deacylation with an organotin compound selected from dibutyltin oxide or [M3u₂SnOH(CI)]₂ or by a rection with an enzyme selected from group consisting of Porcine Pancreatic Lipase, Lipase MY, Lipase PS, Lipase Al, Candida Lipase and Alcalase, or with a reagent selected from the group consisting of guanidine and guanidine/guanidinium nitrate, HBF₄ ^χEt₂O/MeOH and BF₃ ^χEt₂O/MeCN, DBU/MeOH, hydrazine/MeOH and hydrazine hydrate/THF, cyanide/MeOH, l₂/Me0H; i) is performed by an oxidation reaction selected from: dimethyls u Ifoxide-mediated oxidations (Swern oxidation: DMSO-(COCI)₂ couple, Pfitzner-Moffatt procedure: DMSO-dicyclohexylcarbodiimide (DCC) couple, Parikh-Doering procedure: DMSO-SOβXPy couple), /V-oxoammonium-mediated oxidations (2,2,6,6-tetramethyl-1-piperidinyloxyl (TEMPO)-oxidant couple, oxidations with organic hypervalent iodine compound selected from Dess-Martin periodinane (DMP) and o-iodoxybenzoic acid (IBX or SIBX)₁ oxidations with chromium (Vl) oxidants selected from Collins reagent (CrO₃*Py₂), pyridinum dichromate (PDC) (couple PDC-activated molecular sieves 4A), pyridinum chlorochromate (PCC), oxidations with manganese derivatives selected from MnO₂ and BaMnO₄ or oxidations with tetra-n-propylammonium perruthenate: Pr₄N⁺RuO₄ ^' (TPAP).

Yet another aspect of the invention is a process for manufacturing a compound of formula:

or a salt, amide, or lactone thereof, wherein Het is selected from group consisting of:

comprising: preparing an intermediate of formula Via

wherein R₁ and X" are as defined above, by the process which is the first main aspect of the invention as described above preparing the intermediate of formula IX

wherein R₁ is as defined above from the intermediate of formula Via by the process which is the second main aspect of this invention as described above; and reacting the intermediate of formula IX with the compound of formula

O

X® PRxRyRz _^PARxARy

Het _or Het where A can be a bond or O, and wherein R_x, R_y, and R_z, are the same or different and are selected from optionally substituted Ci - C₈ alkyl or C₃-C₆ cycloalkyl or Ci - C₈ alkenyl or Cs-Cβ cycloalkenyl or aryl,

X^" is anion [preferably halide or alkanoate] and Het is as defined above, and optionally comprising one or more subsequent steps in which the compound of formula X

wherein R₁ and Het are as defined above, is transformed into a compound of formula Xl

wherein R₁ and Het are as defined above, or a salt, amide, or lactone thereof. Preferably Het is a heterocyclic skeleton of rosuvastatin with formula

Another specific aspect of teh invention is a process for manufacturing rosuvastatin, characterized in that it comprises steps:

(optionally) reacting alkyl 3(S)-hydroxy-4-chlorobutyrate of formula I,

OH O Cl rø\^ -_QR₂ wherein R₂ is an optionally substituted C₁ - Cs alkyl or C₅ - C₇ cycloalkyl, or, alternatively -COOR2 may also form an amide of formula -CONR₃R_b, where R₃ and Rb may independently be H, an optionally substituted Ci - Ce alkyl or C₅ - C₇ cycloalkyl, aryl or can together with N form a heterocycle with an iodide to give a alkyl 3(S)-hydroxy-4-iodobutyrate of formula Il

wherein R₂ is as above;

(optionally) protecting the compound of Formula Il to give a protected derivative of formula III,

wherein R₁ and R₂ are as above; reacting the compound of formula III with vinylmagnesium halide in presence of copper(l) halide and phosphite derivative with formula:

where each of R', R", and R'" are same or different C₁-C₄ alkyl, C₅-C₇ cycloalkyl, or aryl which may be optionally substituted to give an alkene of formula IV

o ?^■ o

^{<R> 0R2} , wherein R₁ and R₂ are as above; hydrolyzing the compound of formula IV to give compound of formula V

reacting compound of formula V, wherein R₁ is as above, with a source of halogen in the presence of NaHCO₃ to give compound of formula Vl ; (optionally) separating the mixture of diastereoisomers obtained in previous step to obtain compound of formula Via

wherein X" is halo and R₁ as above; converting the compound of formula Via into compound of formula VII,

wherein Ri is as above and R₄ is selected from (optionally halo or alkoxy or aryloxy substituted) C₁-C₄ alkyl ; converting compound of formula VII in compound of formula VIII

wherein Ri is as above; converting the compound of formula VIII by oxidation into compound of formula IX,

; wherein R₁ is as above; reacting said compound of formula IX with the compound of formula

wherein R_x, R_y, and R_z, are the same or different and are selected from optionally substituted C₁ - C₈ alkyl or C₃-C₆ cycloalkyl or C₁ - C₈ alkenyl or C₅-C₆ cycloalkenyl or aryl, X^" is anion; [preferably halide or alkanoate] and removing the protecting group Ri optionally purifying and converting the obtained compound into calcium salt.

Aspect of the invention is also the use for the synthesis of statins of an intermediate Xl

characterized in that it has been prepared from intermediate of formula Via

wherein X" is halo, arylsulfonyl or alkylsulfonyl and Ri is a protecting group and also use for the synthesis of statins of an intermediate of formula

wherein R₁ is an optionally substituted Ci - Ce trialkylsilyl, Ci - Ce dialkylarylsilyl, Ci - C₈ alkyldiarylsilyl, where alkyls may be same or different and R₄ is (optionally halo, alkyl, aryl, alkyl oxy or aryl oxy substituted) Ci-C₄ alkyl.

New compounds of formula:

wherein R₁ is an optionally substituted C₁ - C₈ trialkylsilyl, C₁ - C₈ dialkylarylsilyl, C₁ - C₈ alkyldiarylsilyl, where alkyls and aryls may be same or different and R₄ is (optionally halo, alkyl, aryl, alkyl oxy or aryl oxy substituted) C₁-C₄ alkyl are also aspects of the invention as well as their use as intermediates in the synthesis of statins, preferably rosuvastatin, preferably is R₄ is CH3, C(CH₃)₃, CH₂CI, CHCI₂, CCI_3, CF₃, CH₂OCH₃, CH₂OCPh₃, CH₂OPh, CH₂Ph, CHPh₂, CH₂CH₂Ph₁ CH=CHCH₂CH₃ and CH₂CH₂(C=O)CH₃)., more preferably Ri is t- butyldimethylsilyl and R₄ is CH₃.

Aspect of the invention are also compounds of formula [and its use for the sythesis of statins, preferably rosuvastatin]

wherein Ri is an optionally substituted Ci - Ce trialkylsilyl, Ci - Cs dialkylarylsilyl, Ci - Ce alkyldiarylsilyl, where alkyls and aryls may be same or different, preferably wherein Ri is t-butyldimethylsilyl.

Related to that is also a process for converting compound of formula

into compound of formula

characterized by dissolving in chloroform, dichlormethane, hexane or toluene, preferably toluene, preferably for more than 24. more preferably more than 150 h.

The more specific aspect of the invention is a process for the manufacturing of a compound of the formula X

comprising Wittig reaction in which the compound of formula IX

is reacted with a compound of formula

O

PARxARy

where A can be a bond or O and wherein R_x, R_y, and R_z, are the same or different and are selected from optionally substituted C₁ - C₈ alkyl or C₃-C₆ cycloalkyl or Ci - C₈ alkenyl or C₅-C₆ cycloalkenyl or aryl,

Ri is a protecting group,

X is an anion, and Het is selected so that it forms a heterocyclic skeleton of a statin, characterized in that the reaction is performed in solvent selected from the group consisting of, chloroform or dichloromethane, or hexane and preferably toluene. Preferabyl Het is selected from group consisting of:

Another specific aspect of the invention is a process for the manufacturing of rosuvastatatin comprising Wittig reaction in which the compound of formula IX

s reacted with a compound of formula

where A can be a bond or O and wherein R_x, R_y, and R_z, are the same or different and are selected from optionally substituted Ci - C₈ alkyl or C₃-C₆ cycloalkyl or Ci - C₈ alkenyl or C₅-C₆ cycloalkenyl or aryl,

Ri is a protecting group,

X is an anion, and Het is selected so that it forms a heterocyclic skeleton of a statin, characterized in that the reaction is performed in toluene.

The Witig reaction as described above is specifically characterized in that the compound of formula IX is dissolved in toluene at least 6 hours prior to reaction and/or that it is performed in the presence of a strong base at temperatures between - 80 ⁰C and 40 ⁰C, preferably 0 ⁰C to 40 ⁰C, more preferably 10 ⁰C to 35 ⁰C. Preferably a strong base is selected from the group of metal amides or silazanes, metal hydrides, lithium alkyls or lithium aryls, more preferably from: lithium hexametydisilazane, sodium hexametydisilazane, potassium hexametydisilazane, lithium diisopropylamide, sodium hydride, buthyllithium or Grignard reagents.

In an aspect of the invention the process described above further comprisis a treatment of the reaction mixture, comprising following sequence of steps:

(optionally) concentrating a reaction mixture; acidifying a reaction mixture in the presence of water and extracting a product into water immiscible organic solvent; (optionally) washing an organic solvent solution of a product with water, water solution of an alkali salt or ammonium salt, and/or water solution of mineral acid;

(optionally) washing an organic solvent solution of a product with a mixture water/ polar aprotic organic solvent;

(optionally) drying a solution with a drying agent; concentrating a solution to obtain residue, preferably by evaporation; and purifying a residue.

Specific aspect of the invention are the statins selected from the group comprising rosuvastatin, cerivastatin, fluvastatin, pitavastatin, bervastatin, atorvastatin or analogs thereof characterized in that it is manufactured by the process as described here and a pharmaceutical composition comprising a pharmaceuticaly acceptable carrier and a statin selected from rosuvastatin calcium, fluvastatin sodium, atorvastatin calcium manufactured by the process using the intermediate Via

wherein X" is halo and R₁ is a protecting group.

The various embodiments of the invention are presented in following examples,

Example 1 : Ethyl 3(S)-hvdroxy-4-iodobutyrate (2)

To a solution of ethyl 3(S)-hydroxy-chlorobutyrate (1) (639.0 g, 3.84 mol) in dry acetone (7.7 L) is added anhydrous NaI (2300 g, 15.34 mol). The mixture is stirred vigorously at 58-60 ⁰C for 120 hours under argon atmosphere. The acetone is distilled off under the reduced pressure at 40-60 ⁰C. The residue is diluted with water (5.75 L) followed by the addition of saturated Na₂S₂O₃ solution (1.53 L) and NBuMeO (2.3 L). The mixture is stirred vigorously at ambient temperature for 30 minutes. Then the organic layer is separated and the water phase is extracted additionally with t- BuMeO (2 x 1.15 L). The combined organic layers are washed with water (800 mL) and dried (MgSO₄). Evaporation of the solvent under the reduced pressure (20 mbar) at 40 ⁰C affords 949.9 g (96 %) of ethyl 3(S)-hydroxy-4-iodobutyrate (2) as yellow oil (GC purity 85.9 %). A product with GC purity of 98-99 % can be obtained by vacuum distillation (73 - 89 ⁰C at 0.180 - 0.330 mbar) of the crude product. ¹H NMR (300 MHz, CDCI₃): 54.17 (q, J = 7.2 Hz₁ 2H), 3.99 (m, 1 H)₁ 3.34 (dd, J = 10.3 and 5.2 Hz, 1H), 3.28 (dd, J = 10.3 and 5.7 Hz, 1H), 3.21 (br s, 1H), 2.67 (dd, J = 16.5 and 4.3 Hz, 1H)₁ 2.58 (dd, J = 16.5 and 7.9 Hz, 1H), 1.27 (t, J = 7.2 Hz, 3H). ¹³C NMR (75 MHz, CDCI₃): δ 171.7, 67.4, 61.0, 40.7, 14.1, 12.0.

Example 2: Ethyl 3(S)-(ferf-butyldimethylsilyloxy)-4-iodobutyrate (3)

To a solution of imidazole (252.3 g, 7.36 mol) in dry DMF (7.6 L) are added ethyl 3(S)-hydroxy-4-iodobutyrate (2) (949.6 g, 3.68 mol, GC purity 85.9 %) and anhydrous NaI (1106 g, 7.36 mol) under argon atmosphere at ambient temperature. The suspension is cooled to 0 ⁰C and terf-butyl(chloro)dimethylsilane (838 g, 5.56 mol) is added portionwise. The reaction mixture is stirred at 0 ⁰C for 1.5 hours followed by stirring for 15.5 hours from 0 ⁰C to ambient temperature. Then the mixture is cooled to 0 ⁰C and H₂O (4.2 L) is added. After 2 hours of stirring additional amount of H₂O (6.2 L) and saturated Na₂S₂O₃ solution (0.5 L) are added. The product is extracted with f-BuMeO. The combined organic layers are washed with water and dried (MgSO₄). Ether is removed completely under the reduced pressure (20 mbar) at 60 ⁰C to produce a yellow oily residue. This residue is purified further by vacuum distillation (80 - 89 ⁰C at 0.150 - 0.310 mbar) to give 1193.5 g (97 %) of ethyl 3(S)- (te/t-butyldimethylsilyloxy)-4-iodobutyrate (3) as a pale yellow oil (GC purity 96.1 %). ¹H NMR (300 MHz₁ CDCI₃): 54.13 (qd, J = 7.2 and 2.1 Hz, 2H), 4.01 (m, 1 H), 3.28 (dd, J = 10.2 and 4.2 Hz, 1H), 3.24 (dd, J = 10.2 and 6.0 Hz, 1 H), 2.66 (dd, J = 15.3 and 4.8 Hz, 1 H), 2.51 (dd, J = 15.3 and 7.2 Hz, 1 H), 1.26 (t, J = 7.2 Hz, 3H), 0.87 (s, 9H), 0.10 (s, 3H), 0.05 (s, 3H). ¹³C NMR (75 MHz, CDCI₃): δ 170.8, 68.3, 60.5, 42.5, 25.6, 17.9, 14.1 , 12.9, -4.6, -5.0.

Example 3: Ethyl 3fl?)-(terf-butyldimethylsilyloxy)-5-hexenoate (4)

To a suspension of CuI (83.64 g, 437.0 mmol) in dry THF (875 ml_) is added under argon atmosphere, at -44 to -31 ⁰C in 15 minutes under vigorous stirring, vinylmagnesium chloride (1.9 M in THF, 460.0 ml_, 874.0 mmol). The resulting dark slurry is stirred for 15 minutes, and DMPU (112 g, 874.0 mmol) is added at -42 ⁰C in one portion followed by the dropwise addition (5 minutes) of P(OEt)₃ (160.1 ml_, 874.0 mmol) at -40 °C. The resulting mixture is stirred for 30 minutes and a THF (220 ml_) solution of (S)-ethyl 3-(terf-butyldimethylsilyloxy)-4-iodobutyrate (3) (162.7 g, 437.0 mmol) is added at -40 to -36 ⁰C in 15 minutes. The stirring is continued for 1 hour at -40 to -35 ⁰C before allowing the mixture to warm to 11 ⁰C over a period of 3.5 hours. The reaction is quenched at -2 ⁰C (saturated NH₄CI, 1.0 L) and stirred at 10 ⁰C for 30 minutes. The product is extracted with /-Pr₂O or M3uMeO. Partial evaporation of the solvent under reduced pressure gives a yellow solution which is washed with 0.1 M H₂SO₄, water and dried (MgSO₄). Ether is removed completely under the reduced pressure (15 mbar) at 80 ⁰C to produce a yellow oily residue. This residue is purified further by vacuum distillation (64 - 72 ⁰C at 0.10 - 0.44 mbar) to give 80.8 g (67.8 %) of ethyl 3(T?j-(ferf-butyldimethylsilyloxy)-5-hexenoate (4) as a colorless oil (GC purity 96 %). ¹H NMR (300 MHz, CDCI₃): δ 5.81 (ddt, J = 17.8, 9.6 and 7.2 Hz, 1H), 5.11-5.03 (m, 2H)₁ 4.21 (quint., J = 6.8 Hz, 1H), 4.12 (qt, J = 7.1 and 1.5 Hz, 2H), 2.43 (d, J = 7.1 Hz, 1 H), 2.43 (d, J = 5.4 Hz, 1H), 2.31-2.25 (m, 2H), 1.26 (t, J = 7.2 Hz₁ 3H), 0.87 (s, 9H), 0.07 (s, 3H), 0.04 (s, 3H). ¹³C NMR (75 MHz, CDCI₃): δ 171.7, 134.1 , 117.6, 68.9, 60.2, 42.1 , 42.1 , 25.7, 17.9, 14.1 , -4.6, -5.0.

Example 4: (R)-3-(ferf-Butyldimethylsilyloxy)-5-hexenoic acid (5)

To a solution of ethyl 3(fi;-(te/f-butyldimethylsilyloxy)-5-hexenoate (4) (80.60 g, 295.8 mmol) in MeOH (500 mL) is added a 40 % KOH solution (150 ml_). The mixture is stirred for 2 hours at 40 ⁰C. After the mixture is cooled to ambient temperature and MeOH is removed under the reduced pressure (20 mbar) at 42 °C. The obtained brown solid is dissolved in H₂O (700 mL). The solution is washed with f-BuMeO (1 * 340 mL + 3 x 215 mL) and then acidified with 4N HCI (222 mL) to pH = 2. The yellow oil that separated from the water is extracted into f-BuMeO (6 * 110 mL). The combined organic layers are washed with water and dried (MgSO₄). Ether is removed completely under the reduced pressure (15 mbar) at 40 ⁰C to give an orange-red oily residue (68.2 g, 94.3 %). This residue is filtered two times through a thin pad of silica using /-BuMeO as solvent to afford (ft)-3-(te/?-butyldimethylsilyloxy)-5-hexenoic acid (5) (67.1 g, 93 %) as yellow oil (GC purity 97.3 %). ¹H NMR (300 MHz, CDCI₃): δ 11.03 (br s, 1H)₁ 5.80 (ddt, J = 17.8, 9.5 and 7.2 Hz, 1H)₁ 5.13-5.11 (m, 1H)₁ 5.08- 5.06 (m, 1H), 4.20 (quint., J = 6.5 Hz, 1H), 2.54 (dd, J = 15.1 and 5.1 Hz₁ 1H), 2.46 (dd, J = 15.1 and 7.1 Hz₁ 1H)₁ 2.33-2.28 (m, 2H), 0.88 (s, 9H), 0.09 (s, 3H), 0.07 (s, 3H). ¹³C NMR (75 MHz, CDCI₃): δ 178.1 , 133.8, 118.1, 68.8, 42.0, 41.8, 25.7, 17.9, - 4.5, -5.0. Example 5: (4R6S)-4-(ferf-butyldimethylsilyloxy)-6-(iodomethyl)-tetrahvdropyran-2- one (6a)

+ NaHCO₃ + I₂

To a solution of (fi)-3-(terf-butyldimethylsilyloxy)-5-hexenoic acid (5) (68.00 g, 278.2 mmol) in dry MeCN (950 mL) is added anhydrous NaHCO₃ (708.3 g, 8.347 mol) at ambient temperature. The stirred suspension is cooled to 0 ⁰C. Then iodine (212.9 g, 834.7 mmol) is added to the vigorously stirred suspension in one portion. The reaction mixture is stirred at 0 ^CC for 4 hours followed by the addition of f-BuMeO or /- Pr₂O (410 mL) and saturated Na₂S₂O₃ solution (820 mL). The organic layer is separated and the water phase was extracted additionally with ¹BuMeO or /-Pr₂O (5 * 200 mL). The combined organic layers are dried (MgSO₄). Solvents are removed substantially under the reduced pressure (20 mbar) at 40 ⁰C to produce an orange oily residue. This residue is dissolved in f-BuMeO or /-Pr₂O (200 mL) and the solution is washed additionally with saturated Na₂S₂O₃ solution (2 * 100 mL) and water (2 x 100 mL). The organic layer is dried (MgSO₄). Solvent is removed completely under the reduced pressure (20 mbar) at 50 ^CC to produce a yellow oily residue (99.96 g, 97 %) which solidifies at temperatures below 10 ⁰C to produce a 77 : 23 mixture of (4R,6S)-4-(te/f-butyldimethylsilyloxy)-6-(iodomethyl)-tetrahydropyran-2-one (6a) and (4R,6/?)-4-(feAf-butyl-dimethyl-silyloxy)-6-(iodomethyl)-tetrahydropyran-2-one (6b) as pale yellow solid. Raw mixture is dissolved in mobile phase (hexane and f-BuMeO) and at room temperature successively injected onto HPLC using normal phase silica column (PHENOMENEX 4.6x150 mm, d_p = 5 μm) and eluted at isochratic conditions. Active fraction (whole peak) from preparative run is collected and analysiys on the same system show 97 area% of (6a) and 0.15 % of (6b), with some other impurities present.

Alternatively to chromatographic purification this solid is recrystallized seven times from π-pentane to afford 43.6 g (42.6 %) of (4R6S)-4-(tert-butyldimethylsilyloxy)-6- (iodomethyl)-tetrahydropyran-2-one (6a) (d.e. 99.3 %, HPLC) as colorless needles. M.p. = 64 ⁰C (DSC peak). ¹H NMR (300 MHz, CDCI₃) δ: 4.60 (ddt, 1H₁ J = 11.3, 5.0, 3.2 Hz, 6-H_aχ), 4.35 (br quin, 1 H₁ J = 3.5 Hz, 4-H_eq), 3.40 (d, 2H, J = 5.0 Hz, CH₂I), 2.59 (d, 2H₁ J = 3.5 Hz, 3-CH₂), 2.10 (dddd, 1H, J = 13.9, 3.9, 3.2, 1.7 Hz, 5-H_eq), 1.76 (ddd, 1 H, J = 13.7, 11.3, 2.1 Hz₁ 5-H_3x), 0.89 (s, 9H, SiC(CH₃)₃), 0.09, (s, 6H, Si(CH₃J₂). ¹³C NMR (75 MHz, CDCI₃) δ: 169.0, 73.9, 63.1 , 38.7, 36.2, 25.5, 17.7. 8.6, -5.1 , -5.1.

Example 6: ((2S.4R)-4-(fe/f-butyldimethylsilyloxy)-6-oxo-tetrahvdro-2/-/-pyran-2- vDmethyl acetate (7)

To the solution of (4R6S)-4-(feAf-butyldimethylsilyloxy)-6-(iodomethyl)- tetrahydropyran-2-one (6a) (40.00 g, 108.0 mmol) in AcOH (660 mL) is added AgOAc (20.03 g, 118.8 mmol). The resultant mixture is then heated at 125 ⁰C for 6 hours. The reaction mixture is filtered through diatomite filter medium (Celite®). The obtained filtrate is evaporated to afford the residue. To this residue EtOAc (500 mL) and water (600 mL) are added. The organic layer is separated and the aqueous layer is washed again with EtOAc (5 * 150 mL). The combined organic layers are washed with water (4 x 300 ml_), brine (5 x 300 mL) and dried over anhydrous MgSO₄, filtered and concentrated under the reduced pressure to afford 30.28 g (92.6 %) of ((2S,4R)-4-(te/t-butyldimethylsilyloxy)-6-oxo-tetrahydro-2H-pyran-2-yl)methyl acetate (7) as yellow oil (HPLC purity 98 %). ¹H NMR (300 MHz, CDCI₃): 54.93 (m, 1 H), 4.37 (m, 1H), 4.30 (dd, J = 12 Hz, J = 3 Hz, 1H), 4.21 (dd, J = 12 Hz, J = 5 Hz, 1H), 2.62 (d, J = 4 Hz , 2H), 2.11 (s, 3H), 1.84-1.80 (m, 2H), 0.89 (s, 9H), 0.09, 0.09 (2s, 6H). ¹³C NMR (75 MHz, CDCI₃): δ 170.4, 169.1 , 73.3, 65.5, 63.0, 38.9, 32.2, 20.5, 17.7, - 5.1 , -5.2.

Example 7: (4R6S)-4-(feAt-butyldimethylsilyloxy)-6-(hvdroxymethyl)-tetrahvdropyran- 2-one (8)

((2S,4f?)-4-(tert-Butyldimethylsilyloxy)-6-oxo-tetrahydro-2/-/-pyran-2-yl)methyl acetate (7) (8.36 g, 27.64 mmol) and [f-Bu₂Sn0H(CI)]₂ (1.577 g, 2.764 mmol) are dissolved in MeOH/THF mixture (280 mL). The reaction mixture is stirred at 23-25 ⁰C for 27 h. After the solvent is removed under the reduced pressure and the remained residue is purified by silica gel chromatography (elution with f-BuMeO/hexane mixture) to afford a crude product as white solid (5.59 g, 78 %). Recrystallization from n-hexane affords (3.90 g, 54 %) of (4f?,6S)-4-(tert-butyldimethylsilyloxy)-6-(hydroxymethyl)-tetrahydro- pyran-2-one (8) as white needles. M.p. = 102 ⁰C (DSC peak). ¹H NMR (300 MHz, CDCI₃) δ: 4.80 (m, 1 H), 4.38 (m, 1 H), 3.91 (dd, J = 12 Hz, J = 3 Hz₁I H), 3.66 (dd, J = 12 Hz, J = 5 Hz₁I H), 2.60 (d, J = 4 Hz , 2H), 2.31 (bs, 1H)₁ 1.97-1.75 (m, 2H)₁ 0.88 (s, 9H)₁ 0.09, 0.08 (2s, 6H). ¹³C NMR (75 MHz₁ CDCI₃) δ: 170.1, 76.8, 64.7, 63.4, 39.2, 31.9, 25.6, 17.9, -4.9, -5.0. Example 8: (2S,4f?)-4-(terf-butvidimethylsilyloxy)-6-oxo-tetrahvdro-2/-y-pyran-2- carbaldehvde (9)

Oxidant solvent, T

a) Dess - Martin periodinane or SiBX, CH₂CI₂, or BMIMBF₄ r t or c) Swern oxidation, -30 to -80 ⁰C

A mixture of (4/?,6S)-4-(ter^butyldimethylsilyloxy)-6-(hydroxymethyl)-tetrahydropyran- 2-one (8) (150 mg, 0.58 mmol) and Dess-Martin periodinane (380 mg, 0.86 mmol) in CH₂CI₂ (15 ml_) is stirred at ambient temperature for 3 hours. The mixture is diluted with f-BuMeO (20 ml_), washed with saturated Na₂S₂O₃ solution, saturated NaHCO₃ solution, dried (MgSO₄) and concentrated to give 130 mg (87 %) of crude (2S,4f?)-4- (ferf-butyldimethylsilyloxy)-6-oxo-tetrahydro-2/-/-pyran-2-carbaldehyde (9) which is used in the next step without further purification. ¹H NMR (300 MHz₁ CDCI₃) δ: 9.82 (S, 1H), 5.09 (dd, J = 11 Hz₁ J = 4 Hz₁IH), 4.38 (m, 1H), 2.67 (d, J = 4 Hz , 2H), 2.18- 2.10 (m, 1H)₁ 1.91-1.81 (m, 1 H), 0.89 (s, 9H)₁ 0.09, (s, 6H). ¹³C NMR (75 MHz, CDCI₃) δ: 199.4, 168.0, 79.2, 62.9, 39.6, 31.4, 25.6, 17.9, -4.9. The hydrate form of

(9) has following NMR spectra: ^H NMR (300 MHz, THF-dβ) δ: 5.27 (d, J = 6 Hz, 1H₁

OH), 5.19 (d, J = 6 Hz₁ 1H, OH), 4.90-4.85 (m, 1H), 4.44-4.38 (m, 2H), 2.58 (dd. J = 17 Hz₁ J = 4 Hz₁1 H)₁ 2.44-2.36 (m, 1 H), 1.92-1.87 (m, 2H)₁ 0.91 (s, 9H)₁ 0.10₁ (s, 6H).

13C NMR (75 MHz, THF-d₈) δ: 168.7, 91.7, 79.0, 65.1 , 40.3, 31.0, 26.2, 18.7, -4.8, - 4.8.

Example 9: Λ/-(5-((a-2-((2S,4ff)-4-(tert-butyldimethylsilyloxy)-6-oxo-tetrahvdro-2H- pyran-2-yl)vinyl)-4-(4-fluorophenyl)-6-isopropylpyrimidin-2-yl)-Λ/- methylmethanesulfonamide (10) example a)

To a cold (- 30 ⁰C), stirred suspension of ((4-(4-fluorophenyl)-6-isopropyl-2-(/V- methylmethylsulfonamido)pyrimidin-5-yl)methyl)triphenylphosphonium bromide (376 mg, 0.55 mmol) in dry tetrahydrofuran (10 ml_) is added lithium hexamethyldisilazane in THF (0.42 ml_ of 1.33 M, 0.55 mmol). The reaction mixture is stirred for 30 min, cooled to -78 ⁰C, and treated with a solution of (2S,4ft)-4-(teAf-butyldimethylsilyloxy)- 6-oxo-tetrahydro-2H-pyran-2-carbaldehyde (9) (130 mg, 0.50 mmol) in 5 ml_ of tetrahydrofuran. After 60 min, the solution is warmed to ambient temperature, stirred for 10 min, and treated with saturated ammonium chloride solution. The aqueous phase is extracted with f-BuMeO (2 * 10 ml_), and the combined organic layers dried and concentrated. The residue is purified by silica gel chromatography (elution with t- BuMeO/hexane mixture) to give 190 mg (65 %) of Λ/-(5-((E)-2-((2S,4ft)-4-(terf- butyldimethylsilyloxy)-6-oxo-tetrahydro-2H-pyran-2-yl)vinyl)-4-(4-fluorophenyl)-6- isopropylpyrimidin-2-yl)-Λ/-methylmethanesulfonamide (10) as white amorphous solid. example b)

To a stirred suspension of ((4-(4-fluorophenyl)-6-isopropyl-2-(Λ/-methylmethyl- sυlfonamido)pyrimidin-5-yl)methyl)tributylphosphonium 2,2,2-trifluoro-acetate (260 mg, 0.4 mmol) at room temperature in dry toluene (4 ml_) is added sodium hexamethyldisilazane in toluene (0.67 ml_ of 0.6 M, 0.4 mmol) portionwise in 10 minutes. The reaction mixture is stirred for 60 min and treated at room temperature with a solution of (2S,4/?)-4-(terf-butyldimethylsilyloxy)-6-oxo-tetrahydro-2H-pyran-2- carbaldehyde (9) (105 mg, 0.40 mmol) in 13 ml_ of dry toluene. After 24 hours of stirring at room temperature the solution is treated with saturated ammonium chloride solution or water. The aqueous phase is extracted with f-BuMeO (2 x 10 mL), and the combined organic layers dried and concentrated. The residue is purified by silica gel chromatography (elution with f-BuMeO/hexane mixture) to give 104 mg (45 %) of Λ/- (5-((E)-2-((2S,4R)-4-(teλf-butyldimethylsilyloxy)-6-oxo-tetrahydro-2H-pyran-2-yl)vinyl)- 4-(4-fluorophenyl)-6-isopropylpyrimidin-2-yl)-Λ/-methylmethanesulfonamide (10) as white amorphous solid.

¹H NMR (300 MHz₁ CDCI₃) δ: 7.62 (dd, J = 9 Hz, J = 5 Hz₁ 2H), 7.09 (t, J = 9 Hz, 2H), 6.69 (dd, J = 16 Hz, J = 1 Hz₁ 1H)₁ 5.49 (dd, J = 16 Hz₁ J = 6 Hz₁ 1 H)₁ 5.22-5.16 (m, 1H), 4.29-4.27 (m, 1 H), 3.56 (s, 3H), 3.50 (s, 3H), 3.32 (septet, 1H)₁ 2.61-2.59 (m, 2H), 1.80-1.73 (m, 1 H)₁ 1.64-1.54 (m, 1 H)₁ 1.26 (d, J = 7 Hz , 6H), 0.87 (s, 9H), 0.07, 0.06 (2s, 6H). ¹³C NMR (75 MHz₁ CDCI₃) δ: 174.9, 169.5, 163.5, 163.2 (d, J_C-F = 250 Hz), 157.4, 134.7, 134.1 (d, J₀-_F = 3 Hz), 132.0 (d, J₀-_F = 8 Hz), 125.3, 120.5, 115.0 (d, Jc-_F = 22 Hz)₁ 75.3, 63.2, 42.3, 39.2, 36.2, 33.0, 32.1 , 25.5, 21.5, 17.8, -5.0, -5.0.

Example 10: Calcium salt of (3R5S.E)-7-(4-(4-fluorophenyl)-6-isopropyl-2-(Λ/- methylmethylsulfonamido)pyrimidin-5-yl)-3,5-dihvdroxyhept-6-enoic acid (11 )

To a stirred solution of /V-(5-((£)-2-((2S,4/?)-4-(ferf-butyldimethylsilyloxy)-6-oxo- tetrahydro-2H-pyran-2-yl)vinyl)-4-(4-fluorophenyl)-6-isopropylpyrimidin-2-yl)-Λ/- methylmethanesulfon-amide (10) (190 mg, 0.33 mmol) in 3 ml_ of anhydrous tetrahydrofuran is added a solution of ammonium fluoride (73 mg, 1.97 mmol)/AcOH (2 ml_) in THF. The reaction mixture is warmed to 60 ⁰C, stirred for 5 h, treated with 3 mL of aqueous ammonium chloride solution, and extracted several times with t- BuMeO. The combined organic layers are washed with water, dried and concentrated. The residue is dissolved in 3 mL of a 4:1 mixture of THF/H₂O. The clear solution is warmed to 30 ⁰C and 8.0 M NaOH (0.044 mL, 0.35 mmol) is added portionwise. The reaction mixture is stirred at 30 ⁰C for 2 hours giving a clear yellow solution. Then THF is removed completely under the reduced pressure (20 mbar) at 40 ⁰C. The remained water solution is diluted with H₂O to 1.5 mL and washed with AcOEt (2^χ1 mL). After separation from the organic layer aqueous phase is distilled under the reduced pressure (20 mbar) at 40 ⁰C to completely remove the dissolved AcOEt. The remained clear solution of sodium rosuvastatinate (1.3 mL) is diluted with H₂O to 1.5 mL and warmed to 40 ⁰C. To a vigorously stirring solution of sodium rosuvastatinate is added dropwise Ca(OAc)₂ ^χH₂O (44 mg, 0.25 mmol in 0.3 ml_ of H₂O) over 5 minutes at 40 ⁰C to precipitate rosuvastatin calcium. After the complete addition the suspension is stirred further for 30 minutes at 40 ⁰C. The white precipitate is filtered off. Then a wet white solid is suspended in H₂O (1 ml_) and vigorously stirred for 1 hour at 20 ⁰C. The undissolved precipitate is collected by filtration, washed with H₂O (1 mL) and dried in vacuum at 40 ⁰C to give 143 mg (87 %) of rosuvastatin calcium salt (11) as white powder.

Claims

1. A process for preparing the compound of formula Via

wherein X" is halo and Ri is a protecting group, comprising steps: a) (optionally) reacting alkyl 3(S)-hydroxy-4-chlorobutyrate of formula I,

OH O Ck

wherein R₂ is an optionally substituted Ci - Ce alkyl or C₅ - C₇ cycloalkyl, or, alternatively -COOR₂ may also form an amide of formula -CONR_aRt_>, where R_a and R_b may independently be H, an optionally substituted C₁ - Ce alkyl or C₅ - C₇ cycloalkyl, aryl or can together with N form a heterocycle with an iodide to give a alkyl 3(S)-hydroxy-4-iodobutyrate of formula Il

wherein R₂ is as above; b) protecting the compound of Formula Il to give a protected derivative of formula III,

wherein Ri and R₂ are as above; c) reacting the compound of formula III with vinylmagnesium halide in presence of copper(l) halide and phosphite derivative with formula:

where each of R¹, R", and R¹" are same or different C₁-C₄ alkyl, C₅-C₇ cycloalkyl, or aryl which may be optionally substituted to give an alkene of formula IV wherein R₁ and R2 are as above,

d) hydrolyzing the compound of formula IV to give compound of formula V

e) reacting compound of formula V, wherein R₁ is as above, with a source of halogen in the presence of NaHCOa; and f) (optionally) separating the mixture of diastereoisomers obtained in previous step.

2. The process according to previous claim, wherein X" is I.

3. The process according to any of the previous claims, wherein a source of halogen is selected from the group consisting of: iodine, bromine, chlorine, alkali metal and earthalkali metal halides or oxohalides, interhalogens, haloacetates, N-iodosuccinimide (NIS), N-bromosuccinimide (NBS), bispyridine iodonium tetrafluoroborate and hypervalent halogen electrophiles.

4. The process according to any of the previous claims, wherein vinyl magnesium halide is vinyl magnesium chloride.

5. The process according to any of the previous claims, wherein the hydrolysis of the compound of formula IV is performed with an alkali followed by acidification.

6. The process according to any of the previous claims,, wherein the compound of the Formula Via is isolated in optical purity higher than 99 % d.e. as determined by HPLC.

7. The process according to any of the previous claims where Ri is a protecting group selected from optionally substituted Ci - Ce trialkylsilyl, Ci - Cs dialkylarylsilyl, Ci - Cs alkyldiarylsilyl, where alkyls may be same or different.

8. Use of a solvent selected from the group consisting of /-BuMeO, /-Pr₂O, pentane, hexane, heptane, cyclopentane, cyclohexane, AcOEt, methylene chloride, chloroform and mixture(s) thereof in any of the processes as claimed above.

9. Use of vacuum distillation in the process of purification of the compounds obtained in any of the processes as claimed above.

10. The process according to any of the previous claims further comprising preparing the compound of formula IX

where Ri is as defined above from compound of formula Via

where X" is a halogen, alkylsulfonyl, or arylsulfonyl.

11. The process according to previous claim where compound of formula IX

wherein Ri is as defined above, is prepared by process comprising one or more steps selected from (optionally) converting the compound of formula Via where X" is alkylsulfonyl, or arylsulfonyl into compound of formula Via where X" is halo; g) converting the compound of formula Via

where X" is halo, alkylsulfonyl, or arylsulfonyl into compound of formula VII

wherein R₄ is (optionally halo, alkyl, aryl, alkyl oxy or aryl oxy substituted) Ci-

C₄ alkyl; h) converting compound of formula VII into compound of formula VIII

i) converting the compound of formula VIII by oxidation into compound of

12. The process according to claim 10 where step g) is performed with an acylation reagent selected from the group consisting of NaOAc, LiOAc, KOAc, CsOAc, AgOAc, CuOAc, Mg(OAc)₂, Ca(OAc)₂, R₄NOAc.

13. The process according to claim 10, where step h) is performed by deacylation with an organotin compound selected from dibutyltin oxide or [f-Bu₂Sn0H(CI)]₂ or by a rection with an enzyme selected from group consisting of Porcine Pancreatic Lipase, Lipase MY, Lipase PS, Lipase Al, Candida Lipase and Alcalase, or with a reagent selected from the group consisting of guanidine and guanidine/guanidinium nitrate, HBF₄ ^χEt₂O/MeOH and BF₃ ^χEt₂O/MeCN, DBU/MeOH, hydrazine/MeOH and hydrazine hydrate/THF, cyanide/MeOH, l₂/Me0H.

14. The process according to claim 14, where step i) is performed by an oxidation reaction selected from: dimethylsulfoxide-mediated oxidations (Swern oxidation: DMSO-(COCI)₂ couple, Pfitzner-Moffatt procedure: DMSO- dicyclohexylcarbodiimide (DCC) couple, Parikh-Doering procedure: DMSO- SOβXPy couple), Λ/-oxoammonium-mediated oxidations (2,2,6,6-tetramethyl-1- piperidinyloxyl (TEMPO)-oxidant couple, oxidations with organic hypervalent iodine compound selected from Dess-Martin periodinane (DMP) and o- iodoxybenzoic acid (IBX or SIBX), oxidations with chromium (Vl) oxidants selected from Collins reagent (CrO₃XPy₂), pyridinum dichromate (PDC) (couple PDC-activated molecular sieves 4A), pyridinum chlorochromate (PCC), oxidations with manganese derivatives selected from MnO₂ and BaMnO₄ or oxidations with tetra-n-propylammonium perruthenate: Pr₄N⁺RuO₄ ^" (TPAP).

15. A process for manufacturing a compound of formula:

comprising: a) preparing an intermediate of formula Via

wherein Ri and X" are as defined above, by the process according to any of the claims 1 to 9; b) preparing the intermediate of formula IX

wherein Ri is as defined above from the intermediate of formula Via by the process according to any of the claims 10 to 14; and c) reacting the intermediate of formula IX with the compound of formula

O

X ® PRxRyRz .PARxARy

Het _or Het where A can be a bond or O, and wherein R_x, R_y, and R_z, are the same or different and are selected from optionally substituted Ci - Cs alkyl or C₃-C₆ cycloalkyl or Ci - Ce alkenyl or Cs-Cε cycloalkenyl or aryl, X^' is anion and Het is as defined above, and d) optionally comprising one or more subsequent steps in which the compound of formula X

wherein Ri and Het are as defined above, or a salt, amide, or lactone thereof.

16. A process according to previous claim wherein Het is

17. A process for manufacturing rosuvastatin, characterized in that it comprises steps: a) (optionally) reacting alkyl 3(S)-hydroxy-4-chlorobutyrate of formula I,

OH O ^cι- -?^SΓ-^ -OR₂ wherein R₂ is an optionally substituted Ci - C₈ alkyl or C₅ - C₇ cycloalkyl, or, alternatively -COOR₂ may also form an amide of formula -CONR₃Rb, where R_a and R_b may independently be H, an optionally substituted Ci -

C₈ alkyl or C₅ - C₇ cycloalkyl, aryl or can together with N form a heterocycle with an iodide to give a alkyl 3(S)-hydroxy-4-iodobutyrate of formula Il

wherein R₂ is as above; b) (optionally) protecting the compound of Formula Il to give a protected derivative of formula III,

where each of R', R", and R'" are same or different Ci-C₄ alkyl, C₅-C₇ cycloalkyl, or aryl which may be optionally substituted to give an alkene of formula IV

, wherein R₁ and R₂ are as above; d) hydrolyzing the compound of formula IV to give compound of formula V

e) reacting compound of formula V, wherein R₁ is as above, with a source of halogen in the presence of NaHCO₃ to give compound of formula Vl ; f) (optionally) separating the mixture of diastereoisomers obtained in previous step to obtain compound of formula Via

wherein X" is halo and R₁ as above; g) converting the compound of formula Via into compound of formula VII,

wherein Ri is as above and R₄ is selected from (optionally halo or alkoxy or aryloxy substituted) CrC₄ alkyl ; h) converting compound of formula VII in compound of formula VIII

wherein R₁ is as above; i) converting the compound of formula VIII by oxidation into compound of formula IX,

; wherein R₁ is as above; j) reacting said compound of formula IX with the compound of formula

wherein R_x, R_y, and R_Z) are the same or different and are selected from optionally substituted Ci - C₈ alkyl or C₃-C₆ cycloalkyl or Ci - C₈ alkenyl or C₅-C₆ cycloalkenyl or aryl, X^" is anion; and k) removing the protecting group Ri , optionally purifying and converting the obtained compound into calcium salt.

18. A process according to any of the previous 3 claims, wherein the anion X^" is a halide or alkanoate.

19. Use for the synthesis of statins of an intermediate Xl

characterized in that it has been prepared from intermediate of formula Via

wherein X" is halo, arylsulfonyl or alkylsulfonyl and R₁ is a protecting group.

20. Use for the synthesis of statins of an intermediate of formula

wherein Ri is an optionally substituted Ci - C₈ trialkylsilyl, Ci - C₈ dialkylarylsilyl, Ci - C₈ alkyldiarylsilyl, where alkyls may be same or different and R₄ is (optionally halo, alkyl, aryl, alkyl oxy or aryl oxy substituted) CrC₄ alkyl.

21. A compound of formula

wherein Ri is an optionally substituted Ci - C₈ trialkylsilyl, Ci - C₈ dialkylarylsilyl, Ci - C₈ alkyldiarylsilyl, where alkyls and aryls may be same or different and R₄ is (optionally halo, alkyl, aryl, alkyl oxy or aryl oxy substituted) C₁-C₄ alkyl.

22. A compound according to previous claim, wherein R₄ is selected from group consisting of: CH₃, C(CH₃J₃, CH₂CI, CHCI₂, CCI₃, CF₃, CH₂OCH₃, CH₂OCPh₃, CH₂OPh₁ CH₂Ph₁ CHPh₂, CH₂CH₂Ph, CH=CHCH₂CH₃ and CH₂CH₂(C=O)CH₃).

23. A compound according to previous claim, wherein Ri is t-butyldimethylsilyl and R₄ is CH₃.

24. A compound of formula

wherein Ri is an optionally substituted Ci - C₈ trialkylsilyl, Ci - Cs dialkylarylsilyl, Ci - C₈ alkyldiarylsilyl, where alkyls and aryls may be same or different.

25. A compound according to previous claim, wherein Ri is t-butyldimethylsilyl.

26. A process for converting any of compounds of formula

where Ri is a protecting group, preferabyl silyl protecting group, into compound of formula

characterized by dissolving in chloroform, dichloromethane, hexane, preferably toluene.

27. A process for the manufacturing of a compound of the formula X

comprising Wittig reaction in which the compound of formula IX

is reacted with a compound of formula

where A can be a bond or O and wherein R_x, R_y, and R_z, are the same or different and are selected from optionally substituted Ci - C₈ alkyl or C₃-C₆ cycloalkyl or Ci - C₈ alkenyl or C₅-

C₆ cycloalkenyl or aryl,

Ri is a protecting group,

X is an anion, and Het is selected so that it forms a heterocyclic skeleton of a statin, characterized in that the reaction is performed in solvent selected from the group consisting of toluene, hexane, chloroform or dichloromethane.

28. A process according to previous claim, wherein solvent is toluene.

29. A process according to previous claim, wherein Het is selected from group consisting of:

30. A process for the manufacturing of rosuvastatatin comprising Wittig reaction in which the compound of formula IX

is reacted with a compound of formula

CQ cycloalkenyl or aryl,

Ri is a protecting group,

31. A process according to any of previous 5 claims characterized in that the compound of formula IX is dissolved in toluene at least 6 hours prior to reaction.

32. A process according to any of previous 5 claims characterized in that the Wittig reaction is performed in the presence of a strong base at temperatures between - 80 ⁰C and 40 ⁰C.

33. A process according to previous claim, wherein a strong base is selected from the group of metal amides or silazanes, metal hydrides, lithium alkyls, lithium aryls or Grignard reagents.

34. A process according to previous claim, wherein a strong base is selected from: lithium hexametydisilazane, sodium hexametydisilazane, potassium hexametydisilazane, lithium diisopropylamide, sodium hydride, buthyllithium of phenylmagnesium halide.

35. A process according to any of the previous claims, further comprising a treatment of the reaction mixture, comprising following sequence of steps: a) (optionally) concentrating a reaction mixture; b) acidifying a reaction mixture in the presence of water and extracting a product into water immiscible organic solvent; c) (optionally) washing an organic solvent solution of a product with water, water solution of an alkali salt or ammonium salt, and/or water solution of mineral acid; d) (optionally) washing an organic solvent solution of a product with a mixture water/ polar aprotic organic solvent; e) (optionally) drying a solution with a drying agent; f) concentrating a solution to obtain residue, preferably by evaporation; and g) purifying a residue.

36. A process according to any of the claims 27 to 35, wherein the anion X^" is halide or an (optionally substituted) alkanoate.

37. A process according to previous claim, wherein an (optionally substituted) alkanoate is trifluroacetate.

38. A statin selected from the group comprising rosuvastatin, cerivastatin, fluvastatin, pravastatin, bervastatin, atorvastatin or analogs thereof characterized in that it is manufactured by the process as claimed above.

39. A pharmaceutical composition comprising a pharmaceuticaly acceptable carrier and a statin selected from rosuvastatin calcium, fluvastatin sodium, atorvastatin calcium manufactured by the process using the intermediate Via

wherein X" is halo and R₁ is a protecting group.