US20040161474A1 - Rare earth metal compounds methods of making, and methods of using the same - Google Patents

Rare earth metal compounds methods of making, and methods of using the same Download PDF

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Publication number
US20040161474A1
US20040161474A1 US10/444,774 US44477403A US2004161474A1 US 20040161474 A1 US20040161474 A1 US 20040161474A1 US 44477403 A US44477403 A US 44477403A US 2004161474 A1 US2004161474 A1 US 2004161474A1
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US
United States
Prior art keywords
compound
lanthanum
rare earth
oxycarbonate
phosphate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/444,774
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English (en)
Inventor
Rudi Moerck
Timothy Spitler
Edward Schauer
Jan Prochazka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Spectrum Pharmaceuticals Inc
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US10/444,774 priority Critical patent/US20040161474A1/en
Priority to SG2007009418A priority patent/SG173920A1/en
Priority to DE03749033T priority patent/DE03749033T1/de
Priority to BRPI0313737-6A priority patent/BRPI0313737B1/pt
Priority to EA200500352A priority patent/EA009766B1/ru
Priority to EA200800020A priority patent/EA012877B1/ru
Priority to JP2005502047A priority patent/JP4584830B2/ja
Priority to EA200800021A priority patent/EA017083B1/ru
Priority to PCT/US2003/025192 priority patent/WO2004016553A2/en
Priority to ES10151585T priority patent/ES2907070T3/es
Priority to ES03749033T priority patent/ES2311441T1/es
Priority to CA2494992A priority patent/CA2494992C/en
Priority to KR1020057002491A priority patent/KR101108820B1/ko
Priority to EP10151585.6A priority patent/EP2194028B1/en
Priority to BRPI0313737A priority patent/BRPI0313737B8/pt
Priority to EP03749033A priority patent/EP1529015A2/en
Priority to EP06000002A priority patent/EP1647524A3/en
Priority to AU2003268082A priority patent/AU2003268082A1/en
Priority to MXPA05001773A priority patent/MXPA05001773A/es
Assigned to ALTAIR NANOMATERIALS INC. reassignment ALTAIR NANOMATERIALS INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MOERCK, RUDI E., SPITLER, TIMOTHY MALCOME, PROCHAZKA, JAN, SCHAUER, EDWARD A.
Publication of US20040161474A1 publication Critical patent/US20040161474A1/en
Priority to IL166803A priority patent/IL166803A0/en
Priority to US11/181,650 priority patent/US7588782B2/en
Priority to US11/181,538 priority patent/US20050247628A1/en
Priority to US11/181,609 priority patent/US20060002837A1/en
Priority to US11/217,001 priority patent/US20060083791A1/en
Priority to HK06104369.9A priority patent/HK1082242A1/xx
Assigned to ALTAIRNANO, INC. reassignment ALTAIRNANO, INC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: ALTAIR NANOMATERIALS, INC.
Priority to US12/051,726 priority patent/US20080226735A1/en
Priority to US12/197,157 priority patent/US20090053322A1/en
Assigned to SPECTRUM PHARAMACEUTICALS, INC. reassignment SPECTRUM PHARAMACEUTICALS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALTAIR NANOMATERIALS, INC.
Priority to AU2009238282A priority patent/AU2009238282B2/en
Priority to US12/643,059 priority patent/US8715603B2/en
Priority to US12/814,716 priority patent/US20100278910A1/en
Assigned to SPECTRUM PHARMACEUTALS, INC. reassignment SPECTRUM PHARMACEUTALS, INC. CORRECTION TO REEL FRAME 023463/0076 - CORRECTION TO ASSIGNEE'S NAME AND CORRECTION TO LANGUGAGE CONTAINED IN THE BODY OF THE ASSIGNMENT DOCUMENT. Assignors: ALTAIRNANO, INC.
Assigned to SPECTRUM PHARMACEUTICALS, INC. reassignment SPECTRUM PHARMACEUTICALS, INC. CORRECTIVE ASSIGNEMENT TO CORRECT SPELLING OF ASSGNEE'S NAME PROVIOUSLY RECORDED ON REEL 024910 FRAME 0439 Assignors: ALTAIRNANO, INC.
Priority to US13/018,894 priority patent/US20110123628A1/en
Priority to US13/229,157 priority patent/US20110318410A1/en
Priority to US14/149,299 priority patent/US8852543B2/en
Priority to US14/491,305 priority patent/US20150004086A1/en
Priority to US14/860,023 priority patent/US9511091B2/en
Priority to ES17787111T priority patent/ES2907003T3/es
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07F—ACYCLIC, CARBOCYCLIC OR HETEROCYCLIC COMPOUNDS CONTAINING ELEMENTS OTHER THAN CARBON, HYDROGEN, HALOGEN, OXYGEN, NITROGEN, SULFUR, SELENIUM OR TELLURIUM
    • C07F5/00—Compounds containing elements of Groups 3 or 13 of the Periodic Table
    • C07F5/003—Compounds containing elements of Groups 3 or 13 of the Periodic Table without C-Metal linkages
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    • B01J20/0207—Compounds of Sc, Y or Lanthanides
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    • B01J20/28054—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J20/28057—Surface area, e.g. B.E.T specific surface area
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    • C01P2004/03—Particle morphology depicted by an image obtained by SEM
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Definitions

  • the present invention relates to rare earth metal compounds, particularly rare earth metal compounds having a porous structure.
  • the present invention also includes methods of making the porous rare earth metal compounds and methods of using the compounds of the present invention.
  • the compounds of the present invention can be used to bind or absorb metals such as arsenic, selenium, antimony and metal ions such as arsenic III + and V + .
  • the compounds of the present invention may therefore find use in water filters or other devices or methods to remove metals and metal ions from fluids, especially water.
  • the compounds of the present invention are also useful for binding or absorbing anions such as phosphate in the gastrointestinal tract of mammals. Accordingly, one use of the compounds of the present invention is to treat high serum phosphate levels in patients with end-stage renal disease undergoing kidney dialysis.
  • the compounds may be provided in a filter that is fluidically connected with a kidney dialysis machine such that the phosphate content in the blood is reduced after passing through the filter.
  • the compounds can be used to deliver a lanthanum or other rare-earth metal compound that will bind phosphate present in the gut and prevent its transfer into the bloodstream.
  • Compounds of the present invention can also be used to deliver drugs or to act as a filter or absorber in the gastrointestinal tract or in the blood stream.
  • the materials can be used to deliver inorganic chemicals in the gastrointestinal tract or elsewhere.
  • porous particle structure and the high surface area are beneficial to high absorption rates of anions.
  • these properties permit the compounds of the present invention to be used to bind phosphate directly in a filtering device fluidically connected with kidney dialysis equipment.
  • the specific surface area of compounds according to the present invention as measured by the BET method, varies depending on the method of preparation, and has a significant effect on the properties of the product.
  • the specific properties of the resulting compound can be adjusted by varying one or more parameters in the method of making the compound.
  • the compounds of the present invention have a BET specific surface area of at least about 10 m 2 /g and may have a BET specific surface area of at least about 20 m 2 /g and alternatively may have a BET specific surface area of at least about 35 m 2 /g.
  • the compounds have a BET specific surface area within the range of about 10 m 2 /g and about 40 m 2 /g.
  • the compounds of the present invention and in particular, the lanthanum compounds and more particularly the lanthanum oxycarbonates of the present invention exhibit phosphate binding or removal of at least 40% of the initial concentration of phosphate after ten minutes. Desirably, the lanthanum compounds exhibit phosphate binding or removal of at least 60% of the initial concentration of phosphate after ten minutes. In other words, the lanthanum compounds and in particular, the lanthanum compounds and more particularly the lanthanum oxycarbonates of the present invention exhibit a phosphate binding capacity of at least 45 mg of phosphate per gram of lanthanum compound.
  • the lanthanum compounds exhibit a phosphate binding capacity of at least 50 mg PO 4 /g of lanthanum compound, more suitably, a phosphate binding capacity of at least 75 mg PO 4 /g of lanthanum compound.
  • the lanthanum compounds exhibit a phosphate binding capacity of at least 100 mg PO 4 /g of lanthanum compound, more desirably, a phosphate binding capacity of at least 110 mg PO 4 /g of lanthanum compound.
  • rare earth metal compounds and in particular, rare earth metal oxychlorides and oxycarbonates are provided.
  • the oxycarbonates may be hydrated or anhydrous. These compounds may be produced according to the present invention as particles having a porous structure.
  • the rare earth metal compound particles of the present invention may conveniently be produced within a controllable range of surface areas with resultant variable and controllable adsorption rates of ions.
  • the porous particles or porous structures of the present invention are made of nano-sized to micron-sized crystals with controllable surface areas.
  • the rare earth oxychloride is desirably lanthanum oxychloride (LaOCl).
  • the rare earth oxycarbonate hydrate is desirably lanthanum oxycarbonate hydrate (La 2 O(CO 3 ) 2 .xH 2 O where x is from and including 2 to and including 4). This compound will further be referred to in this text as La 2 O(CO 3 ) 2 .xH 2 O.
  • the anhydrous rare earth oxycarbonate is desirably lanthanum oxycarbonate La 2 O 2 CO 3 or La 2 CO 5 of which several crystalline forms exist. The lower temperature form will be identified as La 2 O 2 CO 3 and the form obtained at higher temperature or after a longer calcination time will be identified as La 2 CO 5 .
  • lanthanum oxycarbonate may be present as a mixture of the hydrate and the anhydrous form.
  • anhydrous lanthanum oxycarbonate may be present as a mixture of La 2 O 2 CO 3 and La 2 CO 5 and may be present in more than a single crystalline form.
  • One method of making the rare earth metal compound particles includes making a solution of rare earth metal chloride, subjecting the solution to a substantially total evaporation process using a spray dryer or other suitable equipment to form an intermediate product, and calcining the obtained intermediate product at a temperature between about 500° and about 1200° C.
  • the product of the calcination step may be washed, filtered, and dried to make a suitable finished product.
  • the intermediate product may be milled in a horizontal or vertical pressure media mill to a desired surface area and then further spray dried or dried by other means to produce a powder that may be further washed and filtered.
  • An alternative method of making the rare earth metal compounds, particularly rare earth metal anhydrous oxycarbonate particles includes making a solution of rare earth metal acetate, subjecting the solution to a substantially total evaporation process using a spray dryer or other suitable equipment to make an intermediate product, and calcining the obtained intermediate product at a temperature between about 400° C. and about 700° C.
  • the product of the calcination step may be washed, filtered, and dried to make a suitable finished product.
  • the intermediate product may be milled in a horizontal or vertical pressure media mill to a desired surface area, spray dried or dried by other means to produce a powder that may be washed, filtered, and dried.
  • Yet another method of making the rare earth metal compounds includes making rare earth metal oxycarbonate hydrate particles.
  • the rare earth metal oxycarbonate hydrate particles can be made by successively making a solution of rare earth chloride, subjecting the solution to a slow, steady feed of a sodium carbonate solution at a temperature between about 30° and about 90° C. while mixing, then filtering and washing the precipitate to form a filter cake, then drying the filter cake at a temperature of about 100° to 120° C. to produce the desired rare earth oxycarbonate hydrate species.
  • the filter cake may be sequentially dried, slurried, and milled in a horizontal or vertical pressure media mill to a desired surface area, spray dried or dried by other means to produce a powder that may be washed, filtered, and dried.
  • the process for making rare earth metal oxycarbonate hydrate particles may be modified to produce anhydrous particles.
  • This modification includes subjecting the dried filter cake to a thermal treatment at a specified temperature between about 400° C. to about 700° C. and for a specified time between 1 h and 48 h.
  • the product of the thermal treatment may be slurried and milled in a horizontal or vertical pressure media mill to a desired surface area, spray dried or dried by other means to produce a powder that may be washed, filtered, and dried.
  • compounds of the present invention may be used to treat patients with hyperphosphatemia.
  • the compounds may be made into a form that may be delivered to a mammal and that may be used to remove phosphate from the gut or decrease phosphate absorption into the blood stream.
  • the compounds may be formulated to provide an orally ingestible form such as a liquid solution or suspension, a tablet, capsule, gelcap, or other suitable and known oral form.
  • the present invention contemplates a method for treating hyperphosphatemia that comprises providing an effective amount of a compound of the present invention.
  • compounds made according to this invention as a porous structure of sufficient mechanical strength may be placed in a device fluidically connected to a dialysis machine through which the blood flows, to directly remove phosphate by reaction of the rare-earth compound with phosphate in the bloodstream.
  • the present invention therefore contemplates a device having an inlet and an outlet with one or more compounds of the present invention disposed between the inlet and the outlet.
  • the present invention also contemplates a method of reducing the amount of phosphate in blood that comprises contacting the blood with one or more compounds of the present invention for a time sufficient to reduce the amount of phosphate in the blood.
  • the compounds of the present invention may be used as a substrate for a filter having an inlet and outlet such that the compounds of the present invention are disposed between the inlet and the outlet.
  • a fluid containing a metal, metal ion, phosphate or other ion may be passed from the inlet to contact the compounds of the present invention and through the outlet.
  • a method of reducing the content of a metal in a fluid comprises flowing the fluid through a filter that contains one or more compounds of the present invention to reduce the amount of metal present in the water.
  • FIG. 1 is a general flow sheet of a process according to the present invention that produces LaOCl (lanthanum oxychloride).
  • FIG. 2 is a flow sheet of a process according to the present invention that produces a coated titanium dioxide structure.
  • FIG. 3 is a flow sheet of a process according to the present invention that produces lanthanum oxycarbonate
  • FIG. 4 is a graph showing the percentage of phosphate removed from a solution as a function of time by LaO(CO 3 ) 2 .x H 2 O, (where x is from and including 2 to and including 4), made according to the process of the present invention, as compared to the percentage of phosphate removed by commercial grade La carbonate La 2 (CO 3 ) 3 .4H 2 O in the same conditions.
  • FIG. 5 is a graph showing the amount of phosphate removed from a solution as a function of time per g of a lanthanum compound used as a drug to treat hyperphosphatemia.
  • the drug in one case is La 2 O(CO 3 ) 2 .x H 2 O (where x is from and including 2 to and including 4), made according to the process of the present invention.
  • the drug is commercial grade La carbonate La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 6 is a graph showing the amount of phosphate removed from a solution as a function of time per g of a lanthanum compound used as a drug to treat hyperphosphatemia.
  • the drug in one case is La 2 O 2 CO 3 made according to the process of the present invention. In the comparative case the drug is commercial grade La carbonate La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 7 is a graph showing the percentage of phosphate removed as a function of time by La 2 O 2 CO 3 made according to the process of the present invention, as compared to the percentage of phosphate removed by commercial grade La carbonate La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 8 is a graph showing a relationship between the specific surface area of the oxycarbonates made following the process of the present invention and the amount of phosphate bound or removed from solution 10 min after the addition of the oxycarbonate.
  • FIG. 9 is a graph showing a linear relationship between the specific surface area of the oxycarbonates of this invention and the first order rate constant calculated from the initial rate of reaction of phosphate.
  • FIG. 10 is a flow sheet of a process according to the present invention that produces lanthanum oxycarbonate hydrate La 2 (CO 3 ) 2 .xH 2 O
  • FIG. 11 is a flow sheet of a process according to the present invention that produces anhydrous lanthanum oxycarbonate La 2 O 2 CO 3 or La 2 CO 5 .
  • FIG. 12 is a scanning electron micrograph of lanthanum oxychloride, made following the process of the present invention.
  • FIG. 13 is an X-Ray diffraction scan of lanthanum oxychloride LaOCl made according to the process of the present invention and compared with a standard library card of lanthanum oxychloride.
  • FIG. 14 is a graph showing the percentage of phosphate removed from a solution as a function of time by LaOCl made according to the process of the present invention, as compared to the amount of phosphate removed by commercial grades of La carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 . 4H 2 O in the same conditions.
  • FIG. 15 shows a scanning electron micrograph of La 2 O(CO 3 ) 2 .x H 2 O, where x is from and including 2 to and including 4.
  • FIG. 16 is an X-Ray diffraction scan of La 2 O(CO 3 ) 2 .x H 2 O produced according to the present invention and includes a comparison with a “library standard” of La 2 O(CO 3 ) 2 .xH 2 O where x is from and including 2 to and including 4.
  • FIG. 17 is a graph showing the rate of removal of phosphorous from a solution by La 2 O(CO 3 )2.xH 2 O compared to the rate obtained with commercially available La 2 (CO 3 ) 3 . H 2 O and La 2 (CO 3 ) 3 .4H 2 O in the same conditions.
  • FIG. 18 is a scanning electron micrograph of anhydrous lanthanum oxycarbonate La 2 O 2 CO 3 .
  • FIG. 19 is an X-Ray diffraction scan of anhydrous La 2 O 2 CO 3 produced according to the present invention and includes a comparison with a “library standard” of La 2 O 2 CO 3 .
  • FIG. 20 is a graph showing the rate of phosphorous removal obtained with La 2 O 2 CO 3 made following the process of the present invention and compared to the rate obtained for commercially available La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 21 is a scanning electron micrograph of La 2 CO 5 made according to the process of the present invention.
  • FIG. 22 is an X-Ray diffraction scan of anhydrous La 2 CO 5 produced according to the present invention and includes a comparison with a “library standard” of La 2 CO 5 .
  • FIG. 23 is a graph showing the rate of phosphorous removal obtained with La 2 CO 5 made following the process of the present invention and compared to the rate obtained for commercially available La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 24 is a scanning electron micrograph of TiO 2 support material made according to the process of the present invention.
  • FIG. 25 is a scanning electron micrograph of a TiO 2 structure coated with LaOCl, made according to the process of the present invention, calcined at 800° C.
  • FIG. 26 is a scanning electron micrograph of a TiO 2 structure coated with LaOCl, made according to the process of the present invention, calcined at 600° C.
  • FIG. 27 is a scanning electron micrograph of a TiO 2 structure coated with LaOCl, made according to the process of the present invention, calcined at 900° C.
  • FIG. 28 shows X-Ray scans for TiO 2 coated with LaOCl and calcined at different temperatures following the process of the present invention, and compared to the X-Ray scan for pure LaOCl.
  • FIG. 29 shows the concentration of lanthanum in blood plasma as a function of time, for dogs treated with lanthanum oxycarbonates made according to the process of the present invention.
  • FIG. 30 shows the concentration of phosphorous in urine as a function of time in rats treated with lanthanum oxycarbonates made according to the process of the present invention, and compared to phosphorus concentration measured in untreated rats.
  • FIG. 31 shows a device having an inlet, an outlet, and one or more compounds of the present invention disposed between the inlet and the outlet.
  • lanthanum compounds While the description will generally refer to lanthanum compounds, the use of lanthanum is merely for ease of description and is not intended to limit the invention and claims solely to lanthanum compounds. In fact, it is contemplated that the process and the compounds described in the present specification is equally applicable to rare earth metals other than lanthanum such as Ce and Y.
  • a process for making a rare earth oxychloride compound, and, in particular a lanthanum oxychloride compound according to one embodiment of the present invention is shown.
  • the source of lanthanum chloride may be any suitable source and is not limited to any particular source.
  • One source of lanthanum chloride solution is to dissolve commercial lanthanum chloride crystals in water or in an HCl solution.
  • Another source is to dissolve lanthanum oxide in a hydrochloric acid solution.
  • the lanthanum chloride solution is evaporated to form an intermediate product.
  • the evaporation 20 is conducted under conditions to achieve substantially total evaporation. Desirably, the evaporation is conducted at a temperature higher than the boiling point of the feed solution (lanthanum chloride) but lower than the temperature where significant crystal growth occurs.
  • the resulting intermediate product may be an amorphous solid formed as a thin film or may have a spherical shape or a shape as part of a sphere.
  • substantially total evaporation or “substantially complete evaporation” as used in the specification and claims refer to evaporation such that the resulting solid intermediate contains less than 15% free water, desirably less than 10% free water, and more desirably less than 1% free water.
  • free water is understood and means water that is not chemically bound and can be removed by heating at a temperature below 150° C. After substantially total evaporation or substantially complete evaporation, the intermediate product will have no visible moisture present.
  • the evaporation step may be conducted in a spray dryer.
  • the intermediate product will consist of a structure of spheres or parts of spheres.
  • the spray dryer generally operates at a discharge temperature between about 120° C. and about 500° C.
  • the intermediate product may then be calcined in any suitable calcination apparatus 30 by raising the temperature to a temperature between about 500° C. to about 1200° C. for a period of time from about 2 to about 24 h and then cooling to room temperature.
  • the cooled product may be washed 40 by immersing it in water or dilute acid, to remove any water-soluble phase that may still be present after the calcination step 30 .
  • the temperature and the length of time of the calcination process may be varied to adjust the particle size and the reactivity of the product.
  • the particles resulting from calcination generally have a size between 1 and 1000 ⁇ m.
  • the calcined particles consist of individual crystals, bound together in a structure with good physical strength and a porous structure.
  • the individual crystals forming the particles generally have a size between 20 nm and 10 ⁇ m.
  • a feed solution of titanium chloride or titanium oxychloride is provided by any suitable source.
  • One source is to dissolve anhydrous titanium chloride in water or in a hydrochloric acid solution.
  • Chemical control agents or additives 104 may be introduced to this feed solution to influence the crystal form and the particle size of the final product.
  • One chemical additive is sodium phosphate Na 3 PO 4 .
  • the feed solution of titanium chloride or titanium oxychloride is mixed with the optional chemical control agent 104 in a suitable mixing step 110 . The mixing may be conducted using any suitable known mixer.
  • the feed solution is evaporated to form an intermediate product, which in this instance is titanium dioxide (TiO 2 ).
  • the evaporation 120 is conducted at a temperature higher than the boiling point of the feed solution but lower than the temperature where significant crystal growth occurs and to achieve substantially total evaporation.
  • the resulting intermediate product may desirably be an amorphous solid formed as a thin film and may have a spherical shape or a shape as part of a sphere.
  • the intermediate product may then be calcined in any suitable calcination apparatus 130 by raising the temperature to a temperature between about 400° C. to about 1200° C. for a period of time from about 2 to about 24 h and then cooling to room temperature (25° C.).
  • the cooled product is then washed 140 by immersing it in water or dilute acid, to remove traces of any water-soluble phase that may still be present after the calcination step.
  • the method of manufacture of the intermediate product according to the present invention can be adjusted and chosen to make a structure with the required particle size and porosity.
  • the evaporation step 120 and the calcination step 130 can be adjusted for this purpose.
  • the particle size and porosity can be adjusted to make the structure of the intermediate product suitable to be used as an inert filter in the bloodstream.
  • the washed TiO 2 product is then suspended or slurried in a solution of an inorganic compound.
  • a desirable inorganic compound is a rare-earth or lanthanum compound, and in particular lanthanum chloride.
  • This suspension of TiO 2 in the inorganic compound solution is again subjected to total evaporation 160 under conditions in the same range as defined in step 120 and to achieve substantially total evaporation.
  • the evaporation steps 120 and 160 may be conducted in a spray drier.
  • the inorganic compound will precipitate as a salt, an oxide, or an oxy-salt. If the inorganic compound is lanthanum chloride, the precipitated product will be lanthanum oxychloride. If the original compound is lanthanum acetate, the precipitated product will be lanthanum oxide.
  • the product of step 160 is further calcined 170 at a temperature between 500° and 1100° C. for a period of 2 to 24 h.
  • the temperature and the time of the calcination process influence the properties and the particle size of the product.
  • the product may be washed 180 .
  • the resulting product can be described as crystals of lanthanum oxychloride or lanthanum oxide formed on a TiO 2 substrate.
  • the resulting product may be in the form of hollow thin-film spheres or parts of spheres.
  • the spheres will have a size of about 1 ⁇ m to 1000 ⁇ m and will consist of a structure of individual bound particles.
  • the individual particles have a size between 20 nm and 10 ⁇ m.
  • the final product consists of crystals of lanthanum oxychloride on a TiO 2 substrate, these crystals may be hydrated. It has been found that this product will effectively react with phosphate and bind it as an insoluble compound. It is believed that, if this final product is released in the human stomach and gastrointestinal tract, the product will bind the phosphate that is present and decrease the transfer of phosphate from the stomach and gastrointestinal tract to the blood stream. Therefore, the product of this invention may be used to limit the phosphorous content in the bloodstream of patients on kidney dialysis.
  • a process for making anhydrous lanthanum oxycarbonate is shown in FIG. 3.
  • a solution of lanthanum acetate is made by any method.
  • One method to make the lanthanum acetate solution is to dissolve commercial lanthanum acetate crystals in water or in an HCl solution.
  • the lanthanum acetate solution is evaporated to form an intermediate product.
  • the evaporation 220 is conducted at a temperature higher than the boiling point of the lanthanum acetate solution but lower than the temperature where significant crystal growth occurs and under conditions to achieve substantially total evaporation.
  • the resulting intermediate product may desirably be an amorphous solid formed as a thin film and may have a spherical shape or a shape as part of a sphere.
  • the intermediate product may then be calcined in any suitable calcination apparatus 230 by raising the temperature to a temperature between about 400° C. to about 800° C. for a period of time from about 2 to about 24 h and then cooled to room temperature.
  • the cooled product may be washed 240 by immersing it in water or dilute acid, to remove any water-soluble phase that may still be present after the calcination step.
  • the temperature and the length of time of the calcination process may be varied to adjust the particle size and the reactivity of the product.
  • the particles resulting from the calcination generally have a size between 1 and 1000 ⁇ m.
  • the calcined particles consist of individual crystals, bound together in a structure with good physical strength and a porous structure.
  • the individual crystals generally have a size between 20 nm and 10 ⁇ m.
  • the products made by methods shown in FIGS. 1, 2, and 3 comprise ceramic particles with a porous structure. Individual particles are in the micron size range. The particles are composed of crystallites in the nano-size range, fused together to create a structure with good strength and porosity.
  • the particles made according to the process of the present invention have the following common properties:
  • the products of the present invention have the potential to be used in a filtration device placed directly in the bloodstream.
  • a desirable lanthanum oxycarbonate is La 2 O(CO 3 ) 2 .xH 2 O, where 2 ⁇ 4. This lanthanum oxycarbonate is preferred because it exhibits a relatively high rate of removal of phosphate.
  • the amount of lanthanum oxycarbonate powder is such that the amount of La in suspension is 3 times the stoichiometric amount needed to react completely with the phosphate.
  • Samples of the suspension are taken at intervals, through a filter that separated all solids from the liquid. The liquid sample is analyzed for phosphorous.
  • FIG. 4 shows that after 10 min, La 2 O(CO 3 ) 2 .xH 2 O has removed 86% of the phosphate in solution, whereas a commercial hydrated La carbonate La 2 (CO 3 ) 3 .4H 2 O removes only 38% of the phosphate in the same experimental conditions after the same time.
  • FIG. 5 shows that the La 2 O(CO 3 ) 2 .xH 2 O depicted in FIG. 4 has a capacity of phosphate removal of 110 mg PO 4 removed/g of La compound after 10 min in the conditions described above, compared to 45 mg PO 4 /g for the commercial La carbonate taken as reference.
  • La 2 O 2 CO 3 Another preferred lanthanum carbonate is the anhydrous La oxycarbonate La 2 O 2 CO 3 .
  • This compound is preferred because of its particularly high binding capacity for phosphate, expressed as mg PO 4 removed/g of compound.
  • FIG. 6 shows that La 2 O 2 CO 3 binds 120 mg PO 4 /g of La compound after 10 min, whereas La 2 (CO 3 ) 3 .4H 2 O used as reference only binds 45 mg PO 4 /g La compound.
  • FIG. 7 shows the rate of reaction with phosphate of the oxycarbonate La 2 O 2 CO 3 . After 10 min of reaction, 73% of the phosphate had been removed, compared to 38% for commercial lanthanum carbonate used as reference.
  • [PO 4 ] is the phosphate concentration in solution (mol/liter)
  • t is time (min)
  • k 1 is the first order rate constant (min ⁇ 1 ).
  • the table gives the rate constant for the initial reaction rate, i.e. the rate constant calculated from the experimental points for the first minute of the reaction.
  • FIG. 8 shows that there is a good correlation between the specific surface area and the amount of phosphate reacted after 10 min. It appears that in this series of tests, the most important factor influencing the rate of reaction is the surface area, independently of the composition of the oxycarbonate or the method of manufacture. A high surface area can be achieved by adjusting the manufacturing method or by milling a manufactured product.
  • FIG. 9 shows that a good correlation is obtained for the same compounds by plotting the first order rate constant as given in Table I and the BET specific surface area.
  • the correlation can be represented by a straight line going through the origin. In other words, within experimental error, the initial rate of reaction appears to be proportional to the phosphate concentration and also to the available surface area.
  • FIG. 10 another process for making lanthanum oxycarbonate and in particular, lanthanum oxycarbonate tetra hydrate, is shown.
  • an aqueous solution of lanthanum chloride is made by any method.
  • One method to make the solution is to dissolve commercial lanthanum chloride crystals in water or in an HCl solution.
  • Another method to make the lanthanum chloride solution is to dissolve lanthanum oxide in a hydrochloric acid solution.
  • the LaCl 3 solution is placed in a well-stirred tank reactor.
  • the LaCl 3 solution is then heated to 80° C.
  • a previously prepared analytical grade sodium carbonate is steadily added over a period of 2 hours with vigorous mixing.
  • the mass of sodium carbonate required is calculated at 6 moles of sodium carbonate per 2 moles of LaCl 3 .
  • the resultant slurry or suspension is allowed to cure for 2 hours at 80° C.
  • the suspension is then filtered and washed with demineralized water to produce a clear filtrate.
  • the filter cake is placed in a convection oven at 105° C. for 2 hours or until a stable weight is observed.
  • the initial pH of the LaCl 3 solution is 2, while the final pH of the suspension after cure is 5.5.
  • a white powder is produced.
  • the resultant powder is a lanthanum oxycarbonate four hydrate (La 2 O(CO 3 ) 2 .xH 2 O).
  • the number of water molecules in this compound is approximate and may vary between 2 and 4 (and including 2 and 4).
  • an aqueous solution of lanthanum chloride is made by any method.
  • One method to make the solution is to dissolve commercial lanthanum chloride crystals in water or in an HCl solution.
  • Another method to make the lanthanum chloride solution is to dissolve lanthanum oxide in a hydrochloric acid solution.
  • the LaCl 3 solution is placed in a well-stirred tank reactor.
  • the LaCl 3 solution is then heated to 80° C.
  • a previously prepared analytical grade sodium carbonate is steadily added over 2 hours with vigorous mixing.
  • the mass of sodium carbonate required is calculated at 6 moles of sodium carbonate per 2 moles of LaCl 3 .
  • the required mass of sodium carbonate solution is added the resultant slurry or suspension is allowed to cure for 2 hours at 80° C.
  • the suspension is then washed and filtered removing NaCl (a byproduct of the reaction) to produce a clear filtrate.
  • the filter cake is placed in a convection oven at 105° C. for 2 hours or until a stable weight is observed.
  • the initial pH of the LaCl 3 solution is 2.2, while the final pH of the suspension after cure is 5.5.
  • a white lanthanum oxycarbonate hydrate powder is produced.
  • the lanthanum oxycarbonate hydrate is placed in an alumina tray, which is placed in a high temperature muffle furnace.
  • the white powder is heated to 500° C. and held at that temperature for 3 hours.
  • Anhydrous La 2 C 2 O 3 is formed.
  • the anhydrous lanthanum oxycarbonate formed as indicated in the previous paragraph may be heated at 500° C. for 15 to 24 h instead of 3h or at 600° C. instead of 500° C.
  • the resulting product has the same chemical formula, but shows a different pattern in an X-Ray diffraction scan and exhibits a higher physical strength and a lower surface area.
  • the product corresponding to a higher temperature or a longer calcination time is defined here as La 2 CO 5 .
  • the device 500 may be in the form of a filter or other suitable container. Disposed between the inlet 502 and the outlet 504 is a substrate 506 in the form of a plurality of one or more compounds of the present invention.
  • the device may be fluidically connected to a dialysis machine through which the blood flows, to directly remove phosphate by reaction of the rare-earth compound with phosphate in the bloodstream.
  • the present invention also contemplates a method of reducing the amount of phosphate in blood that comprises contacting the blood with one or more compounds of the present invention for a time sufficient to reduce the amount of phosphate in the blood.
  • the device 500 may be provided in a fluid stream so that a fluid containing a metal, metal ion, phosphate or other ion may be passed from the inlet 502 through the substrate 506 to contact the compounds of the present invention and out the outlet 504 .
  • a method of reducing the content of a metal in a fluid comprises flowing the fluid through a device 500 that contains one or more compounds of the present invention to reduce the amount of metal present in the water.
  • FIG. 12 shows a scanning electron micrograph of the product, enlarged 25,000 times. The micrograph shows a porous structure formed of needle-like particles. The X-Ray diffraction pattern of the product (FIG. 13) shows that it consists of lanthanum oxychloride LaOCl.
  • Example 1 To determine the reactivity of a commercial lanthanum with respect to phosphate, the relevant portion of Example 1 was repeated under the same conditions, except that commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O was used instead of the lanthanum oxychloride of the present invention. Additional curves on FIG. 14 show the rate of removal of phosphate corresponding to commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ).4H 2 O. FIG. 14 shows that the rate of removal of phosphate with the commercial lanthanum carbonate is faster at the beginning but slower after about 3 minutes.
  • aqueous HCl solution having a volume of 334.75 ml and containing LaCl 3 (lanthanum chloride) at a concentration of 29.2 wt % as La 2 O 3 was added to a four liter beaker and heated to 80° C. with stirring.
  • the initial pH of the LaCl 3 solution was 2.2.
  • Two hundred and sixty five ml of an aqueous solution containing 63.59 g of sodium carbonate (Na 2 CO 3 ) was metered into the heated beaker using a small pump at a steady flow rate for 2 hours. Using a Buchner filtering apparatus fitted with filter paper, the filtrate was separated from the white powder product.
  • FIG. 15 shows a scanning electron micrograph of the product, enlarged 120,000 times.
  • the micrograph shows the needle-like structure of the compound.
  • the X-Ray diffraction pattern of the product (FIG. 16) shows that it consists of hydrated lanthanum oxycarbonate hydrate (La 2 O(CO 3 ) 2 .xH 2 O), with 2 ⁇ 4.
  • Example 3 To determine the reactivity of a commercial lanthanum with respect to phosphate, the second part of Example 3 was repeated under the same conditions, except that commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O was used instead of the lanthanum oxychloride of the present invention.
  • FIG. 17 shows the rate of phosphate removed using the commercial lanthanum carbonate La 2 (CO 3 )3.H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 17 shows the rate of phosphate removed using the commercial lanthanum carbonate La 2 (CO 3 )3.H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 17 shows the rate of phosphate removed using the commercial lanthanum carbonate La 2 (CO 3 )3.H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
  • aqueous HCl solution having a volume of 334.75 ml and containing LaCl 3 (lanthanum chloride) at a concentration of 29.2 wt % as La 2 O 3 was added to a 4 liter beaker and heated to 80° C. with stirring.
  • the initial pH of the LaCl 3 solution was 2.2.
  • Two hundred and sixty five ml of an aqueous solution containing 63.59 g of sodium carbonate (Na 2 CO 3 ) was metered into the heated beaker using a small pump at a steady flow rate for 2 hours. Using a Buchner filtering apparatus fitted with filter paper the filtrate was separated from the white powder product.
  • the filter cake was mixed four times with 2 liters of distilled water and filtered to wash away the NaCl formed during the reaction.
  • the washed filter cake was placed into a convection oven set at 105° C. for 2 hours until a stable weight was observed.
  • the lanthanum oxycarbonate was placed in an alumina tray in a muffle furnace. The furnace temperature was ramped to 500° C. and held at that temperature for 3 hours.
  • the resultant product was determined to be anhydrous lanthanum oxycarbonate La 2 O 2 CO 3 .
  • FIG. 18 is a scanning electron micrograph of the structure, enlarged 60,000 times. The micrograph shows that the structure in this compound is made of equidimensional or approximately round particles of about 100 nm in size.
  • FIG. 19 is an X-ray diffraction pattern showing that the product made here is an anhydrous lanthanum oxycarbonate written as La 2 O 2 CO 3 .
  • FIG. 20 shows the rate of removal of phosphate using the commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 20 shows the rate of removal of phosphate using the commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 21 shows a scanning electron micrograph of the product, enlarged 80,000 times.
  • FIG. 22 shows the X-Ray diffraction pattern of the product and it shows that it consists of anhydrous lanthanum oxycarbonate. The X-Ray pattern is different from the pattern corresponding to Example 5, even though the chemical composition of the compound is the same. The formula for this compound is written as (La 2 CO 5 ). Comparing FIGS.
  • 21 and 18 shows that the compound of the present example shows a structure of leaves and needles as opposed to the round particles formed in Example 5.
  • the particles may be used in a device to directly remove phosphate from an aqueous or non-aqueous medium, e.g., the gut or the bloodstream.
  • FIG. 23 shows the rate of phosphate removal for the commercial lanthanum carbonate La 2 (CO 3 ) 3 .H 2 O and La 2 (CO 3 ) 3 .4H 2 O.
  • FIG. 24 is a scanning electron micrograph of the TiO 2 material obtained. It shows a porous structure with individual particles of about 250 nm connected in a structure. This structure shows good mechanical strength. This material can be used as an inert filtering material in a fluid stream such as blood.
  • Example 9 The product of Example 9 is re-slurried into a solution of lanthanum chloride containing 100 g/l La.
  • the slurry contains approximately 30% TiO 2 by weight.
  • the slurry is spray dried in a spray dryer with an outlet temperature of 250° C.
  • the product of the spray drier is further calcined at 800° C. for 5 h. It consists of a porous TiO 2 structure with a coating of nano-sized lanthanum oxychloride.
  • FIG. 25 is a scanning electron micrograph of this coated product. The electron micrograph shows that the TiO 2 particles are several microns in size.
  • the LaOCl is present as a crystallized deposit with elongated crystals, often about 1 ⁇ m long and 0.1 ⁇ m across, firmly attached to the TiO 2 catalyst support surface as a film of nano-size thickness.
  • the LaOCl growth is controlled by the TiO 2 catalyst support structure. Orientation of rutile crystals works as a template for LaOCl crystal growth.
  • the particle size of the deposit can be varied from the nanometer to the micron range by varying the temperature of the second calcination step.
  • FIG. 26 is a scanning electron micrograph corresponding to calcination at 600° C. instead of 800° C. It shows LaOCl particles that are smaller and less well attached to the TiO 2 substrate.
  • FIG. 27 is a scanning electron micrograph corresponding to calcination at 900° C. instead of 800° C. The product is similar to the product made at 800° C., but the LaOCl deposit is present as somewhat larger crystals and more compact layer coating the TiO2 support crystals.
  • FIG. 28 shows the X-Ray diffraction patterns corresponding to calcinations at 600°, 800° and 900° C. The figure also shows the pattern corresponding to pure LaOCl. The peaks that do not appear in the pure LaOCl pattern correspond to rutile TiO 2 . As the temperature increases, the peaks tend to become higher and narrower, showing that the crystal size of the LaOCl as well as TiO 2 increases with the temperature.
  • aqueous HCl solution having a volume of 334.75 ml and containing LaCl 3 (lanthanum chloride) at a concentration of 29.2 wt % as La 2 O 3 was added to a 4 liter beaker and heated to 80° C. with stirring.
  • the initial pH of the LaCl 3 solution was 2.2.
  • Two hundred and sixty five ml of an aqueous solution containing 63.59 g of sodium carbonate (Na 2 CO 3 ) was metered into the heated beaker using a small pump at a steady flow rate for 2 hours. Using a Buchner filtering apparatus fitted with filter paper the filtrate was separated from the white powder product.
  • the filter cake was mixed four times, each with 2 liters of distilled water and filtered to wash away the NaCl formed during the reaction.
  • the washed filter cake was placed into a convection oven set at 105° C. for 2 hours or until a stable weight was observed.
  • the X-Ray diffraction pattern of the product shows that it consists of hydrated lanthanum oxycarbonate La 2 O(CO 3 ) 2 .xH 2 O, where 2 ⁇ 4.
  • the surface area of the product was determined by the BET method. The test was repeated 3 times and slightly different surface areas and different reaction rates were obtained as shown in Table 1.
  • Plasma lanthanum exposure Overall plasma lanthanum exposure in the dogs is summarized in Table 3 below. The plasma concentration curves are shown in FIG. 29. TABLE 3 Mean (sd) Area Under the Maximum concentration La oxycarbonate Curve 0-72 h (ng ⁇ h/mL); C max (ng/mL); (standard compound tested (standard deviation) deviation) A 54.6 (28.0) 2.77 (2.1) B 42.7 (34.8) 2.45 (2.2)
  • 5 ⁇ 6 Nephrectomy After one week of acclimatization, all animals were subjected to 5 ⁇ 6 nephrectomy surgery. The surgery was performed in two stages. First, the two lower branches of the left renal artery were ligated. One week later, a right nephrectomy was performed. Prior to each surgery, animals were anesthetized with an intra-peritoneal injection of ketamine/xylazine mixture (Ketaject a 100 mg/ml and Xylaject at 20 mg/ml) administered at 10 ml/kg. After each surgery, 0.25 mg/kg Buprenorphine was administered for relief of post-surgical pain. After surgery, animals were allowed to stabilize for 2 weeks to beginning treatment.
  • the results showing urine phosphorus excretion are given in FIG. 30.
  • the results show a decrease in phosphorus excretion, a marker of dietary phosphorus binding, after administration of the lanthanum oxycarbonate (at time>0), compared to untreated rats.
  • Test items were lanthanum oxycarbonates La 2 O 2 CO 3 and La 2 CO 5 (compound B and compound C), each tested at 0.3 and 0.6% of diet. There was an additional negative control group receiving Sigmacell cellulose in place of the test item.
  • test items were mixed thoroughly into Teklad 7012CM diet. All groups received equivalent amounts of dietary nutrients.
  • Table 4 outlines the dietary composition of each group: TABLE 4 Sigmacell Group ID Treatment Test Item cellulose Teklad Diet I Negative 0.0% 1.2% 98.8% control II Compound B - 0.3% 0.9% 98.8% Mid level III Compound B - 0.6% 0.6% 98.8% High level IV Compound C - 0.3% 0.9% 98.8% Mid level V Compound C - 0.6% 0.6% 98.8% High level
  • Rats were maintained in the animal facility for at least five days prior to use, housed individually in stainless steel hanging cages. On the first day of testing, they were placed individually in metabolic cages along with their test diet. Every 24 hours, their output of urine and feces was measured and collected and their general health visually assessed. The study continued for 4 days. Food consumption for each day of the study was recorded. Starting and ending animal weights were recorded.
  • Plasma samples were collected via retro-orbital bleeding from the control (I) and high-dose oxycarbonate groups, III and V. The rats were then euthanized with CO 2 in accordance with the IACUC study protocol.
  • Urine samples were assayed for phosphorus, calcium, and creatinine concentration in a Hitachi 912 analyzer using Roche reagents. Urinary excretion of phosphorus per day was calculated for each rat from daily urine volume and phosphorus concentration. No significant changes were seen in animal weight, urine volume or creatinine excretion between groups. Food consumption was good for all groups.
  • Tests were run to determine the binding efficiency of eight different compounds for twenty-four different elements. The compounds tested are given in Table 6. TABLE 6 Test ID Compound Preparation Technique 1 La 2 O 3 Calcined the commercial (Prochem) La 2 (CO 3 ) 3 .H 2 O at 850° C. for 16 hrs. 2 La 2 CO 5 Prepared by spray drying lanthanum acetate solution and calcining at 600° C. for 7 hrs (method corresponding to FIG. 3) 3 LaOCl Prepared by spray drying lanthanum chloride solution and calcining at 700° C. for 10 hrs (method corresponding to FIG.
  • the most efficient compounds for removing both arsenic and selenium appear to be the titanium-based compounds 5 and 6.
  • the lanthanum oxycarbonates made according to the process of the present invention remove at least 90% of the arsenic. Their efficiency at removing Se is in the range 70 to 80%. Commercial lanthanum carbonate (4 in Table 6) is less effective.

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US10/444,774 US20040161474A1 (en) 2002-05-24 2003-05-23 Rare earth metal compounds methods of making, and methods of using the same
ES10151585T ES2907070T3 (es) 2002-08-14 2003-08-08 Compuestos de metales de tierras raras, métodos de fabricación y métodos de uso de los mismos
KR1020057002491A KR101108820B1 (ko) 2002-08-14 2003-08-08 희토류 금속 화합물, 이의 제조 방법 및 사용 방법
BRPI0313737-6A BRPI0313737B1 (pt) 2002-08-14 2003-08-08 Métodos de fabricação de um oxicarbonato de lantânio cristalino, oxicarbonato de lantânio cristalino, e, usos do mesmo
EA200500352A EA009766B1 (ru) 2002-08-14 2003-08-08 Соединения редкоземельных металлов, способы их получения и применения
EA200800020A EA012877B1 (ru) 2002-08-14 2003-08-08 Соединения редкоземельных металлов, способы их применения для снижения содержания металла в жидкости
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EA200800021A EA017083B1 (ru) 2002-08-14 2003-08-08 Композиция, содержащая кристаллический оксикарбонат лантана, способ получения оксикарбоната лантана, применение оксикарбоната лантана для лечения гиперфосфатемии
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