The reverse addition process in anti-solvent crystallization is safer and more efficient than sieving when dealing with energetic compounds. A new mathematical model has been developed to understand the crystal size mechanism during the reverse addition of solvent in a binary system. This model incorporates droplet dynamics, distribution moments, and mass balance constraints. It can be used to predict the appropriate crystal size for designing explosive recipes with a desired particle size distribution to maximize energy output. The model was validated by conducting reverse-addition crystallization of sodium chloride in a deionized water/ethanol binary system at temperatures ranging from 10 to 50 degrees Celsius. The predicted results closely matched the experimental findings, which were confirmed using a Laser Particle Size Analyzer and Electron Microscope Scanning.
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