Enhancing pharmaceutical crystallization in a flow crystallizer with ultrasound: Anti-solvent crystallization

Ultrasound-assisted continuous crystallization of metastable polymorphic pharmaceutical in a slug-flow tubular crystallizer

Metastable polymorphic pharmaceuticals have garnered significant attention in recent years due to their enhanced physicochemical properties, including solubility, bioavailability, and intellectual property considerations. However, the manufacturing of metastable form pharmaceuticals remains a formidable challenge. The stable preparation of metastable carvedilol (CVD) form Ⅱ crystals during CVD production is elusive, leading to substantial inconsistencies in product quality and regulatory compliance. In this study, we successfully prepared metastable CVD Form Ⅱ crystals using a continuous tubular crystallizer. Our findings demonstrate that the tubular crystallizer exhibits high efficiency and robustness for generating metastable crystal Form Ⅱ. We optimized the crystallization process by incorporating air bubble segments and employing ultrasonic irradiation strategies to overcome blockages and wall sticking issues encountered during operation. Ultimately, we developed an ultrasound-assisted continuous slug-flow tubular crystallization method and evaluated its performance. The results indicate that the CVD crystals produced through this process are resilient, sustainable, and uninterrupted products with promising potential for producing metastable polymorphic pharmaceuticals while effectively addressing encrustation problems associated with continuous tubular crystallization.

Quid Pro Flow

How do you get into flow? We trained in flow chemistry during postdoctoral research and are now applying it in new areas: materials chemistry, crystallization, and supramolecular synthesis. Typically, when researchers think of "flow", they are considering predominantly liquid-based organic synthesis; application to other disciplines comes with its own challenges. In this Perspective, we highlight why we use and champion flow technologies in our fields, summarize some of the questions we encounter when discussing entry into flow research, and suggest steps to make the transition into the field, emphasizing that communication and collaboration between disciplines is key.

Liquid antisolvent crystallization of pharmaceutical compounds: current status and future perspectives

The present work reviews the liquid antisolvent crystallization (LASC) to prepare the nanoparticle of pharmaceutical compounds to enhance their solubility, dissolution rate, and bioavailability. The application of ultrasound and additives is discussed to prepare the particles with narrow size distribution. The use of ionic liquid as an alternative to conventional organic solvent is presented. Herbal compounds, also known for low aqueous solubility and limited clinical application, have been crystalized by LASC and discussed here. The particle characteristics such as particle size and particle size distribution are interpreted in terms of supersaturation, nucleation, and growth phenomena. To overcome the disadvantage of batch crystallization, the scientific literature on continuous flow reactors is also reviewed. LASC in a microfluidic device is emerging as a promising technique. The different design of the microfluidic device and their application in LASC are discussed. The combination of the LASC technique with traditional techniques such as high-pressure homogenization and spray drying is presented. A comparison of product characteristics prepared by LASC and the supercritical CO₂ antisolvent method is discussed to show that LASC is an attractive and inexpensive alternative for nanoparticle preparation. One of the major strengths of this paper is a discussion on less-explored applications of LASC in pharmaceutical research to attract the attention of future researchers.

Fluoropolymer Membranes for Membrane Distillation and Membrane Crystallization

Fluoropolymer membranes are applied in membrane operations such as membrane distillation and membrane crystallization where hydrophobic porous membranes act as a physical barrier separating two phases. Due to their hydrophobic nature, only gaseous molecules are allowed to pass through the membrane and are collected on the permeate side, while the aqueous solution cannot penetrate. However, these two processes suffer problems such as membrane wetting, fouling or scaling. Membrane wetting is a common and undesired phenomenon, which is caused by the loss of hydrophobicity of the porous membrane employed. This greatly affects the mass transfer efficiency and separation efficiency. Simultaneously, membrane fouling occurs, along with membrane wetting and scaling, which greatly reduces the lifespan of the membranes. Therefore, strategies to improve the hydrophobicity of membranes have been widely investigated by researchers. In this direction, hydrophobic fluoropolymer membrane materials are employed more and more for membrane distillation and membrane crystallization thanks to their high chemical and thermal resistance. This paper summarizes different preparation methods of these fluoropolymer membrane, such as non-solvent-induced phase separation (NIPS), thermally-induced phase separation (TIPS), vapor-induced phase separation (VIPS), etc. Hydrophobic modification methods, including surface coating, surface grafting and blending, etc., are also introduced. Moreover, the research advances on the application of less toxic solvents for preparing these membranes are herein reviewed. This review aims to provide guidance to researchers for their future membrane development in membrane distillation and membrane crystallization, using fluoropolymer materials.

Dimensional Optimization for ZnO-Based Mechano-ATRP with Extraordinary Activity

Various piezoelectric nanomaterials were utilized in ultrasound-mediated atom transfer radical polymerization (ATRP), owing to their outstanding piezoelectric effect. However, the relationship between the morphology of those piezocatalysts and polymerization has not been clearly established. Herein, we employed different piezoelectric zinc oxide (ZnO) nanomaterials to achieve novel mechano-induced ATRP (mechano-ATRP). Based on the synergistic effect of piezoelectric properties and specific surface area, the catalytic activity of 1D ZnO nanorods (1D-ZnO NRs) with increased aspect ratio outperformed that of 0D ZnO nanoparticles (0D-ZnO NPs). Compared to the conventional ATRP system, this system exhibited extraordinary activity toward the less activated monomer acrylonitrile (67% conversion after 6 h), with a narrow molecular weight distribution (polydispersity index ∼ 1.19). Furthermore, implications of ZnO loading, copper salt amount, degree of polymerization, monomer, and solvent were also studied for the highly efficient mechano-ATRP.

Experimental and numerical investigation of the effect of ultrasound on the growth kinetics of zeolite A

Ultrasound is a promising technology for the improvement of zeolite production, due to its beneficial effects on mass transfer and nucleation. However, a broad understanding of the sonication parameters that influence the growth of zeolites most is still lacking. In the present work, zeolite A was synthesized and the kinetic model of Gualtieri was used to obtain information about the crystallization parameters. The effect of the sonication power and duration on the relative crystallinity and particle size distribution were investigated using a Langevin-type transducer operating at 40 kHz. The experimental data shows that ultrasound has a significant effect on the nucleation and growth. With that, a reduction of up to 40 % of the initial synthesis time can be achieved. Additionally, a narrower particle size distribution is achieved when ultrasound is used during the zeolite A synthesis.

Recent Progress of Antisolvent Crystallization

Antisolvent crystallization is a significant unit operation in the pharmaceutical industry, especially on drug crystal properties optimization. This paper firstly highlights the applications of antisolvent crystallization in crystal engineering. Antisolvent...

Continuous Cooling Crystallization in a Coiled Flow Inverter Crystallizer Technology—Design, Characterization, and Hurdles

Continuous small-scale production is currently of utmost interest for fine chemicals and pharmaceuticals. For this purpose, equipment and process concepts in consideration of the hurdles for solids handling are required to transfer conventional batch processing to continuous operation. Based on empirical equations, pressure loss constraints, and an expandable modular system, a coiled flow inverter (CFI) crystallizer with an inner diameter of 1.6 mm was designed. It was characterized concerning its residence time behavior, tested for operation with seed crystals or an ultrasonic seed crystal unit, and evaluated for different purging mechanisms for stable operation. The residence time behavior in the CFI corresponds to ideal plug flow behavior. Crystal growth using seed crystals was demonstrated in the CFI for two amino acids. For fewer seed crystals, higher crystal growth rates were determined, while at the same time, secondary nucleation was observed. Feasibility for the interconnection of a sonicated seeding crystal unit could be shown. However, the hurdles are also identified and discussed. Prophylactic flushing combined with a photosensor for distinguishing between solvent and suspension phase can lead to stable and resource-efficient operation. The small-scale CFI technology was investigated in detail, and the limits and opportunities of the technology are presented here.

A review on recent advances in hydrogen energy, fuel cell, biofuel and fuel refining via ultrasound process intensification

Hydrogen energy is one of the most suitable green substitutes for harmful fossil fuels and has been investigated widely. This review extensively compiles and compares various methodologies used in the production, storage and usage of hydrogen. Sonochemistry is an emerging synthesis process and intensification technique adapted for the synthesis of novel materials. It manifests acoustic cavitation phenomena caused by ultrasound where higher rates of reactions occur locally. The review discusses the effectiveness of sonochemical routes in developing fuel cell catalysts, fuel refining, biofuel production, chemical processes for hydrogen production and the physical, chemical and electrochemical hydrogen storage techniques. The operational parameters and environmental conditions used during ultrasonication also influence the production rates, which have been elucidated in detail. Hence, this review's major focus addresses sonochemical methods that can contribute to the technical challenges involved in hydrogen usage for energy.

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

Nucleation kinetics for primary, secondary and ultrasound-induced paracetamol crystallization

Investigation into the effect of different nucleation mechanisms on the nucleation rate for paracetamol crystallization in stirred microvials.

Polymorphs and pharmacokinetics of an antipsychotic drug candidate

A potent antipsychotic drug candidate, 7-(4-(4-(6-fluorobenzo[d]-isoxazol-3-yl)-piperidin-1-yl)butoxy)-4-methyl-8-chloro -2H-chromen-2-one mesylate(CY611), with good in vitro and in vivo antipsychotic effects was investigated for preformulation evaluation by crystallography methods. Three anhydrous polymorphs(Form I-III), a monohydrate(Form IV), and a NMP solvate(Form V) were discovered and characterized by powder X-ray diffraction, thermal analysis, attenuated total reflection-fourier transform infrared spectroscopy and scanning electron microscopy. Form I, monohydrate Form IV, and a NMP solvate Form V of the drug candidate were isolated, and their structures were determined by single crystal X-ray diffraction. IDR and relative stability experiment were performed. Although Form II has the fastest release rate in water, it easy transformed to monohydrate which has the lowest release rate. In vivo pharmacokinetic study showed that the Form III has the highest bioavailability at 35.4%. Considering the balance between the physicochemical properties, bioavailability and manufacturability of the available polymorphs, Form III may be the optimal form candidate for the eventual formulation.

Continuous Ultrasonic Reactors: Design, Mechanism and Application

Ultrasonic small scale flow reactors have found increasing popularity among researchers as they serve as a very useful platform for studying and controlling ultrasound mechanisms and effects. This has led to the use of these reactors for not only research purposes, but also various applications in biological, pharmaceutical and chemical processes mostly on laboratory and, in some cases, pilot scale. This review summarizes the state of the art of ultrasonic flow reactors and provides a guideline towards their design, characterization and application. Particular examples for ultrasound enhanced multiphase processes, spanning from immiscible fluid-fluid to fluid-solid systems, are provided. To conclude, challenges such as reactor efficiency and scalability are addressed.