VISIMIX TURBULENT. CRYSTALLIZER. SCALING-UP .

This example is based essentially on the article ‘Optimizing Crystallizer Scaleup’ by Wayne J.
Genk , Chem. Engng. Progress, June 2003, pp. 36-44.

Problem description:

Accordingly to the existing views, the process rate and particle size distribution in crystallization
and precipitation processes are dependent on chemical composition and physico-chemical
properties of the system. In the same time thay can be
substantially dependent also on some phenomena that are functions of mixing conditions – for
example, on primary and secondary nucleation, attrition and breakage of crystals, distribution of
solid phase and liquid-solid mass transfer.
The following example is related to a particular case when the crystallization is controlled mainly
by these parameters, and scaling-up conditions include reproduction of these phenomena.
The corresponding parameters selected from the list of VisiMix outputs and used below for
crystallization scale-up are presented in the Table 1.

Table 1. Scaling-up parameters for crystallization.

VisiMix Menu Output parameters

section
Energy dissipation – maximum value
Turbulent shear rate near the impeller blade
Relative residence time in zone with maximum
dissipation
Liquid-solid mixing Axial and radial distributions of the solid phase
Maximum energy of collisions
Frequency of collisions of maximum energy
Liquid –solid mass Mass transfer coefficient
transfer

Subject of this example – to illustrate application of VisiMix for scaling-up of the crystallization
process based on these parameters.

For calculation of the Mass transfer coefficient, it is necessary to enter a number of additional
initial data, including the Diffusivity of the solute. In our case the problem consists not in
prediction, but in reproduction of the same value of the Mass transfer coefficient. For a given set
of physical properties of the solution and solute, mass transfer coefficient is tightly connected to
the Average value of turbulent energy dissipation. So, in this example we will use this
parameter as a base for scaling-up instead of the Mass transfer coefficient.

Initial data

Pilot crystallizer:

VisiMix Turbulent. Example 5. 1

Tank (with elliptical bottom):
Inside diameter = 650 mm;
Total volume = 231 liter (61 gal);
Volume of media = 190 liters (50 gal).

Baffle (Flat baffle-1)

Number = 4;
Width = 60 mm;
Length = 500 mm;
Distance from bottom = 150 mm;
Angle to radius = 0 deg.

Impeller (pitch paddle)

Tip diameter = 210 mm;
Number of blades = 3;
Pitch angle = 45 deg;
Width of blade = 40mm;
Distance from bottom = 125 mm;
RPM = 310;
Power of drive = 1000 W;

Production plant crystallizer

Tank (with elliptical bottom):

Inside diameter = 3000 mm;
Total volume = 26.5 m3 (7000 gal);
Volume of media = 23.7 m3 (6250 gal).

Baffles (Flat baffle-2)

Number = 4;
Width = 300 mm;
Length = 3200 mm;
Distance from bottom = 600 mm;
Distance from wall = 50 mm;
Angle to radius = 0 degrees

Impeller (A310)
Tip diameter = 1400 mm;
Distance from bottom = 700 mm;
RPM = 105;
Power of drive = 20 kW;

Media properties

The media is a suspension of crystals in a water mother solution.

Liquid phase properties:
Density = 1050 kg/cub. m;

VisiMix Turbulent. Example 5. 2

 Dynamic viscosity = 0.001 Pa*s;
Solid phase properties:
Mass concentration = 150 kg/cub.m;;
Density = 2300 kg/cub. m;
Average particle size = 150 micron;
Size of largest particles = 250 micron;

The Solution:

Before proceeding to calculations, let us create the projects corresponding to the pilot and
production-scale reactor and enter design data for each of them. Start with the pilot simulation,
and then consider the available production-scale reactor, changing its design characteristics if
necessary.

Following the standard VisiMix procedure, create a new project for the pilot reactor.

Select Project, then New, then enter the name for project Cryst-pilot.vsm as shown in Figure 1.

Figure 1. Starting a new project.

Click Save, and select your tank in the Tank types selection that appears. The tank you have
selected (elliptical bottom without heat transfer device) will appear in the Current choice
window on the right (Figure 2). Click OK to confirm your choice.

VisiMix Turbulent. Example 5. 3

Figure 2. VisiMix graphic tanks selection.

Now you will be requested to enter basic initial data for your project. After you confirm your tank
choice, TANK WITH ELLIPTICAL BOTTOM input table with the selected tank diagram
appears. Supply the internal dimensions of your tank. Enter Inside diameter, Total volume and
Volume of media, and Total tank height and Level of media will be calculated by the program
and entered automatically (Figure 3).

Figure 3. Entering pilot tank data.

After the table has been completed, click anywhere on the field of the window, and the tank
diagram on the screen will change to reflect your input. Click OK to confirm your input.

The Baffle types menu will now appear. Click on the diagram of the selected baffle (Flat baffle –
1 in our case), and it will appear in the Current choice window on the right (Figure 4). Click OK
to confirm the choice.

VisiMix Turbulent. Example 5. 4

Figure 4. Selecting a baffle for pilot tank.

Enter parameters of your baffle in the table that appears (Figure 5).

Figure 5. Entering baffle data for pilot tank.

Now click on the existing impeller of the pilot tank (Pitched paddle) in the Impeller types menu
(Figure 6), and it will arrive in the Current choice window. The single impeller option (for
single-stage mixing device) is already shown (by default).

VisiMix Turbulent. Example 5. 5

Figure 6. Defining impeller type for pilot tank.

The impeller parameters – sizes, position and rotation speed – are entered in the next input table that appears
automatically (Figure 7). After the data are entered, click anywhere in the field of the window, and the
diagram on the screen will change to reflect the last input. Click OK to confirm the input.

Figure 7. Entering impeller data for pilot tank.

VisiMix Turbulent. Example 5. 6

You will now be requested to enter properties of the media in AVERAGE PROPERTIES OF
MEDIA input table. For the first approximation, enter properties of the liquid phase ('mother
solution').

Figure 8. Entering average properties of media.

After you have entered basic data for your pilot reactor, its diagram appears (Figure 8).

Figure 9. Scheme of the pilot crystallizer..

VisiMix Turbulent. Example 5. 7

From now on, it is possible to start calculations.

The first stage of calculation – defining values of the controlling parameters for the pilot tank. In
accordance with the Table 1, we will start with parameters of turbulence.

Figure 10. Menu Turbulence - list of output parameters.

Click the Calculate option in the main menu, select the sub-menu Turbulence (Figure 10) and ‘ask’ for
LOCAL VALUES OF ENERGY DISSIPATION in this submenu. Output table containing the
parameters Energy dissipation – maximum value and Energy dissipation – average value will appear
(Figure 11).

Figure 11. Pilot crystallizer. Local values of energy dissipation.

VisiMix Turbulent. Example 5. 8

The next steps: select Last menu (Figure 12) and click the lines TURBULENT SHEAR
RATES IN DIFFERENT ZONES and RESIDENCE TIME IN ZONES WITH
DIFFERENT TURBULENCE in TURBULENCE section.

Figure 12. Menu Turbulence as the Last menu option.

The output tables (Figures 13 and 14) corresponding to these groups of parameters will appear on
the screen.

Figure 13. Pilot crystallizer. Turbulent shear rates in different zones.

VisiMix Turbulent. Example 5. 9

Figure 14. Pilot crystallizer. Residence time in zones with different turbulence

Accordingly to the Table 1, the next stage of our calculations is based on simulation of
mixing in liquid-solid system.
To proceed, select Calculate in the main menu and click on Liquid-solid mixing. A sub-menu
corresponding to this simulation step will appear (Figure 15). Select this option LIQUID-SOLID
MIXING. MAIN CHARACTERISTICS in this sub-menu.

Figure 15. Menu Liquid-solid mixing - list of output parameters.

VisiMix Turbulent. Example 5. 10

As a response, the program provides an input table for additional initial data (Figure 16).

Figure 16. Entering of properties of solid and liquid phases.

Based on this information, VisiMix re-calculates the average properties of the media. If the calculated
values do not correspond to the data entered earlier, you receive a message shown in Figure 17.

Figure 17. A warning of the discrepancy between entered and calculated average media
properties.

VisiMix Turbulent. Example 5. 11

Let’s follow VisiMix recommendations and correct the data entered in the table AVERAGE
PROPERTIES OF MEDIA. (Figure 18).

Figure 18. Adjusted average properties of media.

After the corrected figures have been entered, the program performs simulation and returns the calculated
results table (Figure 19) corresponding to the requested output option.

Figure 19. Pilot crystallizer. Main characteristics of solid-liquid mixing.

VisiMix Turbulent. Example 5. 12

The next step – select Last menu and click COLLISIONS OF PARTICLES in the Liquid-solid mixing
section. The corresponding table (Figure 20) will arrive.

Figure 20. Pilot crystallizer. Collisions of particles.

The next stage of calculations – evaluation of mass transfer coefficient to suspended solid particles. Click
Calculate > Liquid-solid mass transfer (Figure 21).

Figure 21. Menu Liquid-solid mass transfer - list of output parameters.

This sub-menu covers simulation of dissolution kinetics. Our goal is limited to comparison of mass
transfer coefficients in two different crystallizers, so we select the output option Mass transfer coefficient
vs time (average). Additional information on solubility of solid and concentration of the mother solution
has to be entered. Taking into account the goal of our mass transfer calculations, we may enter some
approximate values of these parameters, and also approximate value of diffusivity (Figure 22).

VisiMix Turbulent. Example 5. 13

Figure 22. Entering approximate data for mass transfer calculations.

Result of calculation returned in a form of graph (Figure 23).The numerical value of the calculated
parameter is presented in the VisiMix report for this project (see Help).

Figure 23. Pilot crystallizer. Mass transfer coefficient.

Based on the output data presented tables in Figures 11,13,14,19,20 and 23, we can prepare a
table for comparison of the pilot and production scale crystallizers. On this stage only the column
related to the pilot crystallizer is filled (Table 2).

VisiMix Turbulent. Example 5. 14

Table 2. Comparizon of the pilot and production scale crystallizers.
Data for pilot crystallizer.
Menu section Parameter Pilot Production
Turbulence Energy dissipation – 106 W/kg
maximum value
Turbulent shear rate near 9660 1/s
the impeller blade
Relative residence time 0.00133
in zone with maximum
dissipation
Energy dissipation – 0.380 W/kg
average value
Liquid-solid mixing Maximum degree of non- 16.8%
uniformity- axial
Maximum degree of non- 1.13%
uniformity- radial
Maximum energy of 8.71e-11 J
collisions
Frequency of collisions of 0.0181 1/s
maximum energy
Liquid-solid mass Average mass transfer 0.000038 m/s
transfer coefficient (approx.)
The data included in the Table 2 represent basic characteristics for the pilot crystallizer.

Now let us enter the initial data for the available production-scale mixing tank that is supposed to be used as
a plant crystallizer. It is assumed that physical properties and regime parameters of the two crystallizers are
identical, and only size and design is different. So, we can rename the existing project and change the
equipment characteristics – Tank, Baffles and Impeller – accordingly to the technical characteristics of the
production scale tank presented above (Figures 24-26).

Figure 24. Entering data for the production plant tank.

VisiMix Turbulent. Example 5. 15

Figure 25. Entering baffles for the production plant tank.

Figure 26. Entering agitator A310 for the production plant tank.

The diagram of the production plant tank is shown in Figure 27. Save the current project under a
new name, for example, Cryst-production.vsm.

VisiMix Turbulent. Example 5. 16

Figure 27. Diagram of the production plant tank.

Now we return to calculations. In order to compare the relevant parameters of the crystallizers, we
perform calculations for the production tank in the same order as it has been done for the pilot
tank.

Select Turbulence in the main menu and click LOCAL VALUES OF ENERGY
DISSIPATION. A table containing the parameters Energy dissipation – maximum value and
Energy dissipation – average value will appear (Figure 28).

Figure 28. Production tank with A310. Local values of energy dissipation.

TURBULENT SHEAR RATES IN DIFFERENT ZONES and RESIDENCE TIME IN

ZONES WITH DIFFERENT TURBULENCE in Turbulence section.

VisiMix Turbulent. Example 5. 17

The tables (Figures 29 and 30) corresponding to these groups of parameters will appear on the
screen.

Figure 29. Production tank with A310. Turbulent shear rates in different zones.

Figure 30. Production tank with A310. Residence time in zones with different turbulence.

In the menu section Liquid-Solid mixing select LIQUID-SOLID MIXING. MAIN

CHARACTERISTICS and get the calculated parameters (Figure 31) on the screen.

VisiMix Turbulent. Example 5. 18

Figure 31. Production tank. Liquid-solid mixing. Main characteristics.

The next step – select Last menu and click COLLISIONS OF PARTICLES in the Liquid-
solid mixing section. The corresponding table (Figure30) will arrive.

Figure 32. Production tank with A310. Collisions of particles.

The last step – calculation of mass transfer coefficient via Calculate>Liquid-solid mass
transfer>Mass transfer coefficient vs time (average) (Figure 33).

VisiMix Turbulent. Example 5. 19

Figure 33. Production tank with A310. Mass transfer coefficient.

Based on the obtained results, we can print the calculated parameters for the plant tank into the Table 2 and
compare them with the corresponding parameters of the pilot crystallizer (see Table 2a).

Table 2a. Comparison of the pilot crystallizer and production scale tank with A310.

Menu section Parameter Pilot Production

with A310
Turbulence Energy dissipation – 106 W/kg 204
maximum value
Turbulent shear rate 9660 1/s 13400
near the impeller blade
Relative residence 0.00133 0.000278
time in zone with
maximum dissipation
Energy dissipation – 0.380 W/kg 0.359
average value
Liquid-solid mixing Maximum degree of 16.8% 13.0
non-uniformity- axial
Maximum degree of 1.13% 0.445
non-uniformity- radial
Maximum energy of 8.71e-11 J 1.34e-10
collisions
Frequency of collisions 0.0181 1/s 0.00474
of maximum energy
Liquid-solid mass Average mass transfer 0.000038 m/s 0.0000375
transfer coefficient (approx.)

VisiMix Turbulent. Example 5. 20

We can see now that the average turbulent dissipation (specific power) in the production tank
with the A310 agitator is very close to the same parameter of the pilot crystallizer. Characteristics
of distribuion of solid phase – the max. degree of non-uniformity - are also good enough.
However, the local value of energy dissipation around the agitator blades, and accordingly – shear
rate and maximum energy of collisions of crystals in this case are much higher than in the pilot
tank. It can result in a higher particle destruction and nucleation rate. So, it would be better to
keep the Max. local value of turbulent dissipation on about the same level as in the pilot tank.
This condition can be satisfied if we replace the A310 agitator with a Pitch paddle with the
following characteristics:

Diameter = 1000 mm;

Number of blades = 3;
Pitch angle = 45 deg;
Width of blade = 200 mm;

The next steps: select Pitch paddle and enter the dimensions of the agitator listed above (Figure
34.

Figure 34. Entering Pitch paddle impeller for the production plant tank.

Now we can perform the calculations in the same order as it has been done for the tank with
A310, complete the Table 2 with the new data and compare the calculated parameters of the tank
with Pitch paddle with the corresponding parameters of the pilot crystallizer (see Table 2b).

VisiMix Turbulent. Example 5. 21

Table 2b. Comparison of the pilot and production scale crystallizers.

Menu section Parameter Pilot Production with Production with

A310 Pitch paddle
Turbulence Energy dissipation – 106 W/kg 204 96.4
maximum value
Turbulent shear rate 9660 1/s 13400 9200
near the impeller blade
Relative residence time 0.00133 0.000278 0.00127
in zone with maximum
dissipation
Energy dissipation – 0.380 W/kg 0.359 0.313
average value
Liquid-solid Maximum degree of 16.8% 13.0 12.9
mixing non-uniformity- axial
Maximum degree of 1.13% 0.445 0.485
non-uniformity- radial
Maximum energy of 8.71e-11 J 1.34e-10 J 8.15e-11 J
collisions
Frequency of collisions 0.0181 1/s 0.00474 1/s 0.0168 1/s
of maximum energy
Liquid-solid Average mass transfer 0.000038 0.0000375 0.00365
mass transfer coefficient (approx.) m/s

Output tables for Maximum values of energy dissipation for the compared mixing conditions
are presented also in the Figure 35.

Figure 35. Maximum values of energy dissipation in the compared mixing tanks.

As it follows from the presented results, in the case under discussion mixing with the Pitch
paddle provides values of the relevant mixing parameters close to the parameters of the pilot
crystallizer.

VisiMix Turbulent. Example 5. 22