The role of ultrasound in pharmaceutical production: sonocrystallization

Extensive investigation of geometric effects in sonoreactors: Analysis by luminol mapping and comparison with numerical predictions

This investigation focuses on the influence of geometric factors on cavitational activity within a 20kHz sonoreactor containing water. Three vessels with different shapes were used, and the transducer immersion depth and liquid height were varied, resulting in a total of 126 experiments conducted under constant driving current. For each one, the dissipated power was quantified using calorimetry, while luminol mapping was employed to identify the shape and location of cavitation zones. The raw images of blueish light emission were transformed into false colors and corrected to compensate for refraction by the water-glass and glass-air interfaces. Additionally, all configurations were simulated using a sonoreactor model that incorporates a nonlinear propagation of acoustic waves in cavitating liquids. A systematic visual comparison between luminol maps and color-plots displaying the computed bubble collapse temperature in bubbly regions was conducted. The calorimetric power exhibited a nearly constant yield of approximately 70% across all experiments, thus validating the transducer command strategy. However, the numerical predictions consistently overestimated the electrical and calorimetric powers by a factor of roughly 2, indicating an overestimation of dissipation in the cavitating liquid model. Geometric variations revealed non-monotonic relationships between transducer immersion depth and dissipated power, emphasizing the importance of geometric effects in sonoreactor. Complex features were revealed by luminol maps, exhibiting appearance, disappearance, and merging of different luminol zones. In certain parametric regions, the luminol bright regions are reminiscent of linear eigenmodes of the water/vessel system. In the complementary parametric space, these structures either combine with, or are obliterated by typical elongated axial structures. The latter were found to coincide with an increased calorimetric power, and are conjectured to result from a strong cavitation field beneath the transducer producing acoustic streaming. Similar methods were applied to an additional set of 57 experiments conducted under constant geometry but with varying current, and suggested that the transition to elongated structures occurs above some amplitude threshold. While the model partially reproduced some experimental observations, further refinement is required to accurately account for the intricate acoustic phenomena involved.

Effect of ultrasonic-induced selenium crystallization behavior during selenium reduction

In this work, the crystallization process of selenium was accelerated by ultrasonic wave. The effects of ultrasonic waves and conventional conditions of selenium crystallization were compared to understand the effects of different conditions on crystallization, including ultrasonic time, ultrasonic power, reduction temperature, and H2SeO3 concentration. The mechanism of ultrasound affecting selenium crystallization was also investigated by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The experimental results showed that ultrasonic time, ultrasonic power, and reduction temperature significantly influenced the crystallization process and morphology of selenium. Ultrasonic time had a large effect on the completeness (all products have been crystallized) and integrity of the crystallization of the products. Meanwhile, ultrasonic power and reduction temperature had no effect on the completeness of crystallization. However, it had a significant effect on the morphology and integrity of the crystallized products, and different morphologies of the nano-selenium materials could be obtained by changing the ultrasonic parameters. Both primary and secondary nucleation are important in the process of ultrasound-accelerated selenium crystallization. The cavitation effect and mechanical fluctuant effects generated by ultrasound could reduce the crystallization induction time and accelerate the primary nucleation rate. The high-speed micro-jet formed in the rupture of the cavitation bubble generated is the most important reason to influence the secondary nucleation of the system.

Solid Features Modification by the Reactor Selection and US Support during Reactive Crystallization

The use of materials requires adjusting their features to current applications/needs. In crystallization, the production methods leading directly to the product with pre-determined characteristics are being sought. The research focuses on the abilities of "shaping" the solid product (CSD, shape, form, etc.) and is based on experimental work carried out in the ultrasound (US)-assisted Koflo static mixer (STM). As the model reaction calcium fluoride precipitation has been used as a "common denominator" that complements the previous authors' studies, providing comprehensive knowledge and a more general look at the mentioned problem. It has been shown that it is possible to obtain crystals with the desired characteristics; however, one should be aware of the used reactors' limitations. The conscious selection of operating conditions, as well as US parameters (if they are used), is also essential. It has been revealed that the introduction of US to the STM only affects the turbulence intensity, but it doesn't change the mixing profile. The kinetics of crystallization remain unchanged, but crystals are subjected to greater attrition. In the stirred tank reactors, one might significantly improve the homogeneity of the unit mixing distribution by the selection of the relative input power ε_rel and, thus, affect the kinetics of crystallization.

Enhanced aqueous dissolution of hydrophobic apixaban via direct incorporation of hydrophilic nanographene oxide

In this study, we have directly incorporated nanographene oxide (nGO) into a hydrophobic drug for enhanced dissolution performance through an antisolvent technique. Apixaban (APX) drug composites were synthesized with nGO incorporation ranging from 0.8% to 2.0% concentration. It was observed that the nGO was successfully embedded without any changes to the original drug crystal structure or physical properties. Dissolution of the drug composites was evaluated using US Pharmacopeia Paddle Method (USP 42). The time needed to reach a 50% release (T₅₀) reduced from 106 min to 24 min with the integration of 1.96% nGO in APX and the T₈₀ also dropped accordingly. Alternatively, dissolution rate showed promising performance with increase in nGO concentration. Initial dissolution rate increased dramatically from 74 µg/min to 540 µg/min. Further, work done in intestinal media revealed T₅₀ went from not dissolving to 79.0 min. Decreased lipophilicity or logP value and increased aqueous solubility are both accredited to hydrophilic nGO water dispersion, producing a hydrophilic channel into the drug crystal surfaces through intermolecular interaction. Additionally, physical, and chemical characterizations confirm that hydrophobic apixaban was successfully transformed into a hydrophilic composite, showing potential for this technology to improve dissolution rate of a model hydrophobic compound.

Enhancement of Crystallization Process of the Organic Pharmaceutical Molecules through High Pressure

The enhancement of the crystallization process through high pressures was studied by using ribavirin (RVB) as a model compound. The effects of high pressure on crystallization thermodynamics, nucleation kinetics, and process yield were evaluated and discussed. The solubility of ribavirin in three pure solvents was measured at different pressures from 283.15 to 323.15 K. The results indicate that the solubility data of ribavirin decreased slightly when pressure was increased. The induction time of the cooling crystallization of ribavirin under different pressures was measured. The results show that high pressure could significantly reduce the nucleation induction period. Furthermore, the nucleation kinetic parameters under different pressures were calculated according to the classical nucleation theory. The effect of high pressure on the anti-solvent crystallization of ribavirin was also studied.

Experimental and numerical investigation of the effect of ultrasound on the growth kinetics of zeolite A

Ultrasound is a promising technology for the improvement of zeolite production, due to its beneficial effects on mass transfer and nucleation. However, a broad understanding of the sonication parameters that influence the growth of zeolites most is still lacking. In the present work, zeolite A was synthesized and the kinetic model of Gualtieri was used to obtain information about the crystallization parameters. The effect of the sonication power and duration on the relative crystallinity and particle size distribution were investigated using a Langevin-type transducer operating at 40 kHz. The experimental data shows that ultrasound has a significant effect on the nucleation and growth. With that, a reduction of up to 40 % of the initial synthesis time can be achieved. Additionally, a narrower particle size distribution is achieved when ultrasound is used during the zeolite A synthesis.

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.

Nanoparticle-Based Drug Delivery System: The Magic Bullet for the Treatment of Chronic Pulmonary Diseases

Chronic pulmonary diseases encompass different persistent and lethal diseases, including chronic obstructive pulmonary disease (COPD), idiopathic pulmonary fibrosis (IPF), cystic fibrosis (CF), asthma, and lung cancers that affect millions of people globally. Traditional pharmacotherapeutic treatment approaches (i.e., bronchodilators, corticosteroids, chemotherapeutics, peptide-based agents, etc.) are not satisfactory to cure or impede diseases. With the advent of nanotechnology, drug delivery to an intended site is still difficult, but the nanoparticle's physicochemical properties can accomplish targeted therapeutic delivery. Based on their surface, size, density, and physical-chemical properties, nanoparticles have demonstrated enhanced pharmacokinetics of actives, achieving the spotlight in the drug delivery research field. In this review, the authors have highlighted different nanoparticle-based therapeutic delivery approaches to treat chronic pulmonary diseases along with the preparation techniques. The authors have remarked the nanosuspension delivery via nebulization and dry powder carrier is further effective in the lung delivery system since the particles released from these systems are innumerable to composite nanoparticles. The authors have also outlined the inhaled particle's toxicity, patented nanoparticle-based pulmonary formulations, and commercial pulmonary drug delivery devices (PDD) in other sections. Recently advanced formulations employing nanoparticles as therapeutic carriers for the efficient treatment of chronic pulmonary diseases are also canvassed.

Continuous Cooling Crystallization in a Coiled Flow Inverter Crystallizer Technology—Design, Characterization, and Hurdles

Continuous small-scale production is currently of utmost interest for fine chemicals and pharmaceuticals. For this purpose, equipment and process concepts in consideration of the hurdles for solids handling are required to transfer conventional batch processing to continuous operation. Based on empirical equations, pressure loss constraints, and an expandable modular system, a coiled flow inverter (CFI) crystallizer with an inner diameter of 1.6 mm was designed. It was characterized concerning its residence time behavior, tested for operation with seed crystals or an ultrasonic seed crystal unit, and evaluated for different purging mechanisms for stable operation. The residence time behavior in the CFI corresponds to ideal plug flow behavior. Crystal growth using seed crystals was demonstrated in the CFI for two amino acids. For fewer seed crystals, higher crystal growth rates were determined, while at the same time, secondary nucleation was observed. Feasibility for the interconnection of a sonicated seeding crystal unit could be shown. However, the hurdles are also identified and discussed. Prophylactic flushing combined with a photosensor for distinguishing between solvent and suspension phase can lead to stable and resource-efficient operation. The small-scale CFI technology was investigated in detail, and the limits and opportunities of the technology are presented here.

Evaluation of different cavitational reactors for size reduction of DADPS

The present study deals with the size reduction based on the recrystallization (antisolvent approach using water) of 3,3'-Diamino Diphenyl Sulfone (DADPS) using different types of cavitational reactors as an alternative to the conventional process of mechanical size reduction, which is an energy intensive approach. Ultrasound was applied for fixed time specific to the reactors namely ultrasonic probes at different power dissipation levels and also ultrasonic bath. A High Speed Homogenizer was also used at varying speeds of rotation to establishing the efficacy for size reduction. The processed sample was analysed for particle size and morphology using particle size analyser and optical microscopy respectively. The final yield of recrystallization was also determined. The power density in W/L and power intensity in W/m² calculated for each equipment has been used to establish efficacy for size reduction since all devices had dissimilar configurations. Based on the studies of varying power intensity of the different US equipment, it was established that larger the power intensity and power density, smaller was the resultant final particle size after treatment for same time. Among the various ultrasonic devices used, Sonics VCX750 probe yielded the best size reduction of 85.47% when operated at 40% amplitude for 60 min for a volume of 200 ml. A High Speed Homogenizer used at 7000 rpm gave 92.35% of size reduction in 15 min operation and also demonstrated the best energy efficiency. The work has elucidated the comparison of different cavitational devices for size reduction for the first time and presented the best reactors and conditions for the desired size reduction.

Sonocrystallization as an Efficient Way to Control the Size, Morphology, and Purity of Coordination Compound Microcrystallites: Application to a Single-Chain Magnet

The size, morphology, and purity control of coordination compound powders is a key stage for their conversion into materials and devices. In particular, surface science techniques require highly pure bulk materials with a narrow crystallite-size distribution together with straightforward, scalable, and reproducible crystallization procedures. In this work we demonstrate how sonocrystallization, i.e. the application of ultrasound during the crystallization process, can afford very quickly powders made of crystallites with controlled size, morphology, and purity. We show that this process drastically diminishes the crystallite-size distribution (low polydispersity indexes, PDI) and crystallite aspect ratio. By comparing sonicated samples with samples obtained by various silent crystallization conditions, we unambiguously show that the improvement in the crystallite morphology and size distribution is not due to any thermal effect but to the sonication of the crystallizing media. The application of sonocrystallization on crystallization batches of single-chain magnets (SCMs) maintains the chemical integrity of the SCMs together with their original magnetic behavior. Moreover, luminescent measurements show that sonocrystallization induces an efficient micromixing that drastically enhances the purity of the SCM powders. We thus propose that sonocrystallization, which is already used on organic or MOF compounds, can be applied to (magnetic) coordination compounds to readily afford bulk powders for characterization or shaping techniques that require pure, morphology- and crystallite-size-controlled powder samples.

Enabling low power acoustics for capillary sonoreactors

Capillary reactors demonstrate outstanding potential for on-demand flow chemistry applications. However, non-uniform distribution of multiphase flows, poor solid handling, and the risk of clogging limit their usability for continuous manufacturing. While ultrasonic irradiation has been traditionally applied to address some of these limitations, their acoustic efficiency, uniformity and scalability to larger reactor systems are often disregarded. In this work, high-speed microscopic imaging reveals how cavitation-free ultrasound can unclog and prevent the blockage of capillary reactors. Modeling techniques are then adapted from traditional acoustic designs and applied to simulate and prototype sonoreactors with wider and more uniform sonication areas. Blade-, block- and cylindrical shape sonotrodes are optimized to accommodate longer capillary lengths in sonoreactors resonating at 28 kHz. Finally, a novel helicoidal capillary sonoreactor is proposed to potentially deal with a high concentration of solid particles in miniaturized flow chemistry. The acoustic designs and first principle rationalization presented here offer a transformative step forward in the scale-up of efficient capillary sonoreactors.

Enantioseparation of racemic bupivacaine via ultrasonic-assisted diastereomeric crystallization using 12,14-dinitrodehydroabietic acid

12,14-Dinitrodehydroabietic acid (12,14-dinitroDHAA), a chiral acid obtained by the nitration of optical dehydroabietic acid (DHAA), was successfully employed as resolving agent. The resolution of racemic bupivacaine by ultrasonic-assisted diastereomeric crystallization in ethanol was investigated. The results indicated that ultrasonic-assist can well facilitate resolution of (R,S)-bupivacaine and a higher enantiomeric excess (ee) and yield was obtained for (S)-bupivacaine, and while without ultrasound, the ee value decreases by increasing the crystallization time. A Box-Behnken experimental design with four factors (amount of 12,14-dinitroDHAA, ethanol amount, ultrasonic power and crystallization temperature) combined with response surface methodology (RSM) was applied to explore resolution effects. A second-order polynomial equation was adequate to model the relationship between the ee (or yield) and the dependent variables. When maintaining a lower limit of 90% for the yield of (S)-bupivacaine, the optimal resolution conditions by RSM were 12,14-dinitroDHAA/bupivacaine molar ratio of 1.6, solvent/propranolol ratio of 16.5 mL/g, 63.2 W ultrasonic power and crystallization temperature of 0 °C, respectively. Under the optimal conditions, the experimental ee and yield of (S)-bupivacaine were 69.8% and 87.5%.

Applications of ultrasound to chiral crystallization, resolution and deracemization

Industrial synthesis of enantiopure compounds is nowadays heavily based on the separation of racemates through crystallization processes. Although the application of ultrasound in solution crystallization processes (sonocrystallization) has become a promising emerging technology, offering several benefits (e.g. reduction of the induction time and narrowing of the metastable zone width, control over the product size, shape and polymorphic modification), little attention has been paid so far to the effects of ultrasound on chiral crystallization processes. Several recent studies have reported on the application of acoustic energy to crystallization processes that separate enantiomers, ranging from classical (diastereomeric) resolution and preferential crystallization to new and emerging processes such as attrition-enhanced deracemization (Viedma ripening). A variety of interesting effects have been observed, which include among others, enhanced crystallization yield with higher enantiomeric purity crystals, spontaneous mirror symmetry breaking crystallization, formation of metastable conglomerate crystals and enhanced deracemization rates. The objective of this review is to provide an overview of the effects of ultrasound on chiral crystallization and outline several aspects of interest in this emerging field.

Ultrasound-assisted emerging technologies for chemical processes

The chemical industry has witnessed many important developments during past decades largely enabled by process intensification techniques. Some of them are already proven at commercial scale (e.g. reactive distillation) while others (e.g. ultrasound-assisted extraction/crystallization/reaction) are on their way to becoming the next-generation technologies. This article focuses on the advances of ultrasound (US)-assisted technologies that could lead in the near future to significant improvements in commercial activities. The aim is to provide an authoritative discussion on US-assisted technologies that are currently emerging from the research environment into the chemical industry, as well as give an overview of the current state-of-the-art applications of US in chemical processing (e.g. enzymatic reactive distillation, crystallization of API). Sufficient information is included to allow the assessment of US-assisted technologies and the challenges for implementation, as well as their potential for commercial applications. © 2017 The Authors. Journal of Chemical Technology & Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry.