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Real-time monitoring of batch crystallization is shown to provide benefits leading to improved methods for process development, optimization and scale-up. This white paper reviews case studies examining many of these benefits for:
- Providing process knowledge that enables real improvements in yield, throughput and profitability of production scale crystallization
- Eliminating downstream bottlenecks by improving filtration/dryer performance
- Accelerating the characterization of critical operating parameters for increased productivity
- Enabling the design of more robust processes to assure batch-to-batch repeatability and consistent meeting of crystal specifications
- Identifying undesired events in real time to help ensure product quality
Batch crystallizers are utilized in the chemical industry to produce high-value fine chemicals, particularly in small-scale operations dealing with difficult-to-handle chemicals. Batch crystallization is distinct from continuous crystallization in that the crystal product is withdrawn only once at the end of the batch run, whereas in continuous crystallization, the mother liquid is continuously flowed in, and the slurry is continuously withdrawn.
Scale-up of crystallization is notoriously complicated and companies are under pressure to develop scalable crystallization processes faster - at lower costs and with higher quality. Companies must control crystallization conditions to improve cycle times and optimize product quality. With the incorporation of Process Analytical Technology (PAT), real-time monitoring of crystallization can be achieved without pulling samples. In-situ Process Analytical Technology (PAT) tools can track critical parameters such as the crystal size and shape, the crystal form, and even the level of supersaturation.
