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CR 3: Crystallizer Selection

CR 3: Crystallizer Selection
     Part 1: Crystallization and Downstream Processing Systems Design
         1. INTRODUCTION
             1.1 Purpose
             1.2 Approach
             1.3 How to use this report
         2. PARAMETERS AND PROPERTIES LINKING DIFFERENT UNIT OPERATIONS
             2.1 Introduction
             2.2 Choice of solvent
             2.3 Particle size
             2.4 Particle size distribution
             2.5 Particle shape
             2.6 Purity
             2.7 Moisture content
             2.8 Mechanical properties
             2.9 Summary of interactions
         3. STAGE 1 - PROBLEM DEFINITION AND PRELIMINARY MASS BALANCE
             3.1 Specify product characteristics required
             3.2 Specify required production rate
             3.3 Specify feedstock properties
             3.4 Initial review of bench-scale data
                 3.4.1 Feed purification
                 3.4.2 Crystallization
                 3.4.3 Precipitation
                 3.4.4 Washing
                 3.4.5 Safety and environmental factors
             3.5 Select method of supersaturation generation
             3.6 Direct powder production from solution
             3.7 Direct slurry drying
             3.8 Feed purification
             3.9 Preliminary overall mass balance
             3.10 Obtain economic data on input and output streams
             3.11 Preliminary assessment of economic potential
         4. STAGE 2 - GENERATION OF BASIC BLOCK FLOWSHEETS
             4.1 Collect data specific to the site
             4.2 Preliminary estimate of principal heating and cooling costs
             4.3 Selection between batch and continuous processing
             4.4 Effect of plant or product life
             4.5 Washing requirements
             4.6 Preliminary definition of principal recycle and waste streams
             4.7 Second assessment of economic potential
         5. STAGE 3 - BASIC EQUIPMENT SELECTION AND PRELIMINARY CAPITAL COST ESTIMATES
             5.1 List suitable equipment types
             5.2 Specify constraints
             5.3 Select equipment types for base case design
             5.4 Selection of material transfer states between sections
             5.5 Selection of crystallizer batch cycle time or residence time
             5.6 Completion of base case mass balance and equipment duty specifications
             5.7 Preliminary estimates of equipment sizes
             5.8 Check suitability of any existing available equipment
             5.9 Preliminary estimates of installed equipment costs
             5.10 Estimate total annualised cost and economic potential
             5.11 Sensitivity studies and evaluation of tradeoffs
             5.12 Repeat for other basic flowsheets under consideration
             5.13 Select systems for further development
         6. STAGE 4 - DETAILED DESIGN OF THE FINAL PROCESS
         7. NOMENCLATURE
         8. REFERENCES
     Part 2: Crystallization Process Selection Guide
         1. INTRODUCTION
             1.1 Structure of Selection Guide
             1.2 Selection Sequence
         2. PRELIMINARY INFORMATION
             2.1 Solute Information
             2.2 Crystallization Process
             2.3 Product Specification
         3. BASIC CRYSTALLIZATION PROCESS
         4. SUPERSATURATION GENERATION METHOD
             4.1 Process Information Required
             4.2 Experimental Measurements
             4.3 Selection of Supersaturation Generation Method(s)
         5 CRYSTALLIZATION MODE
             5.1 Experimental Measurements
             5.2 Selection of Crystallization Mode(s)
         6. CRYSTALLIZATION EQUIPMENT
             6.1 Selection of Agitation Equipment
             6.2 Supersaturation Generation Equipment
                 6.2.1 Cooling
                 6.2.2 Heating
                 6.2.3 Solvent removal
                 6.2.4 Reagent addition
                 6.2.5 Pressurisation
             6.3 Additional Features
         7. REVIEW OF SELECTED PROCESS(ES)
             7.1 Examples of Standard Crystallizers
         8. APPENDIX A - CRYSTALLIZER SELECTION FORM
         9 APPENDIX B - QUICK SELECTION FLOWCHART
             9.1 Quick selection of supersaturation generation method
             9.2 Quick selection of crystallization mode
             9.3 Quick selection of crystallizer type
     Part 3: Crystallizer Manufacturers
         1 Introduction
             1.1 Equipment table: summary of equipment details
             1.2 Company table: summary of manufacturing companies
             1.3 Manufacturing table: summary of claimed manufacturing
             1.4 Equipment diagrams.
         2. Equipment table
             2.1 Equipment type: Cooling
             2.2 Equipment type: Evaporator
             2.3 Equipment type: Melt
             2.4 Equipment type: Reaction
             2.5 Equipment type: Vacuum
         3. Company table
             3.1 Regional area : Africa
             3.2 Regional area : Asia
             3.3 Regional area : Australasia
             3.4 Regional area : Europe
             3.5 Regional area : Far East
             3.6 Regional area : North America
             3.7 Regional area : South America
         4. Manufacturing table.
             4.1 Equipment type: Cooling
             4.2 Equipment type: Evaporator
             4.3 Equipment type: General
             4.4 Equipment type: Melt
             4.5 Equipment type: Vacuum
         5. Equipment diagrams
             5.1 Cooling
             5.2 Evaporative
             5.3 Melt
             5.4 Vacuum
     Terms and Conditions of Use

Volume III contains guides to the selection of crystallization equipment.

Volume CR III   Part 1 Crystallization and downstream processing systems design.

Crystallizers are almost always found with associated solid-liquid separation and drying equipment. The design of one unit can have important repercussions on the design of others; the design of the system as a whole should therefore be considered.

This report presents a systematic approach to identifying and evaluating appropriate overall systems, incorporating crystallization, solid-liquid separation and drying steps, for a new product. It does not aim to repeat the material contained in other SPS Manual Volumes on the individual unit operations. Instead it concentrates on the interactions between them, aiming to give the design engineer an overview of the process before he proceeds to the detailed design of the individual units.


Volume CR III   Part 2 Crystallizer selection guide.

This document presents a systematic approach to selecting which general type or types of crystallizer might be used to crystallize a particular material. Three basic decisions which must be made about the crystallization process and equipment are considered:

  • Determine the available method(s) of generating the supersaturation.
  • Determine what mode (e.g. batch or continuous) of operation to use.
  • Determine what equipment should be used.

At each stage, the information required to make the selections are highlighted, and experimental tests to gain such information suggested.


Volume CR III   Part 2 Addendum crystallizer manufacturers.

Crystallizer manufacturers and their agents are categorised according to the equipment they produce and their geographical location. Typical equipment of each main classification is illustrated.