Phosphoric acid purification by suspension melt crystallization: Parametric study of the crystallization and sweating steps

In order to purify phosphoric acid, the suspension melt crystallization process was studied. The suspension crystallization experiments were carried out with 80, 84 and 88 wt% phosphoric acid melt at the cooling rates of 0.05, 0.1 and 0.2 K/min, respectively. Sweating experiments were executed for various crystals obtained in suspension crystallization step. The purification effects of the sweating parameters including sweating time, initial inclusion amount and initial impurity content were studied. The inclusion fraction increases with the increase in cooling rate. The inclusion fraction of the crystals which were formed with feed concentration of 84 wt% phosphoric acid melt is lowest among the three feed concentrations. Different impurities have different purification performances during sweating. High inclusion amount and low impurity concentration favor the purification of H₃PO₄·0.5H₂O crystals during sweating.     

The effect of diluting crystallization droplets on protein crystallization in vapor diffusion method

In this study, effects of diluting either protein or crystallization agents in the droplets on the success rate of protein crystallization was investigated. Diluting the crystallization agent was found to increase the success rate of protein crystallization. Theoretical analysis showed that, concentration ranges of both protein and crystallization agent that can be scanned during the vapor diffusion process are wider with diluting the crystallization agent than that without dilution, resulting in more opportunities for the crystallization solution to be in the nucleation zone. On the other hand, diluting protein could lead to controversial results depending on the location of the initial concentration relative to that of the nucleation zone in the phase diagram. The method of diluting the crystallization agent is therefore proposed as an alternative modification to the conventional vapor diffusion method for obtaining more crystallization conditions in protein crystallization screening. (© 2011 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Preparation of calcium sulfate whiskers using waste calcium chloride by reactive crystallization

Calcium sulfate whiskers, owing to its good thermal stability, chemical resistance and good compatibility with rubber and plastics, has a strong potential in the application of polymer reinforcing composite materials. This work deals with the preparation of calcium chloride whiskers by reactive crystallization process with sulfuric acid and calcium chloride discharged from Solvay process. Firstly, the orthogonal experiments were carried out using both CaCl₂ and H₂SO₄ in analytic grade as feedstock, and the reactive crystallization conditions were optimized, which included reaction temperature, reactant concentration, reaction time and stirring speed. Based on the optimized reactive crystallization conditions, the new process for the preparation of calcium chloride whiskers was studied using the reactive crystallization process with sulfuric acid and calcium chloride discharged from Solvay process, and the effects of impurity ions in the waste solutions on the growth of whiskers were evaluated. It was found that calcium sulfate whiskers with stable and structured fine crystals (its aspect ratio up to 190) can be prepared using waste CaCl₂ in Solvay process. The experimental results will provide the valuable information for the reasonable disposal of waste CaCl₂ solution from Solvay process. (© 2011 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

The precipitation of calcium carbonate via a bubbling method in the presence of Mg2+ and glucose

Abstract

The effect of Mg²⁺ on the crystallization of precipitated calcium carbonate (PCC) via a bubbling carbonation method and the mechanism of eliminating its influence by glucose were investigated. The polymorph and morphology of crystals were characterized by field emission-scanning electron microscopy, X-ray diffraction, and Fourier transform infrared spectroscopy. These results demonstrated that Mg²⁺ and Mg/Ca molar ratio played significant roles on the morphology of PCC. When the Mg/Ca molar ratio was below 0.5, only spindle-like calcite formed. The rod-like aragonite started to form when the ratio was 0.6. As the ratio increased, the amount of aragonite increased and the length of rod-like aragonite became longer. Notably, the effect of Mg²⁺ could be eliminated efficiently when the 1.5?wt% glucose was added into the carbonation system, in which system, the PCC crystals were all spindle-like calcite. Furthermore, the mechanism of the glucose to eliminate the influence of Mg²⁺ on PCC crystallization was proposed.     

Cooling crystallization of aluminum sulfate in pure water modulated by sodium dodecylbenzenesulfonate

This study investigated the cooling crystallization of aluminum sulfate to explore the basic data for the recovery of aluminum resources from coal spoil. Cooling crystallization process of aluminum sulfate with sodium dodecylbenzenesulfonate (SDBS) was investigated experimentally. The effects of operating conditions, namely rotate speed and cooling rate on the crystal size (Median diameter, D_0.5) were studied. Based on single factor experimental results, the response surface method (RSM) with a Box–Behnken design (BBD) was used to determine the key operating conditions, from which a predictive equation was established to quantitatively describe the relationships of D_0.5 and there relative parameters. The optimum operating conditions for cooling crystallization of aluminum sulfate were as follows: rotate speed of 200–300 rpm, cooling rate of 4–5 °C /min and n (SDBS)/n (Al₂(SO₄)₃) of around 5E‐4. Molecular dynamics (MD) results reveal that SDBS decreases the diffusion coefficient (D) of Al³⁺ molecules, which inhibits nucleation and promotes crystal growth.     

Influence of crystallization conditions on the mechanism and rate of crystal growth of potassium sulphate

Growth rate of potassium sulfate crystals was studied in a fluidized bed crystallizer. Higher growth rates were observed at larger bed heights. Larger crystals grow faster than smaller size crystals due to the changed fluid dynamics. The growth rate was found to be very sensitive to the pH value of the solution. The growth rate increases with increasing the pH value and the increase of growth in the acidic medium is faster than in the basic medium. The presence of small amounts of Cr³⁺ ions reduces the growth rate of potassium sulfate dramatically. The presence of Cr³⁺ ions lowers the saturation temperature and increases the width of the metastable zone, i.e. shifts the metastability of the solution to be at lower level of supersaturation.     

Study of lactose crystallization in water‐acetone solutions

This paper describes a study on the process of lactose crystallization using a water‐acetone solution. The selection of lactose was based on its significance for the pharmaceutical and food industries and on the fact that the crystallization of this organic compound has been little studied and is, unlike inorganic compounds, complex. The objective was to achieve lactose batch crystallization of solutions by analyzing the crystal growth under different operating conditions. To determine solubility curves, the experiments were carried out based on gravimetric methods. All the crystallization experiments were performed according to the methodology proposed by Nývlt in 1985, who uses the temperature at which the first crystals appear (nucleation) to establish the width of the metastable zone and the induction time. The results showed that crystals with different average diameters, shape factors, and recovered mass were obtained for different water‐acetone compositions. (© 2007 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Preparation of Li2CO3 by gas‐liquid reactive crystallization of LiOH and CO2

A spinning disk reactor (SDR) was used in this research to prepare Li₂CO₃ by gas‐liquid reactive crystallization of LiOH and CO₂. It was found that the end pH value of the above reaction should be controlled within the range of 9.0‐9.5 to obtain a high yield of Li₂CO₃. The effects of operational parameters (including the temperature, the concentration of LiOH solution, the rotation rate of the spinning disk, the circulation rate of LiOH slurry, the flow rate of CO₂ and the ultrasound field) on the particle size and the yielding rate were investigated by an orthogonal experiment. The results show the significant factors influencing the particle size are the ultrasound field, the temperature and the flow rate of CO₂. As for the yielding rate, the temperature, the concentration of LiOH solution and the flow rate of CO₂ exert obvious impacts, while the effects of ultrasound field and the rotation rate of the spinning disk are limited. The SEM images show the Li₂CO₃products are flower‐like particles, which are composed of plate‐like primary crystals. The size analysis shows the volume mean particle size of the Li₂CO₃products ranges 37‐90 μm depending on the various experimental conditions. (© 2012 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Solvent freeze out crystallization of lysozyme from a lysozyme‐ovalbumin mixture

Hen egg white lysozyme (HEWL) crystallization conditions from an ovalbumin‐lysozyme mixture were found by screening tests and further located in pseudo‐phase diagrams. This information was used to set up the initial conditions for the solvent freeze out (SFO) process. The process uses the freezing of ice to create the supersaturation for the proteins to crystallize out of the solution. The crystallization of HEWL (15 mg/mL) out of a lysozyme‐ovalbumin mixture (1.7 mg/mL) is carried out by SFO. Under the reported conditions, a crystallization yield of 69 % was obtained. A mean crystal size of 77.8 µm was enhanced in a crystallization time of 15.1 h. The lysozyme nature of the crystals is proven by SDS PAGE and enzymatic activity tests. (© 2012 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)     

Preparation of strontium chloride hexahydrate by batch‐cooling crystallization: Control of crystal size and morphology

The effects of initial supersaturation, cooling rate, and stirring rate on the morphology of strontium chloride hexahydrate (SrCl₂·6H₂O) crystals were investigated by batch‐cooling crystallization, providing optimal operating conditions. Uniform needle‐like crystals with a length of 1200.50 μm and a width of 100.92 μm on average were obtained. The corresponding aspect ratio of length to width was about 11.90. Moreover, the morphological modification of SrCl₂·6H₂O crystals using cetyltrimethylammonium chloride (CTAC) was studied. When 20.30 mmol·L⁻¹ of CTAC was added, the length and width of crystals were 792.71 μm and 233.25 μm, respectively, and the corresponding aspect ratio decreased to 3.40. The shape of SrCl₂·6H₂O crystal changed to granule‐like, probably because of the strong interaction of CTAC with the SrCl₂·6H₂O facets with a denser distribution of Cl⁻ ions. This study offers a simple, flexible, and highly efficient approach to regulate the morphology of SrCl₂·6H₂O crystals and opportunities for multiple applications of SrCl₂·6H₂O.     

Kinetic study of ultrasonic antisolvent crystallization of sirolimus

Sirolimus, generally used in organ transplantation, is derived from bacterium Streptomyces hygroscopicus. Mass transfer controlled ultrasonic antisolvent method was used for determining the precipitation kinetics of sirolimus. The effect of temperature was determined on the particles size, percentage recovery, critical radius of nucleus, mass transfer coefficient, etc. for sirolimus dissolved in methanol and antisolvent water using ultrasonic treatment. The study was done using classical nucleation theory, which can also be applied to precipitation processes. Experiments were carried out at various temperatures; viz: 45, 50, 60 and 70 °C and the percentage recoveries of sirolimus were found to be 90.74, 91.5, 92.64 and 93.61%, respectively, for initial amount of 8 mg dissolved in 1 mL of solvent and further introduced into 12 mL of HPLC water. The final average diameters of crystals observed for the temperatures were 1371, 1287, 1063 and 863 nm, respectively. The systems were found to be mass transfer controlling and that the mass diffusivities were found to be about 3.97×10^–9, 4.00×10^–9, 3.01×10^‐9 and 1.92×10^–9 m²/s, respectively. (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

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)     

Enhancement of nucleation during hanging drop protein crystallization using HF Treatment of cover glasses

We examined a simple approach, i.e., etching cover glasses using hydrofluoric acid (HF), to determine whether cover glass treatment enhances nucleation in hanging drop protein crystallization. Hen egg white lysozyme and proteinase K were used as the model proteins. We found that the treatment increased the success rate of crystallization. The results indicated that the simple treatment, which is easy to adopt without changing much in the hanging drop method, can be utilized as an alternative method to enhance protein crystallization screens (© 2010 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Preparation of monodispersed aragonite microspheres via a carbonation crystallization pathway

Monodispersed calcium carbonate microspheres were prepared by carbonating a calcium acetate aqueous solution with CO₂ gas at a high pressure of 40 bar and a high temperature of 80 °C after 60 minutes of reaction. The products were characterized by X‐ray powder diffraction (XRD) and scanning electron microscopy (SEM), respectively. The XRD pattern showed that the crystal polymorph of the as‐prepared monodispersed microspheres was aragonite. The SEM images also displayed needle‐like aragonite self‐organized into microsphere superstructure with diameters ranging from 5 to 15 μm. Analysis of the formation mechanism of the calcium carbonate microsphere superstructure revealed that the rod‐dumbbell‐sphere morphogenesis mechanism along with the phase transformation of vaterite to aragonite was responsible for the growth of the monodispersed aragonite microspheres. (© 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.     

Low temperature polycrystalline silicon film formation by metal induced crystallization with nickel salt derived by ultrasonic spray pyrolysis

Solution‐based nickel induced crystallization of amorphous silicon (a‐Si) films was performed. The nickel solution was prepared by dissolving (CH₃CO₂)₂Ni in deionized water and applied uniformly on a‐Si films by low‐cost ultrasonic spray pyrolysis method. Crystallization could be realized for a‐Si films coated with a 0.2 M nickel solution and annealed at 500 °C. The effect of substrate temperature during nickel solution deposition was analyzed. Micro‐Raman and x‐ray diffraction measurement show that a‐Si is fully crystallized at 550 °C for 7 h with a nickel concentration of 0.8 M. (© 2011 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Sea water desalination by dynamic layer melt crystallization: Parametric study of the freezing and sweating steps

This work aims at developing a dynamic layer crystallizer operated batchwise, for freezing desalination of sea water. The experiments were performed with water/NaCl solutions and with samples of sea water from Nice, Rabat and Marseille. The pilot crystallizer consists of a cooled tube immersed in a cylindrical double jacketed tank. The solution is poured into the tank and the crystallization takes place on the external surface of the tube, by applying a cooling ramp in the tube. The solution is agitated by air bubbling. The whole process involves the freezing step, leading to the crystallization of the ice layer and the sweating step, which consists of purifying in depth the ice layer by melting the impure zones. A parametric study on the effect of the operating parameters has allowed quantifying the role of the different key parameters of the freezing and sweating steps. Three experiments allowed reaching salinities lower than 0.5 g/kg, satisfying the standards of drinking water. The duration of the whole process dropped to only 8 h (5 h for freezing and 3 h for sweating), with a yield of sweating equal to about 50%, provided severe conditions were applied for sweating. Higher yields required longer times. Overall, the results show the feasibility of the technique.     

Antisolvent crystallization of aqueous ammonium dihydrogen phosphate solutions by addition of acetone at different rates

Results of an investigation of in situ measurements of laser‐beam intensity I_s and I_m transmitted through aqueous ammonium dihydrogen phosphate (ADP) solutions saturated at 30 °C and water, respectively, and temperature T_s of solution and T_m of water during feeding of antisolvent acetone at different rates R_A, using an indigenously designed experimental setup, are presented and discussed. It was found that: (1) for the measurement of MSZW, defined as the maximum volume fraction of acetone content Δx_max in the solution, obtained from temperature measurements are more reliable than transmitted laser‐beam intensity measurements for solutions, (2) two minima ΔT_min1 and ΔT_min2 associated with endothermic reactions, separated by a maximum ΔT_max due to exothermic reactions appear in the plots of temperature difference ΔT = T_s−T_m against acetone feeding time t, and (3) in the ΔT(t) plots there are time intervals Δt of constant rates R_T of increase in ΔT of aqueous ADP solutions, and these values of R_T increase linearly with acetone feeding time rate R_A. The experimental data on the observed dependence of MSZW on antisolvent feeding rate R_A, the appearance of minima ΔT_min1 and ΔT_min2 and maximum ΔT_max and their dependence on R_A, and the relationship between R_T and R_A are discussed from consideration of processes of nucleation and growth of crystallites.