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.     

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)     

Advancements (and challenges) in the study of protein crystal nucleation and growth; thermodynamic and kinetic explanations and comparison with small-molecule crystallization

This paper reviews advancements and some novel ideas (not yet covered by reviews and monographs) concerning thermodynamics and kinetics of protein crystal nucleation and growth, as well as some outcomes resulting therefrom. By accounting the role of physical and biochemical factors, the paper aims to present a comprehensive (rather than complete) review of recent studies and efforts to elucidate the protein crystallization process. Thermodynamic rules that govern both protein and small-molecule crystallization are considered firstly. The thermodynamically substantiated EBDE method (meaning equilibration between the cohesive energy which maintains the integrity of a crystalline cluster and the destructive energies tending to tear-up it) determines the supersaturation dependent size of stable nuclei (i.e., nuclei that are doomed to grow). The size of the stable nucleus is worth-considering because it is exactly related to the size of the critical crystal nucleus, and permits calculation of the latter. Besides, merely stable nuclei grow to visible crystals, and are detected experimentally. EBDE is applied for considering protein crystal nucleation in pores and hydrophobicity assisted protein crystallization. The logistic functional kinetics of nucleation (expressed as nuclei number density vs. nucleation time) explains quantitatively important aspects of the crystallization process, such as supersaturation dependence of crystal nuclei number density at fixed nucleation time and crystal size distribution (CSD) resulting from batch crystallization. It is shown that the CSD is instigated by the crystal nucleation stage, which produces an ogee-curve shaped CSD vs. crystal birth moments. Experimental results confirm both the logistic functional nucleation kinetics and the calculated CSD. And even though Ostwald ripening modifies the latter (because the smallest crystals dissolve rendering material for the growth of larger crystals), CSD during this terminal crystallization stage retains some traces of the CSD shape inherited from the nucleation stage. Another objective of this paper is to point-out some biochemical aspects of the protein crystallization, such as bond selection mechanism (BSM) of protein crystal nucleation and growth and the effect of electric fields exerted on the process. Finally, an in-silico study on crystal polymorph selection is reviewed.     

Uncertainties in crystallization of hen‐egg white lysozyme: reproducibility issue

The reproducibility of biomacromolecular crystallization (tetragonal and orthorhombic lysozyme crystals) was studied by monitoring the evolution of protein concentration during the crystallization process using Mach‐Zehnder interferometer. It was found that formation of both tetragonal and orthorhombic crystals exhibited poor reproducibility. When the crystallization occurred under isothermal conditions, the protein concentration in the solution varied differently in different experiments under identical conditions (for both types of crystals). Moreover, in the case of orthorhombic lysozyme crystallization (under either isothermal or thermal gradient conditions), it is clear that the crystals could not be always readily formed. When formation of tetragonal lysozyme crystals was conducted at a temperature gradient condition, however, the evolution of concentration was reproducible. The phenomena found in this study revealed that biomacromolecular crystallization can be uncertain, which is probably caused by the process of nucleation. Such uncertainties will be harmful for the efforts of screening crystallization conditions for biomacromolecules. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

超声波对甲硝唑溶液结晶热力学性质的影响

本文采用降温结晶的方法,在搅拌和超声波作用下,分别测量了甲硝唑溶液结晶成核的介稳区和诱导期.通过分析超声波对甲硝唑溶液结晶的介稳区、诱导期产生的影响,从扩散系数、温度及能量角度分析了超声波促进晶体成核作用的机理.通过比较搅拌和超声波下得到的产品,从理论上对影响晶体粒度及结晶产率的因素进行了分析.     

Mechanism of aggregation and intergrowth of crystals during bulk crystallization from solutions

Available literature data on aggregation kinetics of crystals of a number of salts during their bulk crystallization from solutions have been analysed. The proposed earlier mechanism of aggregation and intergrowth of crystals during bulk crystallization owing to formation of nucleus‐bridges between crystals was tested and confirmed. The aggregation kinetics of crystals was described by the familiar Smoluchowski equation for coagulation of colloidal particles. However, in a bulk crystallization process, the aggregation constant in this equation decreased as supersaturation in a solution lowered. An expression for the aggregation constant in this equation was proposed. The proposed mechanism of crystal intergrowth duringt bulk crystallization allowed evaluating the specific surface energy of tested salts, which turned out to be in reasonable agreement with published literature data. It was concluded that the intergrowth of crystals during bulk crystallization from solutions proceeded via formation of nucleus‐bridges between crystals. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Protein crystallization under microgravity conditions. Analysis of the results of Russian experiments performed on the International Space Station in 2005−2015

Conditions of mass transport to growing crystals have a considerable effect on the crystal size and quality. The reduction of convective transport can help improve the quality of crystals for X-ray crystallography. One approach to minimizing convective transport is crystallization in a microgravity environment, in particular, in space. The data obtained by our research team in protein crystallization experiments on the International Space Station are surveyed and analyzed.     

Crystallization of proteins under an external electric field

An external electric field affects the crystallization of proteins when applied under some conditions of temperature, pH, and precipitating agent composition. As suggested in the theoretical part of this paper, it produces large protein concentration gradients inside the mother liquor leading to a local supersaturation area in the crystallization solution. Such an experiment has been used for the first time on the crystallization of a protein. The effects of an external electric field on the crystallization of hen egg-white lysozyme at 293 K, pH 4.5, and two NaCl concentrations (0.6–0.7 M) have been investigated using the vapor diffusion method. The application of electric field results in a smaller number of crystals with larger size. The crystals grew at the droplet surface, near the cathode. The nucleation rate is drastically reduced and this experimental method could be used to control the number of crystals in the droplet.     

Crystallization of zinc lactate in presence of malic acid

The influence of malic acid, which acts as an impurity on the cooling crystallization of zinc lactate is investigated in this paper by monitoring the relative supersaturation and the number of crystals during crystallization. The presence of malic acid increases the solution solubility and makes the metastable zone wider; it also changes the habit of the crystal. The purity of the final products is shown to be influenced by the amount and size of seed crystals, cooling rate, seeding temperature and final temperature, but appears to depend mainly on the particle size and level of supersaturation. Residual supersaturation thresholds are observed that depend on the final temperature. A model is proposed to predict the steady-state supersaturation value from the final temperature at a given impurity concentration. This model is based on Kubota and Gibbs equations.     

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)     

Impact of agglomeration on crystalline product quality within the crystallization process chain

The quality of crystalline products, defined by e.g. purity or crystal size distribution (CSD), is primarily dominated by crystallization conditions but influenced by further downstream processes like solid‐liquid separation and drying also. Through uncontrolled agglomeration within the crystallization process chain the purity or CSD can be negatively affected. Therefore, in context of process optimization, missing knowledge of the impacts on the final product can lead to product batches out of specification. To increase the understanding of agglomeration and to provide insight into the relevance of holistic process optimization the agglomeration behavior of L‐alanine crystals is exemplarily quantified over the crystalline process chain. For the quantification the agglomeration degree (Ag) and the agglomeration degree distribution (AgD) are determined. The results show that the product quality achieved after crystallization is significantly affected by agglomeration during drying. Especially if washing after solid‐liquid separation is omitted, a broadening of the CSD is observed. Moreover, the evaluation by the AgD indicates that the final product can be ‐ despite similar characteristics of the CSD ‐ highly different. Consequently, it can be concluded that the characterization of the product quality by the CSD alone is insufficient and the quantification of agglomeration is essential for process optimization.     

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.     

Simplex optimization of protein crystallization conditions

Simplex algorithms have been used to optimize for size, number and morphology of lysozyme and apoferritin crystals. This approach requires fewer experiments than the single-factor-at-a-time method or factorial designs and will be useful in conserving materials on the International Space Station. The simplex method has the possible advantage that it conserves on materials by reducing the number of experiments required to optimize a crystallization system. The process is iterative and exploratory and should allow optimum microgravity conditions to be determined which might very well be different from the optimum conditions on Earth. Because the simplex method uses simple mathematical operations to calculate the next set of crystallization conditions it will be easier for crystal growers to implement than factorial designs. Factorial experiments are based on varying all factors simultaneously at a limited number of factor levels. This results in a model that is used to determine the influence of each factor and their interactions. Factorial design experiments are especially useful at the beginning of an experimental study and as a screening tool to investigate a large number of factors. The simplex method is an optimization method which is model-independent and requires no fitting of models to data. Also, when applied to protein crystal growth the simplex method does not rely on an absolute quality score. Instead, with each iteration a comparison is made to the last experiment and the results are assigned as being “better or worse”. In this study, commercially obtained apoferritin was purified from 65% monomeric apoferritin to 92% monomeric apoferritin by size exclusion chromatography. Simplex optimization found the best apoferritin crystals were obtained at 15 mg/ml apoferritin, 2.0% CdSO₄, 25°C using the hanging drop vapor diffusion method of crystallization and at 24 mg/ml apoferritin, 1.5% CdSO₄, 25°C using the containerless crystallization method. For lysozyme, the simplex method found the best crystals at 19 mg/ml lysozyme, 7.0% (w/v) NaCl, pH 4.0, 25°C using the hanging drop vapor diffusion method of crystallization. For both proteins, the optimum conditions were found with less than ten experiments using very little protein. Finally, we report that the factors to be considered in the successful application of this method to crystallization are the number of variables to be studied, the initial conditions, step size and analysis of crystal quality.     

Detection of the II–I Etiracetam solvent-mediated polymorphic transformation through the online monitoring of the suspension apparent viscosity

Although going to complex techniques can be useful at some stage of process development of crystallization processes, the goal of this article is to show that process control can also be achieved with relatively simple measurements, depending of course on what type of control is needed. Focusing on the Etiracetam crystallization process, this work demonstrates the potential of the online monitoring of the power dissipated in the suspension, a property that can be directly related to the suspension apparent viscosity for the detection of the solvent-mediated polymorphic transformation from form II to form I. Even if the work presented in this paper focused on a specific crystallization process, this easy-to-use method seems promising for the control of other crystallization processes exhibiting solvent-mediated polymorphic transformations with similar characteristics: (i) significant difference in the PSD of the crystals of the stable and the metastable forms, (ii) solid volumetric fraction in the suspension higher than 40% and (iii) absence of phenomena (breaking, attrition, agglomeration, secondary nucleation, etc.) interfering with the polymorphic transformation and affecting the PSD of the crystals.     

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 potassium sulfate by cooling and salting‐out using 1‐propanol in a calorimetric reactor

A study was made on a isothermal process for the crystallization of potassium sulfate as an alternative to the cooling process. The process employs addition of 1‐propanol to aqueous salt solutions to achieve the “saltingout” of the K₂SO₄. This work was carried out using an automated Mettler Toledo model RC1 reactorcrystallizer with 800 ml capacity, and controlled isothermally at 25 °C to test the crystallization of K₂SO₄ by addition of the alcohol, and from 50 to 10 °C for the cooling crystallization. In both systems, the line of nucleation points was shown to be approximately parallel to the saturation curve, with an average width of 13°C or 3 % mass for crystallization by cooling, compared with 0.2 to 1 % by salting‐out. In experiments on crystallization by cooling, the K₂SO₄ crystals were 0.27 mm in mean size, showed 7 % agglomeration, and contained 8.5 % moisture. Crystals obtained by salting‐out had a mean size of 0.79 mm, 28 % agglomeration, and 9‐10 % moisture content. A crystal shape factor of approximately of 0.7 was obtained in both systems, apart from the agglomeration.     

Crystallization mechanisms of acicular crystals

In this contribution, we present an experimental investigation of the growth of four different organic molecules produced at industrial scale with a view to understand the crystallization mechanism of acicular or needle-like crystals. For all organic crystals studied in this article, layer-by-layer growth of the lateral faces is very slow and clear, as soon as the supersaturation is high enough, there is competition between growth and surface-activated secondary nucleation. This gives rise to pseudo-twinned crystals composed of several needle individuals aligned along a crystallographic axis; this is explained by regular over- and inter-growths as in the case of twinning. And when supersaturation is even higher, nucleation is fast and random.In an industrial continuous crystallization, the rapid growth of needle-like crystals is to be avoided as it leads to fragile crystals or needles, which can be partly broken or totally detached from the parent crystals especially along structural anisotropic axis corresponding to weaker chemical bonds, thus leading to slower growing faces. When an activated mechanism is involved such as a secondary surface nucleation, it is no longer possible to obtain a steady state. Therefore, the crystal number, size and habit vary significantly with time, leading to troubles in the downstream processing operations and to modifications of the final solid-specific properties.These results provide valuable information on the unique crystallization mechanisms of acicular crystals, and show that it is important to know these threshold and critical values when running a crystallizer in order to obtain easy-to-handle crystals.     

Designed additives for controlled growth of crystals of phospholipid interacting proteins: Short chain phospholipids

A new approach to crystallization of proteins that interact with lipids has been applied to the protein crambin. Short chain phospholipids are water-soluble additives and effectively lower the amount of protein needed to form crambin crystals by lowering protein solubility and inhibiting crystal growth in the fastest growing direction. Compared with optimal crystallization conditions without phospholipid, which gave large crambin crystals (1.5 × 0.7 × 0.5 mm), a 30–60-fold decrease in protein concentration as well as 5-fold decrease in volume were achieved. As a result, the efficiency of crystal production was increased by 150–300-fold. The crystals obtained diffracted beyond 1.5 Å resolution. The most effective additive, phosphotidylcholine, had a size comparable to the proposed binding site on crambin and on the homologous membrane-active toxins. The procedure developed may be useful for crystallization of other phospholipid interacting proteins as well as transmembrane proteins.     

A short overview on practical techniques for protein crystallization and a new approach using low intensity electromagnetic fields

This contribution deals with a practical overview of some popular and sophisticated crystallization methods that help increase the success rate of a crystallization project and introduces a newly developed method involving low intensity electromagnetic fields. Aiming to suggest a methodology to follow, the present contribution is divided into two main parts in a logical order to get the best crystals for high resolution X-ray crystallographic analysis. The first part starts with a short review of the chemical and physical fundamentals of each crystallization method through different strategies based on physicochemical approaches. Then, practical non-conventional techniques for protein crystallization are presented, not only for growing protein crystals, but also for controlling the size and number of crystals. These include crystal growth in gels, counter-diffusion, seeding, and macromolecular imprinted polymers (MIPs). The second part shows the effects of coupling low intensity electric fields (in the scale of units of  μAmperes) with weak magnetic fields (in the scale of milli Tesla) applied to protein crystallization. This approach consists of a novel experimental set up, which was used to study the influence of the coupled fields on the crystallization of lysozyme in solution and in gel media. This new approach is based on the classical theories of transport phenomena and offers a more accessible strategy to obtain suitable crystals for X-ray characterization or Neutron diffraction investigations.     

Synthesis of Submicron Silicalite‐1 Crystals from Clear Solutions

Discrete and monodisperse submicron crystals of silicalite‐1 with a mean size of 0.3 μ m were synthesized from clear crystallization solutions. The effects of silica content, alkalinity of batch and the nature of silica source on the product yield, crystal morphology and particle size distribution were investigated. The crystal shape was sphere‐like or hexagonal twinned disks when silicic acid was the silica source. Change of silica source to sodium silicate solution leads to the formation of rounded‐edged‐hexahedron crystals. Silica content of batch does not influence crystal morphology. Alkalinity of clear crystallization solution has a strong effect both on the particle size distribution and yield of product. Increase of alkalinity caused bimodal particle size distribution and decrease of yield.