Problems, potentials and future of industrial crystallization

X-ray Absorption Spectroscopy as a Process Analytical Technology: Reaction Studies for the Manufacture of Sulfonate-Stabilized Calcium Carbonate Particles

Process analytical technologies are widely used to inform process control by identifying relationships between reagents and products. Here, we present a novel process analytical technology system for operando XAS on multiphase multicomponent synthesis processes based on the combination of a conventional lab-scale agitated reactor with a liquid-jet cell. The preparation of sulfonate-stabilized CaCO3 particles from polyphasic Ca(OH)2 dispersions was monitored in real time by Ca K-edge XAS to identify changes in Ca speciation in the bulk solution/dispersion as a function of time and process conditions. Linear combination fitting of the spectra quantitatively resolved composition changes from the initial conversion of Ca(OH)2 to the Ca(R-SO3)2 surfactant to the ultimate formation of nCaCO3·mCa(R- SO3)2 particles. The system provides a novel tool with strong chemical specificity for probing multiphase synthesis processes at a molecular level, providing an avenue to establishing the relationships between critical quality attributes of a process and the quality and performance of the product.

Applications of Artificial Intelligence and Machine Learning Algorithms to Crystallization

Artificial intelligence and specifically machine learning applications are nowadays used in a variety of scientific applications and cutting-edge technologies, where they have a transformative impact. Such an assembly of statistical and linear algebra methods making use of large data sets is becoming more and more integrated into chemistry and crystallization research workflows. This review aims to present, for the first time, a holistic overview of machine learning and cheminformatics applications as a novel, powerful means to accelerate the discovery of new crystal structures, predict key properties of organic crystalline materials, simulate, understand, and control the dynamics of complex crystallization process systems, as well as contribute to high throughput automation of chemical process development involving crystalline materials. We critically review the advances in these new, rapidly emerging research areas, raising awareness in issues such as the bridging of machine learning models with first-principles mechanistic models, data set size, structure, and quality, as well as the selection of appropriate descriptors. At the same time, we propose future research at the interface of applied mathematics, chemistry, and crystallography. Overall, this review aims to increase the adoption of such methods and tools by chemists and scientists across industry and academia.

Design, Development, and Analysis of an Automated Sampling Loop for Online Monitoring of Chiral Crystallization

Enantiomeric purity is of prime importance for several industries, specifically in the production of pharmaceuticals. Crystallization processes can be used to obtain pure enantiomers in a suitable solid form. However, some process variants inherently rely on kinetic enhancement (preferential crystallization) of the desired enantiomer or on complex interactions of several phenomena (e.g., attrition-enhanced deracemization and Viedma ripening). Thus, a process analytical technology able to measure the enantiomeric composition of both the solid phase and the liquid phase would be valuable to track and eventually control such processes. This study presents the design and development of a novel automated analytical monitoring system that achieves this. The designed setup tracks the enantiomeric excess (ee) using a continuous closed-loop sampling loop that is coupled to a polarimeter and an attenuated total reflection Fourier transform infrared spectroscopy spectrometer. By heating the loop and alternately sampling either the liquid or the suspension, the combination of these measurements allows tracking of the ee of both the liquid and the solid. This work demonstrates a proof of concept of both the experimental and theoretical aspects of the new system.

Insight into the role of hydrochloric acid in the thermodynamics and nucleation kinetics behavior of Arbidol hydrochloride monohydrate from metastable zone widths

Contributions of hydrochloric acid to thermodynamics and nucleation kinetics of AHM were revealed by metastable zone width and modified Sangwal's theory, implying the nucleation rate monotonously increases with increment of hydrochloric acid.

Enhancing the Physiochemical Properties of Puerarin via L-Proline Co-Crystallization: Synthesis, Characterization, and Dissolution Studies of Two Phases of Pharmaceutical Co-Crystals

Puerarin (PUE) is a Chinese traditional medicine known to enhance glucose uptake into the insulin cells to downregulate the blood glucose levels in the treatment of type II diabetes. Nevertheless, the bioavailability of pristine PUE is limited due to its poor solubility and low intestinal permeability. In this work, we demonstrate that the solubility of PUE can be significantly enhanced via its co-crystallization with L-Proline (PRO). Two crystalline phases, namely, the solvate-free form [PUE][PRO] (I) and the solvated form [PUE]₂[PRO]∙EtOH∙(H₂O)₂ (II) are isolated. These two phases are characterized by single-crystal X-ray diffraction (SCXRD), powder X-ray diffraction (PXRD), Fourier-transformed infrared (FT-IR) spectra, nuclear magnetic resonance (NMR), and thermogravimetric analysis in association with differential scanning calorimetry (TGA-DSC). The solubility and dissolution rate of both I and II in water, gastrointestinal tract at pH 1.2, and phosphate buffer at pH 6.8 indicates a nearly doubled increase as compared to the pristine PUE. 3-(4,5-Dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT) assay of pristine PUE, I and II against murine colon cancer cell lines CT-26 and human kidney cell lines HEK-293 indicated that neither compound exhibits obvious cytotoxicity after 24 h. This work showcases that the readily available and biocompatible PRO can be a promising adjuvant to enhance the physicochemical properties of PUE toward orally administered drug formulation with improved pharmacokinetics.

A robust new tool for online solution-phase sampling of crystallizations

Dynamically flushed filter allows for sampling of crystallizations.

Crystallization of paracetamol from mixtures of ethanol and water in a planar oscillatory flow crystallizer: effect of the oscillation conditions on the crystal growth kinetics

Crystal growth kinetic data is reported for a planar oscillatory flow crystallizer.

A Novel Shadowgraphic Inline Measurement Technique for Image-Based Crystal Size Distribution Analysis

A novel shadowgraphic inline probe to measure crystal size distributions (CSD), based on acquired greyscale images, is evaluated in terms of elevated temperatures and fragile crystals, and compared to well-established, alternative online and offline measurement techniques, i.e., sieving analysis and online microscopy. Additionally, the operation limits, with respect to temperature, supersaturation, suspension, and optical density, are investigated. Two different substance systems, potassium dihydrogen phosphate (prisms) and thiamine hydrochloride (needles), are crystallized for this purpose at 25 L scale. Crystal phases of the well-known KH2PO4/H2O system are measured continuously by the inline probe and in a bypass by the online microscope during cooling crystallizations. Both measurement techniques show similar results with respect to the crystal size distribution, except for higher temperatures, where the bypass variant tends to fail due to blockage. Thiamine hydrochloride, a substance forming long and fragile needles in aqueous solutions, is solidified with an anti-solvent crystallization with ethanol. The novel inline probe could identify a new field of application for image-based crystal size distribution measurements, with respect to difficult particle shapes (needles) and elevated temperatures, which cannot be evaluated with common techniques.

Separation and Recycling of Concentrated Heavy Metal Wastewater by Tube Membrane Distillation Integrated with Crystallization

Tube membrane distillation (MD) integrated with a crystallization method is used in this study for the concurrent productions of pure water and salt crystals from concentrated single and mixed system solutions. The effects of concentrated Zn2+ and Ni2+ on performance in terms of membrane flux, permeate conductivity, crystal recovery rates, and crystal grades are investigated. Preferred crystallization and co-crystallization determinations were performed for mixed solutions. The results revealed that membrane fluxes remained at 2.61 kg·m-2·h-1 and showed a sharp decline until the saturation increased to 1.38. Water yield conductivity was below 10 μs·cm-1. High concentrated zinc and nickel did not have a particular effect on the rejection of the membrane process. For the mixed solutions, membrane flux showed a sharp decrease due to the high saturation, while the conductivity of permeate remained below 10 μs·cm-1 during the whole process. Co-crystallization has been proven to be a better method due to the existence of the SO42- common-ion effect. Membrane fouling studies have suggested that the membrane has excellent resistance to fouling from highly concentrated solutions. The MD integrated with crystallization proves to be a promising technology for treating highly concentrated heavy metal solutions.

Enhancing pharmaceutical crystallization in a flow crystallizer with ultrasound: Anti-solvent crystallization

Continuous crystallization is a fast growing application domain in the pharmaceutical industry. Application of ultrasound has been proven to have positive effects like reduction in induction time and Metastable Zone Width (MSZW) in both batch and flow systems. Further understanding of flow-based sonocrystallization is required to achieve industrial level scale up. This work investigates the sonocrystallization of pharmaceutical compounds in a tubular flow crystallizer. Acetyl Salicylic Acid (ASA-Aspirin) is used as a model compound with ethanol and water as solvent and anti-solvent, respectively. Experiments were conducted in silent and sonicated conditions to study the MSZW. Ultrasound made it possible to achieve crystallization within the crystallizer which was not possible in silent conditions, under the tested conditions. Continuous crystallization was achieved at as low as 48 wt% of anti-solvent and crystallization was already seen at a supersaturation of 1.02. In some experiments, temperature rise with ultrasound caused the crystals to re-dissolve within the channels. Better crystallization - no re-dissolution - was achieved by using low ultrasonic power without any loss in the yield. Particle sizes of product crystals were in the range of 4-46 µm. In conclusion, ultrasound was highly effective in enabling anti-solvent crystallization of a pharmaceutical compound in a tubular flow crystallizer.

Liquid Metastable Precursors of Ibuprofen as Aqueous Nucleation Intermediates

The nucleation mechanism of crystals of small organic molecules, postulated based on computer simulations, still lacks experimental evidence. In this study we designed an experimental approach to monitor the early stages of the crystallization of ibuprofen as a model system for small organic molecules. Ibuprofen undergoes liquid–liquid phase separation prior to nucleation. The binodal and spinodal limits of the corresponding liquid–liquid miscibility gap were analyzed and confirmed. An increase in viscosity sustains the kinetic stability of the dense liquid intermediate. Since the distances between ibuprofen molecules within the dense liquid phase are similar to those in the crystal forms, this dense liquid phase is identified as a precursor phase in the nucleation of ibuprofen, in which densification is followed by generation of structural order. This discovery may make it possible to enrich poorly soluble pharmaceuticals beyond classical solubility limitations in aqueous environments.