The development of
robust process scale-up involves a clear understanding
of mixing hydrodynamics in crystallization. In the present work, particle
imaging velocimetry (PIV) was used to determine the fluid turbulent
shear stress (TSS) as a function of scale-up involving cooling
crystallization experiments at different agitation rates. At a given
scale, with increased agitation rate from 300 to 370 rpm, the secondary
nucleation threshold (SNT) and product mean particle size were observed
to decrease due to increased TSS. In nuclei breeding, the nucleated
crystals at the seed surface are readily sheared off by the increased
fluid shear stress. This catalytic process enhanced the rate of secondary
nucleation, and hence a decrease in SNT. The SNT and mean particle
size increased with scale size due to a decrease in average turbulent
dissipation rate which resulted from a decrease in TSS. Secondary
nucleation due to nuclei breeding was found to have a quantitative
link with TSS. This resulted in a constant SNT under the influence
of the same TSS which led to a consistent particle size distribution
(PSD), independent of the scale. The presented approach shows that
a controlled PSD can be obtained across different crystallization
scales by controlling secondary nucleation through hydrodynamics.