Salting-out precipitation of potassium dihydrogen phosphate (KDP). I. Precipitation mechanism

The precipitation of KDP produced by salting-out with aqueous solutions with different contents of ethanol, 1-propanol and 2-propanol have been studied at 30°C. Induction periods were determined as function of the solution initial supersaturation by a visual procedure. From the experimental results it was possible to conclude that the formation of the new solid phase is controlled by primary nucleation followed by normal growth. The interfacial surface tension of KDP in different solvents was also obtained.     

Influence of a polyacrylate antiscalant on gypsum nucleation and growth

Calcium sulphate dihydrate (gypsum) crystallization was studied under conditions, of supersaturation and temperature, simulating a brackish water desalination unit using solar energy. The effect of an commercial sodium salt of poly(acrylic acid), based compound known as RPI, on homogeneous nucleation and growth of gypsum was also examined. Gypsum was precipitated by mixing aqueous CaCl₂ and Na₂SO₄ solutions. It was found that, with increasing temperature or supersaturation, the induction time decreases and the growth rate increases. By using classical nucleation theory, the interfacial tension and the nucleation rate values were estimated. It was shown that the interfacial tension is temperature dependent. The addition of increasing quantities of RPI, in the same conditions of temperature and supersaturation, prolongs the induction time, decreases the nucleation rate and increases the interfacial tension. The addition mode of RPI (in calcium or in sulphate solution) was found as an important parameter in controlling the inhibition process of gypsum crystallization. XRD and SEM analysis showed that RPI antiscalant strongly affected the texture and the morphology of the deposit gypsum. (© 2008 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

A Stochastic Model for Nucleation Kinetics Determination in Droplet-Based Microfluidic Systems

The measured induction times in droplet-based microfluidic systems are stochastic and are not described by the deterministic population balances or moment equations commonly used to model the crystallization of amino acids, proteins, and active pharmaceutical ingredients. A stochastic model in the form of a Master equation is formulated for crystal nucleation in droplet-based microfluidic systems for any form of nucleation rate expression under conditions of time-varying supersaturation. An analytical solution is provided to describe the (1) time evolution of the probability of crystal nucleation, (2) the average number of crystals that will form at time t for a large number of droplets, (3) the induction time distribution, and (4) the mean, most likely, and median induction times. These expressions are used to develop methods for determining the nucleation kinetics. Nucleation kinetics are determined from induction times measured for paracetamol and lysozyme at high supersaturation in an evaporation-based high-throughput crystallization platform, which give low prediction errors when the nucleation kinetics were used to predict induction times for other experimental conditions. The proposed stochastic model is relevant to homogeneous and heterogeneous crystal nucleation in a wide range of droplet-based and microfluidic crystallization platforms.     

Raman and ATR FTIR spectroscopy in reactive crystallization: Simultaneous monitoring of solute concentration and polymorphic state of the crystals

Batch-reactive crystallization of the two polymorphs of l-glutamic acid was studied using in-line Raman and ATR FTIR spectroscopy. It was observed that the barrier to the nucleation of the stable β-form was higher, and thus the occurrence of β-form nucleation requires a higher supersaturation level. The local supersaturation level inside the reactive crystallizer is significantly affected by the feeding manner of the reactant. When the reactant was fed to a poorly mixed zone, such as the surface of the liquid, a high local supersaturation level was generated near the feeding point. This high local supersaturation level drastically increased with the increase in the concentrations of the reactants. As a consequence, the fraction of the β-form increased with the increase in reactants concentrations. On the other hand, feeding the reactant to a well-mixed zone near the impeller can avoid the occurrence of high local supersaturation, and therefore the dependence of the polymorphic composition of the final product on the concentration of the reactants can be reduced. The information obtained from the spectroscopy leads to improved understanding of the precipitation process and offers great potential for process optimization and control of crystalline quality.     

Polymorphism and morphology of calcium carbonate precipitated in mixed solvents of ethylene glycol and water

The influence of (mono) ethylene glycol (MEG) on polymorphism and the resulting morphology of calcium carbonate have been studied for activity-based supersaturation ratios in the range of 3–10 and temperatures from 25–80 °C in mixed solvents of ethylene glycol and water at ratios of 0–90 wt%. The presence of a co-solvent in the solution affects the supersaturation, because of changes in the activity coefficients and the solubility of the salt, a fact that is usually not accounted for in similar studies in the literature. In the present study, the effect of the solvent was isolated from the accompanying change in the supersaturation. MEG was found to affect both the polymorphic abundance in the precipitates, the morphology of the particles and the transformation rates. High concentrations of MEG favoured the precipitation of vaterite and higher temperatures promoted the formation of aragonite. The particle size was reduced in experiments with high MEG concentrations at supersaturations ratios comparable to water solutions, illustrating that the nucleation rate is affected by the co-solvent. The morphology of the calcium carbonate particles was changed at various conditions of MEG concentrations and temperatures from cubes of calcite to spherical, flower-like and dumbbell particles of vaterite and aragonite needles. MEG prolongs the transformation time of metastable polymorphs and the effect was shown to be caused by the solvent itself, probably as a result of kinetic stabilization by delaying the growth rate of the more stable polymorphs.     

Size-dependent nucleation and growth kinetics model for potassium chloride—Application in Qarhan salt lake

The nucleation process and crystallization kinetics of KCl were studied in order to investigate the problems in KCl production in Qarhan salt lake. The correlation between particle size and KCl crystal growth rate was studied in a continuous mixed-suspension mixed-product removal (MSMPR) crystallizer. Classical theory of primary nucleation was used to study the homogeneous and heterogeneous nucleation mechanism of KCl crystallization. Several size-independent growth models and size-dependent growth models, such as Bransom, C-R, MJ2, ASL, and MJ3, were examined by the population balance theory. Results showed that MJ3 model closely fitted the experimental data, the mean relative deviation was 0.94%, the crystal growth rate G=2068{1−exp[−1.081×10−5(L+961.882)]}.     

The induction time,interfacial energy and growth mechanism of maltitol in batch cooling crystallization

Maltitol is crystallized with seeds by cooling mode in industry, often with large amount of fine crystals and wide crystal size distribution. To eliminate the fine nucleation, it's necessary to understand the nucleation kinetics. In this work, the solubility of maltitol in water was measured by the gravimetric method, the nucleation kinetics of maltitol in batch cooling crystallization was investigated using focus beam reflectance measurement (FBRM), and a novel method was proposed to determine the induction time from the trend of the crystal median chord given by FBRM. Based on the relationship between the induction time and the supersaturation, the nucleation mechanism was obtained, including homogenous nucleation at high supersaturation and heterogenous nucleation at low supersaturation. Additionally, combining the classical nucleation theory (CNT) and Arrhenius’ principle, the crystal‐solution interfacial energy and the energy barrier of homogenous nucleation were calculated. From the scanning electron microscope (SEM) images, the growth mechanism of maltitol was identified as surface nucleation growth and the surface entropy factor calculated from the kinetic analyses of t_ind data corroborated this growth mechanism.     

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)     

Determination of the solid liquid interfacial energy and thereby the critical nucleus size of paracetamol in different solvents

The effect of the type of solvent on the solid liquid interfacial energy was determined by performing induction time measurements of paracetamol in methanol, 1‐propanol, acetone and water at a constant supersaturation temperature of 30 °C and different levels of supersaturation (a/a*) ranging from 1.03 to 1.24. At equal supersaturation level and temperature the induction time increases with decreasing solubility whereas the solid liquid interfacial energy decreases with increasing solubility. The interfacial energy has a minimum value of 1.45 mJ/m² in the solvent where paracetamol has a maximum solubility (methanol) whereas it has its maximum value of 2.91 mJ/m² in the solvent with minimum solubility. The interfacial energy is a function of the solubility has been established. The critical radius for homogeneous nucleation was found to be minimum in the solvent of highest solubility. (© 2006 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Investigation of nucleation kinetics and crystal defects of HMX

The nucleation kinetics of HMX (cyclotetramethylene tetranitramine, C₄H₈N₈O₈) in γ‐butyrolactone was studied in cooling process by induction time method. The laser scattering method was used to measure the solubility data and metastable region of HMX in γ‐butyrolactone. The induction time was measured over a range of supersaturation at different temperatures. Then, the nucleation mechanism of HMX in γ‐butyrolactone was investigated by analysis the relationships between induction time and supersaturation. The results indicated homogeneous nucleation dominated at high supersaturation of S >1.35, while the heterogeneous nucleation dominated at low supersaturation of S < 1.35. The values of interfacial tension at different final temperatures were calculated to indicate the ability of HMX to be crystallized. The growth mechanism of HMX was investigated by the data fitting applying different growth mechanism models and identified as two‐dimensional nucleation‐mediated (2D) growth. Finally, the effects of supersaturation and temperature on the crystal defects were analyzed based on the nucleation kinetics. When the temperature is below 303.15K, homogeneous nucleation dominated the nucleation process at higher supersaturation. Fine HMX crystals with more defects were produced. On the contrary, heterogeneous nucleation mechanism dominated at lower supersaturation. large regular HMX crystals with fewer defects were formed when the temperature is above 318.15K.     

Nucleation Studies in Supersaturated Triglycine Sulphate Solutions

Rates of nucleation of supersaturated aqueous solutions of Triglycine sulphate are measured by the induction period over the temperature range 30–50 °C. The effects of temperature and supersaturation on the induction period are reported. The interfacial tension, energy of formation and radius of the critical nuclei of the crystal are calculated in accordance with classical nucleation theory. Nucleation rate increases with increase in supersaturation and temperature, while interfacial tension decreases with increase in temperature.     

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.     

Understanding the effect of solvent polarity on the habit modification of monoclinic paracetamol in terms of molecular recognition at the solvent crystal/interface

The habit change of monoclinic paracetamol crystallized from solutions with different solvents such as water, ethanol, methanol, acetone, isopropyl alcohol, tetrahydrofuran, cyclohexanone, acetonitrile and 1, 4 ‐ dioxane was investigated. Change in solubility, pH and nucleation time of paracetamol in these solvents at ambient condition was studied. The polymorphic form of the nucleated paracetamol was observed under in‐situ optical microscopy. Solutions with different solvents having different chemical nature and polarity yielded paracetamol crystals with different habits: columnar morphology from polar protic water and prismatic morphology from other selected polar protic, aprotic and in non‐polar solvents. The significant differences on the growth rate of various crystal habit faces of the monoclinic paracetamol grown from different solvents are attributed in context with the solubility of the solute, solvent polarity, evaporation number of the solvent, rate of generation of supersaturation and the role of hydrogen bonding interaction between the solvent molecules and protruding solute molecules on the crystal surface. Among the solution with different solvents, bulk monoclinic paracetamol single crystal was grown from ethanolic solution using seed rotation technique by controlled cooling method.     

Supersaturation Dependence of Induction Period for Three-Dimensional Nucleation of Substances from Aqueous Solutions Revisited

The available experimental data on the supersaturation dependence of induction period for the nucleation of some compounds crystallizing from solutions are analysed from the standpoint of the classical nucleation theory and the mononuclear and polynuclear models in order to obtain values of interfacial tension and pre-exponential factor for homogeneous and heterogeneous nucleation. It was found that the contributions of homogeneous and heterogeneous nucleations to the experimental data can be separated by assuming that the nucleation rates due to the two nucleations are additive and that the polynuclear model in combination with the separated contribution of homogeneous nucleation to the induction period gives a satisfactory agreement between theoretical estimates and experimental values of the interfacial tension and the pre-exponential factor.     

Nucleation time-lag from nucleation and growth experiments in deeply undercooled glass-forming liquids

A new approach is proposed to explain the strong difference between the induction periods (nucleation time-lags) obtained from nucleation rate measurements and from crystal growth experiments for lithium silicate glasses; and their similar magnitude for a Na₂O · 2CaO · 3SiO₂ glass. For these two glass families, the time-lags for nucleation estimated from crystal growth kinetics were compared with those directly obtained from nucleation experiments. A theoretical analysis was performed employing analytical solutions of the Frenkel-Zeldovich equation. In such analysis, the frequently assumed condition of size-independence of the thermodynamic properties of the crystallites was used. Provided this assumption is correct, time-lag data obtained in the two above mentioned ways should coincide. Consequently the significant difference between the values of nucleation time-lag for lithium silicate glasses from nucleation and growth data gives a strong indirect evidence for the deviation of the properties of critical nuclei from the respective parameters characterizing the state of the newly evolving macrophase. For Na₂O · 2CaO · 3SiO₂ glass at intermediate stages of crystallization we show that the average composition of the growing crystals is close to that of the near-critical nuclei. The fact that the nucleation and growth rates of this soda-lime-silica glass refer to the same phase provides an explanation for the similarity of the induction periods estimated from nucleation and growth experiments.     

Nucleation kinetics of the formation of low dimensional calcium sulfate dihydrate crystals in isopropyl alcohol medium

Calcium sulfate dihydrate, constituted as uniform crystals of low dimensions, is a potential biomaterial for clinical applications like bone graft substitution and drug delivery. In this work, isopropyl alcohol has been used as a solvent to obtain low dimensional calcium sulfate dihydrate crystals from calcium nitrate ‐ sulfuric acid system. Reactants in 0.5 molar concentration at ambient conditions generated uniform rod‐shaped crystals of length 3–5 µm. Analysis using X‐ray Diffractometry and Fourier Transform Infrared Spectrometry showed the material to be well crystallized, phase‐pure calcium sulfate dihydrate. The nucleation kinetics has been studied by observing the induction time of phase formation in solutions of millimolar concentrations through turbidimetry at 300 K. The data have been analysed using classical nucleation theory to deduce parameters like interfacial tension (or surface free energy), nucleation rate and critical radius. The surface free energy obtained (5.6 mJ/m²) is comparatively lower than that reported for aqueous precipitation, which could be attributed to the presence of isopropyl alcohol. On escalating the supersaturation ratio, the nucleation rate drastically increased and the critical radius decreased exponentially. Particles formed at supersaturation 1.39 showed a monomodal distribution centered at 8.2 nm in Dynamic Light Scattering analysis. Comparable particle sizes were obtained in Transmission Electron Microscopy.     

Effects of the rate of supersaturation generation on polymorphic crystallization of m-hydroxybenzoic acid and o-aminobenzoic acid

Effects of the rate of supersaturation generation on polymorphic crystallization have been investigated through evaporation and cooling crystallization experiments of m-hydroxybenzoic acid (m-HBA) in methanol, acetone and ethyl acetate, and o-aminobenzoic acid (o-ABA) in ethanol. The rate of supersaturation generation has been altered by systematically changing either the cooling rate or the evaporation rate of solvent using a jacketed crystallizer and a microfluidic evaporation device, respectively. The results have revealed that the rate of supersaturation generation and the tendency of the formation of the less stable polymorph are positively correlated. Kinetic effects are dominant when the rate of supersaturation generation is high, thereby producing the metastable polymorphs (orthorhombic m-HBA; Form II of o-ABA); on the contrary, more stable polymorphs (monoclinic m-HBA; Forms III and I of o-ABA) are formed when the rate of supersaturation generation is low and the thermodynamic effects are prevailing.     

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.     

Nucleation kinetics of selenium (+4) precipitation from an acidic copper sulphate solution

The removal of selenium from copper sulphate solution prior to the electrowinning of copper is desirable in order to minimise contamination of the copper cathodes by selenium and other impurities. The selenium removal is effected by a precipitation process that takes place under high supersaturation conditions, which favour nucleation over any other particle formation processes. There is currently no fundamental information on the nucleation kinetics of this important process. In this study, the nucleation kinetics of selenium (+4) precipitation from an acidic copper sulphate solution was determined using the classical nucleation theory (CNT). Experiments were carried out by varying the levels of supersaturation from 8.66×10¹⁵ to 4.33×10¹⁷ at a temperature of 95 °C under atmospheric pressure. The nucleation rates for four different levels of supersaturation, the nucleation work and the nucleus size were determined. The kinetic constant A was found to be 3.92×10²⁷ m⁻³ s⁻¹, which shows that the nucleation process takes place through a homogeneous mechanism. The associated thermodynamic parameter (B) was determined to be 8.98×10⁰⁴.     

Determination of metastable zone width for combined anti-solvent/cooling crystallization

The metastable zone width (MSZW), induction time and primary nucleation kinetics have been measured and estimated for simultaneous anti-solvent and cooling crystallization of paracetamol in iso-propanol/water solution. ATR-FTIR spectroscopy and laser back-scattering are used to measure the solute concentration and primary nucleation event, respectively. Response surface analysis was applied to find the contribution of the crystallization mechanism on the MSZW and obtain a statistical model for quick estimation of the MSZW. Two theoretical approaches for the estimation of nucleation rate kinetic parameters from experimental data are presented. The methods are obtained by modifying the classical Nyvlt's correlation for simultaneous cooling/anti-solvent crystallizations. The nucleation order n for primary nucleation was deduced from the slope of a linear plot of log(MSZW) vs. log(cooling and anti-solvent rates). The induction time was also estimated by changing the classical methods for combined cooling and anti-solvent crystallization.