Crystal-production process

Crucible-free economic crystal-production process... 

Hybrid Crystallization/Adsorption Process. In 1994, IFP and Chevron announced the development of a hybrid process that reportedly combines the best features of adsorption and crystallization (59,99). In this option of the Eluxyl process, the adsorbent bed is used to initially produce PX of 90—95% purity. The PX product from the adsorption section is then further purified in a small single-stage crystallizer and the filtrate is recycled back to the adsorption section. It is reported that ultrahigh (99.9+%) purity PX can be produced easily and economically with this scheme for both retrofits of existing crystallization units as well as grass-roots units. A demonstration plant was built at Chevron s Pascagoula refinery in 1994. 

Essentially all the ammonium sulfate fertilizer used in the United States is by-product material. By-product from the acid scmbbing of coke oven gas is one source. A larger source is as by-product ammonium sulfate solution from the production of caprolactam (qv) and acrylonitrile, (qv) which are synthetic fiber intermediates. A third but lesser source is from the ammoniation of spent sulfuric acid from other processes. In the recovery of by-product crystals from each of these sources, the crystallization usually is carried out in steam-heated sa turator—crystallizers. Characteristically, crystallizer product is of a particle size about 90% finer than 16 mesh (ca 1 mm dia), which is too small for satisfactory dry blending with granular fertilizer materials. Crystals of this size are suitable, however, as a feed material to mixed fertilizer granulation plants, and this is the main fertilizer outlet for by-product ammonium sulfate. 

The polycrystaUine EGS is converted to siagle-crystal silicon via the C2okralski (CZ) crystal growing process, based on the solidification of silicon atoms from the Hquid phase at a moving iaterface. Volume production of 200-mm diameter crystals is standard. Development of crystals having diameters of up to 400 mm has been predicted (3). 

First Alternative. Figure 1 illustrates the first of the two alternative production processes. Here the mother Hquor from the sodium nitrate crystallization plant, normally containing about 1.5 g/L iodine as iodate, is decanted for clarification and concentration homogenization. From there the solution is spHt into two fractions. The larger fraction is fed into an absorption tower where it is contacted with SO2 obtained by sulfur combustion. In the absorption tower iodate is reduced to iodide according to the following reaction ... 

Insofar as they are used to purify other products, several processes used in the refinery fall under the classification of dewaxing processes however, such processes must also be classified as wax production processes (2). Most commercial dewaxing processes utilize solvent dilution, chilling to crystallize the wax, and filtration (28). The MEK process (methyl ethyl ketone—toluene solvent) is widely used. Wax crystals are formed by chilling through the walls of scraped surface chillers, and wax is separated from the resultant wax—oil—solvent slurry by using fliUy enclosed rotary vacuum filters. 

Aluminum sulfate is a starting material in the manufacture of many other aluminum compounds. Aluminum sulfate from clay could potentially provide local sourcing of raw materials for aluminum production. Processes have been studied (24) and the relative economics of using clay versus bauxite have been reviewed (25). It is, however, difficult to remove impurities economically by precipitation, and purification of aluminum sulfate by crystallization is not practiced commercially because the resulting crystals are soft, microscopic, and difficult to wash effectively on a production scale (26—28). 

Leucrose, 6-0-(a-D-glucopyranosyl)-P-D-fmctopyranose [7158-70-5] is synthesized from sucrose usiag a dextranase enzyme from l euconostoc mesenteriodes and a small proportion of fmctose (2%). Pfeifer Langen of Germany have developed a production process for leucrose that iavolves extraction of the enzyme, treatment with 65% aqueous solution of sucrose and fmctose (1 2 wt/wt) at 25°C, separation of the product from fmctose by ion-exchange column chromatography, and crystallization. The product has not yet been launched on the market as of this writing (1996). 

Several features of the hypothetical system in Eigure 2 can be used to illustrate proper selection of crystallizer operating conditions and limitations placed on the operation by system properties. Suppose a saturated solution at temperature is fed to a crystallizer operating at temperature T. Because the feed is saturated, the weight fraction of in the feed is given as shown in Eigure 2. The maximum crystal production rate from such a process depends on the value of and is given by... 

Thus, methods are now becoming available such that process systems can be designed to manufacture crystal products of desired chemical and physical properties and characteristics under optimal conditions. In this chapter, the essential features of methods for the analysis of particulate crystal formation and subsequent solid-liquid separation operations discussed in Chapters 3 and 4 will be recapitulated. The interaction between crystallization and downstream processing will be illustrated by practical examples and problems highlighted. Procedures for industrial crystallization process analysis, synthesis and optimization will then be considered and aspects of process simulation, control and sustainable manufacture reviewed. 

Figure 9.6 EJfect of process system on crystal product characteristics after Bennett, 1962)...

Rossiter (1986) demonstrated the procedure for the production process of crystalline common salt from brine. It was found that the optimal median size is determined by the entrainment limit in the crystallizer. The crystallizer had to be operated at maximum allowable temperature and the slurry density measured for quality constraints. It was also suggested that cost discontinuities should be imposed based on temperatures of the available heat sources, possible materials of construction and other intrinsic properties of the system. 

In the multistage process described on Fig. 20-14 feed enters one of several crystallizers installed in series. Crystals formed in each crystallizer are transferred to a hotter stage and the liquid collected in the clarified zone of the crystallizer is transferred to a colder stage and eventually discharged as residue. At the hot end, crystals are transferred to a vertical purifier where countercurrent washing is performed by pure, hot-product reflux. TSK refers to this multistage process as the countercurrent cooling crystallization (CCCC) process. In... 

Food products can generally be considered as a mixture of many components. For example, milk, cream and cheeses are primarily a mixture of water, fat globules and macromolecules. The concentrations of the components are important parameters in the food industry for the control of production processes, quality assurance and the development of new products. NMR has been used extensively to quantify the amount of each component, and also their states [59, 60]. For example, lipid crystallization has been studied in model systems and in actual food systems [61, 62]. Callaghan et al. [63] have shown that the fat in Cheddar cheese was diffusion-restricted and was most probably associated with small droplets. Many pioneering applications of NMR and MRI in food science and processing have been reviewed in Refs. [19, 20, 59]. 

The production of memory chips requires highly pure silicon, which is grown as a single crystal (Czochrabki process). 

Crystallization remains the primary means of controlling the polymorphic or solva-tomorphic state of a compound, and various groups have examined the influences of processing parameters on the identity and quality of the isolated form. Seeding was used to reduce the size of the metastable zone of eflucimibe, and thereby control the identity of the desired polymorphic identity of the product through a reduction in concomitant crystallization [16], Process improvements have been developed that were found to improve the filterability and enhance the bulk density of ranitidine Form-1 [17], while the variation of process parameters used in an oscillatory baffled crystallizer enabled better selection to be made between the metastable a- and /i-forms of (z.)-glutamic acid [18]. 

The resulting PI is very novel and useful. It is an important product for your company. The polymer and its production process are relatively new and suffer from several problems, including variability in the quality of the DA monomer. To produce DA monomer, it is crystallized from alcohol using a decolorizing carbon. Last month, your supplier of the carbon-decolorizing agent went out of business, so your company... 

The aim of this section is to provide a generic step by step methodology for the design of a final purification process for a non-salt form API using crystallization. The process objective is to consistently manufacture API of the desired purity and polymorphic form, within the constraints of a typical batch production facility. A brief outline of the analytical techniques that may be required is presented in section 4.6. 

Condensation is generally a transient operation in which, as discussed by Ueda and Takashima(106), simultaneous heat and mass transfer are further complicated by the effects of spontaneous condensation in the bulk gaseous phase. After the creation of supersaturation in the vapour phase, nucleation normally occurs which may be homogeneous in special circumstances, but more usually heterogeneous. This process is followed by both crystal growth and agglomeration which lead to the formation of the final crystal product. As a rate process, the condensation of solids from vapours is less well understood than vaporisation(98). Strickland-Constable(107) has described a simple laboratory technique... 

According to the model, a perturbation at one site is transmitted to all the other sites, but the key point is that the propagation occurs via all the other molecules as a collective process as if all the molecules were connected by a network of springs. It can be seen that the model stresses the concept, already discussed above, that chemical processes at high pressure cannot be simply considered mono- or bimolecular processes. The response function X representing the collective excitations of molecules in the lattice may be viewed as an effective mechanical susceptibility of a reaction cavity subjected to the mechanical perturbation produced by a chemical reaction. It can be related to measurable properties such as elastic constants, phonon frequencies, and Debye-Waller factors and therefore can in principle be obtained from the knowledge of the crystal structure of the system of interest. A perturbation of chemical nature introduced at one site in the crystal (product molecules of a reactive process, ionized or excited host molecules, etc.) acts on all the surrounding molecules with a distribution of forces in the reaction cavity that can be described as a chemical pressure. 

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