Reaction crystallization in strained fluid films

The detailed conditions during the ultimate stage of micromixing of the reactants in a reaction crystallization process are analysed. A mathematical model is developed to describe mass transfer, chemical reaction, and crystallization of a molecular compound in strained lamellar structures of reactant solutions inside the smallest vortices. The numerical calculation show that the supersaturation varies significantly in space and time, and suggest that significant crystallization may occur inside these vortices in the case of low-soluble and sparingly soluble compounds. At the end of the vortex lifetime, the crystal size distribution is quite dependent on the properties of the system and on the processing conditions. The number of crystals generated correlates strongly tot he maximum supersaturation occurring during the vortex lifetime, and this maximum supersaturation is as a first approximation well described by simplified mass transfer models where crystallization is neglected. Often a significant supersaturation remains at the end of the vortex lifetime and the size of the crystals leaving the vortex is determined by the growth rate rather than by nucleation and mass constraint. The mean size is usually larger than the limiting size for Ostvald ripening in the bulk and the size distribution is quite narrow. The results show that neglect of the detailed conditions in reaction crystallization of a molecular compound may not be justified.