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.     

Study of batch maltitol (4-O-α-d-glucopyranosyl-d-glucitol) crystallization by cooling and water evaporation

It is obvious that maltitol, like other disaccharides, owes some of its functional properties to structural features such as the flexibility of the glycosidic bond and hydrogen bonding and to its aqueous solution physicochemical properties, especially solubility and metastable zone width. This is particularly the case for molecular arrangements, which take place before and during crystallization process. We have previously used FTIR spectra to study structural properties of the maltitol molecule in concentrated solution like molecular associations or changes in conformation [1]. To complement these molecular properties, the different maltitol solution physicochemical properties having a relationship with maltitol–water or maltitol–maltitol interactions like solubility, metastable zone width, viscosity, and density were determined [2]. In this work we used these physicochemical results to optimize maltitol crystallization both by reducing the process duration and by improving the obtained crystal quality. Two strategies have been tested: the optimization of the time/temperature profile during the classical cooling crystallization and the application to maltitol of evaporative crystallization, a process usually used for sucrose preparation. The obtained results mainly showed remarkable difference in crystal mean size and crystal size distribution when the cooling profile was modified. On the other hand, evaporative crystallization was shown to make it possible to lower considerably the crystallization time compared to the cooling process but crystal morphological properties seem to be considerably modified by evaporation.     

Nucleation, growth and characterization of L-tartaric acid—nicotinamide NLO crystals

The solubility, metastable zone width and nucleation parameters of organic nonlinear optical material L-tartaric acid–nicotinamide (LTN) have been determined. The crystals of LTN are grown by the slow cooling method. The grown crystals are morphologically interpreted. The crystalline powder of the grown crystals has been examined by X-ray diffraction and thermogravimetric analysis. The different modes of vibrations present in the crystal are identified by the Fourier infrared spectroscopy analysis. The powder SHG efficiency of LTN is comparable with that of KDP.     

Growth kinetics of CaF2 in a pH-stat fluidized-bed crystallizer

In this study, experiments were first conducted in a stirred vessel to establish the metastable region of calcium fluoride, using a pH-stat apparatus for controlling the pH value of solution. The effects of pH value on the solubility and metastable region were observed. Then, operating variables, including supersaturation, superficial velocity, pH value, seed size, and types of seed and solution, that influenced the crystal growth of the same system were investigated in a fluidized-bed crystallizer. The crystal growth rates were determined from the consumption rates of fluoride ions. The growth kinetics was explored by using the two-step growth model. The effectiveness factor was used to judge whether a controlling step was existing. The kinetics of crystal growth in a lean bed and a dense bed was also discussed.     

Simulation of metastable zone width and induction time for a seeded aqueous solution of potassium sulfate

The metastable zone width (MSZW, ΔT_m) and induction time (t_ind) were determined with computer simulation for seeded batch crystallization of potassium sulfate from aqueous solution. The MSZW and induction time determined with simulation showed the same behavior as experimental values reported in the literature; log (ΔT_m) increased linearly with an increase in log R (R: cooling rate) and t_ind decreases in proportion to (ΔT)⁻ⁿ (ΔT: supercooling, n: nucleation order in the secondary rate expression of B=k_n(ΔT)ⁿ). The secondary nucleation parameters (k_n and n) were deduced both from the simulated MSZW and induction times by using the previously proposed model [J. Cryst. Growth, 2010, 312, 548–554]. The secondary nucleation rate calculated with the deduced parameters was in agreement with that calculated with the parameters input for simulation.     

Investigation of the growth rate of β-cyclodextrin in water during both flow-cell and batch experiments

Growth rate measurements of β-cyclodextrin in water were performed both ways. Firstly, experiments were conducted with single monocrystals located in a supersaturation-controlled flow cell. Diffusional limitations and perturbations due to a competition between surface secondary nucleation and growth at high level of supersaturation have been put in evidence. The evolution of the growth rate with supersaturation has been modelled with a BCF law, assuming a screw dislocation mechanism. Secondly seeded cooling batch trials have been carried on in a well-mixed suspension crystallizer in order to assess the growth rate of the seeds. Refractometry was used as an in situ sensor for measuring the evolution of the concentration of the solute. Measurements of the crystals size distribution of the seeds and of the final crystals are performed off line with laser diffraction technique. A kinetic law with three parameters allows a consistent assessment of the growth of the seeds. The comparison of the two sets of data shows that overall growth rate of the seed is partially limited by diffusion. Nevertheless, the estimation of a surface integration growth kinetic coefficient from batch trials is rather difficult. The theoretical framework of nucleation models developed by Mersmann et al. (Crystallization Technology Handbook, second ed., Marcel Dekker, New York, 2001, pp. 45–80 and 81–144) coupled with the estimated growth kinetics can therefore be used to better monitor the seeding process during batch crystallization operations so as to favor the growth of the seed crystals.     

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.     

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.     

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.     

Nucleation kinetics of paracetamol–ethanol solutions from metastable zone widths

A study of the nucleation kinetics for a cooling crystallisation of paracetamol–ethanol solutions in a batch reactor is described in this paper. Metastable zone width (MSZW) experiments were conducted in order to estimate the nucleation kinetics of the system. Measured MSZWs can be affected by numerous process parameters, such as cooling rate, concentration, agitation rate, and working volume. Two theoretical approaches were employed to estimate the nucleation kinetics, the classical mass based approach of Nývlt, and a more recent approach by Kubota, which also considers number density. Both approaches were found to produce similar estimates for the nucleation rates of the paracetamol–ethanol solutions as a function of supersaturation for an assumed nucleus size of 10 μm. The theory of Kubota was found to predict satisfactory estimates for the induction time of the nucleation process from MSZW data. The induction time was observed to be independent of the solution temperature as suggested by Kubota’s theory. This is a novel finding and serves to validate the induction time theory of Kubota. In this investigation, MSZWs were observed to decrease with increased levels of agitation and found to be independent of working volume.     

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.     

Kinetics of (R,S)- and (R)-mandelic acid in an unseeded cooling batch crystallizer

The objective of this work is to determine the nucleation and growth kinetics of (R,S)-mandelic acid ((R,S)-MA) and (R)-mandelic acid ((R)-MA) in aqueous solutions using an unseeded cooling crystallization process. To obtain the nucleation and growth kinetics, the solubility, metastable zone limits, and supersaturation were measured by in-situ attenuated total reflection Fourier transform infrared (ATR-FTIR) spectroscopy and focused beam reflectance measurement (FBRM). The nucleation rate and growth rate parameters were determined by a nonlinear optimization algorithm. The effects of initial concentration and cooling rate on supersaturation and the nucleation rate are also discussed.     

Influence of Magnetic Field in the Kinetics of Crystallization of Diamagnetic and Paramagnetic Inorganic Salts

The influence of the magnetic field on some kinetic crystallization parameters of the systems zinc sulfate - water and copper sulfate - water were investigated in a series of controlled batch cooling experiments. The solutions were exposed to magnetic fields with different intensities, up to a maximum of 0.7T. A clear influence of magnetic field on the zinc sulfate crystallization parameters was found: an increase in the saturation temperature, a decrease in the metastable zone width, and increased growth rate and average crystal size. These effects were observed for the diamagnetic zinc sulfate, but not in similar experiments with paramagnetic copper sulfate.     

Influences of ethanol on the thermodynamics and kinetics in the crystallization of xylitol

The metastable zone and crystal growth rates of xylitol in water were investigated under the influence of small volume fractions of ethanol. The utilization of low amounts of ethanol is necessary to help adding slightly soluble ingredients during the fabrication of xylitol products, e.g. in food industry. Therefore, the metastable zone and crystal growth rates were determined by means of an ultrasound measurement technique and batch crystallization experiments. It can clearly be seen that the addition of ethanol is lowering the solubility of xylitol in water. The higher the volume fraction of ethanol, the lower the solubility. The metastable zone width is increased whereas the smallest investigated ethanol content results in the widest metastable zone. The crystal growth of xylitol is inhibited by the addition of ethanol whereby the crystal growth rates are decreasing with increasing ethanol content.     

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.     

A Study of the Metastable Zone in Nylon 12-Toluene Solution

The metastable zone for a nylon 12-toluene solution was determined in an established constant cooling rate apparatus. Supersaturation solubility curves and the equilibrium solubility curve are unparallel one to another. The metastable zone width under seeded conditions is dependent on the cooling rate, the retention time and the saturation temperature. And the metastable zone width under unseeded conditions is dependent on the cooling rate, the agitation rate and the saturation temperature. Through constant cooling rate crystallization experiments, two empirical correlations pertaining to the metastable zone of the solution have been found.     

Microcomputer Programming of Temperature in a Batch Cooling Crystallizer

A new highly flexible batch crystallizer control system and suite of software using a BBC model B microcomputer to programme the cooling rate and log data is described. The programs were tested satisfactorily with the cooling crystallization of potassium sulphate solutions. Both linear and controlled cooling increased the mean crystal size with lower coefficient of variation compared to natural cooling crystallization with a consequent improvement in filtrability characteristics.     

Thermal-induced phase transition and assembly of hexagonal metastable In2O3 nanocrystals: A new approach to In2O3 functional materials

This paper reports on the thermal-induced performance of hexagonal metastable In₂O₃ nanocrystals involving in phase transition and assembly, with particular emphasis on the assembly for the preparation of functional materials. For In₂O₃ nanocrystals, the metastable phase was found to be thermally unstable and transform to cubic phase when temperature was higher than 600 °C, accompanied by assembly as well as evolution of optical properties, but the two polymorphs coexisted at the temperature ranging from 600 to 900 °C, during which the content of product phase and crystal size gradually increased upon increasing temperature. The assembly of In₂O₃ nanocrystals can be developed to fabricate In₂O₃ functional materials, such as various ceramic materials, or even desired nano- or micro-structures, by using metastable In₂O₃ nanocrystals as precursors or building blocks. The electrical resistivity of In₂O₃ conductive film fabricated by a hot-pressing route was as low as 3.72×10⁻³ Ω cm, close to that of In₂O₃ single crystal, which is important for In₂O₃ that is always used as conductive materials. The findings should be of importance for both the wide applications of In₂O₃ in optical and electronic devices and theoretical investigations on crystal structures.     

Scale-up synthesis of zinc borate from the reaction of zinc oxide and boric acid in aqueous medium

Synthesis of zinc borate was conducted in a laboratory and a pilot scale batch reactor to see the influence of process variables on the reaction parameters and the final product, 2ZnO·3B₂O₃·3.5H₂O. Effects of stirring speed, presence of baffles, amount of seed, particle size and purity of zinc oxide, and mole ratio of H₃BO₃:ZnO on the zinc borate formation reaction were examined at a constant temperature of 85 °C in a laboratory (4 L) and a pilot scale (85 L) reactor. Products obtained from the reaction in both reactors were characterized by chemical analysis, X-ray diffraction, particle size distribution analysis, thermal gravimetric analysis and scanning electron microscopy. The kinetic data for the zinc borate production reaction was fit by using the logistic model. The results revealed that the specific reaction rate, a model parameter, decreases with increase in particle size of zinc oxide and the presence of baffles, but increases with increase in stirring speed and purity of zinc oxide; however, it is unaffected with the changes in the amount of seed and reactants ratio. The reaction completion time is unaffected by scaling-up.     

Crystallization kinetics of the borax decahydrate

The growth and dissolution rates of borax decahydrate have been measured as a function of supersaturation for various particle sizes at different temperature ranges of 13 and 50 °C in a laboratory-scale fluidized bed crystallizer. The values of mass transfer coefficient, K, reaction rate constant, k_r and reaction rate order, r were determined. The relative importances of diffusion and integration resistance were described by new terms named integration and diffusion concentration fraction. It was found that the overall growth rate of borax decahydrate is mainly controlled by integration (reaction) steps. It was also estimated that the dissolution region of borax decahydrate, apart from other materials, is controlled by diffusion and surface reaction. Increasing the temperature and particle size cause an increase in the values of kinetic parameters (K_g, k_r and K). The activation energies of overall, reaction and mass transfer steps were determined as 18.07, 18.79 and 8.26 kJmol⁻¹, respectively.