Population Balance Modeling and Optimization of an Integrated Batch Crystallizer–Wet Mill System for Crystal Size Distribution Control

Abstract

In this work, the modeling, simulation, and optimization of an integrated batch crystallizer, wet mill system are presented. It is shown that by coupling the external wet mill to the crystallizer it is possible to increase the overall system flexibility, increase the attainable crystal size distribution (CSD), and provide a significantly better distribution shaping control than the crystallizer alone. The population balance modeling approach with appropriate mechanisms is applied for the description of crystal population in both the crystallizer and wet mill. This description generates a system of partial differential-integral equations, which are solved with a high resolution finite volume method, involving calculations on parallel graphical processing unit for improved solution time. In the batch crystallizer, it is assumed that primary nucleation and crystal growth are the key mechanisms, whereas in the wet mill, attrition and fragmentation of crystals occurs. The nucleation and growth rate kinetics ar...