Continuous Crystallization Apparatus with Porous Membrane Mixing
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Solution Overview
Problem
Batch-type crystallization processes for obtaining crystals of target substances are costly and prone to issues like widened crystal size distribution, blockage, and adhesion, and existing continuous methods like MSMPR and microreactors face challenges in achieving high-concentration crystals and efficient treatment.
Innovation Solution
A continuous crystallization apparatus with a treatment container partitioned by a porous membrane, where a raw material liquid and a poor solvent or reaction liquid are mixed and continuously supplied to precipitate and grow crystals, featuring a supply and extraction system, an aging unit for crystal growth, and optional components like gas-liquid separation and cooling units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batch-type crystallization process is used, then crystal precipitation can be achieved, but production cost increases due to complicated switching operations
Solution Approach 1:
The patent applies preliminary action by pre-mixing the poor solvent and raw material liquid in a mixing unit before they enter the treatment container. This pre-mixing operation prepares the mixed liquid in advance with controlled composition, eliminating the need for complicated switching operations during the crystallization process and reducing production costs while maintaining effective crystal precipitation.
2Productivity
If MSMPR process is used for continuous crystallization, then continuous operation is achieved, but crystal size distribution widens and high-concentration crystals are difficult to obtain
Solution Approach 1:
The patent segments the crystallization process into distinct functional units: a mixing unit for pre-mixing poor solvent and raw material liquid, a treatment container for crystal precipitation, and an aging unit for crystal growth. This segmentation allows each unit to perform its specific function optimally, maintaining narrow crystal size distribution while enabling continuous operation. The mixed liquid flows sequentially through these units, ensuring controlled crystal formation and growth.
Solution Approach 2:
The patent applies local quality by creating specific flow conditions in different regions of the treatment container. The mixed liquid flows through the treatment container in a controlled manner, creating localized zones with different flow characteristics that favor uniform crystal precipitation. The extraction unit continuously removes mixed liquid from a specific location, maintaining consistent local conditions that produce uniform crystal size distribution.
3Ease of operation
If microreactor is used for continuous crystallization, then mixing efficiency is improved, but treatment amount is limited
Solution Approach 1:
The patent uses the mixed liquid as an intermediary between the mixing unit and the treatment container. The poor solvent and raw material liquid are thoroughly mixed in the mixing unit to create a homogeneous mixed liquid, which then serves as the medium for crystal precipitation in the treatment container. This intermediary approach ensures efficient mixing while allowing the system to handle large treatment amounts through the continuous flow capability of the treatment container and extraction unit.
4Ease of manufacture
If poor solvent is dripped into raw material liquid in batch process, then crystal precipitation occurs, but blockage and crystal adhesion are likely to occur
Solution Approach 1:
The patent implements continuity of useful action by maintaining continuous flow of mixed liquid through the treatment container and continuous extraction by the extraction unit. This continuous operation prevents the accumulation of crystals that could cause blockage or adhesion issues. The steady-state flow conditions ensure that crystals are continuously formed and removed, eliminating the start-stop operations inherent in batch processes that lead to blockage and adhesion problems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous, efficient precipitation and growth of high-quality crystals with controlled crystal size and reduced production costs by uniformly mixing the poor solvent with the raw material liquid, preventing blockages and maintaining high treatment capacity.
Implementation Method 1
a treatment liquid supply unit continuously supplying a treatment liquid to the second flow space at a pressure at which the treatment liquid passes through the porous membrane and enters the first flow space
Implementation Method 2
an aging unit precipitating and growing a crystal of the target substance from a mixed liquid extracted from the extraction unit
Implementation Method 3
crystals of the target substance are precipitated by mixing of a raw material liquid containing a raw material substance with a reaction liquid generating a target substance with lower solubility
Data Source
AI summary
Provided is a technique for continuously performing poor solvent crystallization or reactive crystallization. A porous membrane in which multiple pores through which a liquid passes are formed internally partitions the treatment container into a first flow space and a second flow space. A raw material liquid supply unit continuously supplies a raw material liquid to the first flow space. A treatment liquid supply unit continuously supplies a treatment liquid to the second flow space at a pressure at which the treatment liquid passes through the porous membrane and enters the first flow space. An extraction unit continuously extracts a mixed liquid of the raw material liquid and the treatment liquid from the first flow space. An aging unit precipitates and grows crystals of a target substance from a mixed liquid.