Microreactor Flow Synthesis of the Secondary High Explosive 2,6-Diamino-3,5-dinitropyrazine-1-oxide (LLM-105)

The secondary high explosive 2,6-diamino-3,5-dinitropyrazine-1-oxide, or LLM-105, has been synthesized using a commercially available flow microreactor system. Investigations focused on optimizing flow nitration conditions of the cost effective 2,6-diaminopyrazine-1-oxide (DAPO) in order to test the feasibility and viability of flow nitration as a means for the continuous synthesis of LLM-105. The typical benefits of microreactor flow synthesis including safety, tight temperature control, decreased reaction time, and improved product purity all appear to be highly relevant in the synthesis of LLM-105. However, the process does not provide any gains in yield, as the typical 50-60% yields are equivalent to the batch process. A key factor in producing pure LLM-105 lies in the ability to eliminate any acid inclusions in the final crystalline material through both a controlled quench and recrystallization. The optimized flow nitration conditions, multigram scale-up results, analyses of sample purity, and quenching conditions for purity and crystal morphology are reported.