Crystallization-in-emulsion process of a melted organic compound: In situ optical monitoring and simultaneous droplet and particle size measurements

Abstract The crystallization-in-emulsion process allows the production of solid particles exhibiting specific features. Here, the batch crystallization process carried out by cooling a melted oil dispersed as an oil-in-water emulsion was studied. Two experimental set-ups allowing the in situ visualization of the nucleation and growth phenomena occurring in the dispersed liquid phase were developed. Observations in quiescent medium of motionless droplets having a diameter of few tens of micrometers showed that primary nucleation started on the inner surface of the droplets. The fast growth of the crystals consumed all the liquid contained within each droplet and was confined within each droplet by the oil–water interface. Solid polycrystalline particles similar in size to the parent droplets were produced. Dynamic tracking of the transient evolution of the size distributions of the two populations of droplets and solid particles during the cooling process in a stirred vessel was carried out using an in situ optical probe. It was shown that the droplets crystallized very progressively during cooling, starting with the largest droplets and ending with the smaller size droplets since the induction time of primary nucleation was dependent on droplet volume. In dilute conditions (1% wt% of dispersed phase) each droplet was converted into a single solid particle. Secondary nucleation based on inter-droplet collisions was not observed in these conditions.