Industrial Crystallization
Industrial Crystallization
Industrial Crystallization
Industrial crystallization is an important density problems in transport and process conditions in real time to consis-
separation and purification step in the consequently particle size and quality tently achieve targeted particle size, yield
chemical, food ingredient, and mining variability in the final product. Particle and quality specifications, in the lab or
industries, yet it is often treated as an art size is also directly correlated with yield. manufacturing.
rather than a science. If misunderstood, Many of these process inconsistencies can
the thermodynamics and kinetics of be solved by understanding, optimizing, Today, inline particle characterization
crystallization can sometimes result and controlling the crystallization unit technologies are used to provide inline
in unexpected behavior such as rapid operation. particle size, shape and count measure-
precipitation or agglomeration which ments at full process concentrations
leads to variability in yield, centrifugation In the crystallizer, solvent addition rates, and in translucent or opaque slurries.
times, and other critical quality attributes. impurities, mixing conditions, seeding, Companies including the American
It has been established that the root cause and cooling rates, all impact process Crystal Sugar Company3, Dow5, Archer
of this variability is often inconsistency performance. By tracking the rate and Daniels Midland (ADM) 6, and Nestle7
in the particle size distribution1,2,3,4. degree of change to particles and particle have successfully applied best practices
Fines or agglomerates can form in the structures as they naturally exist in with inline particle size characterization
crystallizer which cause slow throughput process, scientists and engineers proac- to collect real time data and ensure true
in the centrifuge, caking, dust, or bulk tively measure, understand, and optimize statistical understanding of their process.
Possible Process Bottlenecks Where Particles Play a Role
A challenge with traditional particle size measurement techniques is that most technolo-
gies are offline and require sampling, sample preparation, and remote analysis which
is time consuming. Offline samples are often prepared and altered through dilution,
dispersion, or drying, which can change or destroy particle or droplet components and
their relationship to critical quality attributions. Offline measurements also cannot
be applied to make real-time process optimization and control decisions. With estab-
lished particle characterization technology (ParticleTrack™ with FBRM® technology
and PVM® inline imaging), scientists and engineers can measure and observe crystal
behavior in situ without sampling or dilution and track the crystallization process at
full concentration and operating temperature. This enables real-time feedback and fast
decisions to improve the root cause of variability in the crystallizer and optimize the
consistency of final product particle size and yield.
Lactose Crystallization
(page 3) Food Consumer
Dextrose Crystallization Ingredients Product
(page 8)
L-Lysine Crystallization
Chemical Formulation
(page 6)
Lithium Carbonate
Mining and
Crystallization Biotech
(page 8)
Minerals
2
Understand THEN Optimize (Lactose Study)
Gaining basic process understanding is the first step in optimizing crystallization.
Important steps such as measuring the solubility curve provide a fundamental under-
standing of crystallization thermodynamics and are discussed in detail in several
journal publications (see references, page 14).
The empirical knowledge provided by microscopy is perhaps the easiest way to understand
a crystallization process8. Inline imaging has been established as one of the fastest ways
100 µm
to understand crystal shape and size, as well as, identify fundamental crystallization
mechanisms such as nucleation, growth, agglomeration, and breakage9,10. Lactose, a
Figure 1. Seed crystal aggregation would have
by-product of the cheese industry derived from milk whey, is typically crystallized on a caused inconsistent surface area and secondary
massive industrial scale via cooling crystallization. Product quality and yield are highly nucleation. As the process was observed using
dependent on particle size and the crystallization process is complicated by seasonal in-process measurement, the issue was seen in
real-time and the batch was quickly reheated,
variability in milk quality, the presence of mineral impurities and slow crystal growth re-dissolved, then re-seeded to ensure consistent
kinetics - which historically require long batch times. Lactose crystallization is a perfect seed surface area.
opportunity to use inline microscopy for rapid process understanding. In the example
below, three lactose crystallization batches were processed and all image sequences
were captured inline and in real time. No sampling or dilution was necessary. It is clear
that within one batch, the crystals undergo changes including nucleation, aggregation,
secondary nucleation and growth.
By quickly comparing images from different batches at the same process temperatures,
the effect which process conditions (such as impurities, seeding, and cooling rate) have
on the final crystal properties can be observed. By measuring inline, process conditions
are quickly optimized to achieve a desired crystal size and shape and improve centrifuge
performance and process yield downstream.
25 ºC 25 ºC 25 ºC
Fast Cooling
(79°C to 25 °C over
°C
1 hr), Isothermal
Hold (8 hrs)
Findings:
Understanding Process Implications Optimization
Batch cooled quickly, seeding Filtration was difficult and yield Apply slower cooling rate to
induced rapid nucleation and the was low due to losses in filtration next batch
final crystals were very fine and washing
3
Batch 2 (60 wt % deprotonated whey powder in di water; 0.1 % Seed)
Adjusted cooling curve based on Batch 1 findings
70 ºC 65 ºC 25 ºC
Controlled
Cooling °C
Over 8 hours
Relative Time
8 hrs
Findings:
Understanding Process Implications Optimization
Slower cooling rate was applied, Long filtration rates persisted, Apply a slower cooling rate in
however secondary nucleation was and yields were lower due to next batch
observed resulting in a fine crystal losses associated with the
distribution presence of fines
70 ºC 57 ºC 25 ºC
Controlled
Cooling °C
Over 18 hours
Relative Time
18 hrs
Findings:
Understanding Process Implications Optimization
Slower cooling rate was applied Much higher yield and faster Process ready for scale-up
and ideal seed distribution is filtration rate - meets target
observed specifications
4
In the same lactose crystallization process, 90
6000
engineers applied inline particle tracking
tools to quantify the differences in crystal 5000
80
Temperature (°C)
70
Counts (fines)
these measurements were acquired inline 4000 Batch 2, Counts (0.5-50 µm)
Temperature (°C)
Counts (fines)
Batch 3, endpoint
150
100
50
0
1 10 100 1000
Chord Length (µm)
Concentration
process, to one that is consistent and produces particles with the required particle size Seeding too Early
specification. Inconsistent yield, filtration rate, drying time, bulk density, flow property, Metastable Zone Limit (Figure 6)
and particle size distribution can also be traced back to uncontrolled crystallizations
with inconsistent nucleation or non-optimized seeding. Important parameters must be
Solubility
considered when designing a seeding strategy such as seed size, seed loading (mass)
and seed addition temperature. These are generally optimized based on process kinetics
and the desired final particle properties, and must remain consistent during scale-up Temperature
40
300
Counts (No. Wt. 1-100 µm) Seeding has
Counts (No. Wt. 200-1000 µm)
minimal effect
In either case, when seeds dissolve or when
seeds are added after primary nucleation, 200 20
the process is effectively unseeded and can
often result in a less controlled process 100
7
Seed Size and Seed Mass (Dextrose and Lithium Carbonate Studies)
Questions often asked in relation to seeding are “How much seed mass to add?” and
“What size should it be?”. This depends on the final particle size required or impurity
concerns associated with the crystallization. Seeds are generally added to provide the
necessary surface area for particle growth or to induce nucleation. The size and number
of seed particles added determines this available surface area. Generally seed particles
are small as this increases the number of ‘points’ for crystal growth and reduces the
chance for secondary nucleation. If large particles are required, less seeds are added
producing a fewer number of particles which grow very large in size. On the other hand,
if small particles are required, larger seed loading is necessary so that the growth is
spread across a greater number of particles, consequently growing each particle only
by some small amount. Typical seed loadings can vary from as little as 0.1 wt % to as
much as 5 wt % (and even more) depending on the requirements.
T=0s T = 60 s T = 90 s
Counts (#/sec)
saturation which affects the growth and 6000
nucleation kinetics. In Figure 12, three
crystallization processes are shown which 4000
had the same seed mass (0.75 g/L) added
at the same temperature and supersatu- 2000
ration (3.4), but with varying mean seed
size (401 µm, 225 µm, and 21 µm). At 0
Time=0, the crystallization batch with 0 100 200 300 400
the smallest seed size has the highest Relative Time (s)
number of particles. However, due to the
higher surface area for growth created Figure 12. Process trends for three lithium
carbonate batches tracking the total crystal counts
by these small seed particles, the rate of over time. Seed size varied. All batches were
increase in particle number is less than seeded at supersaturation of 3.413.
that observed for the batches with larger
seed size. Effectively this means that the 4000
Batch 1 (Seed Size: 401 µm)
batch with the smallest seed has resulted Batch 3 (Seed Size: 225 µm)
in less secondary nucleation. Figure 13 Batch 5 (Seed Size: 21 µm)
Counts (#/sec)
3000
presents the same lithium carbonate
seeded crystallization experiments but
2000
at a lower supersaturation (2.7). In this
example the number of particles remains
constant for all three batches for the first 1000
7 % Impurities
Slower crystallization kinetics with 11 % Impurities
10
“Without data, crystallization may
seem like an art. But by applying
Conclusions real-time measurements, scientists
The desire to produce products with a specific particle size distribution and powder and engineers understand when
handling properties continues to drive crystallization research. The need for a targeted and why inconsistencies occur and
particle size is also a driver to reduce batch time, improve yield, and solid-liquid
separation rates. In certain bulk chemical processes large particles are produced to
make informed decisions to produce
ensure fast separation times - maximizing the economic efficiency of the process. On repeatable, high quality products.”
the other hand, in some processes small particles are required to meet final customer
requirements. Regardless of the product’s critical quality attribute, there is a requirement
to target a pre-defined particle size distribution that if not met can result in additional
processing costs or, in extreme cases, loss of product.
www.mt.com/wp-E25
11
Appendix A:
Focused Beam Reflectance Measurement
(FBRM®)
Measurement for optimization in real time – FBRM is a highly precise
and sensitive technology which tracks changes to particle dimension,
particle shape, and particle count. Over a wide detection range from
0.5 to 2000µm, measurements are acquired in real time while particles
are forming and can still be modified enabling process optimization
and control. No sampling or sample preparation is required – even in
highly concentrated (70% and higher) and opaque suspensions.
Laser Return
Optics Module
1 2 3 4
Figure b.
Figure a.
CCD Camera
Objective Lens
Illumination Lens
Sapphire Window
200 µm
13
References
1. T. A. Bell, Powder Technology, 150 (2): 60-71 (2004).
2. Kim S. et al. Organic Process Research & Development, 9, 894-901 (2005).
3. Sobolik, J. In situ Partcle Size Analysis, American Crystal Sugar Company, USA (2002).
4. Mousaw, P., Saranteas, K. & Prytko, B., Organic Process Research & Development,
12(2), 243-248 (2008).
5. Larsen, Paul (The Dow Chemical Company). Tips and Tools for Solution Crystallization www.mt.com/crystallization
Process Design, AIChE Process Development Symposium (2013)
Benjamin Smith
6. Archer Daniels Midland (ADM). De Zaan Cocoa Manual, 123-124 (2009). http://www.
adm.com/en-US/products/food/cocoa/Documents/deZaan-Cocoa-Manual.pdf
[email protected]
7. Rousset, P. et al. Fat crystallization in w/o emulsions controlled by shear and cooling
conditions, Nestle (2006).
8. McCrone, Walter C. The Particle Atlas. Elsevier Science & Technology Books, (1979).
Our People
METTLER TOLEDO has a global
9. Duffy, D., Cremin, N., Napier, M., Robinson, S., Barrett, M., Hao, H., & Glennon, B.
Chemical Engineering Science, 77, 112–121. (2012). network of Technology and Application
Consultants with extensive research and
10. Barrett, M., Hao, H., Maher, A., Hodnett, B. K., Glennon, B., & Croker, D. Organic Process
Research & Development, 15(3), 681–687. (2011). industry experience supporting inline
particle characterization applications.
11. Bakar, M. R. A., et al. Organic Process Research & Development, 13(6), 1343–1356
(2009).
Email: [email protected]
12. Markande, A., Fitzpatrick, J., Nezzal, A., Aerts, L., & Redl, A. Application of inline
monitoring for aiding interpretation and control of dextrose monohydrate crystallization. Phone: 410-910-8500
Journal of Food Engineering, 114(1), 8–13. (2013). http://www.sciencedirect.com/
science/article/pii/S0260877412003639 Blog
13. Sun, Yu-zhu. et al. Seeded Induction Period and Secondary Nucleation of Lithium Chemical Research, Development and
Carbonate. The Chinese Journal of Process Engineering. Vol.9 No.4. Aug. (2009). Scale-up is our Blog highlighting the
http://www.jproeng.com/qikan/manage/wenzhang/209138.pdf
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14. Markande, A., Nezzal, A., Fitzpatrick, J., Aerts, L., & Redl, A. (2012). Influence of impuri- commentary from our own internal
ties on the crystallization of dextrose monohydrate. Journal of Crystal Growth, 353(1),
145–151. experts and from academic and indus-
try professionals.
15. Barrett, P. and B. Glennon, Characterizing the metastable zone width and solubility
curve using Lasentec FBRM and PVM, Chemical Engineering Research & Design 80
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