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.     

Influence of emulsion types on nucleation kinetics and growth habit in the cooling crystallization

Experiments on unseeded batch cooling crystallization were made to investigate the influence of emulsion [solution in non‐solvent (S/NS) emulsion and non‐solvent in solution (NS/S) emulsion] on crystal size and growth habit of various materials such as hexahydro‐1,3,5‐trinitro‐1,3,5‐triazine, ammonium sulfate, potassium dihydrogen phosphate (KDP), and γ‐glycine. Size of crystals obtained from the S/NS emulsions was found to be significantly larger than that obtained from the NS/S emulsions. Those results were explained by broad induction time distribution of nucleation in the isolated solution droplets and subsequent seeding effect by free movement of early‐induced crystals by vigorous agitation. As a result, the population density of crystals was shown to be smaller in the S/NS emulsions than that in the NS/S emulsions. In the S/NS emulsions, desupersaturation rate should be slow and high supersaturation is subsequently generated during crystal growth stage. Therefore, it may be concluded that crystal morphology of the materials with supersaturation dependent growth habit, such as ammonium sulfate, KDP and γ‐glycine, can be controlled by selection of emulsion type.     

Crystallization of silicalite‐1 from clear synthesis solutions: Effect of template concentration on crystallization rate and crystal size

Synthesis of silicalite‐1 powders and membranes from initially clear solutions with different tetrapropylammonium hydroxide or bromide concentrations was studied. While tetrapropylammonium bromide acts only as template, tetrapropylammonium hydroxide provides both the template and hydroxyl ions to the synthesis medium. The effects of template and hydroxyl ion concentration on the product yield, crystallization rate and crystal size were investigated. Pure and highly crystalline silicalite‐1 was obtained with all compositions. The nucleation time decreases from 100 h to 20 h and the crystal size decreases from 3.5 μm to 0.35 μm as the template amount x is increased from 5 to 30 moles at a batch composition of 80SiO₂.xTPAOH.1500H₂O at 95 °C. Yield of silicalite‐1 passes through a maximum at intermediate TPA concentration. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Calcium oxalate crystallization in the presence of amino acids,proteins and carboxylic acids

Reactive crystallization of calcium oxalate was investigated in the presence of amino acids, proteins and carboxylic acids at different pH and temperatures. Average particle size, filtration rates of calcium oxalate crystals obtained in the absence and presence of additives were determined. The influence of pH, temperatures and additives on crystal morphology of calcium oxalate were also investigated and discussed by SEM analysis. TG‐DTA, FT/IR and XRD analysis were carried out for all investigated conditions. Average particle size of calcium oxalate was affected significantly by the additive type and concentration. Variation of crystal morphology depending on type and concentration of the additives affected the filtration characteristics. Majority of calcium oxalate crystals occurred in the form of calcium oxalate monohydrate except those in the presence of tartaric acid. TG‐DTA, FT/IR and XRD analysis proved that calcium oxalate monohydrate and calcium oxalate dihydrate mixtures are formed in the presence of tartaric acid. The effect of all additives on scale formation was also investigated. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Spontaneous crystallization of potassium chloride from aqueous and aqueous‐ethanol solutions; Part 3: Model of the crystallization process

A model of spontaneous crystallization process was proposed. The model describes kinetics of the crystallization process after the end of the induction period. To test the model the published earlier data on crystallization and aggregation kinetics of potassium chloride at its spontaneous crystallization from supersaturated aqueous and aqueous‐ethanol solutions were used. It was found excellent coincidence of the experimental and theoretical data on concentration of the salt and the total number of crystals in solution at crystallization. Somewhat change for the worse was at the theoretical calculations of crystal size distribution at the end of the crystallization process. It indicated that the ways of calculation of size of crystals and their weight fraction in deposit were very approximate. The model allows predicting with satisfactory accuracy kinetics of crystallization using such general parameters of potassium chloride as the specific surface energy and the height of the nucleus‐bridges between crystals at coalescence. It needs further test of the model for other salts. (© 2006 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)     

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)     

Influence of stirring speed on the crystallization of calcium carbonate

Control over crystal morphology of calcium carbonate (CaCO₃) was investigated by simply changing the stirring speeds in the process of CaCO₃ formation. Scanning electron microscopy (SEM) and powder X‐ray diffraction (XRD) measurements explore the morphology evolution of CaCO₃ at varying stirring speeds. As the stirring speeds increase, rhombohedral calcite, spherical vaterite, and monoclinic crystal with coexistence of calcite phase and vaterite phase were formed, suggesting a facile control over calcium carbonate crystallization in constructing crystals with desired morphology. Moreover, almost pure vaterite spherical particles of narrow particle size distribution were formed at optimum stirring speed. Finally, also elucidated in this work is the mechanism investigation into the construction of various crystal forms via this simple route. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Ageing of spherulites of an industrial relevant aromatic amine derivative

Polycrystalline spherulites of an aromatic amine derivative have been precipitated in a batch process by pH‐shift with hydrochloric acid from stirred aqueous solutions. The time dependent behaviour of the spherulites has been studied during crystallization in the temperature range from 5 °C to 60 °C. Cake resistance values have been obtained from batch filtration tests performed at 2 bar pressure difference at different stages of the crystallization process. The FBRM mean chord length of the crystals decreases with time as a result of crystal ageing into plate‐like crystals. The rate of the ageing process increases with temperature. XRD‐studies show no significant differences in the crystal structure during the ageing process, and the mechanism of the transformation was not established. The filterability of aromatic amine crystals deteriorates as the crystallization progresses. The decrease in the filterability is attributed to the appearance of small plate‐like crystals and a change in the interaction between the crystal surface and the solution, during the ageing of the particles. (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Effect of seeded surface area on crystal size distribution in glycine batch cooling crystallization: a seeding methodology

In batch cooling crystallization, if the seeding process is not carefully carried out, the crystal size distribution (CSD) is dispersed. The aim of this work is to determine the optimal conditions for seeding operations. Results show that the CSD is controlled if the seed surface area reaches a specific value called critical surface S_c. Nevertheless, S_c is not the only parameter to be considered. The mean crystal size of the product obtained actually depends on the size of the seeds used because of the growth rate distribution. In fact, seeds behave differently according to their crystal sizes, which accounts for the difference in crystal growth rates. Rules are proposed for seeding with the view to obtain a uni-modal CSD and a final product size predefined by the seed crystals.     

Influence of essential and non‐essential amino acids on calcium oxalate crystallization

The investigation on the mechanism of nucleation and growth of crystals at organic‐inorganic interfaces is crucial for understanding biological and physiological calcification processes such as the formation of urinary stones. The effects of five different amino acids on the crystallization of calcium oxalate have been investigated at pH 4.5 and 37 °C in aqueous solutions in the batch type crystallizer. The products were characterized by Scanning Electron Microscopy (SEM), Fourier Transfer Infrared Spectroscopy (FT/IR) and X‐Ray diffraction (XRD) analysis. Crystal size distribution (CSD) and filtration rate measurements were done. In order to determine the adsorption characteristics of amino acids on the calcium oxalate crystal surfaces, zeta potential measurements were also done and discussed. The results indicate that in the presence of all investigated amino acids, calcium oxalate monohydrate (COM) crystals were preferentially produced, but the crystal morphology varied with amino acid types and concentrations. Various crystal morphologies such as elongated hexagonal, coffin or platy habits were observed. In the presence of all investigated amino acids, the calcium oxalate crystallized in a monohydrate form. Electrostatic/ionic interaction, different adsorption properties and special functional effects of amino acids led to find different crystal morphology. (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Growing CuI crystals with decomplexation method modified by concentration programming

An attempt to grow CuI single crystal with decomplexation method modified by concentration programming in silica gel was performed. The results show that decreasing the concentration of feeding solution gradually can yield pure regular single crystals with larger size compared with those of increasing concentration. Replenishing feeding solution every 24 h produces crystals with higher quality than those of every 48 h. (© 2004 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.     

Study of lactose crystallization in water‐acetone solutions

This paper describes a study on the process of lactose crystallization using a water‐acetone solution. The selection of lactose was based on its significance for the pharmaceutical and food industries and on the fact that the crystallization of this organic compound has been little studied and is, unlike inorganic compounds, complex. The objective was to achieve lactose batch crystallization of solutions by analyzing the crystal growth under different operating conditions. To determine solubility curves, the experiments were carried out based on gravimetric methods. All the crystallization experiments were performed according to the methodology proposed by Nývlt in 1985, who uses the temperature at which the first crystals appear (nucleation) to establish the width of the metastable zone and the induction time. The results showed that crystals with different average diameters, shape factors, and recovered mass were obtained for different water‐acetone compositions. (© 2007 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Investigation of the Conditions for the Production of Calcium Magnesium Acetate (CMA) Road Deicer in an Extractive Crystallization Process

Calcium magnesium acetate (CMA) is considered as the best road deicer to replace the environmentally unacceptable NaCl and CaCl₂. However, the high cost of CMA prohibits its widespread use. The present study is dealing with the investigation of a crystallization method for the production of deicing CMA crystals of desired physical properties and the elucidation of the conditions under which such a product can be formed. Extractive crystallization is promising for the low cost production of CMA crystals considering that acetic acid is produced by a biochemical method and removed from the fermentation broth in situ by organic extractant systems. In this method, this organic phase, which contains the acetate ions is contacted with an aqueous phase which is the source of calcium and magnesium ions. The extractive crystallization process resulted in the production of well‐formed, large, and non‐spherical crystals of calcium acetate (CA), magnesium acetate (MA), and calcium magnesium acetate double salt (CMADS). The crystal size was affected by the concentration of acetic acid in both the organic and aqueous phases, whereas the crystal type and hydration level were determined primarily by the acetic acid concentration in the aqueous phase. The molar ratio of the precursor salts (CaCO₃/MgCO₃) in the reaction mixture was found to be the major factor for determining the habit and Ca/Mg content of crystals. Crystallization of CMADS was favored at high concentrations of acetic acid in the aqueous phase and at higher temperatures as shown from supplementary evaporation‐to‐dryness experiments.     

Crystallization of calcium sulfate dihydrate at different supersaturation ratios and different free sulfate concentrations

Free Sulfate is a major parameter affecting gypsum crystallization during phosphoric acid production. Gypsum crystal size, shape and filtration rate are significantly affected by the concentration of free sulfate. It is, therefore, important to evaluate the effectiveness of different sulfate levels from 1.5% to 3.5% on induction time and gypsum morphology. The crystallization of gypsum was carried out under simulated conditions of phosphoric acid production by the dihydrate process. Calcium hydrogen phosphate and sulfuric acid were mixed with dilute phosphoric acid at 80 °C, and the turbidity of the reaction mixture was measured at different time periods to calculate the induction time of gypsum crystals formation. With increasing free sulfate concentration, the induction time was significantly decreased. Chemical processing of Central and South Florida phosphate concentrates under different concentrations of free sulfate from 1.5% to 5.5% was carried out. The change on crystal size distribution and filtration rate were traced with free sulfate concentrations. The results show that, filtration rate of phosphogypsum was correlated to the mean diameter of crystals. In addition, induction time and co‐crystallized (lattice) P₂O₅ % in gypsum are decreased with increasing free sulfate content from 1.5% to 3.5%. Morphology of formed gypsum crystals at different sulfate contents and different supersaturation ratios are investigated. (© 2004 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Preparation and characterization of superfine ammonium perchlorate (AP) crystals through ceramic membrane anti-solvent crystallization

In this paper, a novel ceramic membrane anti-solvent crystallization (CMASC) method was proposed for the safe and rapid preparation ammonium perchlorate (AP) crystals, in which the acetone and ethyl acetate were chosen as solvent and anti-solvent, respectively. Comparing with the conventional liquid anti-solvent crystallization (LASC), CMASC which successfully introduces ceramic membrane with regular pore structure to the LASC as feeding medium, is favorable to control the rate of feeding rate and, therefore, to obtain size and morphology controllable AP. Several kinds of micro-sized AP particles with different morphology were obtained including polyhedral-like, quadrate-like to rod-like. The effect of processing parameters on the crystal size and shape of AP crystals such as volume ratio of anti-solvent to solvent, feeding pressure and crystallization temperature were investigated. It is found that higher volume ratio of anti-solvent to solvent, higher feeding pressure and higher temperature result in smaller particle size. Scaning electron microscopy (SEM) and X-ray diffraction (XRD) were used to characterize the resulting AP crystals. The nucleation and growth kinetic of the resulting AP crystals were also discussed.     

Crystallization Kinetics of Silicalite-1: Use of Tetrapropylammonium Bromide and Chloride as Templates

Silicalite-1, the aluminum-free end number of the ZSM-5 zeolites, was synthesized from a batch composition of 3.25 Na₂O · 40.0 SiO₂ · 552 H₂O · 2.00 TPA by using tetrapropylammonium bromide (TPA-Br) or chloride (TPA-Cl) as templates in the temperature range of 100 to 175 °C in a batch system. Conversion of silica in the starting batch composition into silicalite-1 in the product was followed quantitatively. The activation energies of nucleation and crystallization were determined as 37.2 and 66.5 kJ/mol, respectively. The use of TPA-Cl as the template instead of TPA-Br results in longer induction period for crystallization to start and a larger crystal size in product.     

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.     

Influence of solvent and crystallization method on the crystal habit of metronidazole

In the present study, metronidazole was crystallized in several solvents, according to both the “cooling crystallization” and the “crystallization by non‐solvent addition”. Particle properties, such as crystal habit, elongation ratio, and mean particle size, were determined by SEM analysis. Structural changes and development of polymorphic forms were excluded by both Differential Scanning Calorimetry (DSC) and X‐Ray Powder Diffractometry (XRPD). Crystal habit (and thus elongation ratio) was typically influenced by both the solvent polarity index and the crystallization method: solvents with higher polarity index tended to promote acicular or stick‐shaped crystals with a high elongation ratio, while isodimensional crystals were promoted by decreasing the polarity index, as was particle aggregation. (© 2007 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)