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Crystallization Solutions

In crystallization processes, mixing quality directly determines crystal size distribution, purity and yield. Mechanimix enables you to achieve repeatable results in your crystallization processes with CFD-assisted impeller design and custom reactor solutions.

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Crystallization Process
PARTICLE CONTROL

Precise Crystal Particle Size Control

Achieving a homogeneous and narrow particle size distribution in the crystallization process is the key to product quality and the efficiency of subsequent filtration/drying steps. Mechanimix NP series impellers maintain crystal growth rate under control by providing uniform flow throughout the tank.

High product quality with narrow particle size distribution
Controlled nucleation with homogeneous supersaturation profile
Increased efficiency in filtration and drying steps
Batch-to-batch repeatability
NP MixerHP Mixer
CFD OPTIMIZATION

Crystallization Process Optimization with CFD

In crystallization tanks, flow pattern, temperature distribution and concentration profile are closely interrelated. Mechanimix CFD engineers perform flow simulations of your crystallization tanks to identify dead zones and optimize impeller configuration.

Dead zone detection with 3D flow simulation
Temperature and concentration gradient analysis
Impeller type and position optimization
Scale-up verification
HM Impeller
REACTOR SOLUTION

Crystallization Reactors and Jacketed Systems

Precise temperature control is critical in the crystallization process. Mechanimix RC-M series jacketed reactors maximize crystal quality by precisely managing cooling/heating ramps. HWM series impellers provide effective suspension even at high solid ratios.

Precise cooling/heating ramps with jacketed reactor
Effective suspension at high solid ratios
316L and Hastelloy material options
Design suitable for vacuum crystallization
RC-M ReactorHWM Impeller
INDUSTRY APPLICATIONS

Crystallization in Chemical and Pharmaceutical Industries

Mechanimix crystallization solutions are used across a wide range of applications, from sugar crystallization to pharmaceutical active ingredient production, salt crystallization to specialty chemicals. A custom impeller and reactor configuration is designed for each process.

Pharmaceutical sector: API crystallization, GMP compliant
Chemical sector: salt, sugar and specialty chemical crystallization
Mining sector: solution crystallization and purity control
Food sector: lactose and citric acid crystallization
Blog: Particle Size Control in Crystallization →
FREQUENTLY ASKED QUESTIONS

Frequently Asked Questions

How does mixing speed in a crystallization tank affect crystal size?+
Mixing speed sets the tank's supersaturation profile and shear forces. Too slow a speed causes non-uniform supersaturation and a broad crystal size distribution, while too fast a speed causes crystal breakage (attrition) and secondary nucleation, producing unwanted fines. Mechanimix uses CFD to determine the optimum impeller speed and tip speed (Vtip) for your target crystal size distribution.
What's the difference in mixing requirements between vacuum and cooling crystallization?+
In vacuum crystallization, flash evaporation can create localized cooling and supersaturation shocks, so the mixer must achieve fast tank-wide homogenization. In cooling (jacketed) crystallization, the main challenge is avoiding localized over-cooling zones near the jacket surface, which requires an impeller configuration with high surface-to-volume circulation. Mechanimix designs the RC-M series jacketed reactor and matching impeller combination for both process types.
Which impeller type should be used in a crystallization reactor?+
Axial-flow HWM-type impellers are generally preferred because they provide effective suspension even at high solids ratios and have a low-shear profile that minimizes crystal breakage. HM-type impellers can also be used depending on process conditions (viscosity, solids ratio, tank geometry); the final selection is validated with CFD analysis.
How is nucleation controlled in a crystallization process?+
Nucleation depends on the degree of supersaturation and local mixing quality within the tank. A homogeneous supersaturation profile prevents uncontrolled primary nucleation and makes crystal growth more predictable. Mechanimix's CFD-driven impeller design eliminates dead zones to maintain a consistent supersaturation distribution throughout the tank.

Engineering Support for Your Crystallization Process

With our CFD simulation expertise and process experience, we design the most efficient mixing solution for your crystallization tanks.

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