A Robust Process Analytical Technology (PAT) System Design for Crystallization Processes

A generic computer-aided framework for systematic design of a process monitoring and control system for crystallization processes has been developed to study various aspects of crystallization operations. The design framework contains a generic multidimensional modelling framework, a tool for generation of the supersaturation setpoint for a supersaturation controller, a tool for design of a process monitoring and control system (also called Process Analytical Technology (PAT) system) as well as a tool for performing uncertainty and sensitivity analysis of the PAT system design. The uncertainty analysis is important in order to produce an estimate of the risk of not achieving the desired product quality with its corresponding target crystal properties.
Application of the framework is highlighted through a case study involving the design of a robust PAT system for a potassium dichromate crystallization process to achieve the target crystal size distribution (CSD) in the presence of parametric uncertainties.