EKATO
Industrial Crystallization
Optimized Solutions for Batch and Continuous Processes
Learn how to Optimize your Crystallization Performance
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Your Challenges, Our Expertise
Crystallization comes with its own set of challenges: achieving consistent particle sizes, minimizing energy consumption, and preventing scaling and fouling. These challenges can disrupt operations, increase costs, and compromise product quality.
EKATO leverages its decades of experience to address these issues, supporting both end users and engineering companies in scaling up and optimizing crystallization processes.
With solutions for both batch and continuous crystallization, EKATO ensures your systems meet production demands while delivering reliable, high-performance results.
The Key Challenges in Crystallization
Achieving Consistent Particle Sizes
Uniform particle size distribution is critical for efficient downstream processes like filtration and drying. Both batch and continuous systems often face issues caused by uneven supersaturation, turbulence, or suboptimal equipment design.
Why It Happens:
- Batch processes: Inefficient impeller designs can cause inconsistent flow and localized shear forces
- Continuous processes: Poor feed point placement and high shear on particles disrupt uniform crystal growth
How We Solve It:
For batch crystallization, EKATO offers a range of impellers designed for specific process needs:
- EKATO VISCOPROP for versatile applications and precise shear control
- EKATO ISOJET-B for high axial flow with minimal shear
- EKATO PARAVISC for high-viscosity applications requiring gentle mixing
For continuous crystallization in Draft-Tube-Baffled (DTB) crystallizers, our TORUSJET impeller ensures shear-reduced flow, uniform supersaturation, and efficient energy use.
What It Means for You:
- Improved product quality with consistent particle sizes
- Faster downstream processing like filtration and drying, reducing energy and maintenance costs
- Reliable performance across a wide range of industries
Optimizing Energy Use
Energy inefficiency in crystallization processes can significantly increase costs, strain equipment, and hinder sustainability goals.
Why It Happens:
- Inefficient agitators and impellers increase energy demands
- Suboptimal reactor and draft tube designs combined with poor flow conditions waste resources
How We Solve It:
EKATO’s impeller designs and engineering expertise deliver energy savings across both batch and continuous systems.
In batch crystallization, impellers like EKATO VISCOPROP and INTERMIG provide optimal flow while minimizing power consumption.
For continuous processes, the TORUSJET reduces flow inconsistencies and mechanical strain, achieving energy savings of up to 30%.
What It Means for You:
- Lower operational costs with reduced energy use
- Longer equipment lifespan due to optimized flow dynamics
- A more sustainable production process
Scaling and Fouling
Scaling and fouling can disrupt flow, reduce pump efficiency, and increase downtime, but their impact varies between batch and continuous processes.
Why It Happens:
- Batch systems: Inadequate suspension or insufficient flow speed near heat exchangers or heated/cooled vessel walls leads to sedimentation and scaling on vessel surfaces
- Continuous systems: Stagnant zones in draft tubes promote deposit formation
How We Solve It:
For batch systems, EKATO designs impellers and agitator systems to ensure the right power input and customized impeller diameters.
This achieves optimal flow speeds near critical areas, such as heat exchangers and vessel walls, preventing sedimentation and fouling.
For continuous systems, EKATO’s TORUSJET impeller, when paired with optimized draft-tube design, minimizes stagnant zones and ensures consistent flow dynamics. This approach reduces fouling risks and enhances long-term operational stability.
What It Means for You:
- Prolonged equipment lifespan with reduced downtime and maintenance needs
- Stable and efficient operations across various process scales, ensuring reliable productivity
Scaling Up Crystallization Processes
Scaling up crystallization processes isn’t just about making equipment larger—it’s about achieving the perfect balance between power input, efficiency, and consistent product quality. EKATO’s decades of expertise ensure seamless transitions from lab-scale to industrial-scale production, whether for batch reactors or continuous draft-tube crystallizers.
What Sets EKATO Apart:
- Proven Experience: With decades of successful scale-ups across industries, we deliver solutions tailored to the specific needs of each process
- State-of-the-Art Tools: Our approach combines CFD simulations, empirical data, and detailed process analyses to design efficient and reliable scale-up strategies
- Continuous Innovation: Our R&D lab, featuring a dedicated draft-tube test pit, helps us refine designs and enhance scale-up reliability. This ensures superior performance for both end users and engineering companies
Whether you’re an end user seeking optimized crystallization or an engineering company looking for a trusted sparring partner, EKATO ensures your processes achieve exceptional results, every time.
Revamping Existing Crystallization Systems
When your crystallization systems fall short of meeting modern production demands, EKATO is here to help. Our comprehensive revamp solutions breathe new life into older systems, ensuring they meet today’s performance, efficiency, and reliability standards.
Our state-of-the-art upgrades include the integration of advanced impellers like the TORUSJET, which deliver exceptional energy efficiency, reduced maintenance requirements, and consistent performance. Beyond upgrading the agitator, we also re-engineer critical components, such as draft tubes, to optimize flow dynamics and eliminate stagnant zones.
Using cutting-edge tools like Finite Element Analysis (FEA), we ensure the mechanical integrity and durability of revamped systems, providing you with solutions that are both robust and efficient.
What You Gain:
- Modernized systems that meet current production and quality demands
- Enhanced energy efficiency and reduced operational costs
- Prolonged equipment lifespan with improved reliability
Whether you aim to increase throughput, lower costs, or improve product consistency, EKATO’s revamp solutions set your crystallization systems up for future success.
Products Made Possible with EKATO Solutions
EKATO’s cutting-edge technologies empower the production of diverse and essential products across industries. From chemicals to advanced battery materials, our solutions ensure precision, efficiency, and reliability at every stage of the crystallization process.
Chemicals & Fertilizers
Our advanced impellers and engineering solutions facilitate the efficient production of industrial chemicals and fertilizers, including:
- BHET (Bis(2-hydroxyethyl) terephthalate) for polyester production
- Ammonium sulfate for fertilizers and industrial applications
- Nickel sulfate for electroplating and battery precursors
- Sodium sulfate and potassium nitrate for specialized chemical processes
- Potash and potassium chloride for agricultural and industrial applications
- Magnesium sulfate, commonly used in food additives and healthcare
Batteries:
For advanced battery technologies, EKATO supports the production of high-purity materials critical for performance, such as:
- Lithium hydroxide for lithium-ion batteries
- Lithium carbonate for battery-grade energy solutions
Our expertise in crystallization ensures consistent particle size, improved purity, and enhanced efficiency, driving success across these vital industries.
Our Products and Technologies
Batch Crystallization Impellers
EKATO offers a wide range of specialized impellers tailored for batch crystallization, ensuring optimal mixing, particle control, and efficiency:
- VISCOPROP: A versatile impeller delivering energy-efficient and precise mixing control
- ISOJET-B: Provides strong axial flow for consistent mixing and crystallization
- PARAVISC: Ideal for high-viscosity processes requiring delicate yet effective mixing solutions
Continuous Crystallization Impellers
For continuous crystallization systems, EKATO delivers advanced impeller technology:
- TORUSJET: Revolutionizing draft-tube crystallizers with shear-free flow, optimized energy efficiency, and reduced maintenance needs
Engineering Studies
Leveraging state-of-the-art tools like CFD (Computational Fluid Dynamics) and FEA (Finite Element Analysis), our engineering studies focus on:
- Optimizing flow dynamics to enhance process efficiency
- Improving feed point positions
- Minimizing scaling and fouling risks to improve operational reliability
- Ensuring the mechanical stability of your equipment through detailed simulations
R&D and Innovation
Our dedicated draft-tube test pit in EKATO’s R&D lab enhances our knowledge of continuous crystallization processes. Combined with decades of scale-up expertise, this ensures your processes are both reliable and high-performing.
EKATO’s test setups, ranging from 3 to 250 liters, enable precise process development and scale-up. Our facilities deliver reliable data to bridge the gap between lab-scale testing and full-scale production, reducing the risk of scale-up errors.
Industries We Serve
Chemicals
Supporting high-capacity production of essential chemicals and fertilizers, inlcuding:
- Fertilizers like ammonium sulfate, potassium nitrate and potash
- Specialty chemicals such as BHET and nickel sulfate for industrial applications
Pharmaceuticals
Delivering precision mixing for APIs (Active Pharmaceutical Ingredients) with controlled particle size distributions to meet strict quality standards.
Food
Optimizing crystallization processes for sugar production and food additives like potassium chloride and magnesium sulfate.
Lithium Processing
Tailored solutions for producing high-purity lithium carbonate and lithium hydroxide, vital for advanced battery technologies.
Partner with EKATO
Whether you’re scaling up a batch reactor, optimizing energy use in continuous crystallization, or revamping older systems, EKATO is your trusted partner.
With decades of expertise, cutting-edge tools, and a commitment to innovation, we help transform your crystallization processes to meet today’s demands and tomorrow’s challenges.
Contact us today to discover how EKATO can elevate your operations with tailor-made solutions and proven expertise.
Dr. Bernd Nienhaus
Senior Process Consultant
EKATO Rühr- und Mischtechnik GmbH
Enhance your Crystallization Process
Maximize efficiency in your crystallization process with EKATO’s expertise. Reach out to our specialist for tailored solutions and innovative technologies!