Crystallization

  • Superior Crystal Quality Attributes (CQAs)
  • Continuous Operation without Transfer Lines
  • Easy Scale Up from Lab to Plant

 

Description

Zaiput has developed a continuous crystallizer for Pharmaceutical and fine chemical
applications which utilizes 11 Tanks-in-Series to achieve plug flow characteristics. The novel A-
PUSH system ensures adequate slurry transfer through the device and eliminates the major
issue of fouling of transfer lines, typically seen in other continuous crystallizers.
There are many significant challenges when performing crystallizations in batch or flow in
traditional process vessels. Zaiput Flow Technologies’ patented crystallizer makes dealing with
challenging crystallizations easier by offering enhanced tight control on your process
parameters, improving critical quality attributes (CQAs).

Crystallizations can be optimized at the lab scale and then directly scaled to production using
our technology.

Whether you are new to crystallization or a veteran, KryZr is the ultimate tool for your
process.

 

Features

Important Features:

  • Superior Plug Flow Characteristics
    The 11 connected tanks in series offer unprecedented plug flow characteristics within one unique device.
  • No Need for Transfer Lines
    The tanks are all connected, thus there is no need to worry about transfer lines or fouling.
  • Minimal Internal Volume
    Our devices have a small internal volume to minimize footprint, reagent consumption, and material costs during development.
  • Continuous Operation
    Our devices can boost productivity and can be easily used and integrated within either a batch process or a continuous one.

Other Advantages:

  • Excellent Supersaturation Control & Fast Mixing
    The innovative impeller design and small internal volume of each tank offer fast mixing and very tight control on supersaturation conditions, improving your CQAs.
  • Excellent Temperature Control
    The innovative design offers very tight control on the temperature within each tank to improve your CQAs.
  • Chemical Compatibility
    Machined in materials with excellent chemical resistance, Zaiput crystallizers work with a wide range of organic solvents, in acidic and basic solutions.
  • Easy Usage and Maintenance
    Plug and play functionality at all scales.
  • Rapid Scaling
    Processes can be optimized at the lab scale and then directly scaled to production quickly thanks to the scaling geometry factor which maintains residence time and performance constant across scales.

How It Works

Zaiput Flow Technologies’ patented crystallizer can carry out continuous crystallization processes by guaranteeing a uniform and consistent flow distribution of the reagents and the crystals through the device while optimizing supersaturation conditions and control, leading to better critical quality attributes (CQAs).

  • The saturated process stream enters the vessel at the bottom of the device and travels upward through the connected tanks.
  • Antisolvent can be added at any tank inside the device through dedicated ports based on user preferences.
  • The distributed antisolvent ports provide means for increased control of supersaturation in each tank.
  • Temperature control at the extremities of the device allows for a linear gradient or uniform temperature during crystallization.
  • The crystallizer is also designed to maintain a constant temperature inside each tank even when conditions are fluctuating.
  • Liquid and slurry transfer is powered by the A-PUSH system, which is depicted in the figure below.
  • The internal structure of the reactor components enhances mixing and mass transfer while maintaining plug flow characteristics.
  • Nonreturn valves at the bottom of each tank prevent any back mixing of liquid or crystals.
  • The crystallization process happens inside the device based on user-specified settings in a very controlled manner. This leads to a narrow RTD and optimal supersaturation conditions to boost performance and obtain optimal CQAs.
  • Formed crystals are ejected at the top of the device.


Zaiput’s Crystallizer allows to carry out crystallization processes in a small confined space, highly engineered to boost performance and optimal CQAs.

Literature

Scientific articles featuring our crystallizer:

Specifications

Crystallizer – Laboratory Scale
Crystallizer – Laboratory Scale
Part Number KryZr-10
Volume 86 mL
Wetted Parts 316 Stainless Steel or Hastelloy
Flow Rate 0–7 mL/min
Temperature Range −10–80°C
Recommended Particle Size ≤ 500 µm
Solid–Liquid Density Difference 0–0.56 g/cm³

*Scroll left to see more of the table

Crystallizer – Pilot Scale
Crystallizer – Pilot Scale (Coming Soon)
Part Number KryZr-100
Volume ~850 mL
Wetted Parts 316 Stainless Steel or Hastelloy
Flow Rate 0–70 mL/min
Temperature Range −10–80°C
Recommended Particle Size ≤ 500 µm
Solid–Liquid Density Difference 0–0.56 g/cm³

*Scroll left to see more of the table

Crystallizer – Production Scale
Crystallizer – Production Scale (Coming Soon)
Part Number KryZr-1000
Volume ~8.5 L
Wetted Parts 316 Stainless Steel or Hastelloy
Flow Rate 0–700 mL/min
Temperature Range −10–80°C
Recommended Particle Size ≤ 500 µm
Solid–Liquid Density Difference 0–0.56 g/cm³

 

*Scroll left to see more of the tab*

Ordering Information

FAQ

FAQs about the Zaiput Crystallizer

What is the temperature range of the Zaiput crystallizer?

Zaiput crystallizers can be operated between -10 and 80 °C. If you need to go below or above these limits, please contact us at support@zaiput.com for a potential customized option.

What makes the Zaiput crystallizers unique among conventional crystallizers?

Zaiput crystallizers allow you to carry out crystallization processes in flow without having to worry about handling slurries or transfer lines that are prone to fouling. They offer a turn-key solution that can be tuned to address any crystallization needs, thanks to superior control over process parameters such as mixing, antisolvent addition, and supersaturation conditions. Performance and control are also strongly enhanced by the substantial engineering design behind the crystallizer structure and its components. The minimal internal tank volume allows you to carry out research studies without requiring excessive amounts of reagents or starting material. Additionally, the technology is easily scalable from lab to pilot to plant due to the smaller tank volumes.

Can Zaiput crystallizers handle acidic or basic solutions?

The standard material of construction is 316 SS. However, to enhance chemical compatibility we also provide a version made with Hastelloy C276. Please contact Zaiput at support@zaiput.com for a potential customized option with a different material or added coating.

What throughput can the Zaiput crystallizer accommodate?

The lab-scale Zaiput crystallizer is an 86 mL (total) vessel composed of 11 tanks, which can accommodate liquid flow rates up to 7 mL/min. The pilot-scale crystallizer is one order of magnitude larger, with approximately 850 mL of total volume and flow rates up to 70 mL/min. The production-scale crystallizer is a further order of magnitude larger, with approximately 8.5 L of total volume and flow rates up to 700 mL/min.