Graphical processing unit (GPU) acceleration for numerical solution of population balance models using high resolution finite volume algorithm

© 2016 Elsevier LtdPopulation balance modeling is a widely used approach to describe crystallization processes. It can be extended to multivariate cases where more internal coordinates i.e., particle properties such as multiple characteristic sizes, composition, purity, etc. can be used. The current study presents highly efficient fully discretized parallel implementation of the high resolution finite volume technique implemented on graphical processing units (GPUs) for the solution of single- and multi-dimensional population balance models (PBMs). The proposed GPU-PBM is implemented using CUDA C++ code for GPU calculations and provides a generic Matlab interface for easy application for scientific computing. The case studies demonstrate that the code running on the GPU is between 2–40 times faster than the compiled C++ code and 50–250 times faster than the standard MatLab implementation. This significant improvement in computational time enables the application of model-based control approaches in real time even in case of multidimensional population balance models

Measurement, modelling, and closed-loop control of crystal shape distribution: Literature review and future perspectives

Crystal morphology is known to be of great importance to the end-use properties of crystal products, and to affect down-stream processing such as filtration and drying. However, it has been previously regarded as too challenging to achieve automatic closed-loop control. Previous work has focused on controlling the crystal size distribution, where the size of a crystal is often defined as the diameter of a sphere that has the same volume as the crystal. This paper reviews the new advances in morphological population balance models for modelling and simulating the crystal shape distribution (CShD), measuring and estimating crystal facet growth kinetics, and two- and three-dimensional imaging for on-line characterisation of the crystal morphology and CShD. A framework is presented that integrates the various components to achieve the ultimate objective of model-based closed-loop control of the CShD. The knowledge gaps and challenges that require further research are also identified

Model-based optimization of batch- and continuous crystallization processes

Crystallization is an important separation process, extensively used in most chemical industries and especially in pharmaceutical manufacturing, either as a method of production or as a method of purification or recovery of solids. Typically, crystallization can have a considerable impact on tuning the critical quality attributes (CQAs), such as crystal size and shape distribution (CSSD), purity and polymorphic form, that impact the final product quality performance indicators and inherent end-use properties, along with the downstream processability. Therefore, one of the critical targets in controlled crystallization processes, is to engineer specific properties of the final product. The purpose of this research is to develop systematic computer-aided methodologies for the design of batch and continuous mixed suspension mixed product removal (MSMPR) crystallization processes through the implementation of simulation models and optimization frameworks. By manipulating the critical process parameters (CPPs), the achievable range of CQAs and the feasible design space (FDS) can be identified. Paracetamol in water and potassium dihydrogen phosphate (KDP) in water are considered as the model chemical systems.The studied systems are modeled utilizing single and multi-dimensional population balance models (PBMs). For the batch crystallization systems, single and multi-objective optimization was carried out for the determination of optimal operating trajectories by considering mean crystal size, the distribution s standard deviation and the aspect ratio of the population of crystals, as the CQAs represented in the objective functions. For the continuous crystallization systems, the attainable region theory is employed to identify the performance of multi-stage MSMPRs for various operating conditions and configurations. Multi-objective optimization is also applied to determine a Pareto optimal attainable region with respect to multiple CQAs. By identifying the FDS of a crystallization system, the manufacturing capabilities of the process can be explored, in terms of mode of operation, CPPs, and equipment configurations, that would lead to the selection of optimum operation strategies for the manufacturing of products with desired CQAs under certain manufacturing and supply chain constraints. Nevertheless, developing reliable first principle mathematical models for crystallization processes can be very challenging due to the complexity of the underlying phenomena, inherent to population balance models (PBMs). Therefore, a novel framework for parameter estimability for guaranteed optimal model reliability is also proposed and implemented. Two estimability methods are combined and compared: the first is based on a sequential orthogonalization of the local sensitivity matrix and the second is Sobol, a variance-based global sensitivities technic. The framework provides a systematic way to assess the quality of two nominal sets of parameters: one obtained from prior knowledge and the second obtained by simultaneous identification using global optimization. A multi-dimensional population balance model that accounts for the combined effects of different crystal growth modifiers/ impurities on the crystal size and shape distribution of needle-like crystals was used to validate the methodology. A cut-off value is identified from an incremental least square optimization procedure for both estimability methods, providing the required optimal subset of model parameters. In addition, a model-based design of experiments (MBDoE) methodology approach is also reported to determine the optimal experimental conditions yielding the most informative process data. The implemented methodology showed that, although noisy aspect ratio data were used, the eight most influential and least correlated parameters could be reliably identified out of twenty-three, leading to a crystallization model with enhanced prediction capability. A systematic model-based optimization methodology for the design of crystallization processes under the presence of multiple impurities is also investigated. Supersaturation control and impurity inclusion is combined to evaluate the effect on the product's CQAs. To this end, a morphological PBM is developed for the modelling of the cooling crystallization of pure KDP in aqueous solution, as a model system, under the presence of two competitive crystal growth modifiers/ additives: aluminum sulfate and sodium hexametaphosphate. The effect of the optimal temperature control with and without the additives on the CQAs is presented via utilizing multi-objective optimization. The results indicate that the attainable size and shape attributes, can be considerably enhanced due to advanced operation flexibility. Especially it is shown that the shape of the KDP crystals can be affected even by the presence of small quantity of additives and their morphology can be modified from needle-like to spherical, which is more favourable for processing. In addition, the multi-impurity PBM model is extended by the utilization of a high-resolution finite volume (HR-FV) scheme, instead of the standard method of moments (SMOM), in order for the full reconstruction and dynamic modelling of the crystal size and shape distribution to be enabled. The implemented methodology illustrated the capabilities of utilizing high-fidelity computational models for the investigation of crystallization processes in impure media for process and product design and optimization purposes

Numerical Study of Crystallization Process Using CFD Tools

Crystallization is the formation of solid particles within a homogenous phase. Crystallization is considered a last stage purification step in pharmaceutical, chemical, agrochemical and food industries. Crystallization is mostly used for separation of a pure product from an impure solution and the product formed is suitable for packing and marketing. Good yield and purity are important for crystallization; apart from it crystal size distribution also plays a vital role in the design of crystallization. The energy required for crystallization is less than distillation. The study is made on crystallization process of sucrose in a continuous rectangular flow chamber. The present work is aimed to compare the simulation results with experimental results and to study the parametric sensitivity on mean crystal diameter of sucrose and total crystal production with variation in inlet velocity of solution, inlet mass fraction of sucrose and wall temperature of crystallizer. The transient simulations are carried out to study the crystallization process. The simulation results when validated against experimental results are found to be consistent.The simulation results show that as the inlet mass fraction of sucrose is increased, then the mean crystal size and total crystal production are observed to be increased. The mean crystal size is increased and total crystal production is decreased with decrease in inlet velocity of solution. The mean crystal size is observed to be invariant with change in wall temperature of the crystallizer but the total crystal production is increased with increase in wall temperature

Modelling, Simulation, and Control of Polymorphic Crystallization

Ph.DDOCTOR OF PHILOSOPH

Detailed modelling and optmization of crystallization process

Orientador: Rubens Maciel FilhoTese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia QuimicaResumo: O foco de estudo neste trabalho é a cristalização, processo bastante utilizado industrialmente, principalmente na obtenção de produtos de alto valor agregado nas indústrias farmacêuticas e de química fina. Embora seja um processo de clássica utilização, seus mecanismos, sua modelagem e o real controle de sua operação ainda requerem estudos. A tese apresenta discussões e desenvolvimentos na área de modelagem determinística detalhada do processo e sua otimização, tanto por métodos determinísticos quanto estocásticos. A modelagem é discutida detalhadamente e os desenvolvimentos presentes na literatura de métodos numéricos aplicáveis à solução do balanço de população, parte integrante da modelagem, são apresentados com enfoque nos processos de cristalização e nas principais vantagens e desvantagens. Estudos preliminares de melhoria do processo de cristalização em modo batelada operada por resfriamento indicam a necessidade de otimização da política operacional de resfriamento. Uma vez que o método determinístico de otimização de Programação Quadrática Sucessiva se apresenta ineficiente para resolução do problema de otimização, a utilização de Algoritmo Genético, um método estocástico de otimização bastante estabelecido na literatura, é avaliada, para a busca do ótimo global deste processo, em um estudo pioneiro na literatura de aplicação dessa técnica de otimização em processos de cristalização. Uma vez que o uso de Algoritmos Genéticos exige que se executem sucessivas corridas com diferentes valores para os seus parâmetros no intuito de se aumentar a probabilidade de alcance do ótimo global (ou suas cercanias), um procedimento original, geral e relativamente simples é desenvolvido e proposto para detecção do conjunto de parâmetros do algoritmo de influência significativa sobre a resposta de otimização. A metodologia proposta é aplicada a casos de estudo gerais, de complexidades diferentes e se mostra bastante útil nos estudos preliminares via Algoritmo Genético. O procedimento é então aplicado ao problema de otimização da trajetória de resfriamento a ser utilizada em um processo de cristalização em modo batelada. Os resultados obtidos na tese apontam para a dificuldade dos métodos determinísticos de otimização em lidar com problemas de alta dimensionalidade, levando a ótimos locais, enquanto os métodos evolucionários são capazes de se aproximar do ótimo global, sendo, no entanto, de lenta execução. O procedimento desenvolvido para detecção dos parâmetros significativos do Algoritmo Genético é uma contribuição relevante da tese e pode ser aplicado a qualquer problema de otimização, de qualquer complexidade e dimensionalidadeAbstract: This work is focused on crystallization, a process widely used in industry, especially for the production of high added-value particles in pharmaceutical and fine chemistry industries. Although it is a process of established utilization, its mechanisms, modeling and the real control of its operation still require research and study. This thesis presents considerations and developments on the detailed deterministic modeling area and the process optimization with both deterministic and stochastic methods. The modeling is discussed in detail and the literature developed numerical methods for the population balance solution, which is part of the modeling, are presented focusing on crystallization processes and on the main advantages and drawbacks. Preliminary studies on batch cooling crystallization processes improvement drive to the need of cooling operating policy optimization. Since the Sequential Quadratic Programming deterministic method of optimization is inefficient for the optimization problem, the use of Genetic Algorithm (GA), a stochastic optimization method well established in literature, is evaluated in the global optimum search for this process, in a pioneering literature study of GA application in crystallization processes. Since the GA requires that many runs, with different values for its parameters, are executed, in order to increase the probability of global optimum (or its neighborhood) achievement, an original, general and relatively simple procedure for the detection of the parameters set with significant influence on the optimization response is developed and proposed. The proposed methodology is applied to general case studies, with different complexities and is very useful in the preliminary studies via GA. The procedure is, then, applied to the cooling profile optimization problem in a batch cooling optimization process. The results of the study presented in this thesis indicate that the deterministic optimization methods do not deal well with high dimensionality problems, leading to achievement of local optima. The evolutionary methods are able to detect the region of the global optimum but, on the other hand, are not fast codes. The developed procedure for the significant GA parameters detection is a relevant contribution of the thesis and can be applied to any optimization problem (of any complexity and of any dimensionality)DoutoradoDesenvolvimento de Processos QuímicosDoutor em Engenharia Químic

Experimental kinetics studies and wavelet-based modelling of a reactive crystallisation system

This thesis has made two significant contributions to the field of reactive crystallisation. First, new data from batch cooling crystallisation and semi-batch reactive crystallisation experiments of mono-ammonium phosphate (MAP) were obtained to describe the key factors that influence crystal nucleation and growth rates, crystal size distribution (CSD), and crystal shape. The second contribution is the development of a numerical scheme for solving the population balance equations, which can be used to describe the evolution of CSD during the crystallisation process. This scheme combines the finite difference method with a wavelet method, and is the first reported application of this approach for crystallisation modelling and simulation.Experiments into the batch cooling crystallisation of MAP were conducted both with and without seed crystals. The effects of key factors such as cooling rate, initial level of supersaturation and seeding technique, including seed concentration and seed size, on the real time supersaturation, final CSD, crystal yield and crystal shape were investigated. It was found that a seed concentration of 20-30% effectively suppressed nucleation. The growth and nucleation rate were estimated by using an isothermal seeded batch approach and their parameters were calculated by non-linear optimisation techniques.The second series of experiments involved the semi-batch reactive crystallisation of MAP. Both single-feed and dual-feed systems were investigated. In the single-feed arrangement, an ammonia solution was fed into a charge of phosphoric acid. In the dual-feed system, phosphoric acid and ammonia solution were fed into a charge of saturated MAP solution. The molar ratio of the reactants, initial supersaturation, presence or absence of seed crystals, initial MAP concentration, reactants’ flow rate, feeding time and stirring speed were varied, and the effects upon the real time supersaturation, final CSD, crystal yield, crystal shape and solution temperature were measured. X-ray diffraction analysis showed that MAP can be produced in both the single-feed and dual-feed arrangements. For the single feed system, the N/P mole ratio controlled the degree of reaction and the CSD of the product. Di-ammonium phosphate (DAP) was not be observed in the single-feed system due to its high solubility. In the dual-feed system, a seeded solution with slow feed addition, moderate stirring speed and a low initial supersaturation provided the most favourable conditions for generating a desirable supersaturation profile, and thus obtaining a product with good CSD and crystal shape.A comparative numerical study was undertaken in order to evaluate the existing numerical schemes for solving the population balance equations (PBE) that describe crystallisation. Several analytical solutions to the PBE were used to benchmark the following numerical schemes: Upwind Finite Difference, Biased Upwind Finite Difference, Orthogonal Collocation with Finite Elements, and Wavelet Orthogonal Collocation. The Wavelet Finite Difference (WFD) method has been applied here for the first time for solving PBE problems. The WFD scheme was adapted to solve the batch cooling and the semi-batch reactive crystallisation models, and the solutions were validated against experimental data that we obtained.In summary, the experimental data provide an improved understanding of MAPreaction and crystallisation mechanisms. The adaptability of the WFD method has beendemonstrated validating the two crystallisation systems, and this should help extendthe application of wavelet-based solutions beyond crystallisation processes and intomore diverse areas of chemical engineering