For crystal-impurity systems with
similar structures and molecular
weights, the impurity has a strong tendency to incorporate into the
crystal lattice, making it difficult to obtain high purity with a
single crystallization or even multiple crystallizations. In such
cases, complexation of the impurity with an additive can be used to
sterically prevent impurity incorporation in the host lattice. A nanofiltration
membrane can be used to preferentially reject the higher molecular
weight impurity complex in solution, while allowing the lower molecular
weight API to permeate through. This permeate stream can be concentrated
and recycled to operate the crystallization in a continuous mode with
the aim of enhancing both yield and crystal purity simultaneously.
In the present work, this strategy was applied to the continuous cooling
crystallization of two systems in a mixed-suspension mixed-product
removal (MSMPR) crystallizer from their solutions in 50:50 (by volume)
water–ethanol mixed solvent. The first system consists of benzamide
with 3-nitrobenzoic acid added as an impurity, while the second one
is the active pharmaceutical ingredient (API) ketoprofen containing
two impurities, ibuprofen and α,4-dimethylphenylacetic
acid. A working strategy for selecting the complexing agent and nanofiltration
membrane was established. For both systems, the membrane-coupled continuous
mode with recycle and complexation was found to have a better performance
in terms of higher crystallization yield and lower impurity incorporation
in crystals compared to both the batch process as well as the continuous
process without recycle.