High-speed observation of the effects of ultrasound on liquid mixing and agglomerated crystal breakage processes

Sonofragmentation of Organic Molecular Crystals vs Strength of Materials

Mechanochemistry, the interface between the chemical and the mechanical worlds, includes the relationship between the chemical and mechanical properties of solids. In this work, fragmentation of organic molecular crystals during ultrasonic irradiation of slurries has been quantitatively investigated. This has particular relevance to nucleation processes during sonocrystallization, which is increasingly used in the processing and formulation of numerous pharmaceutical agents (PAs). We have discovered that the rates of sonofragmentation are very strongly correlated with the strength of the materials (as measured by Vickers hardness and Young's modulus). This is a mechanochemical extension of the Bell-Evans-Polanyi Principle or Hammond's Postulate: the kinetics (i.e., rates) of solid fracture correlate with thermodynamic properties of solids (e.g., Young's modulus). The mechanism of the particle breakage is consistent with a direct interaction between the shockwaves or localized microjets created by the ultrasound (through acoustic cavitation) and the solid particles in the slurry. Comparisons of the sonofragmentation patterns of ionic and molecular crystals showed that ionic crystals are more sensitive to sonofragmentation than molecular crystals for a given Young's modulus. The rates of sonofragmentation are proposed to correlate with the types and densities of imperfections in the crystals.

Sonocrystallisation of ZIF-8 in water with high excess of ligand: Effects of frequency, power and sonication time

A systematic study on the sonocrystallisation of ZIF-8 (zeolitic imidazolate framework-8) in a water-based system was investigated under different mixing speeds, ultrasound frequencies, calorimetric powers and sonication time. Regardless of the synthesis technique, pure crystals of ZIF-8 with high BET (Brunauer, Emmett and Teller) specific surface area (SSA) can be obtained in water after only 5 s. Furthermore, 5 s sonication produced even smaller crystals (~0.08 µm). The type of technique applied for producing the ZIF-8 crystals did not have any significant impact on crystallinity, purity and yield. Crystal morphology and size were affected by the use of ultrasound and mixing, obtaining nanoparticles with a more spherical shape than in silent condition (no ultrasound and mixing). However, no specific trends were observed with varying frequency, calorimetric power and mixing speed. Ultrasound and mixing may have an effect on the nucleation step, causing the fast production of nucleation centres. Furthermore, the BET SSA increased with increasing mixing speed. With ultrasound, the BET SSA is between the values obtained under silent condition and with mixing. A competition between micromixing and shockwaves has been proposed when sonication is used for ZIF-8 production. The former increases the BET SSA, while the latter could be responsible for porosity damage, causing a decrease of the surface area.

Behaviors and physical mechanism of ceftezole sodium de-agglomeration driven by ultrasound

Ultrasound-mediated method, which can effectively disperse agglomerates or even eliminate agglomeration, has received more and more attentions in industrial crystallization. However, the ultrasound-mediated de-agglomeration mechanism has not been well understood, and no general conclusions have been drawn. In this study, the crystallization and de-agglomeration process of ceftezole sodium agglomerates under ultrasound irradiation were systematically investigated. Kapur function was selected to investigate the de-agglomeration process under different ultrasonic powers. The results revealed that ultrasound could efficiently inhibit agglomeration. Besides, the de-agglomeration of large sized agglomerate particles was found to be easier to occur in comparison with small sized particles due to its higher specific breakage rate. Finally, the de-agglomeration mechanism under ultrasonic irradiation was proposed on the basis of the calculated cumulative breakage functions.

A review on possible mechanisms of sonocrystallisation in solution

Sonocrystallisation is the application of ultrasound to the crystallisation process. The benefits obtained by sonication have been widely studied since the beginning of the 20th century and so far it is clear that ultrasound can be a very useful tool for enhancing crystallisation and controlling the properties of the final product. Crystal size, polymorphs, purity, process repeatability and lower induction time are only some of the advantages of sonocrystallisation. Even though the effects of sonication on crystallisation are quite clear, the physical explanation of the phenomena involved is still lacking. Is the presence of cavitation necessary for the process? Or is only the bubbles surface responsible for enhancing crystallisation? Are the strong local increases in pressure and temperature induced by cavitation the main cause of all the observed effects? Or is it the strong turbulence induced in the system instead? Many questions still remain and can only be appreciated with an understanding of the complexity behind the individual processes of crystallisation and acoustic cavitation. Therefore, this review will first summarise the theories behind crystallisation and acoustic cavitation, followed by a description of all the current proposed sonocrystallisation mechanisms, and conclude with an overview on future prospects of sonocrystallisation applications.

Effect of ultrasound on bubble-particle interaction in quartz-amine flotation system

In this study, the effect of ultrasound (US) on the quartz-amine flotation system was investigated in detail by considering various surface chemistry techniques. The effect of ultrasound on particle size, shape factor, and surface roughness were characterized by using Brunauer-Emmett-Teller (BET) surface area measurements and scanning electron microscopy (SEM) analyses. The contact angle and bubble-particle attachment time, as well as adsorption density measurements was carried out to evaluate the effect of ultrasound on quartz surface wetting ability. In addition, atomic force microscopy (AFM) analyses were conducted, and finally micro-flotation studies were performed. As a result, it was found that the micro-flotation recovery at 2 × 10^-5 M dodecyl amine hydrochloride (DAH) concentration increased from 45.45% to 63.64% with 30 W ultrasonic application at conditioning step. However, the micro-flotation recovery decreased to 37.50% when the ultrasonic power increased to 150 W. The results showed some effect of ultrasound on particle size, particle shape, and surface roughness in some extent. The increase in the contact angle and the decrease in the bubble-particle attachment time were observed. A slightly high adsorption density was measured. All these show a positive effect of ultrasound on quartz flotation with amine as a collector.

In situ observation of ultrasonic cavitation-induced fragmentation of the primary crystals formed in Al alloys

The cavitation-induced fragmentation of primary crystals formed in Al alloys were investigated for the first time by high-speed imaging using a novel experimental approach. Three representative primary crystal types, Al₃Ti, Si and Al₃V with different morphologies and mechanical properties were first extracted by deep etching of the corresponding Al alloys and then subjected to ultrasonic cavitation processing in distilled water. The dynamic interaction between the cavitation bubbles and primary crystals was imaged in situ and in real time. Based on the recorded image sequences, the fragmentation mechanisms of primary crystals were studied. It was found that there are three major mechanisms by which the primary crystals were fragmented by cavitation bubbles. The first one was a slow process via fatigue-type failure. A cyclic pressure exerted by stationary pulsating bubbles caused the propagation of a crack pre-existing in the primary crystal to a critical length which led to fragmentation. The second mechanism was a sudden process due to the collapse of bubbles in a passing cavitation cloud. The pressure produced upon the collapse of the cloud promoted rapid monotonic crack growth and fast fracture in the primary crystals. The third observed mechanism was normal bending fracture as a result of the high pressure arising from the collapse of a bubble cloud and the crack formation at the branch connection points of dendritic primary crystals. The fragmentation of dendrite branches due to the interaction between two freely moving dendritic primary crystals was also observed. A simplified fracture analysis of the observed phenomena was performed. The specific fragmentation mechanism for the primary crystals depended on their morphology and mechanical properties.

Intensified oxalic acid crystallization using ultrasonic reactors: Understanding effect of operating parameters and type of ultrasonic reactor

The present work reports the comparison of the effectiveness of ultrasonic bath and horn for intensifying the cooling crystallization of oxalic acid for the first time. The effect of various parameters such as temperature, crystallization time, irradiation time, ultrasonic frequency and ultrasonic power on the crystal characteristics has been investigated. The average particle size of oxalic acid crystals reduced with an increase in irradiation time and ultrasonic power dissipation. Comparison of crystal characteristics obtained in ultrasonic bath with that obtained in the ultrasonic horn under optimized parameters revealed that the average size in the case of ultrasonic horn and bath were only marginally different. The studies related to the effect of different cooling modes using ultrasonic horn revealed that a narrow size distribution and lower average size of 357.2µm was obtained for the cooling using ice cold water as compared to air cooling where observed mean size was 439.7µm. A narrow particle size distribution was also obtained in the scale-up studies using ultrasound horn with mean size of 96.70µm, which was significantly lower than 161.1µm obtained under conventional approach. Overall significant process intensification benefits have been established for the ultrasound assisted approach for cooling crystallization of oxalic acid.

Ultrasonic reactivation of phosphonate poisoned calcite during crystal growth

The effect of ultrasonic irradiation (42,150 Hz, 17 W dm(-3)/7.1 W cm(-2)) on the growth of calcite in the presence of the inhibitor nitrilotris(methylene phosphonic acid) (NTMP) was investigated at constant composition conditions. In seeded growth experiments, it was found that the inhibiting effect of NTMP on crystal growth could be seriously mitigated under influence of ultrasonic irradiation. An approximately twofold increase in volumetric growth rate was achieved during ultrasonic irradiation, and recovery of the growth rate following inhibition was strongly enhanced compared to growth experiments without ultrasonic irradiation. The results could be explained in part by the physical effect of ultrasound that causes breakage and attrition of poisoned crystals, which resulted in an increase in fresh surface area. Mass spectroscopy analysis of sonicated NTMP solutions revealed that there is also a chemical effect of ultrasound that plays an important role. Several breakdown products were identified, which showed that ultrasound caused the progressive loss of phosphonate groups from NTMP, probably by means of physicochemically generated free radicals and/or pyrolysis in the hot bubble-bulk interface.

Visualization of acoustic cavitation effects on suspended calcite crystals

The acoustic cavitation (42,080 Hz, 7.1 W cm(-2) or 17 W) effects on suspended calcite crystals, sized between 5 and 50 μm, have been visualized for the first time using high speed photography. High speed recordings with a duration of 1 s containing up to 300,000 frames per second, revealed the effect of cluster and streamer cavitation on several calcite crystals. Cavitation clusters, evolved from cavitation inception and collapse, caused attrition, disruption of aggregates and deagglomeration, whereas streamer cavitation was observed to cause deagglomeration only. Cavitation on the surface gave the crystals momentum. However, it is shown that breakage of accelerated crystals by interparticle collisions is unrealistic because of their small sizes and low velocities. Crystals that were accelerated by bubble expansion, subsequently experienced a deceleration much stronger than expected from drag forces, upon bubble collapse. Experiments with pre-dried crystals seemed to support the current theory on bubble nucleation through the presence of pre-existing gas pockets. However, experiments with fully wetted crystals also showed the nucleation of bubbles on the crystal surface. Although microjet impingement on the crystal surface could not be directly visualized with high speed photography, scanning electron microscopy (SEM) analysis of irradiated calcite seeds showed deep circular indentations. It was suggested that these indentations might be caused by shockwave induced jet impingement. Furthermore, the appearance of voluminous fragments with large planes of fracture indicated that acoustic cavitation can also cause the breakage of single crystal structures.