Selective product crystallization for separation and
recycling
of homogeneous catalysts represents one novel promising method to
develop sustainable chemical processes. This specific application
holds two main challenges: (1) In the crystallization and subsequent
filtration and washing process, isolation of a pure crystalline product
is required to obtain the maximum quantity of catalyst in the filtrate
for recycling, and (2) the entire process must be operated in an inert
atmosphere to maintain the catalytic activity of oxygen-sensitive
species. Key to the isolation of a pure product is precise control
of the crystallization process, which is realized in this work by
gassing-induced nucleation using inert argon. Assuming that the nucleation
step is crucial for the control of particle properties of the crystalline
product and the related efficiency of downstream separation by filtration
and washing, we systematically investigated the effect of controlled
nucleation by gassing on these quantities using the oleo-chemical
model system, 1,12-dimethyl dodecanedioate/methanol. The experimental
results verify that by gassing with argon, the nucleation step can
be initiated at lower supersaturation compared to uncontrolled cooling
crystallization with spontaneous nucleation despite the comparably
small metastable zone width of the investigated model system in the
range of 1–3 K. It is further demonstrated that consequently
less nuclei are formed that grow to larger product crystals, which
can be more efficiently separated from the mother liquor in the filtration
and washing step, reducing the mother liquor leaching to the isolated
product to nearly 100 ppm. Finally, it is verified that gassing crystallization
with argon offers a considerable benefit for the isolation of a pure
crystalline product while maintaining inert operating conditions required
for recycling of oxygen-sensitive catalysts.