Crystallization of potash alum: effect of power ultrasound

Ultrasound induced grain refinement of crystallization in evaporative saline droplets

We investigate the effect of ultrasound on the evaporation and crystallization of sessile NaCl solution droplets which were positioned in traveling or standing wave ultrasound field. The experimental results indicated that the ultrasound field can significantly accelerate the evaporation rate of the sessile droplets and refine the crystal grains. By adjusting the distance between the sessile droplets and the ultrasound emitter, it is found that, in traveling wave ultrasound field, the sessile droplet evaporation time and the time for the appearance of NaCl grains exhibited a fluctuating increase as the droplet-emitter distance increased. While in the standing wave ultrasound, the sessile droplet evaporation rate increases with the increasing droplet-emitter distance. Overall, the traveling wave ultrasound field has a stronger effect on grain refinement of the sessile droplets than the standing wave ultrasound field. The grain refinement is attributed to the decrease of critical nucleation radius caused by ultrasound energy and the increase of the nucleation rate caused by the accelerated evaporation rate. In addition, the breakage of grains caused by ultrasonic cavitation would also lead to grain refinement.

Separation performance and agglomeration behavior analysis of solution crystallization in food engineering

This study employed solution crystallization in food engineering to prepare a high-purity vitamin intermediate, optimize its crystal morphology and regulate its particle size distribution. Model analysis was performed to investigate the quantitative correlations between the process variables and target parameters, indicating the substantial effect of temperature on separation performance. Under optimal conditions, the product purity exceeded 99.5%, which meets the requirement of the subsequent synthesis process. A high crystallization temperature reduced the agglomeration phenomenon and increased particle liquidity. Herein, we also proposed a temperature cycling strategy and a gassing crystallization routine to optimize the particle size. The results illustrated that the synergistic control of temperature and gassing crystallization could substantially improve the separation process. Overall, based on a high separation efficiency, this study combined model analysis and process intensification pathways to explore the process parameters on product properties such as purity, crystal morphology, and particle size distribution.

Improvements in azithromycin recrystallization using ultrasound for size reduction

The primary motive of the current work is to achieve smaller mean particle size with narrow size distribution that can enhance the bioavailability of azithromycin (ARZ), an essential requirement due to its poor water solubility. Recrystallization of ARZ was evaluated using cooling as well as antisolvent crystallization approaches in the presence of ultrasonic irradiation with detailed study into effect of different parameters such as ultrasonic power, time and temperature. Ultrasound assisted antisolvent crystallization at low temperatures (<10℃) yielded best size reduction up to 80% with narrower distribution and also gave better yield of the product, that too within 5 min of sonication. With scale up considerations, recirculation mode of operation was also evaluated which offered promising results for the size reduction. Images captured using optical microscope and SEM revealed a nearly uniform rod/plate-shaped geometry. Increase in amorphous nature of ARZ was confirmed based on XRD analysis. FTIR analysis showed no significant changes in the functional groups when compared to the original sample. Overall, the work demonstrated an improved reprocessing approach based on the use of ultrasound with insights into effect of operating parameters and effect of ultrasound on various characteristics.

Study on the formation mechanism of isoniazid crystal defects and defect elimination strategy based on ultrasound

In crystallization, crystal growth defects may reduce the strength and purity of crystals, which are not welcomed in the industry. Herein, isoniazid (INH) crystals were chosen as an example to investigate the formation of crystal defects at the molecular scale by combining experiments and molecular dynamics simulations. It was found that the strong interaction between the solvent and the crystal surface, high temperature, small stirring rate, and low supersaturation can lead to more pronounced crystal defects. The bulk severity of INH crystal defects was reflected by N₂ adsorption-desorption measurement. Besides, the single-crystal growth experiments manifested the rough growth mechanism for the (110) surface in the axial direction and the stepwise growth mechanism for the (002) surface in the radial direction. For the (110) surface, cavities occurred under the condition where the growth rate of the crystal edges and corners was greater than that of the surface center due to the starvation phenomenon of diffusion. While for the (002) surface, when the solvent removal rate was lower than the solute insertion rate, liquid inclusions were formed, which was verified by Raman microscopy. Furthermore, the ultrasonic strategy was successfully proposed to eliminate INH crystal defects and prepare perfect INH crystals. Moreover, the mechanism of ultrasound to reduce the crystal defect was proposed. We believe this work can provide insights into the design and preparation of defect-free crystals in crystallization.

Nucleation in continuous flow cooling sonocrystallization for coiled capillary crystallizers

Nucleation in continuously operated capillary coiled cooling crystallizers is experimentally investigated under the influence of ultrasound. It was found that there is no sharp boundary but rather a transition zone for nucleation under sonication. For this purpose, a tube with an inner diameter of 1.6 mm and a length of 6 m was winded in a coiled flow inverter (CFI) design and immersed into a cooled ultrasonic bath (37 kHz). The CFI design was chosen for improved radial mixing and narrow residence time distribution, which is also investigated. Amino acid l-alanine dissolved in deionized water is employed in a supersaturation range of 1.10 to 1.46 under quiet and sonicated conditions. Nucleation is non-invasive detected using a flow cell equipped with a microscope and camera.

Graphical abstract

Since the interest and demand for small-scale, continuous crystallization increases, seed crystals were generated in a coiled tube via sonication and optically investigated and characterized. No distinct threshold for nucleation could be determined in a wide range of supersaturations of l-alanine in water

Synthesis and Characterization of Nano-Sized 4-Aminosalicylic Acid-Sulfamethazine Cocrystals

Drug–drug cocrystals are formulated to produce combined medication, not just to modulate active pharmaceutical ingredient (API) properties. Nano-crystals adjust the pharmacokinetic properties and enhance the dissolution of APIs. Nano-cocrystals seem to enhance API properties by combining the benefits of both technologies. Despite the promising opportunities of nano-sized cocrystals, the research at the interface of nano-technology and cocrystals has, however, been described to be in its infancy. In this study, high-pressure homogenization (HPH) and high-power ultrasound were used to prepare nano-sized cocrystals of 4-aminosalysilic acid and sulfamethazine in order to establish differences between the two methods in terms of cocrystal size, morphology, polymorphic form, and dissolution rate enhancement. It was found that both methods resulted in the formation of form I cocrystals with a high degree of crystallinity. HPH yielded nano-sized cocrystals, while those prepared by high-power ultrasound were in the micro-size range. Furthermore, HPH produced smaller-size cocrystals with a narrow size distribution when a higher pressure was used. Cocrystals appeared to be needle-like when prepared by HPH compared to those prepared by high-power ultrasound, which had a different morphology. The highest dissolution enhancement was observed in cocrystals prepared by HPH; however, both micro- and nano-sized cocrystals enhanced the dissolution of sulfamethazine.

Evaluation of different cavitational reactors for size reduction of DADPS

The present study deals with the size reduction based on the recrystallization (antisolvent approach using water) of 3,3'-Diamino Diphenyl Sulfone (DADPS) using different types of cavitational reactors as an alternative to the conventional process of mechanical size reduction, which is an energy intensive approach. Ultrasound was applied for fixed time specific to the reactors namely ultrasonic probes at different power dissipation levels and also ultrasonic bath. A High Speed Homogenizer was also used at varying speeds of rotation to establishing the efficacy for size reduction. The processed sample was analysed for particle size and morphology using particle size analyser and optical microscopy respectively. The final yield of recrystallization was also determined. The power density in W/L and power intensity in W/m² calculated for each equipment has been used to establish efficacy for size reduction since all devices had dissimilar configurations. Based on the studies of varying power intensity of the different US equipment, it was established that larger the power intensity and power density, smaller was the resultant final particle size after treatment for same time. Among the various ultrasonic devices used, Sonics VCX750 probe yielded the best size reduction of 85.47% when operated at 40% amplitude for 60 min for a volume of 200 ml. A High Speed Homogenizer used at 7000 rpm gave 92.35% of size reduction in 15 min operation and also demonstrated the best energy efficiency. The work has elucidated the comparison of different cavitational devices for size reduction for the first time and presented the best reactors and conditions for the desired size reduction.

Ultrasound-assisted intensified crystallization of L-glutamic acid: Crystal nucleation and polymorph transformation

In this paper, the crystallization of L-glutamic acid with application of ultrasound was explored in detail, including the process of nucleation, polymorphic control and polymorphic transformation. The induction time and metastable zone widths (MSZWs) were measured with and without ultrasound during the nucleation process. The induction time and MSZWs were decreased by ultrasound and the induction time was further decreased by higher ultrasonic power. The calculated nucleation parameters (such as interfacial energy, critical nucleus size and critical Gibbs energy) showed an obvious decrease in the presence of ultrasound, indicating that the nucleation was enhanced with application of ultrasound. By adjusting the ultrasonic power in the quench cooling process, the difference in nucleation temperatures would determine the distribution of polymorphs. In further, the polymorphic transformation was investigated quantitatively, and to the best of our knowledge, it was the first time to study the transformation kinetics with ultrasound using Avrami-Erofeev model. In the transformation process, the crystallization mechanism of the stable form was modified by ultrasound. The ultrasound eliminated the nucleation element in the rate-limiting step and facilitated the crystal growth of stable form. Thus, the ultrasound has a profound influence on L-glutamic acid crystallization.

Effects of ultrasonic irradiation on crystallization kinetics, morphological and structural properties of zeolite FAU

In this work, NaX zeolite was synthesized and the effect of ultrasound irradiation on reaction kinetics, morphological and structural properties was investigated. Ultrasound was applied, by using a plate transducer (91.8 kHz), for the first time during the crystallization of zeolite NaX, at high temperature, varying the irradiation moment and its duration. Furthermore, ultrasound was applied after the crystallization by a horn-type transducer (20-24 kHz) at low temperature. The effects of irradiated volume (100-300 mL), sonication time (2-10 min) and ultrasound power (10-200 W) were studied with a power intensity up to 100 W/cm². It was found that the application of ultrasound during the first hour of crystallization resulted in 20% reduction of reaction time compared to a standard crystallization. Ultrasound can also reduce the agglomeration degree of the final powder by combining high power and long sonication time. After 5 min sonication time at 0.3 W/mL, the tapped density of the powder was increased by 10%, from 0.37 to 0.41 g/mL. Finally, by scanning electron microscopy (SEM) it was demonstrated that ultrasound can disrupt the agglomerates without affecting the morphology of individual crystals.

A review on possible mechanisms of sonocrystallisation in solution

Sonocrystallisation is the application of ultrasound to the crystallisation process. The benefits obtained by sonication have been widely studied since the beginning of the 20th century and so far it is clear that ultrasound can be a very useful tool for enhancing crystallisation and controlling the properties of the final product. Crystal size, polymorphs, purity, process repeatability and lower induction time are only some of the advantages of sonocrystallisation. Even though the effects of sonication on crystallisation are quite clear, the physical explanation of the phenomena involved is still lacking. Is the presence of cavitation necessary for the process? Or is only the bubbles surface responsible for enhancing crystallisation? Are the strong local increases in pressure and temperature induced by cavitation the main cause of all the observed effects? Or is it the strong turbulence induced in the system instead? Many questions still remain and can only be appreciated with an understanding of the complexity behind the individual processes of crystallisation and acoustic cavitation. Therefore, this review will first summarise the theories behind crystallisation and acoustic cavitation, followed by a description of all the current proposed sonocrystallisation mechanisms, and conclude with an overview on future prospects of sonocrystallisation applications.

Ultrasound assisted size reduction of DADPS based on recrystallization

The present study investigates the use of ultrasound in size reduction based on recrystallization of a commercially important compound, 3,3'-diaminodiphenyl sulfone, popularly known as DADPS. Typically the applications of DADPS depends on the size distribution, more importantly on the mean size and hence the ultrasound assisted recrystallization has been applied for controlling the size as an alternative to energy intensive mechanical size reduction. For the size reduction studies, DADPS was dissolved in methanol and irradiated with ultrasound during the anti-solvent crystallization operation using water. Effect of different operating parameters such as temperature, rate of addition of antisolvent and its nature (whether neutral, acidic or basic) and ultrasonic parameters such as time of irradiation, power dissipation and duty cycle on the mean size and overall distribution has been studied. The particle characteristics of the original sample and processed samples have been analyzed using particle size analyzer, optical microscopy and X-Ray Diffraction (XRD). The positive effect of ultrasound for size reduction was clearly established from particle size analysis with reduction in the mean size to almost one-third the initial value under optimum conditions of 100 W as the power dissipation, 70% as the duty cycle and 60 min as the time of operation. In terms of the trends of the operating parameters, an increase in the rate of addition of antisolvent yielded the best results in terms of lower size and also alkaline conditions for antisolvent gave better size reduction. The microscopic images revealed a uniform and well-defined crystal shape on processing using ultrasound while XRD analysis established that ultrasound did not alter the crystalline structure. Ultrasound was overall established as an effective approach for size reduction without any changes in the crystalline structure.

Improved crystallization of ammonium sulphate using ultrasound assisted approach with comparison with the conventional approach

In chemical processing industries, crystallization is one of the most important operations to obtain solid products with desired purity and characteristics. With distinct processing problems for the conventional approaches for crystallization, research into alternate approaches such as ultrasound assisted crystallization has been on the forefront. The present work deals with comparison of the conventional approach and ultrasound assisted approach for crystallization of ammonium sulphate followed by detailed understanding into the effect of important operating parameters (initial concentration, pH, agitation speed, depth of horn, and cooling approach) on the metastable zone width and average crystal size. Ultrasound assisted crystallization has been investigated using both ultrasonic bath and ultrasonic horn to understand the effect of type of irradiation. It has been observed that the maximum reduction in the MSZW was obtained using ultrasonic horn under conditions of optimized initial concentration. The order of average crystal size obtained for ammonium sulphate was conventional cooling crystallization>ultrasonic bath>ultrasonic horn. The average crystal size obtained was in the range of 411-450µm for conventional approach of cooling crystallization, 350-400µm using ultrasonic bath and 200-250µm using ultrasonic horn. The analysis of crystal size distribution and surface characteristics using the SEM analysis was also performed under set of optimized parameters established using the particle size analysis. Overall the work has clearly established that the ultrasound assisted crystallization gave better results as compared to the conventional cooling crystallization in terms of reduced metastable zone width, better crystal characteristics and less agglomeration.

The role of ultrasound in pharmaceutical production: sonocrystallization

Objectives

The main aim of this review was to develop a critical discussion of the key role ultrasound (US) can play on the production of active pharmaceutical ingredients (APIs) by discussing the versatile effect this type of energy produces.

Methods

The different crystallization techniques that can be assisted and improved by US are discussed in the light of the available US devices and the effect pursued by application of US energy. Simple and complex analytical methods to monitor API changes are also discussed.

Key findings

The countless achievements of API US-assisted production are summarized in a table, and outstanding effects such as narrower particle size distribution; decreased particle size, induction time, metastable zone and supersaturation levels; or a solubility increase are critically discussed.

Conclusions

The indisputable advantages of sonocrystallization over other ways of API production have been supported on multiple examples, and pending goals in this field (clarify the effect of US frequency on crystallization, know the mechanism of sonocrystallization, determine potential degradation owing to US energy, avoid calculation of the process yield by determining the concentration of the target drug remaining in the solution, etc.) should be achieved.

Ultrasound assisted nucleation and growth characteristics of glycine polymorphs--a combined experimental and analytical approach

For the first time, the effect of ultrasound in the diagnostic frequency range of 1-10 MHz on the nucleation and growth characteristics of glycine has been explored. The investigation employing the ultrasonic interferometer was carried out at a constant insonation time over a wide range of relative supersaturation from σ=-0.09 to 0.76 in the solution. Ultrasound promotes only α nucleation and completely inhibits both the β and γ nucleation in the system. The propagation of ultrasound assisted mass transport facilitates nucleation even at very low supersaturation levels in the solution. The presence of ultrasound exhibits a profound effect on nucleation and growth characteristics in terms of decrease in induction period, increase in nucleation rate and decrease in crystal size than its absence in the solution. With an increase in the frequency of ultrasound, a further decrease in induction period, increase in nucleation rate and decrease in the size of the crystal is noticed even at the same relative supersaturation levels. The increase in the nucleation rate explains the combined dominating effects of both the ultrasound frequency and the supersaturation in the solution. Analytically, the nucleation parameters of the nucleated polymorph have been deduced at different ultrasonic frequencies based on the classical nucleation theory and correlations with the experimental results have been obtained. Structural affirmation of the nucleated polymorph has been ascertained by powder X-ray diffraction.

Accelerated synthesis of deca-dodecasil 3 rhombohedral (DDR3) zeolite crystals via hydrothermal growth coupled with ultrasonic irradiation method

In the present work, DDR3 zeolite crystals were synthesized via hydrothermal heating coupled with ultrasonic irradiation method.

Influence of population and radius of cavity bubbles on size of sodium chloride crystals in ultrasound ablation

Crystal size distribution as a function of power in ultrasound ablation is simulated by using a theoretical method based on population and radius of bubbles. In this method, population and radius of bubbles are related to ultrasound power and Debye temperature of crystals. The best power for production of crystals with uniform size is obtained from the theory. In addition, it is shown that the population of bubbles effects the radius of the productions and the radius of bubbles influences the population of products. Results from the theory are supported by experimental results.

Effects of ultrasound on the synthesis of silicalite-1 nanocrystals

Application of power ultrasound, offers potential in the degree of control over the preparation and properties of nanocrystalline zeolites, which have become increasingly important due to their diverse emerging applications. Synthesis of silicalite-1 nanocrystals from a clear solution was carried out at 348 K in the absence and presence of ultrasound of 300 and 600 W, in an attempt to investigate the effects of sonication, in this respect. Variation of the particle size and particle size distribution was followed with respect to time using a laser light scattering device with a detector set to collect back-scattered light at an angle of 173°. Product yield was determined and the crystallinity was analyzed by X-ray diffraction for selected samples collected during the syntheses. Nucleation, particle growth and crystallization rates all increased as a result of the application of ultrasound and highly crystalline silicalite-1 of smaller average particle diameter could be obtained at shorter synthesis times. The particle size distributions of the product populations, however, remained similar for similar average particle sizes. The rate of increase in yield was also speeded up in the presence of ultrasound, while the final product yield was not affected. Increasing the power of ultrasound, from 300 to 600 W, increased the particle growth rate and the crystalline domain size, and decreased both the final particle diameter and the time required for the particle growth to reach completion, while its effect on nucleation was unclear.

Ultrasonic pretreatment for hydrothermal synthesis of SAPO-34 nanocrystals

Synthesis of SAPO-34 nanocrystals which has been recently considered as a challenging task was successfully performed by sonochemical method using TEAOH as structure directing agent (SDA). The products were characterized by XRD, SEM, EDX, BET and TGA. The average crystal size of the final product prepared sonochemically is 50 nm that is much smaller than that of synthesized under hydrothermal condition and the morphology of the crystals changes from uniform spherical nanoparticles to spherical aggregates of cube type SAPO-34 crystals respectively. In the case of sample synthesized sonochemically with aid of hydrothermal condition, the surface area is significantly upper than that of obtained by the conventional static hydrothermal technology with almost the same crystallinity. SAPO-34 framework synthesized by just ultrasonic treatment is unstable and a significant part of SAPO-34 nanocrystals is transformed to the dense phase of AlPO(4) structure, i.e., Cristobalite. Contrary to hydrothermal method that at least 24h of the synthesis time is required to obtain fully crystalline SAPO-34, sonochemical-assisted hydrothermal synthesis of samples leads to form fully crystalline SAPO-34 crystals taking only 1.5h. In a sonochemical process, a huge density of energy for crystallization is provided by the collapse of bubbles which formed by ultrasonic waves. The fact that small SONO-SAPO-34 crystals could be prepared by the sonochemical method suggests a high nucleation density in the early stages of synthesis and slow crystal growth after nucleation.

Ultrasonic reactivation of phosphonate poisoned calcite during crystal growth

The effect of ultrasonic irradiation (42,150 Hz, 17 W dm(-3)/7.1 W cm(-2)) on the growth of calcite in the presence of the inhibitor nitrilotris(methylene phosphonic acid) (NTMP) was investigated at constant composition conditions. In seeded growth experiments, it was found that the inhibiting effect of NTMP on crystal growth could be seriously mitigated under influence of ultrasonic irradiation. An approximately twofold increase in volumetric growth rate was achieved during ultrasonic irradiation, and recovery of the growth rate following inhibition was strongly enhanced compared to growth experiments without ultrasonic irradiation. The results could be explained in part by the physical effect of ultrasound that causes breakage and attrition of poisoned crystals, which resulted in an increase in fresh surface area. Mass spectroscopy analysis of sonicated NTMP solutions revealed that there is also a chemical effect of ultrasound that plays an important role. Several breakdown products were identified, which showed that ultrasound caused the progressive loss of phosphonate groups from NTMP, probably by means of physicochemically generated free radicals and/or pyrolysis in the hot bubble-bulk interface.

Effect of ultrasonic irradiation on crystallization kinetics of potassium dihydrogen phosphate

The ultrasound effect applied on potassium dihydrogen phosphate was investigated in a continuous crystallization system. The studied process variables were ultrasonic power (W) and residence time. The crystal size distributions of the final products obtained with and without ultrasonic power were determined and the data were evaluated by using modified form of Abegg, Stevens and Larson (ASL) model. The supersaturation limit decreased with ultrasonic waves and the crystal morphology was modified. The average crystal size decreased in the presence of ultrasonic power. An abrasive effect was observed at a high ultrasonic power input.

Visualization of acoustic cavitation effects on suspended calcite crystals

The acoustic cavitation (42,080 Hz, 7.1 W cm(-2) or 17 W) effects on suspended calcite crystals, sized between 5 and 50 μm, have been visualized for the first time using high speed photography. High speed recordings with a duration of 1 s containing up to 300,000 frames per second, revealed the effect of cluster and streamer cavitation on several calcite crystals. Cavitation clusters, evolved from cavitation inception and collapse, caused attrition, disruption of aggregates and deagglomeration, whereas streamer cavitation was observed to cause deagglomeration only. Cavitation on the surface gave the crystals momentum. However, it is shown that breakage of accelerated crystals by interparticle collisions is unrealistic because of their small sizes and low velocities. Crystals that were accelerated by bubble expansion, subsequently experienced a deceleration much stronger than expected from drag forces, upon bubble collapse. Experiments with pre-dried crystals seemed to support the current theory on bubble nucleation through the presence of pre-existing gas pockets. However, experiments with fully wetted crystals also showed the nucleation of bubbles on the crystal surface. Although microjet impingement on the crystal surface could not be directly visualized with high speed photography, scanning electron microscopy (SEM) analysis of irradiated calcite seeds showed deep circular indentations. It was suggested that these indentations might be caused by shockwave induced jet impingement. Furthermore, the appearance of voluminous fragments with large planes of fracture indicated that acoustic cavitation can also cause the breakage of single crystal structures.