Advances and Opportunities Concerning Nucleation Measurement and Control Technology in Crystallization

Nucleation as a unique phenomenon in the crystallization process has always been a hot topic. With the development of nucleation theory and process analysis technology (PAT), nucleation control technology (NCT) has been widely applied in industrial crystallization processes. This paper provides a comprehensive review of advancements in nucleation measurement and control technologies within crystallization processes, systematically analyzing the principles, advantages, disadvantages, and application scopes of various NCTs, and particularly the factors affecting nucleation and nucleation-assisted technologies, including ultrasound, gassing, and membranes, are elaborated. These technologies are crucial for managing the unpredictable nature of nucleation to improve the consistency and quality of crystalline products. These advanced or novel control technologies are very attractive in providing continuous and stable high-purity seeds without externally adding additional seeds and have proven to be effective alternative methods for generating internal seeds. In addition, the challenges and opportunities were pointed out from the stability, controllability, and consistency of nucleation to promoting the efficient development of crystallization technology. NCTs play a vital role in industrial applications by ensuring control over the size, purity, and morphology of crystals. This review also explains the application of NCTs in industrial scenarios, positioning these technologies as essential for the advancement of various industrial applications.