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IbD PU Deliverable 3.1 4.1.1 Crystallization An SDR is capable of producing fine crystals with a low risk of fouling or plugging. Oxley et al. (2000) presented results on using the SDR operating continuously, compared to batch processing, for the phase transfer-catalyzed (ptc) Darzen’s reaction to make a drug intermediate and the recrystallization of an active pharmaceutical ingredient (API). The ptc Darzen’s reaction in the SDR was performed at 99.9% reduced reaction time, 99% reduced inventory, and 93% reduced impurity level. Production capacity was predicted to be around 8 tonnes/year. The SDR was found to be capable of providing particles with a tight particle size distribution and a mean size of about 3 microns in recrystallization of API. 4.1.2 Nanoparticle synthesis/precipitation Compared with the conventional mechanical agitated contactor, an SDR provides finer and more uniform particles. The advantages of the continuous-flow SDR, such as rapid mixing, and effective heat and mass transfer, made the SDR an efficient reactor in the study of superparamagnetic Fe3O4 nanoparticles by Chin et al. (2008). By controlling the operational parameters of an SDR and coating surfactants onto the nanoparticles, it could be used to stabilize the nanoparticles and control their size (Figure 6), which demonstrated the capabilities of the SDR in producing ultra-small superparamagnetic magnetite nanoparticles. Khan and Rathod (2014) utilized the spinning disk reactor for the continuous preparation of curcumin nanoparticles via solvent–nonsolvent (S-NS) precipitation. By increasing the operational parameters, such as disk speed, disk size, and non-solvent flow rate, the average curcumin nanoparticles size can be reduced, which also benefits from the low concentration of curcumin in the solvent. The reactive-precipitation process in an SDR has been explored in various earlier studies (Cafiero et al., 2002; Tai et al., 2007; Dehkordi and Vafaeimanesh, 2009; Jacobsen and Hinrichsen, 2012; Khan and Rathod, 2014; Mohammadi et al., 2014). In Cafiero et al. (2002), it was found that it was possible to produce a very high specific number of crystals (size range 0.5-1 μm) in a SDR with a much lower power dissipation (115 W/kg) than the conventional continuous-flow stirred tank reactor (of the order of 100 kW/kg). The variation of operation and reactor design parameters, such as the initial supersaturation, rotating speed, surface structure of the disk, and the disk diameter, influences the precipitation in the spinning disk 10PDF Image | Solids handling for intensified process technology
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