Optimization of batch cooling crystallization systems considering crystal growth, nucleation and dissolution. Part I: Simulation

IF 4.1 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology Pub Date : 2024-11-09 DOI:10.1016/j.partic.2024.10.018

Qilei Xu , Bin Lian , Yan Long , Baoming Shan , Xuezhong Wang , Fangkun Zhang

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Abstract

Optimal control of batch crystallization systems is still a focus and hot topic in the field of industrial crystallization, which seriously affects the consistency of batch product quality. In this paper, a new method with a new objective function and improved optimization algorithm was proposed for optimization of crystal size distribution (CSD) in case of fine crystals occurrence. The new objective function was developed with better margin metric and weighting technique to minimize fine crystal mass, meanwhile, a newly constructed sinusoidal weight function was introduced to improve the particle swarm optimization (PSO) algorithm. A precise control of CSD with suppressed numerical discrepancy caused by fine crystals removal was developed by combining seed recipe and temperature-swing. In addition, the effects of temperature curve segments on CSD during process optimization were systematically investigated to achieve optimal results. Two typical batch cooling crystallization systems were used to verify the effectiveness of the proposed method in controlling product CSD while minimizing fine crystal mass. Results demonstrated that the desired product CSD can be achieved with minor errors while the fine crystals could be shrunk to be negligible, i.e., the fine crystal mass and number can be reduced by over 90%. This work has an important guiding significance for the removal of fine crystals in industrial crystallization processes, especially when only operational optimization rather than equipment updating is considered.

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考虑晶体生长、成核和溶解的批量冷却结晶系统优化。第一部分：模拟

批量结晶系统的优化控制仍然是工业结晶领域的焦点和热点话题，它严重影响着批量产品质量的一致性。本文提出了一种具有新目标函数和改进优化算法的新方法，用于在出现细小晶体的情况下优化晶体尺寸分布（CSD）。新的目标函数采用了更好的余量指标和加权技术，以最小化细晶质量，同时引入了新构建的正弦加权函数，以改进粒子群优化（PSO）算法。通过结合种子配方和温度摆动，开发了一种精确控制 CSD 的方法，抑制了细晶去除引起的数值偏差。此外，还系统地研究了工艺优化过程中温度曲线段对 CSD 的影响，以获得最佳结果。使用两个典型的批量冷却结晶系统来验证所提出的方法在控制产品 CSD 同时最大限度减少细晶质量方面的有效性。结果表明，在微小误差的情况下就能达到所需的产品 CSD，而细小晶体则可缩小到忽略不计，即细小晶体的质量和数量可减少 90% 以上。这项工作对于在工业结晶过程中去除细小晶体具有重要的指导意义，尤其是在只考虑操作优化而不是设备更新的情况下。

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来源期刊

Particuology 工程技术-材料科学：综合

CiteScore

6.70

自引率

2.90%

发文量

1730

审稿时长

32 days

期刊介绍： The word ‘particuology’ was coined to parallel the discipline for the science and technology of particles. Particuology is an interdisciplinary journal that publishes frontier research articles and critical reviews on the discovery, formulation and engineering of particulate materials, processes and systems. It especially welcomes contributions utilising advanced theoretical, modelling and measurement methods to enable the discovery and creation of new particulate materials, and the manufacturing of functional particulate-based products, such as sensors. Papers are handled by Thematic Editors who oversee contributions from specific subject fields. These fields are classified into: Particle Synthesis and Modification; Particle Characterization and Measurement; Granular Systems and Bulk Solids Technology; Fluidization and Particle-Fluid Systems; Aerosols; and Applications of Particle Technology. Key topics concerning the creation and processing of particulates include: -Modelling and simulation of particle formation, collective behaviour of particles and systems for particle production over a broad spectrum of length scales -Mining of experimental data for particle synthesis and surface properties to facilitate the creation of new materials and processes -Particle design and preparation including controlled response and sensing functionalities in formation, delivery systems and biological systems, etc. -Experimental and computational methods for visualization and analysis of particulate system. These topics are broadly relevant to the production of materials, pharmaceuticals and food, and to the conversion of energy resources to fuels and protection of the environment.