Crystallization

Applications of simulation and modelling

"We reduced batch time by 20%" (Purac Biochem)

"We increased median crystal size from 350 to 415 µm" (Purac Biochem)

Advanced Process Modelling is used to enhance design and operation through the use of quantitative predictive information based on a combination of fundamental physics and validation against experimental data.

This leads to improved product quality and throughput and lower production costs, and hence enhanced revenues.

There are numerous other financial benefits from the application of modelling, including 'soft' benefits such as the greater understanding of processes.

PSE has experience in the model-based design and operation of a wide variety of crystallisation processes – batch, semi-batch and continuous, for a wide variety of products in all process industry sectors.

Examples of application

A subset of PSE's modelling experience is shown in the table below. Click on the highlighted rows for more details.

Company	Products	Process type	Objective & benefits
Kemira Oy	Potassium dihydrogen phosphate (KH₂PO₄)	Batch evaporative	Optimal recipe generation
Major petrochemical co	Terephthalic acid	Continuous multi-stage flash cooling	Process optimisation; reduction in volume fraction of coarse crystals
Roquette	Dextrose	Continuous cooling	Process optimisation; reduction in fouling
Japanese chemical company	Confidential	Large-scale continuous multi-stage	Significant increase in quality and throughput; c. $10m/year increase in profitability of unit
Major UK pharmaceuticals	Confidential	Batch cooling	Scale-up crystallisation process for an Active Pharmaceutical Ingredient (API)
Danisco	Sucrose	Batch evaporative	Operator training
DSM	Confidential	Large-scale continuous with solid-liquid separation	Debottlenecking
PURAC	Lactitol monohydride	Batch cooling/evaporative	Process optimisation; implementation of Model-based Predictive Control; reduced batch time
Mining company	Sodium Nitrate	Cyclic continuous	Optimal seeding policy and locations
US consumer products company	Personal hygiene product	Mixing of different temperature streams	Enhance product uniformity and overall quality
Dutch dairy company	Lactose	Batch cooling	Reduce batch-to-batch variability; extend range of production grades