Development and Commissioning of a Small-Scale, Modular and Integrated Plant for the Quasi-Continuous Production of Crystalline Particles

Abstract

Increasing global competition, volatile markets and the demand for individual products challenge companies in almost all business sectors and require innovative solutions. In the chemical and pharmaceutical industries, these include modular design, the integration of several unit operations in one apparatus and the development of small-scale, versatile multipurpose plants. An example for such a modular, integrated and small-scale system is the belt crystallizer. This device combines the process steps cooling crystallization, solid-liquid separation and contact drying in a single plant. The basis of the apparatus is a belt filter in which the vacuum trays below the filter medium are replaced by temperature control and filtration units. Due to identical dimensions, it is possible to arrange the individual functional units in any order, which in turn allows a high degree of flexibility and rapid adaptation to customer requirements. Within the scope of the publication, the commissioning of the belt crystallizer takes place. First of all, the general functionality of the plant concept is demonstrated using sucrose as model system. Further experiments show that the particle size and the distribution width of the manufactured crystals can be specifically influenced by the selected process parameters, e.g., temperature profile during cooling and residence time.

From Lab to Pilot Scale: Commissioning of an Integrated Device for the Generation of Crystals

“…The pilot plant used in this work is based on the laboratory-scale belt crystallizer [5,15,18] and includes the process steps crystallization, solid-liquid separation, washing, and drying. The setup is schematically displayed in Fig.…”

“…Furthermore, the integration of several process steps in a single apparatus is attracting more and more research attention. The main advantages are the minimized risk of contamination, the small space requirement, and the elimination of transport equipment [15]. On the one hand, this improves product quality and, on the other hand, reduces acquisition costs.…”

“…On the one hand, this improves product quality and, on the other hand, reduces acquisition costs. Examples from the field of process engineering are the Titus-Nutschen Dryer [16] and the belt crystallizer first discussed in Dobler et al [15]. The latter is a modified belt filter that incorporates the unit operations crystallization, solid-liquid separation, washing, and drying.…”

“…The latter is a modified belt filter that incorporates the unit operations crystallization, solid-liquid separation, washing, and drying. The functionality of the device was demonstrated by experiments with sucrose-water [15].…”

“…So far, all experiments using the belt crystallizer have been carried out on laboratory scale [5,15,18]. Based on the promising results generated in this way, a scale-up to pilot level seems reasonable.…”