Crystallization of vitamin C in a continuous DT MSMPR crystallizer – Size independent growth kinetic model approach

The experimental results concerning continuous mass crystallization process in L(+)‐ascorbic acid – water system are presented and discussed. Influence of L(+)‐ascorbic acid concentration in a feeding solution and mean residence time of suspension in laboratory DT MSMPR crystallizer on product crystal size distribution as well as nucleation and growth kinetics were determined. Kinetic parameter values were evaluated on the basis of size–independent growth (SIG) kinetic model (McCabe's ΔL law). It was observed, that within the examined range of crystallizer productivity (120–1600 kg LAA crystals m^–3h^–1) crystal product population of mean size L_m from 0.2 to 0.3 mm and CV from 66.6 to 49% is withdrawn. Linear growth rate values present decreasing trend (from ca. 7 · 10^–8 to ca. 6 · 10^–8 m s^–1) with the productivity increase (assuming constant mean residence time of suspension τ = 900 s). Occurrence of secondary nucleation within the circulated and mixed suspension, resulting from crystal attrition and breakage, was observed. The parameter values in design equation connecting linear growth rate and suspension density with nucleation rate were determined. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

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.     

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)     

Mathematical model of particle size distribution of crystals taking into account the growth dispersion

This paper presents a mathematical model to describe the effect which the growth dispersion has on the particle-size distribution of crystals which are formed in a crystallizer with an ideally mixed suspension and ideal product discharge (MSMPR crystallizer). This model starts from a number density distribution of crystals, which shows dependence on the process duration, the rate of crystal growth and the crystal size. The model differs from the diffusion model. The distribution data calculated are in agreement with distribution data measured and published by a number of other authors. The influence of the two parameters b and r_LH on the mathematically determined frequency distributions is being studied.     

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.     

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)     

Effect of mixing on the crystal size distribution of borax decahydrate in a batch cooling crystallizer

The effect of the impeller speed upon the metastable zone width, supersaturation level, crystal growth and the crystal size distribution of borax decahydrate have been investigated to find operating conditions of a batch cooling crystallizer. The importance of impeller speed was studied in baffled stirred crystallizer with a volume of about 2 dm³, equipped with four straight blade turbine (4-SBT) cooling at a constant cooling rate. The metastable zone width was determined by visual method, while concentration changes during the process were monitored in line using ion-selective electrode. The crystal size distribution was determined by optical microscope and sieve analysis respectively. The power consumption measurements were performed for all impeller speeds examined as well. On the basis of the experimental results and observations it is evident that in an agitated batch crystallizer the above mentioned parameters are significantly influenced by hydrodynamic regime in the system determined by impeller used and its revolution speed.     

The effect of crystal surface roughness on impurity adsorption

The effect of crystal surface roughness on impurity adsorption was investigated in a fluidized bed crystallizer and in a batch crystallizer. The crystallisation of sucrose in pure and impure systems was the study subject. Calcium chloride was utilized as impurity in this work. The results show that the impurity adsorption is growth rate dependent and is strongly influenced by the crystal surface properties. Crystals with high surface roughness have lower impurity adsorption. Based on experimental evidences, a new theoretical model is proposed to quantify the surface roughness influence on the impurity adsorption, allowing, by operating at the more adequate supersaturation, to control the impurity transfer into crystals. The used impurity does not have a significant influence on the growth rates at the studied temperatures. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Nucleation and growth kinetics for the crystallization of ice from dextrose solutions in a continuous stirred tank crystallizer with supercooled feed

The crystallization of ice in aqueous dextrose solutions is studied in an adiabatic continuous stirred tank crystallizer with a supercooled feed stream. The effective diameter of the ice crystals was determined for various values of mean crystal residence time, feed supercooling, magma density, stirring rate, and dextrose concentration. For all process conditions the supercooling was measured at 9-12 different locations in the crystallizer. These local supercoolings were averaged algebraically to yield the bulksupercooling. From the experimental results growth and nucleation rates have been calculated. By comparing the experimental growth rates to growth rates calculated by means of a mathematical model kinetics for the inbuilding of water molecules into the ice lattice have been determined. The growth rate appears to be directly proportional to the interface supercooling. The rate constant decreases exponentially with increasing weight percentage of dextrose in the solution. The nucleation rate was found to be directly proportional to total crystal surface per unit volume of suspension and proportional to the bulksupercooling to the power 2.1. Nucleation is believed to occur by breakage of dendrites from the surface of parent crystals.     

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)     

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)     

The Effect of Volume Shape Factor on the Crystal Size Distribution of Fragments due to Attrition

The effect of volume shape factor on crystal size distribution (CSD) is usually ignored to simplify the analysis of population balance equation. In the present work, the CSD of fragments generated from a mechanically stirred crystallizer as the result of attrition mechanism has been reported when the volume shape factor conforms to normal distribution. The physical model of GAHN and MERSMANN which relates the attrition resistance of a crystalline substances to its mechanical properties has been employed. The simulation of fragment size distribution was performed by Monte Carlo (MC) technique. The results are compared with those reported by GAHN and MERSMANN.     

A simple analysis of the work of crystallisers

An analysis is realized by correlating the data of sieve analyses to the process of crystallisation with different working conditions in a MSMPR crystallizer (mixed suspension – mixed product removal). The informations are: mean size of product crystals, distribution coefficient indicating the deviations from perfect mixing of the suspension, undersize fractions of crystals, actual linear growth rate, detection of fines dissolution, classification, crystals breakage a. o.     

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)     

The Influence of Impurities on Crystallization Kinetics of Sodium Chloride

The influence of impurities on the crystallization kinetics of NaCl was investigated in a fluidized bed crystallizer. The growth and dissolution rates were related to the supersaturation and impurity concentrations. The effect of different impurities on the growth rate of NaCl crystals can be divided into thermodynamic effects where the impurities influence the solubility and kinetic effects where the impurities will suppress the growth rate compared to the pure NaCl. A mathematical model describing crystal growth rates from aqueous solution as a function of impurity concentration is presented. The model explains impurity concentration effects on the crystal growth rate in terms of an impurity effectiveness factor and a Langmuir adsorption isotherm for the impurity.     

Optimierung der Kühlungskristallisation mittels Vermischung einer kalten und einer warmen Lösung

Heated saturated solutions were directly mixed with cold ones in a fluidization crystallizer. Crystals were continuously drawn from the fluid layer, and the outflowing mother liquor of the upper part of this layer recooled and inflown into the crystallizer again. A model enabled to determine that optimum common temperature referring to the given initial solutions, and the temperature of the outflowing mother liquor, when the main part of the crystals precipitates. — The portions of crystals referring to the theoretically found optimum common temperature of the solution in the crystallizer and to the whole circulation process, were determined. We examined the validity of the theoretically found values by experiment and the influence of cooling parameters on crystal size distribution as well as on the productivity of the crystallizer.     

Unsteady-state transfer of impurities during crystal growth of sucrose in sugarcane solutions

In this work, we present growth rate data of sucrose crystals in the presence of impurities that can be used by both sugar technologists and crystal growth scientists. Growth rate curves measured in a pilot-scale evaporative crystallizer suggest a period of slow growth that follows the seeding of crystals into supersaturated technical solutions. The observed trend was enhanced by adding typical sugarcane impurities such as starch, fructose or dextran to the industrial syrups. Maximum growth rates of sucrose resulted at intermediate rather than high supersaturation levels in the presence of the additives. The effects of the additives on the sucrose solubility and sucrose mass transfer in solution were taken into account to explain the observed crystal growth kinetics. A novel mechanism was identified of unsteady-state adsorption of impurities at the crystal surface and their gradual replacement by the crystallizing solute towards the equilibrium occupation of the active sites for growth. Specifically designed crystallization experiments at controlled supersaturation confirmed this mechanism by showing increasing crystal growth rates with time until reaching a steady-state value for a given supersaturation level and impurity content.     

Determination of reactive crystallization kinetics of 5‐(difluromethoxy)‐2‐mercapto‐1H‐benzimidazole in a batch crystallizer

5‐(difluromethoxy)‐2‐mercapto‐1H‐benzimidazole (DMB) was crystallized via the reaction between sodium salt of DMB and acetic acid. In this work, we firstly measured the solubility data of DMB in binary ethanol‐water mixture at different temperatures. Then, the reactive crystallization kinetics of DMB was determined in the batch crystallizer. Based on the population balance and mass balance, the kinetics model of reactive crystallization process of DMB was established. And the nucleation rate, size‐independent crystal growth and agglomeration kernel were determined by method of classes. Finally, based on the population balance, numeric simulation was done using the above crystallization kinetics in order to verify its reliability.     

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)