2016

ChE-06 (A)
Hanan Zulfiqar

[TYPES OF CRYSTALLIZERS]
Submitted to : Mr. Waqas Anjum
I . ABSTRACT
In this excerpt, we shall be discussing about crystallizers utilized on an
industrial scale to achieve crystals from solutions. Moreover, we will be
elaborating on why different types of crystallizers exist rather than having just
a single crystallizer. The applications will also be touched on.

II. TYPES OF CRYSTALLIZERS

The crystallizers are categorized according to their working principles. The
categories are as follows :
Cooling crystallizers
o Non-agitated vessels
o Agitated vessels
o Scraped-surface crystallizers
o Direct-Cooling
Evaporating Crystallizers
Vacuum crystallizers (Adiabatic cooling)
Continuous Crystallizers
o Forced-circulation crystallizers
o Fluidized bed crystallizers
o Draught-tube agitated vacuum crystallizers

A. Non-Agitated Vessels
This particular crystallizer consists of an open tank used for crystallization. The
feed is a hot solution. After entering the tank, it loses heat to the atmosphere
and to the cooling jackets causing it to cool. Thus, resulting in crystal
formation. Metallic rods could also be suspended in the cooling solution to
enhance the rate of crystallization by giving the molecules a surface to
crystallize on.
The pros of having such a type of crystallizer is that it's simple and relatively
easy to construct. However, the labor costs are high and the throughput is
relatively small compared to the feed.

It is used in the formation of salt crystals from sea water.

B. Agitated Vessels
The one main problem with non agitated vessels was that crystallization could
not be controlled. Thus, to get a better control on the process and the size of
the product crystals in turn; Agitators are used. This helps in getting a more
uniform particle size distribution of crystals with better properties.
There can be two configurations from this type of crystallizer.
Internally circulating stream and externally circulating stream of solution.
External circulation enhances the mass and heat transfer rates.
In internally circulating crystallizers, solution is allowed to go through the
draught tube to the growth section where crystal growth occurs and the
cooling is improved by increasing the cross sectional area gradually. Allowing it
to calm.

Crystal encrustation is greatly reduced from before and better throughput is

observed. It can also be used in a continuous format unlike its predecessor.

It is used in Sugar industry to exhaust the molasses.

C. Scraped-Surface
In the crystallizer a semi cylindrical trough is used as a means to store the
solution. The trough is at an angle downwards to the ground to allow for a
natural movement of solution through the trough. Moreover, to improvise a
scraper is installed that keeps the trough clean by scraping off crystals. It is
helically shaped to also improve the movement of the solution.

It is used for substances that have a high solubility in water.

Mainly used in wax & fat processes.

II. Direct cooling

The need to reduce crystal encrustation is real and solution is out there. Infact,
it's this very type of crystallizer. Instead of conventional heat exchangers which
have a tendency to form cold/hot spots. We use a cooling medium. The
properties of the cooling medium coincide with the process need. For instance,
the cooling medium could be :
 easily mixed in the solution, and could boil on heat transfer
easily mixed in the solution, but doesn't boil
hard to mix in the solution, and could boil easily
hard to mix in the solution, but doesn't boil.
Applications range from dewaxing to desalination.

III. Evaporating
Evaporating crystallizers are extremely efficient for substances that don't show
a decline in solubility after reducing the temperature or cooling the solution.
So a better crystallization method for such feed would be to evaporate the
solvent in the solution.
Multi-effect evaporators could be used to increase purity and throughput.
They are operated on low pressures to keep the integrity of the product when
heated.
One of the major uses of such crystallizers is the production if common salt in
food industry.

IV. Vacuum
A vacuum crystallizer works more or less on the same operational
requirements as the evaporating crystallizers. On the contrary, they have an
additional concept that is added to improve crystallization and that is adiabatic
cooling. For this to work, the feed should have a higher temperature when
compared to the temperature in the vessel.
Vacuum crystallizers show up in almost every major industry. For instance,
Pharmaceutical industries to allow for sensitive materials to be crystallized.

V. Forced-circulation
Forced-circulation is a continuous type crystallizer. It greatly reduces the
encrustations by increasing the re-circulating rate of the magma crystals
through a heat exchanger. Thus, also cooling down the magma crystals and
encouraging crystal growth. The feed is pumped to a vessel that has a reduced
pressure to increase nuclei formation and crystal growth.
It is widely used in the manufacture of organic polymers.

VI. Fluidized bed

Also one of the continuous type used in industries today. Fluidized bed
Crystallizers are called this way since the feedstock and the crystal magma
together are pumped through the heat exchanger to achieve supersaturation
of the solution and then inlet into a conical section where crystals are formed
at the bottom. However, the dynamic pressure of the feedstock and the
magma crystals cause fluidization of the crystal particles. The fine particles are
removed and the crystals are collected from the bottom.
It is used in metallurgical industry to produce metal crystals.

VII. Draught-Tube agitated vacuum

The crystal slurry is made to circulate through a tube called the Draft tube. This
is achieved with the help of an agitator. The crystallizer is also effective in
removing fines from mother liquor in the baffle zone. A better control on
crystal size and distribution results.
Used to produce Ammonium sulfate.