Microwave Assisted Direct Nucleation Control for Batch Crystallization: Crystal Size Control with Reduced Batch Time

Direct nucleation control (DNC) is a feedback control strategy, based on an in situ measurement of the number of particles. In batch cooling crystallization processes, the DNC approach utilizes temperature cycling to control the supersaturation profile during the batch. As a result of this cycling, product crystals with a large mean size and a narrow size distribution can be achieved due to the dissolution of undesired fines. However, implementing the temperature cycles may come at the expense of significantly prolonged batch times due to conventional heat transfer limitations and practical limitations for implementing actuation for both conventional heating and cooling. In this work, microwave heating in combination with DNC is presented to eliminate limitations of conventional heating and further improve the effectiveness of DNC. The results show a very rapid response when using microwave heating, which allowed for improved effectiveness of DNC. In particular, batch times under DNC could be reduced by 50% using microwave heating compared to conventional heating, producing crystals with a narrow distribution similar to experiments with conventionally heated DNC.