Prepared by: Roel Ian M.

De La Cruz
 OBJECTIVES
To determine the principles of
crystallization
To enumerate the different types of
crystallizers

To design a crystallizer from a given problem

 CRYSTALLIZERS
Crystallization is a
purification process
that yields highly
purified crystals from
relatively impure
solutions.
 CRYSTALLIZERS
Crystallization is done
by supersaturating the
feed solution. And then
the nucleation of the
solids occur to form the
crystals.
 Types of Crystallizers
Mixed Suspension, Mixed Product
Removal Crystallizers (MSMPRC)

Also called the

circulating magma
crystallizer
 Types of Crystallizers
Mixed Suspension, Mixed Product Removal Crystallizers

In this type of crystallizer,

it is assumed that the
slurry is perfectly mixed
and uniform throughout
the system.
 Types of Crystallizers
Forced Circulation Evaporator - Crystallizer

This type is classified as

evaporative crystallizer,
where the supersaturation
of the solution is done by
evaporation of solvent.
 Types of Crystallizers
Advantages
Forced Disadvantages
Circulation Evaporator - Crystallizer
Least Expensive Crystal Size is difficult to
This type is classified
Large Range of Sizes Available
as control
evaporative
High crystallizer,
Rate of Circulation reduces
where
particle the supersaturation
deposits on walls

of the solution is done by

evaporation of solvent.
 Types of Crystallizers
Draft Tube Baffle Evaporator Crystallizer

DTB crystallizer are used in which

excessive nucleation occurs. Fines are
separated from larger particles and
recycled back through the crystallizer
again.
 Types of Crystallizers
Draft Tube Baffle Evaporator Crystallizer

DTB crystallizer are used in which

excessive nucleation occurs. Fines are
separated from larger particles and
recycled back through the crystallizer
again.
 Types of Crystallizers
Draft Advantages Disadvantages
Tube Baffle Evaporator Crystallizer
Crystal size is easy to control Frequent flushings required to
DTB crystallizer are used in which
Economic due to recyclability of minimize deposits on vessel
walls
excessive nucleation occurs. Fines are
fines
More energy efficient than forced Cannot effectively handle a high
separated from larger particles and
circulation crystallizers density slurry
recycled back through the crystallizer
again.
 Types of Crystallizers
Surface Cooled Crystallizer

Surface cooled
crystallizers combine
DTB body with a
forced circulation
heat exchanger.
 Types of Crystallizers
Surface Cooled Crystallizer

It is used for
operations in which
the solutions boiling
point is extremely
high.
 Types of Crystallizers
Direct Contact Refrigeration Crystallizer

It is used for
operations in which
the solutions boiling
point is extremely
high.
 Types of Crystallizers
Direct Contact Refrigeration Crystallizer

It is used for
operations in which
the solutions boiling
point is extremely
high.
 Types of Crystallizers
Reaction type Crystallizer

In this type of
crystallizer, the
crystals are formed
by reacting two
components.
 Types of Crystallizers
Reaction type Crystallizer

In this type of
crystallizer, the
crystals are formed
by reacting two
components.
 Factors to Consider
Materials of Construction

Method of Supersaturation

Mode of Operation

Solubility Curve
 Factors to Consider
Materials of Construction

Method of Supersaturation

Mode of Operation

Solubility Curve
 Factors to Consider
Materials of Construction

Method of Supersaturation

Mode of Operation

Solubility Curve
 Factors to Consider
Materials of Construction

Method of Supersaturation

Mode of Operation

Solubility Curve
 Factors to Consider
Materials of Construction

Method of Supersaturation

Mode of Operation

Solubility Curve
 Factors to Consider
Materials of Construction

Method of Supersaturation

Mode of Operation

Solubility Curve
 Factors to Consider
Materials of Construction

Method of Supersaturation

Mode of Operation

Solubility Curve
 Crystallizer Design
Design a crystallizer to produce sodium chloride
based on the given data:
Production Rate 20 tons/hr
Feed Concentration 320 kg/m3
Feed Concentration
0.27 kg/kg
(w/w)
Specific heat of
3.29 kJ/kg-K
feed
Crystallizer Design
Density of feed 1185 kg/m3
Vapor Pressure 10 kPa
Vapor Density 68.7 x 10-3 kg/m3
Latent heat of
2400 kJ/kg
vaporization
Product slurry
250 kg/m3
concentration
Density of crystals 2115 kg/m3
Crystallizer Design
Feed Temperature 20oC
Evaporator entry
55oC
temperature
Boiling point
7oC
elevation
Additional
2oC
Undercooling
Crystallizer Design
Vapor
condensation 46oC
temperature
Steam saturation
66oC
temperature
 Design Description
Crystallizers are used in industry to achieve liquid-
solid separation. They are an important piece of
chemical processing equipment because they are
capable of generating high purity products with a
relatively low energy input. Nucleation of solutes
inside the crystallizers occurs in response to the
formation of the supersaturated solution.
 Design Selection
Since the solution is a mixture of water and sodium
chloride wherein the solubility temperature
variation is small, it can be separated by
evaporative crystallization (Tavare, N.S.,1994). The
crystal size is not controlled, which best suit for the
force circulation evaporative crystallizer. The
material of construction used is 316 L stainless steel
which is best suited for sodium chloride.
 Design Selection
Since the solution is a mixture of water and sodium
chloride wherein the solubility temperature
variation is small, it can be separated by
evaporative crystallization (Tavare, N.S.,1994). The
crystal size is not controlled, which best suit for the
force circulation evaporative crystallizer. The
material of construction used is 316 L stainless steel
which is best suited for sodium chloride.
Data and Assumptions
1. 1. Reynolds Number is equal to 5 x 106 to
satisfy the flow similarity criterion (Newman and
Bennett, 1959)
2. 2. Overall Heat Transfer Coefficient is 2
kW/m2-K
3. 3. Volume of the cone is 40 m3
4. 4. Volume of external loop is 40 m3
Data and Assumptions
1. 5. Inlet and Outlet velocity is equal
2. 6. Assume Ideal Conditions
Design Considerations
1. 1. Height of vapor space is 0.75 times the
diameter of the evaporator body (Tavare, N.S.)
 Parts of Crystallizer
Heat Exchanger
The heat exchanger
Crystallizer Body heats the feed inlet
and recycled stream
Condenser
before entering the
Circulation Pump crystallizer body
 Parts of Crystallizer
Heat Exchanger
The crystallizer body
Crystallizer Body is where the
crystallization occurs
Condenser

Circulation Pump
 Parts of Crystallizer
Heat Exchanger The condenser
Crystallizer Body
condenses the vapor.
The condensed vapor
Condenser and the non
condensable is
Circulation Pump
removed
 Parts of Crystallizer
Heat Exchanger The circulation pump
Crystallizer Body
is used to feed the
slurry through the
Condenser heat exchanger and
in to the crystallizer
Circulation Pump
body.
Parts of Crystallizer
 Design Requirements
1. Energy input requirement
2. Circulation rate
3. Diameter of the vessel body
4. Inlet velocity
5. Crystallizer inlet diameter
8. Crystallizer outlet diameter
7. Inlet temperature of the brine
 Design Requirements
8. Minimum height required
9. Volume of the vessel
10. Total residence time
11. Heat transfer Area
 Design Calculations
Mass Balance

=+
( )
=

(20 /)(1.3 )
= 3 = 104 /
0.250 /3
 Design Calculations
Mass Balance

=+

= =

20 /
= = 74 /
0.27 /
 Design Calculations
Mass Balance

=+

= 104 + 74 = 178 /

 Design Calculations
Energy Input Requirement

= +

= 178 3290 55 20


+74 /(2400000 )

 Design Calculations
Energy Input Requirement

= +

= 1.98 = 55000 = 73 756.215 hp

 Design Calculations
Circulation rate

=

1.98 /
=

1300 /3 (2.7 )(4)

 Design Calculations
Circulation rate

=

= 14100 3 /
 Design Calculations
Diameter of the Evaporator Body

0.68

0.5

0.68 74 1000
=
0.5
0.0687 3 3600

 Design Calculations
Diameter of the Evaporator Body

0.68

0.5
= 7.3
* = = 0.75
 Design Calculations
Inlet Velocity

=

6
5 10 (0.0023 )
=
1300 /3 (7.3 )

= 1.21 /
 Design Calculations
Crystallizer Inlet Diameter

4
=
2
3
4(14100 )

=
2(1.21 )(3600 )

 Design Calculations
Crystallizer Inlet Diameter

4
=
2

= 1.43
 Design Calculations
Inlet temperature of Brine

= 55 + 2 + 4 = 61
At this temperature the vapor pressure is 20.86 kPa
=
= 20.86 10

= 10.86
 Design Calculations
Static head (at 1300 kg/m3)
10.86
=
1.300 /3 (9.8067 / 2 )

= 0.85
 Design Calculations
Minimum Height required

= + + +
= 0.85 + 1.43 + .75 7.3 + 0.5

= 8.25
 Design Calculations
Minimum liquor holdup (volume)

2
= + + 0.5 +
4
+

= 7.3 2 0.85 + 1.43 + 0.5 + 40 + 40
4
= 200 3
 Design Calculations
Total residence time

0 =

3
200 0.250 3
0 =

20

0 = 2.5
 Design Calculations
Heat transfer Area

=

ln

61 57
=
66 57
ln
66 61
= 8.5
 Design Calculations
Heat transfer Area

=

2
55000
= 3235 =

2 2 8.5

 Design Specifications
CRYSTALLIZER
Identification
Number of Unit 1
Material Handled Sodium chloride solution
Residence Time 2.5 hours
Materials of Construction 316L Stainless Steel
 Design Specifications
Design Data
Energy input 73 756.215 hp
Circulation rate 14 100 m3/hour
Diameter of the vessel 7.3 m
body
Crystallizer inlet diameter 1.43 m
Crystallizer outlet 1.69 m
diameter
 Design Specifications
Inlet brine temperature 61oC
Height of cylinder 8.25 m
Volume of Crystallizer 200 m3
Heat Transfer Area 3235 m3
Auxiliary Parts
Heat exchanger, Condenser