Crystallisation: solving crystal nucleation problem in the chemical engineering classroom based on the research grade experiments deployed in virtual mode

Crystallization via nucleation can isolate active pharmaceutical ingredients from their crudes. While chemical engineering textbooks provide theoretical knowledge on crystallization and nucleation theories, they often fall short in providing provide practical insights on the nucleation mechanism. To bridge this gap, we introduced a virtual experiment on nucleation in second-year chemical engineering classrooms. The main goal is to educate students on crystallization procedures in research and process industries, teaching them how to analyse and manage collected data while integrating theoretical knowledge. This includes conveying the kind of information that can be obtained from a crystallisation process and instructing students on how to analyse and manage the data collected in the light of the theories learned. We devised an original chemical engineering problem on nucleation, derived directly from the raw data collected in the classroom from virtual experiments. This method differs from the conventional approach of solving standard textbook problems. The textbook problems, regrettably often lack crucial information on how nucleation rate or surface free energy are directly obtained from raw data. By the conclusion of the virtual experiment, students have acquired a comprehensive understanding encompassing both practical and theoretical aspects of crystallization, with a particular focus on nucleation. The methodologies elucidated in this study can be applied across a spectrum of chemical engineering modules, including process engineering, unit operations in chemical engineering, mass transfer, and can even be integrated into specialized courses dedicated to crystallization.