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Volume 111
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Model-based crystallization strategy of viscous systems for biomass crystal production with anti-caking function
Gaolong Song a, Li Tong c, Lingdi Meng d, Linjin Song a, Leida Zhang b, Wei Zhao b, Songgu Wu a c, Mingyang Chen a c *, Mingxuan Li a *, Junbo Gong a c
a State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin, 300072, China
b Shandong Fuyang Biotechnology Co., Ltd., Dezhou, 253100, China
c Institute of Shaoxing, Tianjin University, Shaoxing, 312300, China
d School of Synthetic Biology and Biomanufacturing, Tianjin University, China
10.1016/j.partic.2026.01.032
Volume 111, April 2026, Pages 241-252
Received 5 November 2025, Revised 22 January 2026, Accepted 27 January 2026, Available online 6 February 2026, Version of Record 11 March 2026.
E-mail: chenmingyang@tju.edu.cn; 1021207191@tju.edu.cn
Highlights

• Decoupling of nucleation growth using a two-step crystallization strategy.

• Modeling the crystal caking cycle and the crystallization process.

• The cooling curve aligns better with crystal growth rates at varying temperatures.

• Narrow particle size distribution, homogenized lactone crystals.


Abstract

The crystallization separation of biomass chemical crystals in high-viscosity aqueous solutions has long been a major challenge in the field of biomass refining. Inappropriate crystallization strategies render the prepared biomass prone to caking and subsequent deterioration. To address this challenge, a tailored model-based two-stage crystallization strategy for viscous systems was developed for anti-caking bio-based derivative crystal production. The first stage focused on nucleation to prepare seed crystals with good dispersion in viscous solutions, while the second stage inhibits nucleation to design the crystal product size. Meanwhile, a temperature-governed crystallization kinetic model and a humidity-driven caking model were coupled to develop a crystallization-caking feedback regulation framework, enabling direct generation of optimal crystallization trajectories based on predefined anti-caking targets. In the crystallization of glucono delta-lactone (GDL), compared with the previous anti-caking crystallization strategies, the crystal D50 obtained by the crystallization strategy for viscous systems developed in this study increased from 414 to 486 μm, and the deviation of crystal products from the target particle size decreased from 17.2% to 2.8%. While the anti-caking performance has improved from 27 to 48 days, the design efficiency has also increased by an order of magnitude.

Graphical abstract
Keywords
Crystallization model; Particle size control; Crystal caking; Bio-based crystal
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