Integrated membrane emulsification and solution cooling crystallization to obtain a narrow and predictable crystal size distribution

Prediction of the zeolite crystal size distribution in batchwise hydrothermal synthesis

Crystallization of alpha-lactose monohydrate in a drop-based microfluidic crystallizer

Stability of oil-in-water emulsions produced by membrane emulsification with microporous ceramic membranes

Owing to the rise in population growth and demands for the current living standards, mineral and water resources are depleting at the alarming rate. Also, the mineral–water-energy nexus raises a concern of high-quality water and mineral production at low costs. Membrane distillation crystallization (MDC) has emerged as a promising technology capable of simultaneous water and mineral recovery from wastewater or industrially discharged brines. Herein, the MDC was evaluated for recovery of water and precious minerals from acid mine drainage discharged from the mine tailings. High quality fresh water with 99.9 % salt rejection and permeate flux of 2.32 kg·m−2·h−1 was recovered at 52 °C feed inlet temperature. Also, feed temperatures were varied to determine their impact on mineral crystal morphology, size distribution and growth rate. Predominantly recovered minerals were gypsum, manganese fluoride, potassium iron oxide, nickel oxide hydroxide, sodium sulphate and dihydrogen sulphate. Orthorhombic crystal structure of mineral salts was attained at low feed inlet temperature (34 °C). Higher feed inlet temperatures (i.e. 41° C and 52° C) promoted co-crystallization giving rise to orthorhombic polymorph structures. Narrow crystal size distribution was reported at low water recovery factor (initial growth) for all temperatures. However, the particle size distribution broadened as the recovery factor increased. The crystal sizes ranged from 3.91 ± 0.97 µm to 14.04 ± 3.31. Remarkably, crystal growth rate increased with an increase in feed inlet temperature. These findings open a research direction towards economic recovery of mineral and water to supplement the existing shortages. With a myriad of crystals obtained from the MDC process, an additional operational unit is required to selectively recover high economic minerals.

Segmented microfluidics was applied to the ultrafast crystallization of dicarboxylate based MIL-88B type metal-organic frameworks (MOFs; Fe-MIL-88B-NH2, Fe-MIL-88B, and Fe-MIL-88B-Br). Particular attention was paid to the influence of the temperature, residence time, and slug volume on the size and crystal size distribution of the MOFs. Average sizes in the 90-900 nm range with relatively narrow crystal size distributions were obtained with residence times as short as 20 s depending on the MOF type and synthesis conditions.

Continuous crystallization of levamisole hydrochloride in a segmented flow crystallizer

Crystalline products with a narrow and uniform distribution of crystals by size (CSD), characterized by a desired average size, are necessary in many practices. Therefore, extensive, but mostly experimental, research is devoted to the problem of obtaining such CSDs. Alternatively, this manuscript presents a theoretical approach for calculating CSD resulting from crystallization in unstirred solutions. First, classical equations for the rates of diffusion-controlled and kinetically controlled growth of crystals are used to discuss the size-dependent growth of the nucleated crystals and the initial CSD (which arises from the non-simultaneous nucleation of crystals). Then, applying the law of conservation of matter, it is proved that the CSD continues to expand during the growth stage. Furthermore, it is substantiated that, due to their uneven spatial distribution, crystals of the same size can grow at different rates. This depends on whether the crystals are outside the diffusion fields of other crystals or are clustered together in “nests”. Moreover, by calculating the growth rates of crystals in “nests”, an explanation is given for the observation that closely spaced crystals are smaller in size than the separately growing crystals. Finally, the CSD established during the Ostwald ripening is discussed quantitatively, step-by-step.

The secretome from mesenchymal stem cells (MSCs) has recently gained attention for new therapeutics. However, clinical application requires in vitro cell manufacturing to attain enough cells. Unfortunately, this process often drives MSCs into a senescent state that drastically changes cellular secretion activities. Antioxidants are used to reverse and prevent the propagation of senescence; however, their activity is short-lived. Polymer-stabilized crystallization of antioxidants has been shown to improve bioactivity, but the broad crystal size distribution (CSD) significantly increases the efficacy variation. Efforts were made to crystalize drugs in microdroplets to narrow the CSD, but the fraction of drops containing at least one crystal can be as low as 20%. To this end, this study demonstrates that in-drop thermal cycling of hyaluronic acid-modified antioxidant crystals, named microcrystal assembly for senescence control (MASC), can drive the fraction of microdrops containing crystals to >86% while achieving significantly narrower CSDs (13±3μm) than in bulk (35±11μm). Therefore, this approach considerably improves the practicality of CSD-control in drops. In addition to exhibiting uniform release, MASC made with antioxidizing N-acetylcysteine extended the release time by 40%. MASC further improves the restoration of reactive oxygen species homeostasis in MSCs, thus minimizing cellular senescence and preserving desired secretion activities. We propose that MASC is broadly useful to controlling senescence of a wide array of therapeutic cells during biomanufacturing.

Chitosan and Poly (Vinyl Alcohol) microparticles produced by membrane emulsification for encapsulation and pH controlled release

The ideal requirements for highly efficient evaporative crystallization in batch or semi-batch type operations are a high crystal growth rate, a high density of suspended crystalline particles in a slurry and a sharp crystal size distribution. On the other hand, the initial seed crystal conditions are also very important because they affect the crystal size and distribution during the entire period of operation. In the present study, the influence of seeding conditions (average diameter and mass) and heating rate on both the crystal growth rate of sodium chloride (NaCl) and the crystal size distribution were investigated in an optimal design draft-tube stirred vessel containing high suspension density slurries of sodium chloride particles up to 30 vol%. In order to determine the optimal seeding conditions to simultaneously achieve a high crystal growth rate and narrow size distribution, an optimal operation index Iop has been defined based on a comparison of the experimental data and a model calculation with the assumption of ideal crystal growth. The results show that Iop correlate with the particle number of seed crystals and have a maximum value. With Iop correlation, the appropriate seeding conditions for achieving a high crystal growth rate and sharp size distribution have been determined.

Here, we present physical–chemical properties of Linde type A (LTA) zeolite crystals synthesized via conventional hydrothermal and microwave heating methods. Both heating methods produced LTA crystals that were sub-micron in size, highly negatively charged, super-hydrophilic, and stable when dispersed in water. However, microwave heating produced relatively narrow crystal size distributions, required much shorter heating times, and did not significantly change composition, crystallinity, or surface chemistry. Moreover, microwave heating allowed systematic variation of crystal size by varying heating temperature and time during the crystallization reaction, thus producing a continuous gradient of crystal sizes ranging from about 90 to 300 nm. In ion-exchange studies, colloidal zeolites exhibited excellent sorption kinetics and capacity for divalent metal ions, suggesting their potential for use in water softening, scale inhibition, and scavenging of toxic metal ions from water.

A process was developed for the preparation of strontium titanate powder with a relatively narrow crystal size distribution and an average crystal size ranging from 0.3 to 13.0 μm, as determined from the powder specific surface area.

Membrane distillation crystallization of concentrated salts—flux and crystal formation

Amphipolar diblock copolymers used as admixtures provide a unique effect on crystallization processes from solution. In an example given here, nucleation of ZnO crystals and growth of specific crystal faces is controlled by minute amounts of PEO-b-PMAA copolymers. A narrow crystal size distribution and retardation of growth parallel to [001] are observed in dependence on the concentration of the block copolymer, which is added in the ppm range.

There is currently a significant interest in the production of stable emulsions using particulate emulsifiers. A key design and manufacturing challenge in such systems is the production of emulsions with controlled droplet sizes and narrow polydispersity; one candidate production technique is membrane emulsification. In this study we demonstrate that under optimal conditions, highly stable near monodisperse tricaprylin droplets stabilised with 800 nm silica colloids can be achieved using Rotating Membrane Emulsification (RME). We report the influence of various mechanical and chemical parameters on the droplet sizes and size distributions. The optimal conditions for highly stable emulsions with narrow size distributions using the RME approach are described. Investigating the rotational speed and particle concentration in particular highlights the importance of particle adsorption kinetics onto a growing droplet on the detachment of that droplet from the membrane. The data clearly show that if the particles attach and adsorb to the interface before a critical droplet detachment time, stable monodisperse droplets are produced. However, if the adsorption time takes longer than this critical value, the partially stabilized droplets can coalesce and we observe a wider size distribution.