The shape of a crystalline organic solid has a major impact on its downstream processing and on its end-product quality, issues that are becoming increasingly important in the specialty and fine chemical, as well as the pharmaceutical and life science, industries. Though it is widely known that impro®ed crystal shapes can be achie®ed by ®ary-( ) ing the conditions of crystallization such as sol®ent type and impurity le®els , there is far less understanding of how to effect such a change. Until recently, most methods for predicting crystal shapes were based exclusi®ely on the internal crystal structure, and hence could not account for sol®ent or impurity effects. New approaches, howe®er, offer the possibility of accurately predicting the effects of sol®ents. Models for predicting crystal shape are re®iewed, as well as their utility for process and product design.
IntroductionIn the chemical process industries, numerous organic ma-Ž terials are purified by solid-liquid separation such as adipic . acid, ibuprofen, and bisphenol A . Many of them, in particular specialty chemicals such as pharmaceuticals, are crystallized from solution. As with other separation techniques, the product purity is the primary measure of product quality. However, unlike other separations, solution crystallization produces materials with specific crystal shapes and size distributions, variables that have a substantial impact on downstream processing and product performance.The effects of crystal size and shape on solids processes are far reaching. They influence the rate at which material Ž . can be processed such as filtering, washing, and drying , as well as physical properties such as bulk density, mechanical strength, and wettability. Storage and handling characteristics, the ease with which solids flow, and the extent of dust formation are all, to some extent, a function of crystal morphology; so is the dispersibility and stability of crystals in suspension, which is important for materials, such as pigments, that are eventually formulated as colloids.Crystal morphology also plays a role in the quality and efficacy of solid dose pharmaceuticals. Crystals of different Ž shapes have different bioa®ailabilities rate and extent of adsorption in the human bodyᎏthis is often determined by the . dissolution rates of different crystal faces , in which case Correspondence concerning this article should be addressed to M. F. Doherty.shape must be controlled for both medical and regulatory Ž . purposes Romero et al., 1991 . Crystal morphology also affects the ease with which the drug is compressed into tablets Ž . Gordon and Amin, 1984 . Both are key factors in the pro-Ž cess efficiency and product quality of pharmaceuticals York, .
.The significant impact that crystal size and shape have on crystallization processes requires that they, along with product purity, be tightly controlled. To handle composition and size distribution, there is a plethora of modeling and design Ž . techniques Tavare, 1995;Bermingham et al., 2000 . The phase behavior ...