Chapter 3 Crystal growth CHAPTER 3 CRYSTAL GROWTH 3.1 INTRODUCTION Crystallization is a separation and purification technique employed to produce a wide variety of materials. Crystallization may be defined as a phase change in which a crystalline product is obtained from a solution. A solution is a mixture of two or more species that form a homogenous single phase. Solutions are normally thought of in terms of liquids; however, solutions may include solids suspension. Typically, the term solution has come to mean a liquid solution consisting a solvent, which is a liquid, and a solute, which is a solid, at the conditions of interest. The solution to be ready for crystallization must be supersaturated. A solution in which the solute concentration exceeds the equilibrium (saturated) solute concentration at a given temperature is known as a supersaturated solution [1]. There are four main methods to generate supersaturation that are the following: • Temperature change (mainly cooling), • Evaporation of solvent, • Chemical reaction, and • Changing the solvent composition (e.g. salting out). The Ostwald - Miers diagram shown in Fig. 3.1 illustrates the basis of all methods of solution growth. The solid line represents a section of the curve for the solute / solvent system. The upper dashed line is referred to as the super-solubility line and denotes the temperatures and concentration where spontaneous nucleation occurs [2]. The diagram can be evaluated on the basis of three zones: • The stable (unsaturated) zone where crystallization is impossible. • The Meta stable (supersaturated) zone where spontaneous nucleation is improbable but a crystal located in this zone will grow. • The unstable or labile (supersaturated) zone where spontaneous nucleation is probable and so the growth. ~ 55 ~ Chapter 3 Crystal growth Crystallization from solution can be thought of as a two step process. The first step is the phase separation, (or birth), of a new crystals. The second is the growth of these crystals to larger size. These two processes are known as nucleation and crystal growth, respectively. Analysis of industrial crystallization processes requires knowledge of both nucleation and crystal growth. The birth of new crystals, which is called nucleation, refers to the beginning of the phase separation process. The solute molecules have formed the smallest sized particles possible under the conditions present. The next stage of the crystallization process is for these nuclei to grow larger by the addition of solute molecules from the supersaturated solution. This part of the crystallization process is known as crystal growth. Crystal growth, along with nucleation, controls the final particle size distribution obtained in the system. In addition, the conditions and rate of crystal growth have a significant impact on the product purity and the crystal habit. An understanding of the crystal growth theory and experimental techniques for examining crystal growth from solution are important and very useful in the development of industrial crystallization processes. The many proposed mechanisms of crystal growth may broadly be discussed under a few general headings [2-5]: • Surface energy theories • Adsorption layer theories • Kinematic theories • Diffusion - reaction theories • Birth and spread models ~ 56 ~ Chapter 3 Crystal growth Figure 3.1 - Ostwald-Miers diagram for a solute/solvent system [2]. 3.2 THE THREE-STEP-MODEL Modeling of crystal growth in solution crystallization is often done by the Two- Step-Model. The Two-Step-model describes the crystal growth as a superposition of two resistances: bulk diffusion through the mass transfer boundary layer, i.e. diffusion step, and incorporation of growth unites into the crystal lattice, i.e. integration step [2-5]. The overall growth rate is expressed as: The Two-Step-Model is totally ignoring the effect of heat transfer on the crystal growth kinetics. In the literature there is little evidence for the effects of heat transfer on the crystal growth kinetics in the case of crystallization from solution. Matsuoka and Garside[8] give an approach describing the combined heat and mass transfer in crystal growth processes. The so called Three-Step- ~ 57 ~ Chapter 3 Crystal growth model of combined mass and heat transfer takes the above mentioned effects into account [6-8] . A mass transfer coefficient is defined which includes a dimensionless temperature increment at the phase boundary constituted by the temperature effect of the liberated crystallization heat and the convective heat transfer. For simplicity the transport processes occurring during growth will be described in terms of the simple film theory. This has the advantage that the resulting equations can be easily solved and the predictions do not differ significantly from those derived using the boundary layer theory [9,10] . Conditions in the fluid adjacent to the growing crystal surface are illustrated in Fig. 3.2. The mass transfer step can be presented by the equation: where Ci* and Cb* are the saturation concentrations evaluated at the interface and bulk temperatures, respectively. The effect of bulk flow, important at high mass fluxes, is neglected in Eq. 3.4. It is also assumed that the temperature difference (Ti - Tb) is sufficiently small for the solubility curve to be assumed linear over this temperature range. A heat balance relating heat evolution to convective transfer gives: ~ 58 ~ Chapter 3 Crystal growth Where βd is defined by Matsuoka and Garside [8] as a dimensionless number for the temperature increase at the crystal surface and therefore as measure of the heat effect on growth kinetics. Figure 3.2 - Concentration and temperature profiles to the crystal surface as assumed in the simple film theory [6]. The analogy between mass transfer and heat transfer is given by [11]: The general expression for the overall growth rate can be obtained by combining Eqs. 3.1, 3.2 and 3.6: Matsuoka and Garside [8] give a limit βd must be > 10 -2, for values below which the influence of the heat transfer on the crystal growth kinetics ~ 59 ~ Chapter 3 Crystal growth can be neglected. The dissolution process is, on the contrary, quite frequently described only by use of the diffusion step. What is not true since there is definitely a surface disintegration step[12,13]. In other words dissolution is the 100 % opposite of crystal growth. However, a justification for the model assumption that dissolution can be seen as just diffusion controlled is due to experimental results which show a linear dependence on the concentration difference (under saturation). Furthermore, the dissolution process is happening according to literature much faster (4 to 6 times) than the crystal growth process so that a possible surface reaction resistance is here difficult to observe [12,13] . The assumption that the dissolution of crystals involves the sole diffusion step is therefore, in many cases valid: Two methods, the differential and integration method are mainly used for the measurements of the growth rates in fluidized bed experiments [14] . In this study the differential method was used. In the differential method, the crystallization is seeded by adding a few grams of crystals with a known sieve aperture into a supersaturated solution. The seed crystals grow in the supersaturated solution. Since the amount of crystals is small, it is assumed that the concentration of the solution does not change during the growth. The other assumptions are as follows: • The number of seed crystals put into the crystallizer is equal to the number of crystals taken out from the crystallizer. • There is no crystal loss, an assumption which is always valid for an experienced experiment. • The shape factor of the growing crystals is considered to be the same. This assumption is not always true especially in the case of surface nucleation. In this case, growth values are thought of as average values. If the ~ 60 ~ Chapter 3 Crystal growth amount of the crystals put into the crystallizer is M1 and the amount of the crystals taken out from the crystallizer is M2, they can be related to the size of the crystals L as shown in the following equations[15]: where L1 and L2 are the characteristic size of the crystals input and the output, respectively. The overall linear growth rate G (m/s) is defined as the rate of change of characteristic size: The expression for the growth rate in terms of size of the seed crystals and the weight of the crystals can be given by: G and RG are related to each other as follows: where β1 and α1 are surface and volume shape factors, respectively. M1 and M2 are experimentally obtained. The growth rate, RG, and the dissolution rate, RD, are calculated from Eq. 3.16 by knowing L1 and t. 3.3 CRYSTAL GROWTH TECHNIQUES The mathematical models are based on the Navier-Stokes equations and the heat & mass transport equations in the 2D and 3D approximations. Special models are available for crystallization phenomena and chemical reactions. The mathematical aspects of the models used for the analysis of bulk crystal growth are described in the literature calculations [16-19] [16-31] . The global heat transfer are the basis for a detailed analysis of flows, mass transfer, and crystallization. Usually, the view-factor (surface-to-surface) method is applied to simulate radiative heat exchange; a heat transport conservation ~ 61 ~ Chapter 3 Crystal growth equation is used to predict the temperature distribution. To simulate radiative heat transfer in semitransparent media, we apply an original model based on a combination of the ray-tracing and discrete ordinate approach [30,31]. The moving grid approach is used to find the geometry of the melt/crystal interface. The grid is reconstructed after each step of finding the crystallization front. MELT GROWTH METHODS This method is the most basic. A gas is cooled until it becomes a liquid, which is then cooled further until it becomes a solid. Polycrystalline solids are typically produced by this method unless special techniques are employed. In any case, the temperature must be controlled carefully. Large crystals can be grown rapidly from the liquid elements using a popular method invented in 1918 by the Polish scientist Jan Czochralski and called crystal pulling. Horizontal Boat Growth Methods Horizontal Gradient Freezing (HGF) method Horizontal Bridgman (HB) method Horizontal Zone Melting (HZM) method Vertical Boat Growth Methods Vertical Bridgman (VB) method Vertical Gradient Freezing (VGF) method Vertical Zone Melting (VZM) method Pulling Methods Czochralski (CZ) method Liquid Encapsulated Czochralski (LEC) method Kyropolous and Liquid Encapsulated Kyropolous (LEK) methods Floating Zone (FZ) Method Other Methods Shaped Crystal Growth Method Heat Exchange Method (HEM) ~ 62 ~ Chapter 3 Crystal growth SOLUTION GROWTH METHODS Simple Solution Growth Method Traveling Heater Method (THM) Solute Solution Diffusion (SSD) Method Solvent Evaporation (SE) Method Temperature Difference Method under Controlled Vapor Pressure (TDM-CVP) Hydrothermal Synthesis Method VAPOR PHASE GROWTH METHOD Direct Synthesis (DS) Method Physical Vapor Transport (PVT) Method Open tube method Closed tube method Chemical Vapor Transport (CVT) Method Solid Phase Reaction (Solid State Re-crystallization) MODIFICATION OF CRYSTAL GROWTH METHODS In-Situ Synthesis Vapor Pressure Control Magnetic Field Application Accelerated Crucible Rotation Technique (ACRT) 3.3.1 Solvent evaporation (SE) method for solid crystal growth It is often necessary to remove solvent from a solution to recover either a solid or a high-boiling liquid. There are several ways to do this. 3.3.1.1 Distillation Simple distillation can be used to remove solvent. Distillation works well if the solution is composed of a solid and a low-boiling solvent, or if the solution is composed of a high-boiling liquid and a low-boiling solvent (with boiling point differences greater than 100°). Advantages of distillation are that the solvent can be collected and recycled and that no vapors are released into ~ 63 ~ Chapter 3 Crystal growth the atmosphere. A disadvantage is that it can take a long time. Simple distillation is process covered on the next section. Method 1 - Open-Dish evaporation Solvent can be evaporated by placing the solution in an open container (an Erlenmeyer, evaporating dish, beaker, and vial). The container is set on a heat source (steam bath, hot plate, heating mantle, sand bath) and the solvent boiled off. (If the solvent is water, use a heat source other than a steam bath.) The problem with open-dish evaporation is that the solvent is released into the air. Open-dish evaporation should always be done in a hood if the solvent is anything other than water. Even in a hood, however, vapors are released into somebody’s air. If the solvent is a hazardous compound (for instance, methylene chloride), it is probably better to choose another method of solvent removal. Method 2 - Reduced-Pressure evaporation You can accomplish evaporation from a solution quickly by placing it in a side-arm flask, sealing the flask, and then applying vacuum. Under vacuum reduced pressure - liquids vaporize and boil off at lower temperatures; effectively, the solvents come off a lot faster when under vacuum than at atmospheric pressure. In the Organic Chemistry Teaching Labs, a small (25 or 50 mL) side-arm flask fitted with a rubber stopper is used to strip off small (5-10 mL) amounts of solvent. As a vacuum source, we use the VacuuBrand systems. Details follow. Procedure for crystal growth Put the solution in a 25 or 50 mL side-arm flask. Do not fill the flask more than one-third full, since the evaporation causes the solvent to froth and bubble up and out of the flask. A boiling chip is not necessary, but can be helpful, especially if not plan to hold and swirl the flask during the process. Stopper the flask with a black stopper. (Corks do not give a good seal.) Clamp the flask to a ring stand to prevent it from falling over. ~ 64 ~ Chapter 3 Crystal growth Connect the flask with vacuum tubing to the VacuuBrand vacuum source. Do NOT use Tygon tubing. Have ready a small dish containing warm water. Turn on the vacuum. The solution will bubble and froth, especially when you first turn on the vacuum. The flask will become cool as the solvent evaporates - place it in the warm water bath to speed up the evaporation. Remove the flask from the clamp and hold it in your hand and constantly swirl it during the process both to prevent bumping and to increase the surface area to speed up the process. First turn off the vacuum source connection at your lab bench, Disconnect the flask from the vacuum tubing. Method 3 - Rotary evaporators Rotary evaporators, or roto-vaps, are standard equipment in most organic chemistry research labs. These evaporators are designed to remove solvent rapidly from solutions. Procedure The motor in the roto-vap turns the flask rapidly, providing a greater surface from which evaporation can occur, thus speeding up the process. Cooling coils in the roto-vap condense the vapors and drop them into a collection flask so that they can be recycled or properly disposed. The roto-vap is connected to a vacuum source, again, this speed up the evaporation process. There are three tubing outlets on the roto-vap, one for a vacuum source and two for the cooling coils. Use vacuum tubing to connect the outlet that evacuates the roto-vap chamber to the vacuum source. Use a piece of Tygon tubing to connect one cooling coil outlet to the cold water ~ 65 ~ Chapter 3 Crystal growth faucet, and use another piece of Tygon tubing to connect the other cooling coil outlet to the drain Place the solution to be evaporated in a round bottom flask, then connect the flask to the roto-vap. Do not fill the flask more than about one-third full. Use a joint clamp to secure the flask to the apparatus. Make sure the cool water to the cooling coils is turned on. Turn on the motor so that the flask rotates. Usually the flask containing the solution to be evaporated is warmed by a water bath. Make sure the vent at the top of the cooling coils is closed. Turn the vacuum outlet on the vacuum system on. As the solvent evaporates, you may notice a lot of frothing and bubbling in the evaporating flask. If it starts bubbling out of the flask, you can open the vent a little to release some of the pressure. The (unwanted) solvent condenses on the cooling coils and drips down into the collection flask. When the solvent has evaporated, turn off the motor that turns the flask and turn the vacuum outlet to close. Slowly open the vent to release the pressure in the roto-vap chamber. Remove the flask from the roto-vap. In current research work all methods were used but crystal growth from method 3 - Rotary Evaporators are used for further research work. 3.3.2 Distillation and reflux under heat A process in which a liquid or vapour mixture of two or more substances is separated into its component fractions of desired purity, by the application and removal of heat. Distillation is based on the fact that the vapour of a boiling mixture will be richer in the components that have lower boiling points. ~ 66 ~ Chapter 3 Crystal growth Therefore, when this vapour is cooled and condensed, the condensate will contain more volatile components. At the same time, the original mixture will contain more of the less volatile material. Distillation columns are designed to achieve this separation efficiently. Although many people have a fair idea what “distillation” means, the important aspects that seem to be missed from the manufacturing point of view are that: Distillation is the most common separation technique It consumes enormous amounts of energy, both in terms of cooling and heating requirements It can contribute to more than 50% of plant operating costs To achieve this improvement, a thorough understanding of distillation principles and how distillation systems are designed is essential. Separation of components from a liquid mixture via distillation depends on the differences in boiling points of the individual components. Also, depending on the concentrations of the components present, the liquid mixture will have different boiling point characteristics. Therefore, distillation processes depends on the vapour pressure characteristics of liquid mixtures. The vapour pressure of a liquid at a particular temperature is the equilibrium pressure exerted by molecules leaving and entering the liquid surface. Here are some important points regarding vapour pressure: Energy input raises vapour pressure Vapour pressure is related to boiling A liquid is said to ‘boil’ when its vapour pressure equals the surrounding pressure The ease with which a liquid boils depends on its volatility Liquids with high vapour pressures (volatile liquids) will boil at lower temperatures The vapour pressure and hence the boiling point of a liquid mixture depends on the relative amounts of the components in the mixture ~ 67 ~ Chapter 3 Crystal growth distillation occurs because of the differences in the volatility of the components in the liquid mixture 3.3.2.1 The boiling point diagram The boiling point diagram shows in figure 3.3 how the equilibrium compositions of the components in a liquid mixture vary with temperature at a fixed pressure. Consider an example of a liquid mixture containing 2 components (A and B) - a binary mixture. This has the following boiling point diagram. The boiling point of A is that at which the mole fraction of A is 1. The boiling point of B is that at which the mole fraction of A is 0. In this example, A is the more volatile component and therefore has a lower boiling point than B. The upper curve in the diagram is called the dew-point curve while the lower one is called the bubble-point curve. Figure 3.3 - The boiling point diagram The dew-point is the temperature at which the saturated vapour starts to condense. The bubble-point is the temperature at which the liquid starts to boil. The region above the dew-point curve shows the equilibrium composition of the superheated vapour while the region below the bubble-point curve shows the equilibrium composition of the sub cooled liquid. For example, when a sub cooled liquid with mole fraction of A=0.4 (point A) is heated, its concentration remains constant until it reaches the bubble-point (point B), when it starts to boil. The vapours evolved during the boiling have the equilibrium composition given by point C, approximately 0.8 mole fraction A. This is approximately 50% richer in A than the original liquid. This difference between liquid and vapour compositions is the basis for distillation operations. Heating under ~ 68 ~ Chapter 3 Crystal growth reflux enables a mixture including volatile materials to be heated for a long time without loss of solvent. The system is designed to keep materials in the flask - it follows, therefore, that any apparatus attached to the top of the condenser is redundant. Many organic reactions are quite slow and need heating to achieve a reasonable reaction rate. However, most organic chemicals are quite volatile, and if heated they will evaporate and be lost. The solution to this problem is to heat the reaction mixture under reflux. This involves having the reaction mixture in a flask which is attached to a vertical, open Liebig condenser. Never attempt to stopper the Liebig condenser. This is quite a popular idea among students "to stop the vapour escaping". If you attempt to heat sealed glass apparatus it may explode! There should be no problem with vapour escaping as it hits the cold surface of the condenser it will condense and drip back in to the flask. The use of a hot water bath may be safer and prevent overheating, but will limit the reaction temperature to 100 ºC. 3.4 MATERIAL AND METHOD [1] Materials The ligand which is a p- dimethylaminobenzaldehyde and Schiff base obtained from o-phenylenediamine were used. The stock solutions of FeCl3, NiCl2and CuCl2 were prepared. [2] Preparation of schiff base p-dimethylaminobenzaldehyde (1.4919 gm 0.1 mol) solution in ethanol and o-phenylenediamine (1.0814 gm 0.1 mol) solution in hot water were taken in round bottomed flask, 50 ml absolute ethanol was added and the mixture was refluxed for 3 hour. The refluxed mixture was put in ice bath, then orange coloured precipitate was obtained. It was suctioned filtered and washed with distilled water. Schiff base obtained was dried and kept in vacuum desiccators. The pure Schiff base was recrystallized from absolute ethanol ~ 69 ~ Chapter 3 Crystal growth [3] Preparation of crystals The crystals were prepared by mixing Schiff base (0.1mol) in hot ethanol solution to (0.1mol) metal chloride salt solution prepared in distilled water. The schiff base solution was added slowly with continuous stirring to metal solution. It was refluxed for 2 hours and after refluxation, the mixture was heated for 10 minutes till the contents was reduced to half. Then the metal crystals precipitated out after being cooled. The precipitate was filtered and washed with the distilled water. All complexes were dried and kept in vacuum desiccators. 3.5 CHEMISTRY OF CRYSTAL GROWTH All chemicals used were of reagent grade. Their standard solutions were prepared by using doubly distilled CO2 free water. Metal salt were standardized by complexometric EDTA titration method conductivity water is used throughout the experimental work. Digital µ 361 pH meter with readability + 0.001 with combined glass calomel electrode have been used for pH metric study. Stoichiometrically 1:1:1 concentration of M1, M2, L1 and L2 were maintained in the solution. Metal ligand mixtures of following compositions were prepared for titration keeping total volume 50ml in each case (µ=0.2 M NaClO4). The concentration of ligand and metal solution were checked by pH metric titration against 0.2 N carbonate free sodium hydroxide solution. The following sets were prepared for titration. (A) Known amount of HClO4. (B) Free HClO4 + known amount of ligand L1. (C) Free HClO4 + known amount of ligand L2. (D) Free HClO4 + known amount of ligand L1 + known amount of metal [M1] (Binary). (E) Free HClO4 + known amount of ligand L2 + known amount of metal [M1] (Binary). (F) Free HClO4 + known amount of ligand L1 + known amount of metal [M2] (Binary). ~ 70 ~ Chapter 3 Crystal growth (G) Free HClO4 + known amount of ligand L2 + known amount of metal [M2] (Binary). (H) Free HClO4 + known amount of ligand L1 + known amount of ligand L2 + known amount of metal [M1] (Ternary). (I) Free HClO4 + known amount of ligand L1 + known amount of ligand L2+ known amount of metal [M2] (Ternary). (J) Free HClO4 + known amount of ligand L1 + known amount of ligand L2+ known amount of metal [M1] + known amount of metal [M2] (Quaternary) . (i) M1 L1or L2 and M2L1or L2 → 1:1 Binary mixtures. (ii) M1L1L2 and M2L1L2 → 1:1:1 ternary mixtures. where M1, M2 are CuII, NiII,FeIII as required L1= o-Phenylenediamine L2= p-dimethyleaminobenzaldehyde Crystals of ternary mixtures M1L1L2 and M2L1L2 were used for further work. 3.6 SYSTEM USED Instrument Name: All glass double distillation unit, with borosilicate boiler, borosilicate condenser & Quartz Electric Heater, Vertical type. Figure 3.4 - Photograph of Working of Rotary Reflux Distillation Setup ~ 71 ~ Chapter 3 Crystal growth Specification: Table 3.1 – Specification of Crystal Growth Apparatus Dist. Water o/p capacity 1.5 lt/hr 230-250 volts Electrical requirement Single Phase 1.5x2 Kw Quartz heater Cooling water consumption 100 lt/hr Biological Activity Pyrogen free pH 6.9 – 7 Conductivity S/cm < 1X 10-6 Distillate Temp 65-75 C The boiler is made of high purity quartz and the condenser is of borosilicate/quartz material. The built in heater provides of minimum loss of heat and production of material. The unit is mounted on powder coated metal stand with electrical connections and is easy to dismantle and assemble the unit. Fiber glass insulated wire and silicon rubber boot resist high temperature. Spares for this unit: 1. Borosilicate boiler with water leveler 1.5 lt. 2. Condenser 1.5 lt. 3. Quartz new type heater B-34 complete unit. 4. Flasks – Boling, round bottom, short neck with interchangeable joint. Capacity – 250 ml and Approx Height – 140 mm All apparatus were used have high quality and Pore size of about 90 – 150 microns. All apparatus have excellent resistant to chemical attack. All apparatus are incorporating them are mainly design for the application of vacuum or for passage of gases at relatively low pressure. In all cases the differential pressure must not exceed 100 KN/m2 (15 psi). All apparatus are particularly suited for drying to constant weight. All apparatus at room ~ 72 ~ Chapter 3 Crystal growth temperature can be placed directly 150 C, although customary practice is to dry at 110C. It is advisable that rate of heating should not be more than 2C/min. This prevents internal strains caused by excessive temperature differences between the surrounding glass vessel and the sintered disk, which can lead to fracture of apparatus. 3.7 CRYSTALS SPECIFICATION Photographs and Dimensions of all crystals were measured at Laljibhai Chaturbhai Institute of Technology (LCIT), Mehsana. All apparatus were used have high quality with 5 MP cameras. Crystal of Cu(II) with O-Phenylenediamine and p-dimethyleaminobenzaldehyde ligand Figure 3.5 - Photograph of Crystal Cu(II) A: Photograph of crystal in bulk form B: Photograph of crystal in single form Size: 0.80 mm length and 0.35 mm width ~ 73 ~ Chapter 3 Crystal growth Crystal of Ni(II) with O-Phenylenediamine and p-dimethyleaminobenzaldehyde ligand Figure 3.6 - Photograph of Crystal Ni(II) A: Photograph of crystal in bulk form B: Photograph of crystal in single form Size: 0.68 mm length and 0.47 mm width Crystal of Fe(III) with O-Phenylenediamine and p-dimethyleaminobenzaldehyde ligand Figure 3.7 - Photograph of Crystal Fe(III) A: Photograph of crystal in bulk form B: Photograph of crystal in single form Size: 2.57 mm length and 1.30 mm width ~ 74 ~ Chapter 3 Crystal growth REFERENCE 1. Karpinski, P.H. “Crystallization as a Mass Transfer Phenomenon” Chem. Eng. Sci., 35, 2321-2324 (1980). 2. Mullin, J.W. “Crystallization (3rd ed.)” Butterworth Heinemann, (1993). 3. 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