Conceptual
methods are illustrated for the development of operating
policies for batch reactive crystallization processes. Two processes,
production of barium sulfate and production of l-glutamic
acid, are studied. For barium sulfate, the critical seed loading ratio
is found to be above the practical limit, which suggests that seeding
cannot be employed to suppress nucleation. Conversely, for l-glutamic acid, the critical seed loading ratio is below the practical
limit for a wide range of seed sizes, suggesting that seeding can
be used to suppress nucleation almost entirely. These results are
verified by rigorous process simulation. Furthermore, for the barium
sulfate process, a plot of nucleation rate B versus
growth rate G is concave, indicating that an early
growth trajectory (with supersaturation highest at the beginning of
the batch) will minimize the nucleated mass, while for the l-glutamic acid process the plot is convex, indicating that a late
growth trajectory will minimize the nucleated mass. These results
are also supported by rigorous simulation and optimization.