
過飽和是透過降低產品在溶液中的溶解度產生的,通常是透過冷卻或添加反溶劑來實現。溶液冷卻的速率或反溶劑添加的速率會直接影響過飽和的程度。
在此範例中,製備了苯甲酸在乙醇-水混合物中的欠飽和溶液,並分別以固定速率0.1 g/s和0.2 g/s添加水,溫度固定為25 °C。利用原位傅立葉轉換紅外光譜(FTIR)即時測量液相濃度。右側圖中顯示了苯甲酸在乙醇-水混合物中的溶解度曲線,以及各實驗的去過飽和(desupersaturation)曲線。去過飽和曲線顯示溶液起始於欠飽和區域。隨著水的添加,過程越過溶解度曲線進入過飽和區域。晶體成核時液相濃度下降,並維持接近溶解度曲線。在反溶劑添加結束時,液相濃度降至溶解度曲線。當反溶劑以較快速率添加時,整個過程中的過飽和程度較高,這是因為晶體生長與成核無法足夠快速釋放累積的過飽和。

在本實驗中,變更製程參數與過飽和度會同時影響晶體的大小與形狀。每次實驗結束時,利用PVM技術(ParticleView)所拍攝的影像(如右圖所示)即說明此點。緩慢的添加速率產生大型且形狀良好的細長板狀晶體,而快速的添加速率則產生易於團聚的細針狀晶體。此結果顯示,透過改變結晶系統中的過飽和度,可以調整晶體的大小、形狀及團聚程度。此亦彰顯理解並控制當前過飽和度水平的重要性。此簡單範例說明一項關鍵原則::

控制反溶劑添加速率以調控晶體尺寸是基於紮實科學原理的成熟技術。然而,有效且具證據基礎的結晶工藝開發與改進則更為細緻。例如,快速產生過飽和度可能導致產生以瞬態油相形式存在的不良雜質(a),或產生不期望的多晶型態(b)。同樣地,為了生成大晶體,循環時間並非總能被犧牲,這意味著極慢的冷卻速率或反溶劑添加速率往往不可行。

提出了一種方法,便於在生產和控制定性過飽和度軌跡時,無需校準即可使用原位ATR-FTIR光譜。
結晶單元操作提供了獨特的機會,能夠針對並控制及優化晶體的大小和形狀分佈,以達到以下目的:
Crystallization kinetics are characterized in terms of two dominant processes, nucleation kinetics and growth kinetics, occurring during crystallization from solution. Nucleation kinetics describe the rate of formation of a stable nuclei. Growth kinetics define the rate at which a stable nuclei grows to a macroscopic crystal. Advanced techniques offer temperature control to modify supersaturation and crystal size and shape.
Continuous crystallization is made possible by advances in process modeling and crystallizer design, which leverage the ability to control crystal size distribution in real time by directly monitoring the crystal population.
在反溶劑結晶過程中,溶劑的添加速率、添加位置及混合方式會影響容器或管道中的局部過飽和度。科學家和工程師透過調整反溶劑的添加程序及過飽和度水平,來改變晶體的大小與數量。
一個設計良好的批次結晶 (Batch Crystallization) 過程,能夠成功放大至生產規模,並達到所需的晶體粒徑分布、產率、形態及純度。批次結晶的優化需要維持對結晶器溫度(或溶劑組成)的充分控制。
Solubility curves are commonly used to illustrate the relationship between solubility, temperature, and solvent type. By plotting temperature vs. solubility, scientists can create the framework needed to develop the desired crystallization process. Once an appropriate solvent is chosen, the solubility curve becomes a critical tool for the development of an effective crystallization process.
Lactose crystallization is an industrial practice to separate lactose from whey solutions via controlled crystallization.
播種是優化結晶行為最關鍵的步驟之一。在設計播種策略時,必須考慮種子大小、種子負荷(質量)和種子添加溫度等參數。這些參數通常根據製程動力學和所需的最終顆粒特性進行最佳化,並且在放大和技術轉讓期間必須保持一致。
Liquid-Liquid phase separation, or oiling out, is an often difficult to detect particle mechanism that can occur during crystallization processes.
In-process probe-based technologies are applied to track particle size and shape changes at full concentration with no dilution or extraction necessary. By tracking the rate and degree of change to particles and crystals in real time, the correct process parameters for crystallization performance can be optimized.
改變結晶器中的比例或混合條件會直接影響結晶過程的動力學和最終晶體尺寸。對於冷卻和反溶劑系統來說,傳熱和傳質效應分別是考慮的重要因素,其中溫度或濃度梯度會在普遍的過飽和度水平中產生不均勻性。
Crystal polymorphism describes the ability of one chemical compound to crystallize in multiple unit cell configurations, which often show different physical properties.
深入了解再結晶(Recrystallization)的關鍵七大步驟:從溶解度數據分析、亞穩區晶種添加,到最終的固液分離與乾燥。本指南協助研發人員掌握過飽和度控制技術,優化晶體粒徑分佈並提升產物純度,加速從實驗室開發到大規模生產的進程。
Crystallization kinetics are characterized in terms of two dominant processes, nucleation kinetics and growth kinetics, occurring during crystallization from solution. Nucleation kinetics describe the rate of formation of a stable nuclei. Growth kinetics define the rate at which a stable nuclei grows to a macroscopic crystal. Advanced techniques offer temperature control to modify supersaturation and crystal size and shape.
Solubility curves are commonly used to illustrate the relationship between solubility, temperature, and solvent type. By plotting temperature vs. solubility, scientists can create the framework needed to develop the desired crystallization process. Once an appropriate solvent is chosen, the solubility curve becomes a critical tool for the development of an effective crystallization process.
In-process probe-based technologies are applied to track particle size and shape changes at full concentration with no dilution or extraction necessary. By tracking the rate and degree of change to particles and crystals in real time, the correct process parameters for crystallization performance can be optimized.