A unique semibatch crystallization process, coupling with a
high-speed rotor-stator device, was developed for generation
and control of fine particles. The key underlying mechanism
of this process is controlled secondary nucleation under a high
shear environment during crystallization, in contrast to the
conventional particle breakage mechanism, i.e., milling, after
the crystallization. A recycle mode operation is employed to
control the residence time of the batch in the high shear domain
so as to ensure the scalability of this process. In this work, the
operational sensitivity to the supersaturation and particle size
were first explored in the laboratory. Based on the results of
the laboratory investigation, this process was successfully
demonstrated in multiple 1000-L pilot scale production batches.
The practical issues for the large scale operation are also
illustrated.
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