The
mechanisms of purging structurally similar impurities in solution
crystallization have been evaluated using the model compound salicylic
acid. Of the 11 added impurities, 3 showed appreciable entrapment
in the solid phase: viz., salicylamide, anthranilic acid, and benzoic
acid. X-ray powder diffraction (XRPD), differential scanning calorimetry
(DSC), and the use of a previously reported solubility-limited
impurity purge (SLIP) test have shown that the impurities
are entrapped by a lattice incorporation mechanism. Impurities become
integrated within the product crystals during the crystallization
by forming terminal solid solutions. Most of the impurity entrapment
was found to take place very early in the crystallization, immediately
after seeding. The least entrapment occurred at the end of the crystallization,
despite the mother liquor being enriched in impurities. These changes
caused purity variations in the solids, which were not properly captured
by the average value. A mathematic framework was developed to afford
the material impurity distribution (MID), which represents
the mass-based impurity profile across a material based on the SLIP
test. It is shown that the level of impurities in the crystallized
material is far from constant and in fact varies by orders of magnitude,
in many cases by more than 20 times. These differences give rise to
changes in the physical properties of salicylic acid, as exemplified
by a reduction in crystallinity, a lower and broader melting event,
and a doubling of solubility.