Automated self seeding of batch crystallizations via plug flow seed generation

Abstract In this study, seed slurry from a single addition anti-solvent plug flow crystallization of benzoic acid was used to seed the equivalent batch cooling crystallization. The experimental conditions were carried out to simulate automated self-seeding. This involves withdrawal of solution from a batch crystallizer, which is then mixed with anti-solvent within a plug flow crystallizer, in order to generate a seed slurry which is fed directly back to the batch crystallizer. This seeding strategy allowed the final CSD of the batch crystallization to be controlled by variation of the crystal size from the plug flow seeding device at a constant seed loading. The ability to use unequal feed/anti-solvent inlet flowrates (in the Roughton vortex mixer) proved effective in controlling the batch CSD at 2% seed loading and constant feed composition. The morphology of batch product from plug flow seeding was found to have a much lower aspect ratio than the more needle like dry seed and primary nucleated product. Unlike dry seed, which was found to have rough irregular growth on the crystal surface, the plug flow product had flat regular growth as per primary nucleated batch crystallization.

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