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Issue 5, 2018
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Development of an automated multi-stage continuous reactive crystallization system with in-line PATs for high viscosity process

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Abstract

An automated multi-stage continuous reaction system with in-line PATs for a high viscosity reactive crystallization process was developed in the present study. Data acquisition (DAQ) hardware and Labview software were used as the local control system. A “forward-backward” burst pumping strategy was developed to smoothly transfer the highly viscous hot slurry from one vessel to the next. In addition, a comparative analysis between a plug flow reactor (PFR) and continuous stirred-tank reactors (CSTRs) in series revealed that to achieve the same conversion, the latter would require more volume than the former, but less than a single CSTR. For a second-order reaction, the value of the Damköhler number necessary to achieve conversion of 90.0% in a single CSTR is 90. Thus, it is reasonable to approximate a PFR using CSTRs in series to obtain a high yield with a smaller reaction volume (compared with a single CSTR). As the probes could not be positioned in the hot slurry due to fouling issues, in-line focused beam reflectance measurement (FBRM) and React IR were used to monitor the crystal size and reactant concentration in the vessel containing the cold slurry. E-factors of batch and continuous processes were also compared and the continuous reaction could obtain a lower E-factor because less waste was generated.

Graphical abstract: Development of an automated multi-stage continuous reactive crystallization system with in-line PATs for high viscosity process

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Supplementary files

Article information


Submitted
04 May 2018
Accepted
03 Jul 2018
First published
03 Jul 2018

React. Chem. Eng., 2018,3, 658-667
Article type
Paper

Development of an automated multi-stage continuous reactive crystallization system with in-line PATs for high viscosity process

C. Hu, J. E. Finkelstein, W. Wu, K. Shvedova, C. J. Testa, S. C. Born, B. Takizawa, T. F. O'Connor, X. Yang, S. Ramanujam and S. Mascia, React. Chem. Eng., 2018, 3, 658
DOI: 10.1039/C8RE00078F

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