Impeller geometry effect on crystallization kinetics of borax decahydrate in a batch cooling crystallizer

The effects of impeller type and diameter in a batch cooling crystallizer on the nucleation and crystal growth kinetics as well as on the shape and size distribution of borax decahydrate crystals were investigated. Two different types of impellers of various sizes were applied. Chosen impeller configurations generate completely different fluid flow patterns in the crystallizer what allows to investigate the influence of the axial and radial flow on the kinetic parameters as well. The nucleation in crystallizer was taking place by the heterogeneous nucleation mechanism at all mixing conditions. The number of crystals formed by this mechanism increases as ratio D/dT decreases and it is higher when an axial flow pattern in crystallizer has been developed. The crystal growth rate increases with increasing the impeller size in observed supersaturation range. The radial impeller defined by ratio D2/dT = 0.58 could be considered as viable option for growth of borax crystal, since the further enlargement of this ratio does not increase growth rate and can only cause higher power consumption. The maxima in the coarser and finer fractions of CSD indicate a different influence of mixing conditions on the crystal grow and secondary nucleation. An axial flow pattern in crystallizer favors agglomeration of growing crystals increasing that way product mean crystal size, while radial flow results with more regular shape of borax crystals.

► In this study the effects of impeller type and diameter in a batch crystallizer on the nucleation and crystal growth kinetics of borax were investigated.
► We find that the nucleation was taking place by the heterogeneous nucleation mechanism at all mixing conditions.
► The number of crystals formed by this mechanism increases as ratio D/dT decreases and it is higher when an axial flow pattern in crystallizer has been developed.
► It was found that the crystal growth rate increases with increasing the impeller size in observed supersaturation range.
► An axial flow pattern in crystallizer favors agglomeration of growing crystals increasing that way product crystal size, while radial flow results with more regular shape of borax crystals.