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Leeming R, Mahmud T, Roberts KJ, George N, Webb J, Simone E, Brown CJ. Development of a Digital Twin for the Prediction and Control of Supersaturation during Batch Cooling Crystallization. Ind Eng Chem Res 2023; 62:11067-11081. [PMID: 37484628 PMCID: PMC10360059 DOI: 10.1021/acs.iecr.3c00371] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/06/2023] [Revised: 06/20/2023] [Accepted: 06/20/2023] [Indexed: 07/25/2023]
Abstract
Fine chemicals produced via batch crystallization with properties dependent on the crystal size distribution require precise control of supersaturation, which drives the evolution of crystal size over time. Model predictive control (MPC) of supersaturation using a mechanistic model to represent the behavior of a crystallization process requires less experimental time and resources compared with fully empirical model-based control methods. Experimental characterization of the hexamine-ethanol crystallization system was performed in order to collect the parameters required to build a one-dimensional (1D) population balance model (PBM) in gPROMS FormulatedProducts software (Siemens-PSE Ltd.). Analysis of the metastable zone width (MSZW) and a series of seeded batch cooling crystallizations informed the suitable process conditions selected for supersaturation control experiments. The gPROMS model was integrated with the control software PharmaMV (Perceptive Engineering Ltd.) to create a digital twin of the crystallizer. Simulated batch crystallizations were used to train two statistical MPC blocks, allowing for in silico supersaturation control simulations to develop an effective control strategy. In the supersaturation set-point range of 0.012-0.036, the digital twin displayed excellent performance that would require minimal controller tuning to steady out any instabilities. The MPC strategy was implemented on a physical 500 mL crystallizer, with the simulated solution concentration replaced by in situ measurements from calibrated attenuated total reflection-Fourier transform infrared (ATR-FTIR) spectroscopy. Physical supersaturation control performance was slightly more unstable than the in silico tests, which is consistent with expected disturbances to the heat transfer, which were not specifically modeled in simulations. Overall, the level of supersaturation control in a real crystallizer was found to be accurate and precise enough to consider future adaptations to the MPC strategy for more advanced control objectives, such as the crystal size.
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Affiliation(s)
- Ryan Leeming
- School
of Chemical and Process Engineering, University
of Leeds, Leeds LS2 9JT, U.K.
| | - Tariq Mahmud
- School
of Chemical and Process Engineering, University
of Leeds, Leeds LS2 9JT, U.K.
| | - Kevin J. Roberts
- School
of Chemical and Process Engineering, University
of Leeds, Leeds LS2 9JT, U.K.
| | - Neil George
- Syngenta, Jealott’s Hill, Bracknell RG42 6EY, U.K.
| | | | - Elena Simone
- Department
of Applied Science and Technology, Politecnico
di Torino, Torino 10129, Italy
| | - Cameron J. Brown
- CMAC
Future Manufacturing Research Hub, University
of Strathclyde, Glasgow G1 1RD, U.K.
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Zhang F, Shan B, Wang Y, Zhu Z, Yu ZQ, Ma CY. Progress and Opportunities for Utilizing Seeding Techniques in Crystallization Processes. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00103] [Citation(s) in RCA: 15] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Fangkun Zhang
- College of Automation and Electronic Engineering, Qingdao University of Science & Technology, Qingdao, 266061, P. R. China
| | - Baoming Shan
- College of Automation and Electronic Engineering, Qingdao University of Science & Technology, Qingdao, 266061, P. R. China
| | - Yinglong Wang
- College of Chemical Engineering, Qingdao University of Science and Technology, Qingdao, 266061, P. R. China
| | - Zhaoyou Zhu
- College of Chemical Engineering, Qingdao University of Science and Technology, Qingdao, 266061, P. R. China
| | - Zai-Qun Yu
- Institute of Chemical & Engineering Sciences, Agency for Science, Technology and Research (A*STAR), 1 Pesek Road, Jurong Island, Singapore 627833
| | - Cai Y. Ma
- Centre for the Digital Design of Drug Products, School of Chemical and Process Engineering, University of Leeds, Leeds, LS2 9JT, United Kingdom
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Unno J, Kawase H, Kaneshige R, Hirasawa I. Estimation of Kinetics for Batch Cooling Crystallization by Focused‐Beam Reflectance Measurements. Chem Eng Technol 2019. [DOI: 10.1002/ceat.201800646] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Affiliation(s)
- Joi Unno
- Waseda Daigaku Riko GakujutsuinDepartment of Applied Chemistry 3-4-1 Okubo, Shinjuku 169-8555 Tokyo Japan
| | - Hiroki Kawase
- Waseda Daigaku Riko GakujutsuinDepartment of Applied Chemistry 3-4-1 Okubo, Shinjuku 169-8555 Tokyo Japan
| | - Reiya Kaneshige
- Waseda Daigaku Riko GakujutsuinDepartment of Applied Chemistry 3-4-1 Okubo, Shinjuku 169-8555 Tokyo Japan
| | - Izumi Hirasawa
- Waseda Daigaku Riko GakujutsuinDepartment of Applied Chemistry 3-4-1 Okubo, Shinjuku 169-8555 Tokyo Japan
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Qian H, Dai L, Jiang F, Shi Y, Wang Z, Liu W, Huang D, Chen W. Quantitative Design of Seed Load Based on model identification of nucleation and crystal growth stages without transmittance data. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.05.008] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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Wu S, Shen H, Li K, Yu B, Xu S, Chen M, Gong J, Hou BH. Agglomeration Mechanism of Azithromycin Dihydrate in Acetone–Water Mixtures and Optimization of the Powder Properties. Ind Eng Chem Res 2016. [DOI: 10.1021/acs.iecr.5b04437] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Songgu Wu
- School of Chemical Engineering and Technology,
State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Huan Shen
- School of Chemical Engineering and Technology,
State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Kangli Li
- School of Chemical Engineering and Technology,
State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Bo Yu
- School of Chemical Engineering and Technology,
State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Shijie Xu
- School of Chemical Engineering and Technology,
State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Mingyang Chen
- School of Chemical Engineering and Technology,
State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Junbo Gong
- School of Chemical Engineering and Technology,
State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Bao hong Hou
- School of Chemical Engineering and Technology,
State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
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Imura N, Hirasawa I. Solubility Characteristics and Crystallization Behavior of Oxalic Acid in the Presence of Sulfuric Acid. Chem Eng Technol 2015. [DOI: 10.1002/ceat.201400710] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
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Hrkovac M, Kardum JP, Ukrainczyk N. Influence of NaCl on Granulometric Characteristics and Polymorphism in Batch-Cooling Crystallization of Glycine. Chem Eng Technol 2014. [DOI: 10.1002/ceat.201400462] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
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