Technoforce Plug Flow Crystallizer (TPFC) for Uniform Crystal Size Distribution

After various research and inspections, it was concluded that Technoforce Plug Flow Crystallizer
(TPFC) is more effective Crystallizer than the other ones, as it uses 1000 times lesser energy.

To understand it in detail, let us take a look at the paragraphs below:

When crystals are formed out of a solution, impurities get concentrated in the mother liquor. The purity
of the crystals relies on how efficiently the mother liquor is washed out from the filter cake, after the
process of filtration or centrifugation. Uniformity in size of crystals or narrow crystal size distribution
(CSD) helps in improving the washing of the crystals and thus the purity. Certain important
characteristics like viscosity, maneuverability, density, and compressibility of the powders also depend
upon CSD.

Conventional continuous crystallizers have inherent limitations in achieving uniformity in crystal size.
They tend to produce inconsistent results mainly due to uncontrolled nucleation. In order to achieve
the results, secondary nucleation is also implemented which results in large energy dissipation. An
improved control of crystal size distribution is obtained in a continuous flow design that has negligible
back-mixing with a residence time distribution approaching that of an ideal Plug Flow Crystallizer
(PFC).

The trade-off in the design of conventional crystallizers is overcome by Technoforce Plug Flow
Crystallizer (TPFC). The unique agitator design of TPFC (Technoforce Plug Flow Crystallizer)
achieves uniformity in mixing with minimum power input. The uniform supersaturation eliminates
uncontrolled primary nucleation. The energy dissipation of agitator of TPFC (Technoforce Plug Flow
Crystallizer) is 1000 times less as compared to a batch kettle. Therefore, the formation of fine crystals
due to breakage of existing crystals is minimized. The need of secondary nucleation is also nullified.

Design:

Inside a Plug Flow Crystallizer (PFC), a shaft with uniquely arranged blades rotates within a shell. The
material flows through in a near plug flow manner under uniform and gentle agitation. Multiple
heating/cooling sections provide controlled temperature gradients to it. The Gentle Agitation minimizes
the possibility of any breakage of crystals. It can have several openings along its length for the addition
of seeds or anti-solvents.

Features:

 TPFC runs continuously. It is possible to achieve residence time from 0.5 hours to 10 hours.
 TPFC can be operated in cooling or evaporative mode.
 Crystallization with anti-solvents is possible.
 Can be used with high percentage of solids in slurries.
 Good control of concentration profile to avoid uncontrolled nucleation.
 Plug flow conditions and low attrition between crystals.
  Easy conversion from batch operation to continuous operation.

Applications:

 Bulk drugs and intermediates.

 Fine chemicals.
 Inorganic and organic salts.
 Any application where close crystal size distribution is desired.