Conceptual Design of Crystallization Processes

368 Pages·2020·18.864 MB·English

by  Christianto Wibowo, Ka Ming Ng

ChristiantoWibowo,KaMingNg
ConceptualDesignofCrystallizationProcesses
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Christianto Wibowo, Ka Ming Ng
Conceptual Design
of Crystallization
Processes
Authors
Dr.ChristiantoWibowo
ClearWaterBayTechnologyInc.
671BreaCanyonRoad,Suite5
Walnut,CA91789
USA
E-Mail:[email protected]
Prof.KaMingNg
Dept.ofChemicalandBiologicalEngineering
HongKongUniversityofScienceandTechnology
ClearWaterBay
HongKong
China
E-Mail:[email protected]
ISBN978-1-5015-1987-1
e-ISBN(PDF)978-1-5015-1990-1
e-ISBN(EPUB)978-1-5015-1352-7
LibraryofCongressControlNumber:2020948686
BibliographicinformationpublishedbytheDeutscheNationalbibliothek
TheDeutscheNationalbibliothekliststhispublicationintheDeutscheNationalbibliografie;
detailedbibliographicdataareavailableontheInternetathttp://dnb.dnb.de.
©2021WalterdeGruyterGmbH,Berlin/Boston
Coverimage:christiantowibowo
Typesetting:IntegraSoftwareServicesPvt.Ltd.
Printingandbinding:CPIbooksGmbH,Leck
www.degruyter.com
TothememoryofJimDouglas

About the Authors
ChristiantoWibowoisgroupmanagerandprincipalengineeratClearWaterBayTechnology,Inc.,
Walnut,California.HeobtainedaBSdegreefromBandungInstituteofTechnology,Indonesia,and
aPhDfromtheUniversityofMassachusettsAmherst,bothinchemicalengineering.Hewasa
postdoctoralfellowattheHongKongUniversityofScienceandTechnologybeforejoining
ClearWaterBayTechnologyin2002,wherehehasbeenmanagingconsultingprojectsonawide
rangeoftopicsincludingprocesssynthesis,processmodeling,processimprovement,andenergy
management.Hewasinvolvedinthedevelopmentofnovelprocessessuchasthepatented
processesfortheproductionofmethylisobutylketoneandneopentylglycol.Dr.Wibowoisa
seniormemberoftheAmericanInstituteofChemicalEngineers(AIChE),wherehereceivedthe
ProcessDevelopmentDivisionStudentPaperAwardin2002.HeisanactivememberoftheProcess
DevelopmentDivision.
Dr.Wibowohasbeendevelopingaframeworkfortheconceptualdesignofcrystallization
processes,startingfromhisPhDresearchworkonaunifiedapproachforcrystallizationprocess
synthesis.ThroughhiscontinuingcollaborationswithProf.KaMingNg’sresearchgroupatthe
HongKongUniversityofScienceandTechnology,theframeworkhasbeenexpandedinvarious
directionstoallowitsuseindifferentsystemsandapplications.Concurrently,hewasinvolvedin
consultingprojectsonthedevelopmentofcrystallizationandsolid–liquidseparationprocesses,in
whichtheframeworkwasfine-tunedtosolvereal-lifeproblems.Thelearninghasbeen
disseminatedinpublicaswellasin-houseshortcoursesaroundtheworld.Heistheinstructorof
anonlineversionofthecourse,whichisapartofAIChE’seLearningprogram(http://www.aiche.
org/academy/courses/ela101/crystallization-process-development).
KaMingNgiscurrentlyCTOofCNInnovationsandProfessorEmeritusofChemicalandBiological
EngineeringattheHongKongUniversityofScienceandTechnology.From1980to2000,heserved
asprofessorofchemicalengineeringattheUniversityofMassachusetts(UMass)Amherst.He
joinedtheHongKongdepartmentin2000andservedasHeadfrom2002to2005.HewasCEOof
theNanoandAdvancedMaterialsInstituteLtd.,agovernmentfundedR&Dcenterfrom2006to
2013.Inthispositon,heworkedwithinvestorsandindustrialistsinHongKongandMainland
Chinatodevelopproductsandthecorrespondingmanufacturingprocessesfocusingonthe
applicationofnano-andadvancedmaterials.Heservedascorporatescienceandtechnology
advisorforMitsubishiChemical,Japan,from2001to2013.HeheldvisitingpositionsatDuPont,
MIT,andtheNationalUniversityofSingapore.Hisresearchinterestscenteronproduct
conceptualization,processdesign,andbusinessdevelopment.Heisaneditor/editorialboard
memberofvariousjournals.HefoundedanumberofcompaniesintheUnitedStatesandin
HongKong.Hehasservedasaboardmemberforprivateandlistedcompanies.ProfessorNgisthe
recipientoftheGeneralElectricOutstandingTeachingAward.HeisafellowoftheAmerican
InstituteofChemicalEngineerswherehereceivedtheExcellenceinProcessDevelopmentResearch
Awardin2002.InHongKong,heservedasanadvisorforteamswinningtopprizesintheannual
OneMillionDollarEntrepreneurshipCompetition.
WhileatDuPontCentralR&Din1995–1996,ProfessorNgworkedonreactordesignanddesign
ofcommodityandagriculturalchemicalplants.Inparticular,hearticulatedamultiscale
perspectiveforthedesignofreactionsystems.From1998to2001,hewasateammemberat
MitsubishiChemical,Japan,forthedevelopmentofanovel50,000tonmonomerplantthatwon
theJapanPetroleumInstituteAwardforTechnologicalProgressin2004.Inthisproject,histeam
conceptualized,scaled-up,andcommercializedanovel10-mtalltrickle-bedreactorfor
acetoxylationreactionathighpressureandtemperature.Inacademicresearchofprocesssystems
https://doi.org/10.1515/9781501519901-202
VIII AbouttheAuthors
engineering,hehasbeenfocusingonthedesignofsolidprocessingplants,theconceptualdesign
ofcrystallizationsystems,andconsumerproducts.
ProfessorNgstartedhisresearchonproductdesignofpersonalcareproductsinthelate
1990satUMass.Thiswasexpandedtootherproducts,classifiedintomolecular,functionaland
formulatedproducts,anddevices.In2006,alongwithR.GaniandK.Dam-Johansen,heedited
ChemicalProductDesign:TowardaPerspectiveThroughCaseStudies,publishedbyElsevier.
Basedonhisexperienceinentrepreneurshipandinteractionswithproductinnovators,he
formulatedasystematicmultidisciplinary,multiscale,hierarchicalapproachalongwithsomeof
thenecessarytoolsandmethodstoproductdesign.TheseideasaredescribedinatextProduct
andProcessDesignPrinciples:Synthesis,Analysis,andEvaluation,4thEd.(withW.D.Seider,
D.R.Lewin,J.D.Seader,S.Widagdo,andR.Gani)publishedbyWileyin2017.
Preface
Crystallizationcanbeviewedfromtwoperspectives.Themostcommonperspective,
by far, views crystallization as an isolated chemical processing step or unit opera-
tion from which the crystals of a single compound of desired purity, crystal size,
shape,chirality,and/orpolymorphicformarerecoveredfromasolution.Avolumi-
nous body of literature exists focusing on this point of view. Another perspective
thatviewscrystallizationasamulticomponentseparationprocesshasnotreceived
adequateattention.Thecompoundtobecrystallizedrarelyexistsbyitself.Itisim-
portant to understand how to design a process to recover the crystals of a desired
componentorcomponentsfromamixtureofcompoundsinconjunctionwithother
unitoperationssuchasfiltration,distillation,andsoon.
Our research on crystallization process design started around 1990 at the
University of Massachusetts Amherst (UMass) under the guidance and encourage-
mentofProfessorJimDouglas,whopioneeredconceptualprocessdesign.Acrystalli-
zation separation process is conceptualized by representing it as a sequence of
processpointsonasolid–liquidequilibrium(SLE)phasediagram.Thedisparatetra-
ditionalcrystallizationtechniquessuchasfractional,extractive,reactive,andantisol-
vent crystallization were unified under this approach. The mathematical framework
forrepresentinghigh-dimensionalSLEphasediagramsforbothelectrolyteandnon-
electrolytesystemsweredeveloped,therebyallowingthedesignofamulticomponent
system with complex phase behavior. This effort was continued at the Hong Kong
UniversityofScienceandTechnology(HKUST)startingin2000,focusingonexperi-
mentalaspectsofmulticomponentcrystallization.Therecoveryofisoflavone,ibupro-
fen, various inorganics from a salt lake, stereoisomers from natural herbs, and
proteins were considered. Concurrently, the methods and experimental techniques
developed were successfully applied to a large number of industrial design projects
from companies in the United States, Japan, China, and other countries around the
worldthroughconsultancy.
Theaimofthisbookistoprovideacomprehensiveexpositionofthefundamen-
tal and practical aspects of crystallization as a separation process. Much of the
book is derived from the short courses at the American Institute of Chemical
Engineers meetings, other international conferences, and various industrial sites,
as well as the lectures delivered at UMass and HKUST. This book is intended for
researchers and engineers interested in the design of crystallization processes. As
crystallizationisanintegralpartofchemicalprocesses,itcanalsobeusedasaref-
erencetextforuniversitycoursesonprocessdesign.Exerciseproblemsareprovided
toenhancethepedagogicalaspectofthismonograph.
Wewouldliketoexpressourdeepappreciationforthecontributionofformerstu-
dentsandassociatesatUMassandHKUST:Dr.DavidBerry,Mr.MarcosCesar,Dr.Alex
Chan, Mr. Stephen Chan, Dr. Wen-Chi Chang, Dr. Alice Cheng, Dr. Susan Dye,
Dr. Kelvin Fung, Dr. Benny Harjo, Dr. Priscilla Hill, Dr. Vaibhav Kelkar, Dr. Martin
https://doi.org/10.1515/9781501519901-203
X Preface
Kwok, Dr. Emily Lai, Mr. Arthur Lam, Ms. Carrie Lam, Dr. Candy Lin, Dr. Michelle
Lin, Mr. Owen Luk, Dr. Thomas Pressly, Dr. Shankar Rajagopal, Dr. Ketan Samant,
Dr.JosephSchroer,Dr.SzeKeeTam,andmanyothers,tothecontentsinthisbook.We
alsothankDr.LionelO’YoungandothercolleaguesatClearWaterBayTechnology,as
well as our industrial partners, for valuable discussions during the course of various
projectsinwhichwewereinvolved.