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Design of Crystallizers
Auslegung von Kristallisatoren
ALFONS MERSMANN
Lehrstuhl B fir Verfahrenstechnik, TU Munchen, Arcisstr. 21, 8000 Munich 2 (F.R.G.)
(Received December 7, 1987; in final form February 2, 1988)
Abstract
It is shown how to design a crystallizer starting with data which must be determined in laboratory crystallizers
and other measuring equipment. A survey on kinetic data of a large number of systems is given in order to show
the range of parameters involved in crystallization.
The paper deals with the scale-up problems of crystallizers which are important when laboratory data are
transferred to large-scale crystallizers.
Kurzfassung
Ausgehend von Daten aus Laborkristallisatoren oder einfachen MeDapparaturen wird die Auslegung von
Kristallisatoren beschrieben. Ein ijberblick iiber die kinetischen Gr6Ben zahlreicher Systeme (Keimbildungsrate
und Kristallisationsgeschwindigkeit) sol1 die Bandbreite der Parameter zeigen, welche fur die Auslegung solcher
Apparate benotigt werden.
Ferner beschaftigt sich der Aufsatz mit der MaBstabsvergrdBerung von Kristallisatoren und zeigt, wie
sich experimentelle Daten aus Riihrwerkskristallisatoren zur Auslegung anderer und vor allem such gragerer
Kristallisationsapparate nutzen lassen.
0255-2701/88/$3.50 Chem. Eng. Process., 23 (1988) 213-228 0 Elsevier Sequoia/Printed in The Netherlands
214
Shred Vessel Forced Fluidmd Bed unit time of the stirrer or the stirrer power dissipated
3culotion in the suspension. The suspension flow (i, + 4 of the
solution with the concentration c, and of the solid
product (product stream @ = i,m,/@, - mT)) is dis-
charged from the crystallizer. The enthalpy flows fi
correspond to the mass flows i, AL and P respec-
tively. The Table in Fig. 3 contains the balances for
mass and energy. The general case can be simplified if
certain restrictions are valid. It is important to men-
tion that the mass balance (for instance for the restric-
tion CJJ+ 1 and At = 0),
mT=cO-c*-Ac=c,,-C, (1)
Fig. 2. Industrial crystallizers [2].
cannot be solved since the suspension density m, and
the supersaturation AC are unknown (the equilibrium
and on the operating conditions. The population den- concentration c* can be derived from the energy bal-
sity balance determines the crystal size distribution ance). Only crystallization kinetics (i.e. the growth
and the mean crystal size. The purity of the crystalline rate G of the crystals and the rate B of nucleation, see
product is often connected with the growth rate. $4) determine the relationship between the two un-
It is at last possible to calculate the dimensions of knowns AC and m,.
a crystallizer,
General .&,=Ai+i,
PLO = PL,
or (with i, = i, + At)
mT=*-c,
CO
=_-c*-Ac
1 -Al/Lo
rp*1 mT = co - c,
AL=0
e-1--
Liquid Vapour Suspension Energy
(add = added ; drs = dlschargel
Fig. 3. Balances for mass and energy of a continuously operated crystallizer.
216
(3) large differences in concentration and/or impeller) determine the degree of macromixing and
supersaturation are avoided. micromixing. On the one hand, the entire crystallizer
This presupposes a certain degree of macro- and volume must be mixed well so that all its elements
micromixing. participate equally in the mass transfer process and
hence the entire volume is efficiently utilized. In addi-
tion to this bulk mixing, sufficient micromixing has to
3.1. Suspension of crystals
be present in certain parts of the crystallizer in order
In the crystallizer the crystals have to be kept in to even out quickly any local supersaturation peaks.
suspension by the volumetric flow rate of the solution Such critical zones in the crystallizer are the region of
which is generated by a stirrer or a pump. This implies the feed inlet and the heat transfer areas (i.e. boiling
that the local average flow velocity of the solution and cooling surfaces). The absence of zones with a
must exceed the settling velocity w,, of the swarm of supersaturation AC higher than the metastable super-
particles. This velocity w,, can be calculated with the saturation AC,,, must be aimed at.
aid of a variety of equations and diagrams published When the crystallizer is similar to a loop reactor,
in the literature [4]. supersaturation is generated at the feed inlet or at the
The flow velocity depends on the geometry of the cooling or evaporation surfaces. It is reduced by crys-
apparatus. Figure 4 shows a vertical and a horizontal tal growth during one circulation in the loop. Let us
pipe as well as a fluidized bed, and a large stirred consider a stirred tank of dimensions d/T, = 0.33 and
vessel (left side), a small stirred vessel, and an elbow HIT, = 1. According to ref. 3 the following equation
bend (right side). Recommendations for the flow ve- can be derived for a vessel equipped with a marine
locity wf of the solution are: vertical pipe: up,-> SW,,; type impeller:
>I (2)
horizontal pipe: wy > low,,.
P,aTG
The relationship wF x w,, is valid in fluidized beds -
and also in large stirred vessels (7’JZ > 103). This 0.072 s AC,,,
means that the mean specific power input Bis inversely In Fig. 5 the expression Acme,7 s/mT is plotted against
proportional to the vessel diameter Td (E - l/T,) the term Ac,,,s/p,aTG. It will be pointed out later that
until the minimum value tin = rpw,g(Ap/p) is the crystal growth rate G often only varies by approx-
reached. A constant circumferential stirrer velocity, imately one order of magnitude (lo-’ m s-l -=zG <
w, = ~sd = constant, is a reasonable criterion for scal- 10m7 m SK’). For given values of the suspension den-
ing-up. The situation is quite different in small stirred sity mT and the volumetric specific surface a, of the
vessels (T,/.f < 500) and in elbow bends because of crystals, the speed s, necessary for macromixing, de-
particle settlement in the narrow loopway which leads pends on the residence time 7 and especially on the
to dunes (see Fig. 4). In these cases a constant specific metastable supersaturation AC,,,,,.
power input E is recommended as the suspension crite- The smaller this supersaturation and the shorter
rion. Consequently, it can be said that the larger the the residence time 7, the higher the chosen speed s of
apparatus, the easier is the suspension of crystals. the impeller. Fast growing systems with high values
for mT and a, need large volumetric flqw rates V
3.2. Mixing in crystallizers based on the crystallizer volume V (s N V/V), espe-
cially in the case of small metastable zone width AC,,.
In order to control the process of crystallization, According to the equation
the fluid dynamics have to ensure proper mixing. Lo-
cal and mean values of the specific power input e
(caused, for example, by the rotational speed of the
valid for macromixing, the macromixing time 8,,,, Fig. 7. Temperature (9) and concentration (c) profiles in the vicin-
increases with the power f of the vessel diameter Td ity of a heat transfer wall for a low (upper part) and a high (lower
part) heat flux density 4.
for a given mean specific power input E (see Fig. 5).
Dealing with micromixing of low viscous systems, the
time for micromixing emioro is dependent on the local The meaning of the heat transfer coefficients a, (solu-
specific power input E, the liquid viscosity v, and on tion), and a, (coolant) as well as the wall thickness 6
the Schmidt number of the solution according to Fig. and the wall heat conductivity 1 can be seen from Fig.
6. As can be seen from this diagram the time for 7, in which the profiles of temperature 9 and concentra-
micromixing is short in comparison with the induc- tion c are depicted for the case of cooling crystallization.
tion period obtained in measurements of the meta- In a similar way these profiles can be described for
stable limit. Hence, undesired nucleation owing to evaporation crystallizers. For this purpose the solubil-
insulflcient micromixing can be excluded as long as ity curve c * = f(9) of the system under discussion must
the feed is introduced into the crystallizer in a region be known. The temperature profile depends on the
of high local specific power input. These regions occur local flow and heat transfer conditions.
in the discharge flow in the immediate vicinity of the Incrustation is a quite natural but very often un-
impeller [7]. However, with increasing solution viscos- desired crystallization process in heat transfer areas
ity micromixing becomes more significant. and apparatus or on pipe walls. Let us consider a
It should be mentioned here that the situation is surface over which a crystal free solution flows. At first
different in precipitation crystallizers (not discussed in heterogeneous nuclei must be generated [9]. Further-
this contribution). When dealing with precipitation, more, it is necessary that these nuclei adhere to the
micromixing has a tremendous influence on the crys- wall. These processes are prerequisites of incrustation.
tal size distribution and the mean crystal size [8]. The local supersaturation AC then leads to growth of
nuclei which grow together, thus forming a crust with
a certain growth rate. In order to avoid incrustation
4. Heat transfer in crystallizers caused by heterogeneous nucleation the local supersat-
uration AC must be smaller than the metastable zone
Contrary to most heat exchangers applied in chem- width AC,,,, hst for heterogeneous nucleation:
ical engineering, crystallizer heat exchanges display
reasonable limitations of maximum allowable temper- AC < AC,,, bet = g A%,,,, bet (5)
ature difference AS. The reason for such limitations is
undesired nucleation which occurs in solutions with The upper portion of Fig. 7 depicts the case when the
concentrations higher than the metastable zone AC,,,,, difference ch - c* in the concentration layer near the
wall is smaller than the critical or metastable difference
Acmef,bet (ct, - c* < Ac,~, ,.,&, in which c,, is the bulk
4.1. Allowable temperature differences in heat concentration of the turbulent solution flow assumed.
exchangers The above picture in Fig. 7 is valid for small.heat flux
In a cooling crystallizer the heat flux 0 is to be densities 4 = k AS. However, with increasing flux den-
removed; in the case of an evaporation crystallizer the sities 4 or increasing total temperature differences A9
heat flux 0 must be added. In order to transfer this the difference c,, - c* becomes larger than Ac,,,,,,~~~
energy the heat transfer area A is necessary for a given (cb - e* > Ae,t i,st); see lower part of Fig. 7. In this
temperature difference A9 : case the probability of incrustation is very high. Unfor-
tunately, up until now the metastable zone width
Q=($+~+~)-‘ALM=~AA~ (4) Ac,,t, hct =f kmt, ,,omrwith 0 c f -K1, is not known
E for most systems.
218
0.18
Laminar Nu = 0.664 Ret/* P@ Nu = 1.18 RetI Prt/3 Nu = 1.0 Re’i*pr’is -? Rec2Sx 102
0 %v
0.14
Transition Nu = 0.18 Re213Pr’/’ Nu = 0.38 Rez13 Pr113 Nu = e Re2/s RI/’ 1. 2.5 x 10a=zRe<7x IO5
range 0 KV
c = O.rO.4 without bafiles
c = 0.7-0.9 with bat&s
Similar equations for the calculation of heat trans- from measured crystal size distributions shows that
fer coefficients can be found in the literature for other the operation of ‘mixed suspension mixed product re-
types of crystallizers (forced circulation or fluidized moval’ (MSMPR) crystallizers is most appropriate
beds). for this purpose.
The population density n depending on the crystal
size x is defined as the number dN of crystals per unit
5. Crystallization kinfztics volume suspension in a size interval dx:
Population density
dn d(Gn)
balance F +D(x)+ B(x)+n
z+
Moment Significance
General MSMPR
m, =
J
0
xn(x) dx
cc
m2 = x%(x) dx Total surface area aT = k,m, a, = 2k,n,,(G~)~
s
0
m
m, =
J
0
x%(x) dx Volumetric hold-up cp = k,m,
II
cp = m&, = 6ksdW
Crystal size
Jxh(x)
dx
distribution n(x) = n,, exp( --x/G?) i
48
_=-_
1 _(3.67)3 (3.67)‘G tith cp =3
Rate of nucleation zzzp
9 6k,G”s4 6k& 6k>’ P.
220
5.1. Crystal growth rate Fig. 9. Crystal growth rate plotted against relative supersaturation
Larger crystals in industrial crystallizers are usu- for 23 systems. Note: the capital letters denote the metastable limits
of the systems according to refs. 14 and 15.
ally rounded due to attrition and do not display dis-
tinct faces. The mean mass flux density RB or the
mean crystal growth rate G depends on supersatura- ties can have a great influence on growth (PbCl, on
tion AC, temperature T and on crystal size X. In the KC1 [ 161, ferrocyanate on NaCl [ 11, etc.). In some
case of diffusion controlled growth the relative veloc- cases temperature dependent growth was observed.
ity w,, between solution and crystal plays a certain This behaviour is usually explained by a temperature
role. Impurities and additives (add.) usually have an dependent surface integration which is often de-
important influence: scribed by an Arrhenius expression (see Table 3). But
in reality when dealing with impure systems an inter-
G = 2 = f( Ac, T, x, add., w,,) (8) pretation of AE in the context of an adsorption energy
\ Y I of the foreign substance may be more appropriate
surface
megration than an explanation of an activation energy. Since the
\ I / purities of the systems according to Fig. 9 are un-
ditiuaion known it is not reasonable to compare their crystal
growth rates. However, when dealing with industrial
Figure 9 shows the crystal growth rates G of vari- crystallization, the relative supersaturation AC/C* is
ous systems plotted against the relative supersatura- usually chosen in such a way that for inorganic sys-
tion AC/C* for a temperature of approximately 30 “C. tems a growth rate of IO-* m s-i <G < 10m6 m s-l
The curves are mainly valid for a crystal size range is achieved. This may be mainly due to the desire to
100 pm < x < 2000 ,um. As can be extrapolated from obtain economical size enlargements A_x = Gt of
Fig. 9, the growth rate differs over nine orders of the crystals for reasonable residence times r
magnitude for AC/C* = 0.01. It is known from the (lOOOs<r~lOOOOs; 10-8x104=10-4mcGz~
literature that small amounts of additives or impuri- 1OV x lo3 = 10e3 m).
Elimination of c,
Special case z = 1
Specialcaser=2
BCF model
221
5.2. Nucleation rates 0.001 up to 100. However, nearly all systems were
crystallized at supersaturations between 0.01 and
According to the equation 0.1 mall-‘. Figure 10 shows the maximum mean
crystal sizes f,,, as a function of the relative supersat-
uration AC/C*. Such a diagram was introduced in a
’ = 3x37 [ 6k,,(&)]‘4
previous paper [ 31. A generalized result would be: the
valid for MSMPR crystallizers, the mean crystal size higher the relative supersaturation, the smaller is the
,? depends on the growth rate G and on the rate of mean crystal size, probably in accordance with in-
nucleation B,/cp based on the volumetric crystal creasing nucleation rates. According to the relation-
hold-up. Both of the kinetic parameters G and B, are ship for the mean crystal size 2 (eqn. (9)), the decrease
strongly dependent on supersaturation. Conse- of the mean crystal size 2 with increasing AC/C* is
quently, the mean crystal size is a function of super- caused either by a decrease of G or an increase of B,,Jq
saturation. or by a combination of both effects. In Fig. 11 the
Table 4 contains the molar mass a, the tempera- growth rates G are plotted against AC/C*. It is again
ture 9 and the solubility c* of 17 aqueous systems. important to keep in mind that this diagram describes
According to results in the literature and our own a comparison of various systems. As can he seen the
experimental data, the supersaturation AC at which growth rates decrease only by approximately
the systems were crystallized and the maximum mean G = 5 x lo-’ m SK’ valid for AC/C* < 1 to G = 0.5 x
crystal size Xmax are listed. Further information is 1O-8 m s-i for sparingly soluble systems. Therefore
given in the literature cited. As can be seen from this the decrease of the mean crystal sizes f against AC/C *
Table the solubility ranges from 4.6 mol l- ’ to is mainly caused by an increase of the rate of nucle-
lo-’ mol I-’ and the relative supersaturation from ation (B,/p) based on the volumetric hold-up rp.
TABLE 4. Kinetic data of 17 aqueous systems crystallized by cooling, evaporation, drowning out and reaction
a~ = continuous; b = batch
222
~~e,+K,e,
rpVdt
or
s2.2d3.2
dV
a
cpVdt
=-$ (“febe%,
e + u&~bttt, b) 7
wu
(16)
is plotted in Fig. 15 against the growth rate G for the 6.2. Scale-up problems
aqueous systems of KCl, KNO,, (NH&SO, and Let us assume that kinetic data of the rates of
(NH&CS. According to our results, larger crystals growth and nucleation obtained in a laboratory crys-
with x > 100 pm of these systems grow diffusion con-
tallizer are available and that the mean crystal size f
trolled. Consequently, there is a linear relationship
is known for the system crystallized in this apparatus.
between growth rates G and the supersaturations. In
The question of how to choose the geometry and size
Fig. 15 second abscissae with the supersaturation AC
of the large-scale crystallizer and its operating con-
are drawn for these four systems.
ditions then arises. According to #3.1 and 3.2
Furthermore, the product ( l/k,.?,3)(m,, Jrn,, ,,,) is macromixing demands a higher specific power input
split up into the mass fraction m, eE/ma,tot and the
but suspending can be carried out at lower specific
mean size R, of the effective fragments. The
power inputs. As a compromise a constant specific
nomogram beside the ordinate allows m, Jma, fot val-
power input B (.? 3 Es’,,& is recommended for indus-
ues to be read for given 5 data. Assuming _iY= = 10 pm
trial crystallizers. Then eqns. ( 12) and ( 16) allow eval-
and G = lo-’ m s-’ we obtain m,.,/m, tOtz 0.004
uation of the relationship between the rate of
for (NH&SO4 and m, &m, t,,t NS0.02 for KCl.
secondary nucleation B,,, eR (and the mean crystal size
It is important to mention that the results pre-
2 according to eqn. ( 12)) and the scale-up factor for
sented in Fig. 15 are based on experimental data ob-
systems crystallized at AC/C* < 0.1. This mainly de-
tained in stirred vessels and fluidized bed crystallizers.
pends on the target efficiencies qt, e and qt, ,,. Figure 16
In the case of fluidized beds the contribution of sec-
shows target efficiencies plotted against the Stokes
ondary nucleation due to crystal-rotor collisions is
number
simply zero. Principally speaking, it is possible to ap-
ply eqn. (16) and the results depicted in Fig. 15 also x
* =--P&&
for forced circulation crystallizers equipped with axial
pumps.
18~ 1,
with lc = b, (edge) and I, = b,, (breadth of the im-
peller). U, is the collision velocity between the crystals
6. Design and scale-up and the impeller [44,45]. The curves refer to the ex-
perimental results of Riebel et al. [47], Schuch [48]
The reliable design of a crystallizer is not possible and Longmuir and Blodgett [49]. Three ranges can be
without experimental data. Measurements are usually distinguished:
carried out in a laboratory crystallizer which is often (a) In the case of very small Stokes numbers the
operated as an MSMPR crystallizer. Two questions target efficiency approaches zero; this may occur in
arise: how to design large-scale crystallizers; and very large crystallizers (x/Z, -+ 0).
225
CrystaIhzer 10
design
11 Selection of residence time T for R = R,,, [23]
12 Crystallizer volume V according to desirable f
Crystallizer
scale-up
Fig. 16. Target efficiency plotted against Stokes number according to Schuch [48], - - -, and to Biebel et al. [471, -, with various
values of x/l,.
226
41 A. E. Nielsen, The kinetics of crystal growth in barium sulfate 46 R. PloD, The~i.s, Tech. Univ. Munich, 1988.
precipitation, Actu Chem. Stand., 12 (1958) 11. 47 U. Riebel, U. Zitzmann and F. Liiffler, Mechanische Bean-
42 A. Mersmann, M. Kind and J. Pohlisch, The influence of spruchung suspendierter Teilchen am Leitrohr-Propellerriihrer,
growth and nucleation kinetics on the mean crystal size in sus- Chem.-Ing.-Tech., 59 (1987) 436437.
pension crystallizers, Third Int. @‘or/d Congr. on Chemical Engi- 48 G. Schuch, Theoretische und experimentelle Untersuchungen
neering, Tokyo, 1986. zur Auslegung van NaBentstaubern, Thesis, Univ. Karlsruhe,
43 J. Pohlisch and A. Mersmann, The influence of stress and attri- 1978.
tion on crystal size distribution, Chem. Eng. Technol., I1 (1988) 49 Longmuir and Blodgett, cited in R. Perry and C. Chilton (eds.),
40-49. Chemical Engineer’s Handbook, McGraw-Hill, Tokyo, 5th edn.,
44 R. Ploss and A. Mersmann, A new model of the effect of stirring 1973.
velocity on the rate of secondary nucleation, Chem. Eng. Tech- 50 J. Pohlisch, R. Sangl and A. Mersmann, Some aspects on the
nol., in press. influence of stress and attrition on particle size distribution and
45 A. Mersmann, R. Sangl, M. Kind and J. Pohlisch, Attrition and scale-up ofcrystallizers, in J. Nyvlt and S. Zacek (eds.), Industrial
secondary nucleation in crystallizers, C&m. Eng. Technol., 11 Crystallization, Elsevier, in press.
(1988) 80-88.