Seed loading effects on the mean crystal size of acetylsalicylic acid in a continuous‐flow crystallization device

This study investigates the effects of seed loading on the mean crystal size of the model substance, acetylsalicylic acid, crystallized from ethanol in a continuously seeded tubular crystallizer. A hot, highly concentrated ethanolic acetylsalicylic acid solution was mixed with an acetylsalicylic acid‐ethanol seed suspension. Subsequent cooling of the slurry in the tubing promoted supersaturation and hence crystal growth. The tubular shape of the 15 m‐long crystallizer with an inner diameter of 2 mm enabled narrow residence time distributions of the crystals in the pipe and excellent temperature control in the radial direction and along the tubing. Crystals entering the crystallizer had both identical growth conditions in each section and about the same time for crystal growth. Narrow crystal size distributions were achieved with decreasing differences in the volume‐mean‐diameter sizes of the seed and product crystals as seed loadings increased. Decreasing the seed size had a similar effect as increasing the seed loading, since in that case the same amount of seed mass resulted in more individual seed particles. Altering the arrangement of the coiled crystallizer with respect to spatial directions (horizontal, vertical) did not lead to a significantly different outcome. All experiments produced considerably larger product crystals in comparison to the seeds despite relatively short crystallization times of less than 3 min. Moreover, product mass gains of a few hundred percent at a g/min‐scale were achieved. Similarities in product crystal samples taken at different times at the outlet of the crystallizer showed that steady‐state conditions were rapidly reached in the continuous flow crystallization device. (© 2011 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Continuous reaction crystallization of struvite from phosphate(V) solutions containing calcium ions

Continuous reaction crystallization of struvite from water solutions containing phosphate(V) (1.0 mass%) and calcium ions (from 0.01 to 0.20 mass%) was investigated. Process was carried out in temperature 298 K in continuous DT MSMPR type crystallizer with internal circulation of suspension. Influence of pH (from 9 to 11) and mean residence time of suspension in crystallizer (from 900 to 3600 s) on product crystal size distribution, mean size, population homogeneity and shape of crystals, as well as chemical composition of solid phase was tested. Within the investigated process parameter ranges struvite crystals of mean size from 18 to ca. 50 μm were produced. With the increase in calcium ions concentration in a feed mean crystal size decreased from 34.2 to 18.4 μm (pH 9, τ 900 s). Coexistence of struvite and hydroxyapatite crystals in the solid product was confirmed analytically (Ca content in solid product from 0.3 to 8.4 mass%). Presence of calcium ions favoured crystallization of struvite in a form of tubular crystals, characterized by lengthwise cracks and irregular edges. Co–precipitated hydroxyapatite particles showed relatively small sizes, even below 1 μm, forming agglomerates on the surface of larger struvite crystals and individual agglomerates. (© 2011 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Kinetic studies on the influence of temperature and growth rate history on crystal growth

Crystallization experiments of sucrose were performed in a batch crystallizer to study the effect of temperature and growth rate history on the crystal growth kinetics. In one of the growth methods adopted, the isothermal volumetric growth rate (R_V) is determined as a function of supersaturation (S) at 35, 40 and 45 ºC. In the other, crystals are allowed to grow at constant supersaturation by automatically controlling the solution temperature as the solute concentration decreased. Using the latter method R_V is calculated as the solution is cooled. The obtained results are interpreted using empirical, engineering and fundamental perspectives of crystal growth. Firstly, the overall activation energy (E_A) is determined from the empirical growth constants obtained in the isothermal method. The concept of falsified kinetics, widely used in chemical reaction engineering, is then extended to the crystal growth of sucrose in order to estimate the true activation energy (E_T) from the diffusion‐affected constant, E_A. The differences found in the isothermal and constant supersaturation methods are explained from the viewpoint of the spiral nucleation mechanism, taking into account different crystal surface properties caused by the growth rate history in each method. Finally, the crystal growth curve obtained in the batch crystallizer at 40 ºC is compared with the one obtained in a fluidized bed crystallizer at the same temperature. Apparently divergent results are explained by the effects of crystal size, hydrodynamic conditions and growth rate history on the crystallization kinetics of sucrose. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Crystallization kinetics of ZnS precipitation; an experimental study using the mixed‐suspension‐mixed‐product‐removal (MSMPR) method

The precipitation kinetics of zinc sulfide were studied using a lab scale mixed‐suspension‐mixed‐product‐removal (MSMPR) precipitation reactor. The vessel was operated at different feed concentrations, molar ratios, stirrer speeds, pH‐values, feed injection positions and residence times. Primary nucleation and volume average crystal growth rates as well as agglomeration kernel were determined. Relationships were found between the rates of the different crystallization steps on the one hand and supersaturation, stirrer speeds, pH‐values, Zn²⁺ to S^2‐ ratio, feed positions on the other. These show that larger crystals are obtained at high supersaturation, moderate stirrer speeds, small residence times, a pH‐value of around 5 and high Zn²⁺ to S^2‐ ratios. One should realize though that the applied MSMPR method is not the most optimal technique for examining fast precipitation reactions. (© 2004 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Size-dependent nucleation and growth kinetics model for potassium chloride—Application in Qarhan salt lake

The nucleation process and crystallization kinetics of KCl were studied in order to investigate the problems in KCl production in Qarhan salt lake. The correlation between particle size and KCl crystal growth rate was studied in a continuous mixed-suspension mixed-product removal (MSMPR) crystallizer. Classical theory of primary nucleation was used to study the homogeneous and heterogeneous nucleation mechanism of KCl crystallization. Several size-independent growth models and size-dependent growth models, such as Bransom, C-R, MJ2, ASL, and MJ3, were examined by the population balance theory. Results showed that MJ3 model closely fitted the experimental data, the mean relative deviation was 0.94%, the crystal growth rate G=2068{1−exp[−1.081×10−5(L+961.882)]}.     

Modelling of Growth Rate for MSMPR Crystallizer Data

One of the most important applications of the population balance approach to MSMPR crystallizer modelling is the recovery of crystal nucleation and growth rates data from steady-state crystal size distributions (RANDOLPH, LARSON). A large number of studies have confirmed that both size-dependent (growth rate is a function of crystal size) and growth rate dispersion (crystals of the same size do not have the same growth rate), causes nonlinearities which limit the usefulness of the RANDOLPH and LARSON approach. A discussion of modelling of crystal growth kinetics for simulated and real MSMPR crystallizer data is presented. In the former case, both linear and non-linear log population density distributions are used. The modelling of growth kinetics is done twice – once assuming that growth rate dispersion is a source of curvature in the log population density vs size data plot and, again when this curvature is caused by size-dependent growth. Calculations clearly indicate that even for crystallizing systems which follow the McCabe's δL law, both growth rate dispersion and size-dependent growth models lead to proper estimation of growth kinetics. When log population density vs size data plots exhibit curvature, however, use of the size-dependent growth rate approach gives more reliable growth kinetics across a broad crystal size range than those obtained from modelling of growth kinetics by growth rate dispersion.     

Crystallization kinetics of MgSO4·12H2O from different scales of batch cooling scraped crystallizers

For reliably scaling up of crystallizers, a full kinetic model is required in addition to heat, mass and population balances. A method for extracting nucleation and growth kinetic parameters for scaling‐up seeded batch cooling crystallization was developed and demonstrated with a 15 L and in a 115 L scraped crystallizer using MgSO₄·12H₂O as the model system. The method includes fitting the time resolved measured solute concentration and the crystal size distributions with a dynamic population‐based model. The kinetic parameters extracted from the bench‐scale crystallizer agree with those obtained from the pilot scale, confirming that they can be employed for design purposes. (© 2006 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Precipitation kinetics of sodium bicarbonate in an industrial bubble column crystallizer

Sodium bicarbonate is a substance which is produced in the middle stages of the soda ash production process. In this precipitation process, carbon dioxide gas is continuously injected into the bubble column reactor which contains carbonate and bicarbonate solutions. To elucidate the key parameters affecting precipitation kinetics, an experimental study was conducted to understand nucleation and growth in conditions of industrial reactor. The composition of the solution is followed during the crystallization process by titration. Magma density is also monitored and crystal size distribution (CSD) is obtained by sieving. The method of moments was used to determine nucleation and growth rates of crystals. The nucleation and growth rate correlations for sodium bicarbonate precipitation in industrial scale were correlated by empirical power laws as B = 26.685M_T^0.42Δw^1.31 and G = 1.381×10^–4Δw^1.53. The nucleation and growth rate correlations obtained in this study can be used to simulate the crystallization of sodium bicarbonate plants. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Seeded batch crystallization of ammonium aluminum sulfate from aqueous solution

Seed crystals of ammonium aluminum sulfate ((NH₄)Al(SO₄)₂··12H₂O) were grown in aqueous solution by cooling. The temperature of a crystallizer was lowered with no control by circulating cooling water through the jacket. It fell in an exponential manner. The effects of seed amount and size on the product crystal size distribution were examined. The product crystals obtained were of narrow and uni-modal size distribution with suppressed secondary nucleation if seed crystals were loaded more than a critical value. The critical value was determined and well compared with previously reported values for other material systems. This crystallization technique does not need any prior knowledge of the kinetics of crystal growth and nucleation. It is simple and robust, and can be easily applied to an existing crystallizer without installing any additional control systems.     

Rate of sodium chloride attrition fragment generation in a mixed‐suspension crystallizer

Attrition of crystals in industrial crystallization is the major source of secondary nucleation and has strong effects on product quality. This work describes attrition in industrial crystallizers using an empirical engineering model based on dimensionless groups describing crystal properties, suspension properties, and crystallizer geometry and operating conditions. Here the attrition rate of sodium chloride crystals in a small scale mixed‐suspension crystallizer is studied, varying the following parameters: impeller speed, parent crystal size, suspension density, draft‐tube impeller clearance, off‐bottom impeller clearance, impeller type, and impeller material. It was found that the attrition rate depends on most of the variables investigated. The direction of the dependence is predictable based on intuitive modeling. An empirical power law model based on dimensionless groups predicted by Buckingham‐Pi theory (using variables mentioned above) gives a good fit to the data.     

Study on rapid growth of KH2PO4 and its characterization

Large size crystals of KH₂PO₄ (KDP) were grown by adopting rapid growth technique from point seeds in a 1500‐liter crystallizer which is used to grow KDP crystals by conventional method. The grown KDP crystal size can reach to 310 × 310 × 320 mm³ and the average growth rate was 8mm/day. The optic properties of the rapidly grown KDP crystals were characterized comparing with the KDP crystals grown by the traditional temperature reduction method. We found it that the optical quality of the KDP crystals we grown rapidly are not significantly different from those of KDP crystals grown by traditional method. (© 2005 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Study on crystallization kinetics and the crystal internal defects of HMX

In this paper, the solubility data of HMX (1,3,5,7‐tetranitro‐1,3,5,7‐tetrazocane) in acetone from 323.15 K to 293.15 K were accurately measured by use of the laser‐monitoring observation technique. Intermittent dynamic method was utilized to study crystallization kinetics of HMX in acetone. The data of crystallization kinetics were obtained by moment analysis, and the parameters of the growth rate and nucleation rate equations were derived by using multiple linear least squares method. Subsequently, growth rate and nucleation rate at different conditions were calculated according to these equations. In addition, Optical Microscopy Images (qualitative) and Particle Apparent Density (quantitative) experiments were applied to study the crystal internal defects of HMX under different crystallization conditions. It can be found that the crystal apparent density of HMX is in the range of 1.8993 g·cm⁻³ to 1.9017 g·cm⁻³, very close to the theory density of HMX; the internal defects and the crystal size do not increase after 25 °C, from which we predict that the HMX crystal growth reaches the steady growth segment. These results suggest that the nucleation rate is a significant factor influencing the crystal internal defects, and larger nucleation kinetics can reduce crystal internal defects.     

Graphical Representation of Various Models for Crystal Size Distribution in Continuous Flow Crystallizers

Plots of crystal size distribution of the following crystallizer models are compared: an ideal continuous-flow MSMPR (mixed suspension, mixed product removal) crystallizer with a zero as well as non-zero initial crystal size, an MSMPR crystallizer with size dependent growth of crystals, an MSMPR crystallizer with missing fines, an MSMPR crystallizer with agglomerative growth, and a series of MSMPR crystallizers simulating a crystallizer with nonideal agitation. The shape of the individual size distribution curves can serve as a diagnostic criterion in determination of the most probable model of crystallization.     

Comparison Study of Mixing Effect on Batch Cooling Crystallization of 3‐Nitro‐1,2,4‐triazol‐5‐one (NTO) Using Mechanical Stirrer and Ultrasound Irradiation

The insensitive explosive 3‐Nitro‐1,2,4‐triazol‐5‐one (NTO) has been recrystallized from water in an effort to prepare crystals with smaller size and narrower distribution in a batch cooling crystallizer. Two mixing devices, i.e., a mechanically stirred system with and without ultrasound in aqueous media were employed to compare the mixing effect on the crystallization. Under ultrasound irradiation, the metastable zone width was significantly reduced by more than 2 fold and the crystal size was shifted from 140∼160 μm to 50∼70 μm with a narrower CSD compared to the mechanically stirred system. However in the mechanical stirrer, the mixing effect on NTO crystallization was negligible if the impeller speed was sufficient to suspend all crystals in the crystallizer. It was found that the crystal growth was not influenced by mixing. We suggest that the NTO crystals were formed by primary heterogeneous nucleation that is common in batch cooling system. Finally, the population balance model (PBM), with the empirical nucleation and growth kinetic expressions, was solved numerically to predict the crystal size and the CSD with batch time, and the results were in good agreement with the experimental data.     

Crystallization of phosphogypsum in continuous phosphoric acid industrial plant

Understanding crystallization of phosphogypsum is generally of basic importance for industrial wet‐process phosphoric acid production. In this paper, measuring the phosphogypsum crystal size distribution during primary and secondary nucleation is reported. The results show that, secondary nucleation was occurred at 5 hr run time (12.5% solid content). Crystal growth rates were about 18.4 μm/hr at 2.5% solid content and about 4.5 μm at 30% solid content. At steady state (16 hr run time and 30% solid content), the mean diameter of the crystals and the average specific surface area are about 25 μm and 0.69 m²/g, respectively. (© 2004 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Cooling crystallization of aluminum sulfate in pure water modulated by sodium dodecylbenzenesulfonate

This study investigated the cooling crystallization of aluminum sulfate to explore the basic data for the recovery of aluminum resources from coal spoil. Cooling crystallization process of aluminum sulfate with sodium dodecylbenzenesulfonate (SDBS) was investigated experimentally. The effects of operating conditions, namely rotate speed and cooling rate on the crystal size (Median diameter, D_0.5) were studied. Based on single factor experimental results, the response surface method (RSM) with a Box–Behnken design (BBD) was used to determine the key operating conditions, from which a predictive equation was established to quantitatively describe the relationships of D_0.5 and there relative parameters. The optimum operating conditions for cooling crystallization of aluminum sulfate were as follows: rotate speed of 200–300 rpm, cooling rate of 4–5 °C /min and n (SDBS)/n (Al₂(SO₄)₃) of around 5E‐4. Molecular dynamics (MD) results reveal that SDBS decreases the diffusion coefficient (D) of Al³⁺ molecules, which inhibits nucleation and promotes crystal growth.     

Controlled synthesis of Cu2O cubic and octahedral nano‐ and microcrystals

Cubic and octahedral Cu₂O nano‐ and microcrystals were selectively synthesized via a simple wet chemical reduction route at room temperature, with CuCl₂ and NaOH as starting reactants, and ascorbic acid or hydrazine hydrate as the reducer. Hydrazine hydrate could be preferentially adsorbed on different crystal faces of Cu₂O, affecting the growth rate along the 〈100〉 to that along the 〈111〉 direction, which resulted in the formation of octahedral Cu₂O crystals. When ascorbic acid was used as the reducer, the growth rate along the 〈100〉 to that along the 〈111〉 direction was different, which resulted in the formation of cubic Cu₂O crystals. The size of cubic and octahedral Cu₂O crystals could be varied by adjusting the molar ratio of OH^– to Cu²⁺. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Study of phosphoric acid crystallization using a focused beam reflectance measurement method

A way for restoring the crystal size distributions (CSD) from measured chord length distributions (CLD) was reported in this paper. The kinetics of phosphoric acid crystallization process was investigated in cooling mode using focused beam reflectance measurement (FBRM) and digital photo technique. In order to restore the CSD from measured CLD and verify the reliability of FBRM data, digital photo technique in real time and optical microscope were applied in large crystal size and small range, respectively. Results indicated a converting constant A existed between CLD and CSD when crystal growth follows size‐independent growth (Mcabe's ΔL law) law. It was verified by Malvern particles size analysis method. The converting constant A varied with crystal morphology. The crystal growth order increased with the stirring increasing speed during phosphoric acid crystallization process. The trend was especially notable at higher speed situations. It can illustrate that the state of phosphoric acid hemihydrate crystal growth was controlled by both diffusion and surface‐integration with the increasing stirring speed. (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

The induction time,interfacial energy and growth mechanism of maltitol in batch cooling crystallization

Maltitol is crystallized with seeds by cooling mode in industry, often with large amount of fine crystals and wide crystal size distribution. To eliminate the fine nucleation, it's necessary to understand the nucleation kinetics. In this work, the solubility of maltitol in water was measured by the gravimetric method, the nucleation kinetics of maltitol in batch cooling crystallization was investigated using focus beam reflectance measurement (FBRM), and a novel method was proposed to determine the induction time from the trend of the crystal median chord given by FBRM. Based on the relationship between the induction time and the supersaturation, the nucleation mechanism was obtained, including homogenous nucleation at high supersaturation and heterogenous nucleation at low supersaturation. Additionally, combining the classical nucleation theory (CNT) and Arrhenius’ principle, the crystal‐solution interfacial energy and the energy barrier of homogenous nucleation were calculated. From the scanning electron microscope (SEM) images, the growth mechanism of maltitol was identified as surface nucleation growth and the surface entropy factor calculated from the kinetic analyses of t_ind data corroborated this growth mechanism.