Fractional crystallization (chemistry)

Last updated

Crystallization
Process-of-Crystallization-200px.png
Fundamentals
Concepts
Methods and technology

In chemistry, fractional crystallization is a stage-wise separation technique that relies on the liquid-solid phase change. It fractionates via differences in crystallization temperature and enables the purification of multi-component mixtures, as long as none of the constituents can act as solvents to the others. Due to the high selectivity of the solid – liquid equilibrium, very high purities can be achieved for the selected component.

Contents

Principle of separation

The crystallization process starts with the partial freezing of the initial liquid mixture by slowly decreasing its temperature. The frozen solid phase subsequently has a different composition than the remaining liquid. This is the fundamental physical principle behind the melt fractionating process and quite comparable to distillation, which operates between a liquid and the gas phase.

The crystals will grow on a cooled surface or alternatively as a suspension in the liquid. The heat released by the solidification process is withdrawn through a cooling surface or via the liquid. In theory, 100% of the product could be solidified and recovered. In practice, various strategies such as partial melting of the solid fraction (sweating) need to be applied in order to reach high purity levels.

Advantages

Fractional crystallization has various advantages over other separation technologies. First of all, it makes the purification of close boilers possible. This allows for very high purities even for challenging components. Furthermore, because of the lower operating temperature, the thermal stress applied to the product is very low. This is in particular relevant for products that would otherwise oligomerize or degrade. Next, fractional crystallization is usually an inherently safe technology, because it operates at low pressures and low temperatures. Also, it does not use any solvents and is emission-free. Finally, since the latent heat of solidification is 3–6x lower than the heat of evaporation, the energy consumption is – in comparison to distillation – much lower.

Process steps

Fractional crystallization involves several key steps:

  1. Crystallization: This is the initial phase where the material to be purified is cooled. As it cools, high-purity crystals begin to form on the cooling surface. The purity is achieved because the impurities tend to remain in the liquid phase rather than being incorporated into the crystal structure.
  2. Draining: After the formation of the crystals, the next step is to remove the residual liquid that contains a higher concentration of impurities. This process of draining helps to separate the pure crystals from the impure liquid.
  3. Sweating: This phase is a controlled partial melting process. It further purifies the product by melting only a small portion of the crystal. The melting causes the impurities trapped within or between the crystal structures to be released and separated.
  4. Total Melting: In the final step, the remaining crystallized material, which is now the purified product, is completely melted. This total melting facilitates the removal of the pure substance from the crystallization equipment and prepares it for downstream processing.

Crystallizers

There are three differenct fractional crystallization technologies available:

Falling-film

In the falling-film crystallizer, crystals grow from a melt that forms a thin film along the inside of cooled tubes. A concurrent cooling medium flows on the outside of these tubes. This arrangement allows for reproducible and high transfer rates of heat, facilitating the growth of crystals from the falling film of melt. The solid–liquid separation of the resulting slurry can be accomplished using a wash column or a centrifuge. This technology is more complex than others but offers the advantage of high separation efficiency and very high purities. A typical feed has concentrations between 90–99%, which is purified up to 99.99 wt.-% or greater. For example, glacial acrylic acid, optical grade bisphenol-A and battery grade ethylene carbonate can be purified to their highest grade using a falling-film crystallizer.

Static

The static crystallizer allows crystals to grow from a stagnant melt, making it a versatile and robust technology. It can purify highly challenging products, including those with most challenging properties, such as high viscosities and high or low melting points. Examples of applications include isopulegol, phosphoric acid, wax and paraffins, anthracene / carbazole and even satellite-grade hydrazine.

Suspension

In suspension crystallization, crystals are generated on a cooling surface and then scraped off to continue growing in size within a stirred vessel in suspension or slurry. The solid–liquid separation is performed either through a wash-column or a centrifuge. This method is more complex to operate, but offers the advantage of a high separation efficiency, which translates to considerable engery savings. Examples of applications include paraxylene, halogenated aromatics, and also aqueous feeds.

See also

Related Research Articles

<span class="mw-page-title-main">Distillation</span> Method of separating mixtures

Distillation, also classical distillation, is the process of separating the component substances of a liquid mixture of two or more chemically discrete substances; the separation process is realized by way of the selective boiling of the mixture and the condensation of the vapors in a still.

<span class="mw-page-title-main">Magma</span> Hot semifluid material found beneath the surface of Earth

Magma is the molten or semi-molten natural material from which all igneous rocks are formed. Magma is found beneath the surface of the Earth, and evidence of magmatism has also been discovered on other terrestrial planets and some natural satellites. Besides molten rock, magma may also contain suspended crystals and gas bubbles.

<span class="mw-page-title-main">Zone melting</span> Purification process by moving a molten zone along a metal bar

Zone melting is a group of similar methods of purifying crystals, in which a narrow region of a crystal is melted, and this molten zone is moved along the crystal. The molten region melts impure solid at its forward edge and leaves a wake of purer material solidified behind it as it moves through the ingot. The impurities concentrate in the melt, and are moved to one end of the ingot. Zone refining was invented by John Desmond Bernal and further developed by William G. Pfann in Bell Labs as a method to prepare high-purity materials, mainly semiconductors, for manufacturing transistors. Its first commercial use was in germanium, refined to one atom of impurity per ten billion, but the process can be extended to virtually any solute–solvent system having an appreciable concentration difference between solid and liquid phases at equilibrium. This process is also known as the float zone process, particularly in semiconductor materials processing.

<span class="mw-page-title-main">Phosphoric acid</span> Chemical compound (PO(OH)3)

Phosphoric acid is a colorless, odorless phosphorus-containing solid, and inorganic compound with the chemical formula H3PO4. It is commonly encountered as an 85% aqueous solution, which is a colourless, odourless, and non-volatile syrupy liquid. It is a major industrial chemical, being a component of many fertilizers.

<span class="mw-page-title-main">Freezing</span> Phase transition of liquid to solid

Freezing is a phase transition where a liquid turns into a solid when its temperature is lowered below its freezing point. In accordance with the internationally established definition, freezing means the solidification phase change of a liquid or the liquid content of a substance, usually due to cooling.

<span class="mw-page-title-main">Sublimation (phase transition)</span> Transition from solid to gas

Sublimation is the transition of a substance directly from the solid to the gas state, without passing through the liquid state. The verb form of sublimation is sublime, or less preferably, sublimate. Sublimate also refers to the product obtained by sublimation. The point at which sublimation occurs rapidly is called critical sublimation point, or simply sublimation point. Notable examples include sublimation of dry ice at room temperature and atmospheric pressure, and that of solid iodine with heating.

<span class="mw-page-title-main">Fractional freezing</span> Separating components of a mixture by their melting points

Fractional freezing is a process used in process engineering and chemistry to separate substances with different melting points. It can be done by partial melting of a solid, for example in zone refining of silicon or metals, or by partial crystallization of a liquid, as in freeze distillation, also called normal freezing or progressive freezing. The initial sample is thus fractionated.

<span class="mw-page-title-main">Fractionation</span> Method of separating components of a mixture via phase transition

Fractionation is a separation process in which a certain quantity of a mixture is divided during a phase transition, into a number of smaller quantities (fractions) in which the composition varies according to a gradient. Fractions are collected based on differences in a specific property of the individual components. A common trait in fractionations is the need to find an optimum between the amount of fractions collected and the desired purity in each fraction. Fractionation makes it possible to isolate more than two components in a mixture in a single run. This property sets it apart from other separation techniques.

<span class="mw-page-title-main">Crystallization</span> Process by which a solid with a highly organized atomic or molecular structure forms

Crystallization is the process by which solid forms, where the atoms or molecules are highly organized into a structure known as a crystal. Some ways by which crystals form are precipitating from a solution, freezing, or more rarely deposition directly from a gas. Attributes of the resulting crystal depend largely on factors such as temperature, air pressure, and in the case of liquid crystals, time of fluid evaporation.

The Betterton-Kroll Process is a pyrometallurgical process for refining lead from lead bullion. Developed by William Justin Kroll in 1922, the Betterton–Kroll process is one of the final steps in conventional lead smelting. After gold, copper, and silver are removed from the lead, significant amounts of bismuth and antimony remain. The Betterton–Kroll process is used to remove these impurities. In the process, calcium and magnesium are added to the molten lead at temperatures around 380 °C. The calcium and magnesium react with the bismuth and antimony in the bullion to form alloys with a higher melting point, which then can be skimmed off of the surface. This process leaves behind lead with less than 0.01 percent bismuth by weight. The process is crucial to cheap industrial lead smelting and offers significant advantages over more expensive processes like the Betts Electrolytic process and fractional crystallization.

<span class="mw-page-title-main">Phase-change material</span> Substance with high latent heat of melting or solidifying

A phase-change material (PCM) is a substance which releases/absorbs sufficient energy at phase transition to provide useful heat or cooling. Generally the transition will be from one of the first two fundamental states of matter - solid and liquid - to the other. The phase transition may also be between non-classical states of matter, such as the conformity of crystals, where the material goes from conforming to one crystalline structure to conforming to another, which may be a higher or lower energy state.

Downstream processing refers to the recovery and the purification of biosynthetic products, particularly pharmaceuticals, from natural sources such as animal tissue, plant tissue or fermentation broth, including the recycling of salvageable components as well as the proper treatment and disposal of waste. It is an essential step in the manufacture of pharmaceuticals such as antibiotics, hormones, antibodies and vaccines; antibodies and enzymes used in diagnostics; industrial enzymes; and natural fragrance and flavor compounds. Downstream processing is usually considered a specialized field in biochemical engineering, which is itself a specialization within chemical engineering. Many of the key technologies were developed by chemists and biologists for laboratory-scale separation of biological and synthetic products, whilst the role of biochemical and chemical engineers is to develop the technologies towards larger production capacities.

In geology, igneous differentiation, or magmatic differentiation, is an umbrella term for the various processes by which magmas undergo bulk chemical change during the partial melting process, cooling, emplacement, or eruption. The sequence of magmas produced by igneous differentiation is known as a magma series.

<span class="mw-page-title-main">Flux method</span>

The flux method is a crystal growth method where starting materials are dissolved in a solvent (flux), and are precipitated out to form crystals of a desired compound. The flux lowers the melting point of the desired compound, analogous to a wet chemistry recrystallization. The flux is molten in a highly stable crucible that does not react with the flux. Metal crucibles, such as platinum, titanium, and niobium are used for the growth of oxide crystals. Ceramic crucibles, such as alumina, zirconia, and boron nitride are used for the growth of metallic crystals. For air-sensitive growths, contents are sealed in ampoules or placed in atmosphere controlled furnaces.

Winterizationof oil is a process that uses a solvent and cold temperatures to separate lipids and other desired oil compounds from waxes. Winterization is a type of fractionation, the general process of separating the triglycerides found in fats and oils, using the difference in their melting points, solubility, and volatility.

<span class="mw-page-title-main">Recrystallization (chemistry)</span> Separation and purification process of crystalline solids

In chemistry, recrystallization is a technique used to purify chemicals. By dissolving a mixture of a compound and impurities in an appropriate solvent, either the desired compound or impurities can be removed from the solution, leaving the other behind. It is named for the crystals often formed when the compound precipitates out. Alternatively, recrystallization can refer to the natural growth of larger ice crystals at the expense of smaller ones.

<span class="mw-page-title-main">Pumpable ice technology</span> Type of technology to produce and use fluids or secondary refrigerants

Pumpable icetechnology (PIT) uses thin liquids, with the cooling capacity of ice. Pumpable ice is typically a slurry of ice crystals or particles ranging from 5 micrometers to 1 cm in diameter and transported in brine, seawater, food liquid, or gas bubbles of air, ozone, or carbon dioxide.

<span class="mw-page-title-main">Crystal mush</span>

A crystal mush is magma that contains a significant amount of crystals suspended in the liquid phase (melt). As the crystal fraction makes up less than half of the volume, there is no rigid large-scale three-dimensional network as in solids. As such, their rheological behavior mirrors that of absolute liquids.

While chemically pure materials have a single melting point, chemical mixtures often partially melt at the solidus temperature (TS or Tsol), and fully melt at the higher liquidus temperature (TL or Tliq). The solidus is always less than or equal to the liquidus, but they need not coincide. If a gap exists between the solidus and liquidus it is called the freezing range, and within that gap, the substance consists of a mixture of solid and liquid phases (like a slurry). Such is the case, for example, with the olivine (forsterite-fayalite) system, which is common in Earth's mantle.

References