On‐line monitoring of lithium carbonate dissolution

Dissolution of lithium carbonate (Li₂CO₃) in aqueous solution was investigated using three on‐line apparatuses: the concentration of Li₂CO₃ was measured by electrical conductivity equipment; CLD (Chord Length Distribution) was monitored by FBRM (Focused Beam Reflectance Measurement); crystal image was observed by PVM (Particle Video Microscope). Results show dissolution rate goes up with a decrease of particle size, and with an increase in temperature; stirring speed causes little impact on dissolution; ultrasound facilitates dissolution obviously. The CLD evolution and crystal images of Li₂CO₃ powders in stirred fluid were observed detailedly by FBRM and PVM during dissolution. Experimental data were fitted to Avrami model, through which the activation energy was found to be 34.35 kJ/mol. PBE (Population Balance Equation) and moment transform were introduced to calculate dissolution kinetics, obtaining correlation equations of particle size decreasing rate as a function of temperature and undersaturation. (© 2009 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)     

A simple method to study hemihydrate phosphoric acid crystals growth process

A simple method is introduced in this study to better understand the growth process of hemihydrate phosphoric acid crystals. Using the proposed approach, large particles (>2 mm) can be produced reflecting the true state of the phosphoric acid particulate system. In contrast to previous studies, the principles for the crystallization curves were divided into two regions, based on the consumption of the phosphoric acid in solution. To maintain a constant crystal growth rate, a programmed cooling requirement was needed. In this reported study, the influence of a complexing agent (EDTA) on the crystallization process of phosphoric acid was also investigated. The results of this study showed that the presence of EDTA affected the metastable zone widths, as well as the kinetics of crystal growth.     

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.     

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.     

Anti‐solvent effect of crystallization by feeding ethanol under microwave radiation

The nucleation and crystal growth of sodium chloride in aqueous solution during crystallization by ethanol droplet feeding were investigated by determining the suspension density and crystal size distribution. Crystallization was conducted in a microwave reactor, and the effect of the power, stirring speed, and ethanol concentration were investigated to clarify the anti‐solvent effect under microwave radiation. Molecular diffusion was accelerated by fine particle production due to microwave radiation when the stirring speed was low and ethanol concentration was high. However, moderate microwave power and stirring speed were required for efficient molecular diffusion.     

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)     

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

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

Influence of stirring speed on the crystallization of calcium carbonate

Control over crystal morphology of calcium carbonate (CaCO₃) was investigated by simply changing the stirring speeds in the process of CaCO₃ formation. Scanning electron microscopy (SEM) and powder X‐ray diffraction (XRD) measurements explore the morphology evolution of CaCO₃ at varying stirring speeds. As the stirring speeds increase, rhombohedral calcite, spherical vaterite, and monoclinic crystal with coexistence of calcite phase and vaterite phase were formed, suggesting a facile control over calcium carbonate crystallization in constructing crystals with desired morphology. Moreover, almost pure vaterite spherical particles of narrow particle size distribution were formed at optimum stirring speed. Finally, also elucidated in this work is the mechanism investigation into the construction of various crystal forms via this simple route. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Application of Rosin–Rammler model for analysis of CSD in sugar crystallization

Crystal‐size distribution (CSD) is one of the most important parameters in sugar production. The objective is to grow crystals of uniform sizes or narrow CSD. CSD appears to be determined by the growth‐rate history of the crystals and the relative supersaturation (SS) of the solution from which crystals growth takes place. Three methods for preparation of nucleation seeds were described and used for industrial crystallization of raw and white sugars; these are wet milling filtered sugar (ML), agitating saturated solution (AS) and powdered sugars (PD). Rosin–Rammler (RR) and mathematical models were adopted to investigate CSD and the uniformity of the produced crystals. Higher uniformity coefficients were reported for the AS seeded crystals than the other two seeding methods. Furthermore, higher crystal contents were obtained for the AS seeded white sugar batches in comparison.     

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)     

Coarse crystal layer growth and liquid entrapment study with gradient freeze technology

The coarse crystal layer growth and liquid entrapment processes were investigated with gradient freeze technology in this paper. The research system was hemihydrate phosphoric acid (H₃PO₄·0.5H₂O) crystal‐phosphoric acid aqueous solution. The distribution coefficients of ions (Ca²⁺, Fe³⁺ and Na⁺) in this system were measured. The effect of supercooling degree gradient on layer growth and the effect layer growth rate on ions redistribution were studied. The result indicated that the layer growth rate increased with supercooling degree gradient as an exponential curve. The distribution coefficient tended to increase as an approximate ‘S’ curve when coarse crystal layer growth rate increased. The ‘three region’ theory was applied to explain this phenomenon. Each ion's diffusion parameter was obtained, which contributed to explain the separation differences between different ions. The work in this paper also indicated that layer crystallization was an effective separation technology for electronic grade phosphoric acid preparation.     

Crystallization of calcium sulfate dihydrate at different supersaturation ratios and different free sulfate concentrations

Free Sulfate is a major parameter affecting gypsum crystallization during phosphoric acid production. Gypsum crystal size, shape and filtration rate are significantly affected by the concentration of free sulfate. It is, therefore, important to evaluate the effectiveness of different sulfate levels from 1.5% to 3.5% on induction time and gypsum morphology. The crystallization of gypsum was carried out under simulated conditions of phosphoric acid production by the dihydrate process. Calcium hydrogen phosphate and sulfuric acid were mixed with dilute phosphoric acid at 80 °C, and the turbidity of the reaction mixture was measured at different time periods to calculate the induction time of gypsum crystals formation. With increasing free sulfate concentration, the induction time was significantly decreased. Chemical processing of Central and South Florida phosphate concentrates under different concentrations of free sulfate from 1.5% to 5.5% was carried out. The change on crystal size distribution and filtration rate were traced with free sulfate concentrations. The results show that, filtration rate of phosphogypsum was correlated to the mean diameter of crystals. In addition, induction time and co‐crystallized (lattice) P₂O₅ % in gypsum are decreased with increasing free sulfate content from 1.5% to 3.5%. Morphology of formed gypsum crystals at different sulfate contents and different supersaturation ratios are investigated. (© 2004 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Ageing of spherulites of an industrial relevant aromatic amine derivative

Polycrystalline spherulites of an aromatic amine derivative have been precipitated in a batch process by pH‐shift with hydrochloric acid from stirred aqueous solutions. The time dependent behaviour of the spherulites has been studied during crystallization in the temperature range from 5 °C to 60 °C. Cake resistance values have been obtained from batch filtration tests performed at 2 bar pressure difference at different stages of the crystallization process. The FBRM mean chord length of the crystals decreases with time as a result of crystal ageing into plate‐like crystals. The rate of the ageing process increases with temperature. XRD‐studies show no significant differences in the crystal structure during the ageing process, and the mechanism of the transformation was not established. The filterability of aromatic amine crystals deteriorates as the crystallization progresses. The decrease in the filterability is attributed to the appearance of small plate‐like crystals and a change in the interaction between the crystal surface and the solution, during the ageing of the particles. (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

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.     

Crystallization of phosphogypsum in continuous phosphoric acid industrial plant

Understanding crystallization of phosphogypsum is generally of basic importance for industrial wet‐process phosphoric acid production. In this paper, measuring the phosphogypsum crystal size distribution during primary and secondary nucleation is reported. The results show that, secondary nucleation was occurred at 5 hr run time (12.5% solid content). Crystal growth rates were about 18.4 μm/hr at 2.5% solid content and about 4.5 μm at 30% solid content. At steady state (16 hr run time and 30% solid content), the mean diameter of the crystals and the average specific surface area are about 25 μm and 0.69 m²/g, respectively. (© 2004 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Precipitation kinetics of sodium bicarbonate in an industrial bubble column crystallizer

Sodium bicarbonate is a substance which is produced in the middle stages of the soda ash production process. In this precipitation process, carbon dioxide gas is continuously injected into the bubble column reactor which contains carbonate and bicarbonate solutions. To elucidate the key parameters affecting precipitation kinetics, an experimental study was conducted to understand nucleation and growth in conditions of industrial reactor. The composition of the solution is followed during the crystallization process by titration. Magma density is also monitored and crystal size distribution (CSD) is obtained by sieving. The method of moments was used to determine nucleation and growth rates of crystals. The nucleation and growth rate correlations for sodium bicarbonate precipitation in industrial scale were correlated by empirical power laws as B = 26.685M_T^0.42Δw^1.31 and G = 1.381×10^–4Δw^1.53. The nucleation and growth rate correlations obtained in this study can be used to simulate the crystallization of sodium bicarbonate plants. (© 2009 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

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

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

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)     

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)