Crystallization from solution is a core technology in major sectors of the
chemical process and allied industries. Crystals are produced in varying sizes
ranging from as small as a few tens of nanometers to several millimetres
or more, both as discrete particles and as structured agglomerates. Well-
established examples include bulk and fine chemicals and their intermediates,
such as common salt, sodium carbonate, zeolite catalysts and absorbents,
ceramic and polyester Ñге-cursors, detergents, fertilizers, foodstuffs, pharma
ceuticals and pigments. Applications that are more recent include crystalline
materials and substances for electronics devices, healthcare products, and a
wide variety of speciality applications. Thus, the tonnage and variety of particu
late crystal products worldwide is enormous, amounting to about half the
output of the modern chemical industry. The economic value, social benefit
and technical sophistication of crystal products and processes are ever increas
ing, particularly in the newer high added value sectors of global markets. This
places yet greater demands on the knowledge, skill and ingenuity of the scientist
and engineer to form novel materials of the required product characteristics
and to devise viable process engineering schemes for their manufacture.
Particulate crystallization processes often require subsequent solid liquid
separation. Thus, the unit operation of crystallization is normally only part
of a wider processing system. These systems should preferably be designed and
optimized as a whole problems detected in one part of the plant (poor
filtration say) may in fact arise in another (inadequate crystallizer control).
Attention to the latter rather than the former can result in a simpler, cheaper
and more robust solution. Similarly, the scale of crystallizer operation can have
a large effect on crystal product characteristics and hence their subsequent
separation requirements. Previously a largely empirical art, the design of pro
cess systems for manufacturing particulate crystals has now begun to be put
on a rational basis and the more complex precipitation processes whereby crys
tallization follows fast chemical reactions have been analysed more deeply.
This progress has been aided by the growing power of the population balance
and kinetic models, computational fluid dynamics, and mixing theory. This
not only increases understanding of existing processes but also enhances the
possibility of innovative product and process designs, and speedier times to
market. Several large gaps in knowledge remain to be filled, however, thereby
providing opportunities for further research. This perspective gives the reason
for writing the book, and provides its theme.