The Challenge

Ultrasound has routinely been used across many sectors to monitor industrial manufacturing processes, but instead of simply monitoring the process of crystallisation, LST wanted to see if it was possible to use ultrasound to modify and affect the actual crystallisation process.

The Solution

Working with Professor Megan Povey from University of Leeds, LST monitored crystallisation with ultrasound and, to begin with, the energies needed to affect the ‘critical nucleation processes’ (when a viable crystal is formed that can grow) were calculated. It was predicted that only low power ultrasound was needed and the first experiment was successful in stopping the nucleation of wax from solution and then starting it again when the low power ultrasound was switched off. This idea has now been patented around the world.

Using A4I and EPSRC grant funding, the team were able to further test their theory in situ on Diamond’s I22 beamline to fully understand the process at which crystallisation occurs. Using specially designed and built acoustic cells, they applied SAXS and WAXS analytical techniques to a mixture of waxes, fats and cocoa butter to simulate model systems of diesel fuel and foodstuffs.

In addition, they are extending this invention into the high-pressure regimes with Dr Nick Brooks at Imperial College London. Modern diesel engines are now using extremely high pressures (3 kbar) and this means that wax will crystallise at higher temperatures. Research at Diamond has shed further light on this phenomenon.

The Benefits

By using the instruments at Diamond, LST, Leeds and Imperial were able to monitor the process of crystallisation at the molecular and meso-scales. They were able to combine synchrotron techniques with acoustic methods to understand crystallisation processes happening at a molecular level. By using Diamond’s world-class instruments they were able to watch in situ as the process evolved.

By understanding and manipulating the process at which crystallisation occurs in foodstuff and diesel fuel, we will be better able to create efficient food processes and diesel fuel systems which effectively control vehicle emissions. Future developments are in progress include extending the process to other industries such as polymer processing, e.g. extrusion and injection molding of semi-crystalline polymers.