The influence of mechanical energy on primary nucleation of butyl paraben has been investigated through 1320 cooling crystallization experiments. The induction time has been measured at different supersaturations, temperatures, and levels of mechanical energy input, in two different flow systems. There is an overall tendency in the experiments that primary nucleation is promoted by increased input of mechanical energy. In small vials agitated by magnetic stir bars, the induction time was found to decrease with increasing agitation power input raised to 0.2 in the low agitation region. However, further increase in agitation leads to an increase again in the induction time. In a concentric cylinder apparatus of Taylor−Couette flow type, the induction time is inversely related to the shear rate. By fitting the parameters of the classical nucleation theory to experimental data, it is shown that the results can be explained as an influence on the pre-exponential factor. The treatment behind the pre-exponential factor is extended to account for the contribution of forced convection in a solution exposed to agitation and fluid shear. However, the analysis cannot verify that increased rate of mass transfer can explain the results. Alternative mechanisms are discussed based on a comprehensive review of the relevant literature. Shear-induced molecular alignment and in particular agitation-enhanced cluster aggregation are mechanisms that appear to deserve further attention.
■ INTRODUCTIONCrystallization processes are of significant importance to our society in industrial production of metallurgic and polymeric materials, and of inorganic and organic compounds; in the formation of shells and bone structures in nature; and in diseases such as the appearance of kidney stones and precipitates of amyloid proteins. In the industrial production of pharmaceutical compounds, crystallization is repeatedly used to separate and purify intermediates and is of major importance for the purification of the final product. Primary nucleation denotes the formation of a new particle in the solution, having a size sufficient for it to be thermodynamically stable at the prevailing conditions. Crystal nucleation has a governing influence on product properties and robustness of the process but is the mechanism of crystallization that is the least understood. This leads to significant problems in the design, operation, and control of industrial processes. Nucleation behavior is known to be unreliable and case sensitive. Because of this, industrial processes are developed by trial and error, and they often lack sufficient robustness. Sometimes lack of reproducibility requires rework or even disposal of the batch. The slow development of the fundamental understanding of primary nucleation is due to the nanoscale size range, the very strong nonlinear dependence on the supersaturation, and the significant stochastic component.The earliest evidence on the effect of mechanical stimulus on primary nucleation can be traced to the beginning of the 20th cent...