Solid Features Modification by the Reactor Selection and US Support during Reactive Crystallization

The use of materials requires adjusting their features to current applications/needs. In crystallization, the production methods leading directly to the product with pre-determined characteristics are being sought. The research focuses on the abilities of “shaping” the solid product (CSD, shape, form, etc.) and is based on experimental work carried out in the ultrasound (US)-assisted Koflo static mixer (STM). As the model reaction calcium fluoride precipitation has been used as a “common denominator” that complements the previous authors’ studies, providing comprehensive knowledge and a more general look at the mentioned problem. It has been shown that it is possible to obtain crystals with the desired characteristics; however, one should be aware of the used reactors’ limitations. The conscious selection of operating conditions, as well as US parameters (if they are used), is also essential. It has been revealed that the introduction of US to the STM only affects the turbulence intensity, but it doesn’t change the mixing profile. The kinetics of crystallization remain unchanged, but crystals are subjected to greater attrition. In the stirred tank reactors, one might significantly improve the homogeneity of the unit mixing distribution by the selection of the relative input power ε(rel) and, thus, affect the kinetics of crystallization.