Secondary nucleation
is the key mechanism behind the creation of
new crystals in industrial crystallization processes. Sodium chlorate
has widely been used throughout literature as a model compound to
study secondary nucleation due to its ability to crystallize as a
chiral solid which makes it feasible to determine whether new crystals
have originated from solution or from a seed crystal. Despite its
widespread use, a significant level of ambiguity regarding sodium
chlorate still exists including inconsistent solubility data, nontransferrable
results between batch and continuous experiments and inconclusive
theories about whether secondary nucleation of sodium chlorate is
possible through fluid shear. In the present work, the inconsistencies
around sodium chlorate are resolved using novel continuous shear-induced
secondary nucleation experiments involving stationary seed crystals.
First, accurate solubility data of sodium chlorate in water was determined
using a laser method and compared with literature data. Second, the
metastable zone width was determined to be surprisingly narrow and
continuous shear-induced secondary nucleation experiments of sodium
chlorate using stationary seed crystals were therefore unsuccessful
as heterogeneous nucleation was favored over secondary nucleation.
This explains why previous continuous secondary nucleation experiments
failed. Finally, it was found that mechanical impact readily created
fines on the seed crystal surface and that the resulting fines acted
as new particles through initial breeding. Based on microscopic analysis
it was observed that a washing step was sufficient to remove fines
from the seed crystal surface. Intriguingly, the resulting seed crystals
without fines failed to induce secondary nucleation. Therefore, fluid
shear was insufficient to disperse secondary nuclei of sodium chlorate.
Overall, the results presented herein reveal a better understanding
of secondary nucleation as the impact of initial breeding is reported
in detail for the first time. Initial breeding significantly contributes
to secondary nucleation and controlling initial breeding is therefore
essential to govern crystallization processes.