Optimization of process parameters by Taguchi method in the recovery of lactose from whey using sonocrystallization

Anti‐solvent crystallization of lactose in the presence of ultrasound will reduce crystal size and the level of agglomeration as compared to the commercial cooling crystallization. It offers a potential route to enhance the physical properties as well as the rapid recovery of lactose. Since lactose recovery itself can reduce biological oxygen demand of whey by more then 80%, recovery of lactose from dairy waste stream (whey) solves the problems of dairy industries by improving economics of whey utilization and pollution reduction. In the present study, recovery of lactose from partially deproteinated whey using an anti‐solvent (acetone) by sonocrystallization was optimized for finding the most influencing operating parameters; such as sonication time, anti‐solvent concentration, initial lactose concentration in the whey and initial pH of sample mixture at three levels using L₉‐orthogonal method. The responses were analyzed for recovery of lactose from whey. The anti‐solvent concentration and the sonication time were found to be most influencing parameters for the recovery of lactose and the recovery of lactose was found to be 89.03% at the identified optimized level. The crystal size distribution of recovered lactose was found to be narrower (2.5 – 6.5 μm) as compared to the commercial lactose crystals (3.5 – 9.5 μm). (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Ultrasound assisted crystallization for the recovery of lactose in an anti‐solvent acetone

Continuous worldwide increase in high‐scale production of dairy products leads to the constant generation of vast amounts of liquid by‐product, whey. Disposal of liquid whey is costly due to its high biological oxygen demand (BOD) and water content. More than 90% of whey BOD is due to lactose. Recovery of lactose from whey solves both the problems of improving economics of whey utilization and pollution reduction as lactose recovery itself can reduce BOD of whey by more then 80%. Commercial effluent treatment techniques focus on degradation rather than recovery of useful by‐products like lactose. Also, these techniques are time consuming and hence not effective enough. Sonocrystallization is the use of power ultrasound to control the crystallization process during the nucleation phase. In the present study, the process of lactose crystallization has been studied for the recovery of lactose from reconstituted lactose solutions with the aid of ultrasound, in the presence of ‘acetone’, as an anti‐solvent. The crystallization is found to be completed with excellent yields in the range of 80 – 92% within 4 minutes of sonication. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Characterization of L‐ascorbic acid single crystals grown from solution with different solvents

Single crystals of L‐ascorbic acid, popularly known as vitamin‐C, were grown from solutions with different solvents and solvent combinations by low temperature solution growth methods. The suitability of different solvents and solvent combinations such as acetone, ethanol, methanol, isopropyl alcohol, water, water + acetone (1:1), water + ethanol (3:1), water + isopropyl alcohol (3:1) and isopropyl alcohol + methanol (1:1) for crystal growth of L‐ascorbic acid was found out by assessing the solubility and crystallization behaviours. Solubility of L‐ascorbic acid in selected solvents and solvent combinations in a range of temperatures was determined by gravimetric method. Solution prepared with water, water + acetone (1:1), water + ethanol (3:1) and water + isopropyl alcohol (3:1) were yielded crystals with tabular, columnar and prismatic habits and their morphologies were evaluated by goniometry. Grown single crystals were characterized with various instrumental techniques such as powder X‐ray diffraction, Fourier infrared spectroscopy, optical transmittance study, differential scanning calorimetry and second harmonic generation studies. (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

A more clear insight of the lysozyme crystal composition

Crystallization can be used as a purification method for proteins. Lysozyme was chosen as a model substance. Changing crystallization conditions will lead as shown to different lysozyme crystal morphologies with different properties. Beside others, lysozyme crystals can show a Tetragonal, High Temperature and Low Temperature Orthorhombic crystal morphology. Experiments such as conductivity measurements, pH tests, chloride detection tests, experiments using methylene blue as a dye and dissolution experiments were carried out to investigate the composition of the lysozyme crystals. It is proven that lysozyme crystals are made up of the initial buffer solution components: lysozyme (the protein), water which is part of the crystal lattice, salt ions which are attached to the protein molecule and voids filled with the buffer solution containing the crystallization agent (e.g. salt). Interesting dissolution behaviours of the lysozyme crystals were observed which are not described so far elsewhere (© 2011 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

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)     

Study on crystallization kinetics and the crystal internal defects of HMX

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

Agglomeration of NTO on the surface of HMX particles in water‐NMP solvent

A sensitive explosive was coated with a less sensitive explosive in order to improve stability while maintaining explosion performance. Agglomeration of 3‐nitro‐1,2,4‐triazole‐5‐one (NTO) on the surface of cyclotetramethylene tetranitramine (HMX) crystals in water‐N ‐methyl‐2‐pyrrolidone (NMP) solvent was performed by cooling crystallization. Phenomena for coating by crystallization and agglomeration were studied by in‐situ measurement. The agglomeration kinetic for the coating of NTO on HMX crystals was correlated with the 3rd power of the solution supersaturation and the 2nd power of the number of the suspended particles. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Layered crystals of apo‐ and holoferritin grown by alternating crystallization

We report on the use of alternating crystallization for deposition of layers of different (though closely related) proteins in a single crystal. Investigations were carried out with the unique protein couple consisting of two forms of ferritin, apoferritin and holoferritin from horse spleen, which, despite being of quite different molecular masses, still possess identical organic shells. Crystals of both proteins were used as substrates for subsequent contiguous growth of the partner protein in perfect alignment. We observed continuous growth of combined (onion‐like) single crystals; artificial structures of biological macromolecules can be designed in this way. The homoepitaxial layered growth shows in an unambiguous way that protein crystallization depends only on the surface protein conformation and amino‐acid composition, but not on the internal molecule structure. The limitations of protein crystal growth for designing layered structures of biological macromolecules were revealed by growing of heterogeneous protein crystals onto pre‐existing protein crystalline substrates. Tetragonal crystals of hen egg‐white lysozyme were grown onto cubic apoferritin crystals used as substrates. It was observed that the lysozyme crystals were not lattice‐matched to the ‘host’ apoferritin crystals; this led to mere aggregates of different crystals. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Behavior of LiOH·H2O crystals obtained by evaporation and by drowning out

In the present work, the behavior of crystals derived from two different crystallization methods applied in a concentrated aqueous lithium salt solution was studied. The LiOH·H₂O crystals obtained by a simple evaporation (Crystal I) differed in terms of morphology and solubility from those precipitated from lithium hydroxide solutions by addition of ethanol as a co‐solvent (Crystal II). Solubility of Crystal II at different temperatures (15 to 35°C) and mass ratios of ethanol to water (0 to 0.1) was determined. Polymorphic like behavior of these crystals was evidenced from X‐ray diffraction patterns. Measurement of density, refractive index, absolute viscosity and electrical conductivity of saturated solutions are reported. A thermodynamic analysis in terms of the Chen model for the calculation of activity coefficients, indicate that the polymorphic system in water and in water + ethanol (ethanol/water ratio 0.1) is enantiotropic. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

The crystallization of lysozyme in the system of ionic liquid [BMIm][BF4]‐water

Lysozyme crystallization was conducted in the ionic liquid (IL) 1‐butyl‐3‐methylimidizolium tetrafluoroborate ([BMIm][BF₄]) with different buffer/IL proportions. It was found that the addition of [BMIm][BF₄] could promote the crystallization process, during which more lager single crystals with controllable morphologies could be obtained due to the manageable crystal growth velocity. A probable explanation was proposed based on the influence of the ionic polarization and kinetics in the lysozyme crystallization. Moreover, the transform in coordination number and the relative growth rate of different crystal faces were discussed. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Crystallization of mefenamic acid and polymorphs

The crystallization of Mefenamic Acid, (MA), which has a prevalent usage in drug formulation, was investigated. MA is a high‐dose, anti‐inflammatory, analgesic agent used for pain in menstrual disorders. Some negative properties of MA are a high hydrophobicity and propensity to stick to surfaces, which cause great problems during granulation and tabletting. To facilitate tabletability, enhance dissolution rates, and develop a stable and reproducible dosage form, investigation of the physicochemical properties of mefenamic acid is necessary. Pharmaceutical drugs are commonly crystalline materials and are therefore subject to polymorphism. Polymorphism, the ability of a substance to exist in more than one crystalline form, is a significant phenomenon in the field of chemical engineering sciences, including pharmaceutical development. Establishing the polymorphic behaviour of a drug molecule early in development minimizes the number of unsuitable candidates developed and reduces the risk of encountering issues later which may have a major financial and time impact. Mefenamic acid crystals were recrystallized from five different solvents of N, N‐dimethylformamide (DMF), acetone, N, N‐dimethylacetamide (DMA), Dimethylsulfoxide (DMS) and Ethyl Acetate (EA). In order to characterize the Mefenamic Acid crystal structure and the polymorphic forms of the crystals obtained by recrystallization, the scanning electron microscopy (SEM), Raman diffractometry and X‐ray pattern were used. From the industrial crystallization point of view, the crystal size distribution (CSD), the crystal shape, the polymorphic form and the crystallization steps are important factors that affect the quality and bioavailability of a drug. For the determination of crystal size distribution of MA, The Focused Beam Reflectance Measurement (FBRM) technique was practiced and CSD profiles were obtained. (© 2008 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.     

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)     

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.     

Initial stages of SiC crystal growth by PVT method

Initial stages of SiC crystal growth by Physical Vapor Transport method were investigated. The following features were observed: (a) many nucleation crystallization centres appeared on the seed surface during the initial stage of the growth, (b) at the same places many separate flat faces generated on the crystallization front, (c) the number of facets was dependent on the shape of the crystallization front and decreased during growth, (d) appearance of many facets lead to decrease of structural quality of crystals due to degradation of regions where crystallization steps from independent centres met. The results revealed that the optimal crystallization front should be slightly convex, which permits the growth of crystals with single nucleation centre and evolution of single facet on the crystallization front. The subjects of study were the shape and the morphology of growth interface. Defects in the crystallization fronts and wafers cut from the crystals were studied by optical microscopy, atomic force microscopy (AFM) combined with KOH etching and X‐ray diffraction. (© 2007 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Growth aspects of barium oxalate monohydrate single crystals in gel medium

Single crystals of barium oxalate monohydrate (BaC₂O₄.H₂O, BOM) were grown in pure form by controlled diffusion of Ba²⁺ using the gel technique at different temperatures. Starting from aqueous Ba²⁺ chloride (BaCl₂) and acetic acid (C₂H₂O₄) in gel, this method offers a low‐cost and an easiest alternative to other preparation methods for the production of barium oxalate bulky single crystals. The optimal conditions for the growth of BOM crystals in silica gel were found by investigating different growth parameters such as gel pH, gel aging and crystallization temperature. Irrespective of all such crystallization environments, growth rate of the crystals were initially less and then exhibited supersaturation effect leading to non‐linearity. Gel aging and temperature has profound effect on nucleation density that resulted less number of crystals of maximum size in the gel matrix. Perfect single crystals were grown on gels of higher pH. The macropore morphology and porosity was controlled by changing age of the gel. It has been found that temperature has a fabulous effect in controlling the nucleation density by altering the supersaturation conditions for the formation of critical nuclei. The entire growth kinetics informed that the grown crystals were derived by the one dimensional diffusion controlled process. (© 2008 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)     

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.     

Solvent effect on tolbutamide crystallization induced by compressed CO2 as antisolvent

The aim of this work is to investigate the crystallization of tolbutamide induced by the addition of compressed carbon dioxide, with a particular focus on the role of the liquor solvent on the product characteristics. Crystals morphology and sizes were documented by microscopy and laser diffraction, respectively; since tolbutamide exists in four polymorph forms, characterizations by powder X-rays diffraction, differential scanning calorimetry and Raman spectroscopy were carried out. When processed from acetone or ethyl acetate, the drug crystallizes as polyedres and in a crystal lattice typical of Form III. If ethanol is added to acetone, Form I appears in the powder and becomes predominant for a content of 29% (in mol) and above; at the same time, mean particles size decreases. However, ethanol improves the solubilization of tolbutamide in the formed CO₂–solvent mixture, and is thus not favourable to a good yield of production. Mixtures of acetone with poor solvents such as diethyl ether and water were tested out; both enable the recovery of a mixture of Forms I and III, but with no significant improvement in sizes or yields compared with pure acetone or acetone–ethanol mixtures. Finally, the comparison with crystals obtained by evaporation indicates that the solvent itself was the main cause of the crystal phase observed, rather than the supercritical treatment.     

Effect of different solvents on the habit of meta‐nitroaniline single crystals

The habit of the organic non‐linear optical material meta‐nitroaniline (mNA) crystallized from different organic solvents such as acetone, benzene, ethyl acetate, n‐hexane, methanol and toluene were studied. Solubility of mNA in these solvents at various temperatures in the range between 288 and 323 K was determined by gravimetric method. Crystals were grown by restricted evaporation of solvents method. Solutions with different solvents having different chemical nature and polarity yielded crystals with different habits: one‐dimensional needles, two‐dimensional rhombic platelets and three‐dimensional octahedral. In addition, the mNA crystals show unidirectional growth behaviour along its polar [001] direction irrespective of the solvents used. All the grown crystals were found to be orthorhombic system with point group mm2 and space group Pbc2₁ which was confirmed by powder X‐ray diffraction study. Optical transmittance study showed that the grown mNA single crystals have optical transparency in the wavelength range between 430 and 1550 nm. SHG efficiency of the grown mNA crystal was 3 times grater than KDP. (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)