Choosing a solvent
and an antisolvent for a new crystallization
process is challenging due to the sheer number of possible solvent
mixtures and the impact of solvent composition and crystallization
temperature on process performance. To facilitate this choice, we
present a general computer aided mixture/blend design (CAM
b
D) formulation for the design of optimal solvent mixtures for the
crystallization of pharmaceutical products. The proposed methodology
enables the simultaneous identification of the optimal process temperature,
solvent, antisolvent, and composition of solvent mixture. The SAFT-γ
Mie group-contribution approach is used in the design of crystallization
solvents; based on an equilibrium model, both the crystal yield and
solvent consumption are considered. The design formulation is implemented
in gPROMS and applied to the crystallization of lovastatin and ibuprofen,
where a hybrid approach combining cooling and antisolvent crystallization
is compared to each method alone. For lovastatin, the use of a hybrid
approach leads to an increase in crystal yield compared to antisolvent
crystallization or cooling crystallization. Furthermore, it is seen
that using less volatile but powerful crystallization solvents at
lower temperatures can lead to better performance. When considering
ibuprofen, the hybrid and antisolvent crystallization techniques provide
a similar performance, but the use of solvent mixtures throughout
the crystallization is critical in maximizing crystal yields and minimizing
solvent consumption. We show that our more general approach to rational
design of solvent blends brings significant benefits for the design
of crystallization processes in pharmaceutical and chemical manufacturing.