Design of experiments optimization of N,N,N-trimethyl chitosan synthesis using N,N-diisopropylethylamine base

This study presents a novel synthesis method of N,N,N-trimethyl chitosan (TMC) by using a non-nucleophilic base and optimizing the solvent system for enhanced scalability, while addressing critical factors such as viscosity management and stirring efficiency. The study objectives also included achieving high N,N,N-trimethylation without O-methylation while minimizing reagent use. Eight bases, three solvent systems, and varying levels of dilution were explored to mitigate viscosity challenges and gas evolution. ¹H NMR spectroscopy was used to characterize the TMC products. The integral values of the peaks at 3.3, 3.0, and 2.8 ppm, corresponding to trimethyl, dimethyl, and monomethyl groups, were used to quantify the methylation degrees. The most promising initial results were obtained with N,N-diisopropylethylamine (DIPEA) base, and DMF as solvent. Using 6 eq methyl iodide (MeI) relative to chitosan and DIPEA as base, up to 68 % DTM was achieved. Applying Design of Experiments (DoE), the method was further optimized under diluted conditions, crucial for industrial scalability and viscosity control. Results from a full factorial design (3²) revealed that diluted medium effectively prevented viscosity concerns, achieving a notably low viscosity of 5.9 cP in the reaction mixture, a 16-fold decrease in viscosity, compared to initial experiments. It was also established that both the MeI reagent and the base addition are significant factors for the DTM response, with both factors showing quadratic effects. The DoE model demonstrated high significance (R = 0.97), high precision for future prediction (Q2 = 0.87), good model validity (0.84) and excellent reproducibility (0.96). The results mark a notable advancement in TMC synthesis, offering an efficient and practical method with significant implications for industrial applications.