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Continuous Crystallizer
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Application
Traditional industrial crystallization technology is evolving into advanced crystal engineering technology. Crystallization technology is no longer limited to the separation and purification of substances. Guided by the structure-property relationship concept, it focuses on studying the connection between crystal structure and performance, and enables the preparation of crystals with specific structures tailored to functional requirements.
Batch crystallization processes are simple to operate but still face challenges such as inter-batch variability and suboptimal efficiency. In contrast, continuous crystallization minimizes batch-to-batch differences and achieves higher production efficiency. Continuous crystallization reduces solvent and energy consumption while decreasing downtime required for equipment maintenance and cleaning. Through economic analysis of both processes, continuous crystallization has been shown to effectively lower production costs by 9–40%.
PMG Reaction Crystallizer
The PMG reaction crystallizer consists of two concentric cylinders. The inner cylinder rotates at high speed, and when the critical Taylor number is reached, the fluid generates periodic radial vortices.
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Structural Schematic Diagram |
Product Schematic Diagram |
Case Study
The PMG reaction crystallizer, as a modification solution for customers’ lithium iron phosphate, addresses the following challenges:
● Optimized Control of Particle Size Distribution: By maintaining stable fluid flow and moderate shear forces within the crystallizer, explosive nucleation is prevented. Multi-point feeding can be adopted for enhanced control.
● Batch-to-Batch Consistency: Continuous crystallization enables precise control of residence time with a narrow distribution range. Under steady-state conditions, production can proceed continuously at constant operating parameters, minimizing inter-batch variability.
● Process Intensification: Enhanced micro-mixing and heat/mass transfer within the crystallizer ensure uniform and controllable supersaturation distribution. This drives the development and adoption of equipment with higher mixing intensity and efficiency for crystallization processes.
● Accurate Temperature Control: The plug-flow crystallizer can be segmented into multiple zones with independently controlled temperatures. For example, one zone may apply heating to dissolve fine crystals.
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Normal batch Crystallizer |
Pomegranate Reaction Crystallizer |
Crystal Particle Size Distribution
Comparison of Effects Between Different Production Methods
| Category | Normal batch Crystallizer | Pomegranate Reaction Crystallizer |
| Process Time (h) | 10 | 0.5 |
| **Particle Size (μm) | 5–20 | 5–10 |
| Non-uniformity ([D90-D10]/D50) | 0.5 | 0.2 |
| Bulk Density (g/mL) | 2.1 | 2.2 |
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