Crystallization is one of the most fundamental processes in industrial chemistry, shaping the way we recover, purify, and refine materials ranging from table salt to high-purity chemicals for batteries and pharmaceuticals. At the forefront of this field stands GEA.
Our expertise in solution and melt crystallization is matched only by our commitment to rigorous testing and innovation. Through decades of experience and a relentless focus on research, GEA has developed a suite of crystallization technologies that serve a remarkable variety of industries, all while ensuring that each solution is tailored precisely to our customer’s needs:
- Solution crystallization. The formation of solid crystals from a supersaturated solution is a technique as old as civilization itself. While salt recovery remains its most iconic application, modern solution crystallization is a cornerstone of advanced manufacturing, enabling the extraction of high-purity products with precise control over particle size.
GEA offers all major types of crystallizers: Forced Circulation (FC), Draft Tube Baffle (DTB), and OSLO-either as standalone units or in combination. This flexibility allows GEA to address the unique requirements of each process, whether the goal is to maximize purity, optimize particle size, or minimize energy consumption. The choice of crystallizer and the design of the operation are never arbitrary; they are informed by a deep understanding of the chemical and physical properties of the product, as well as the specific conditions of the customer’s site.
- Melt crystallization is another area where GEA excels. This process separates chemical compounds by cooling a melt until the desired compound crystallizes while impurities remain in solution. The slow growth rates inherent to melt crystallization allow for the formation of exceptionally pure crystals, a feature especially valuable when dealing with close-boiling isomers, heat-sensitive substances, or products prone to polymerization. GEA’s hydraulic wash column technology, a key innovation in this field, enables the continuous and efficient separation of crystals from the mother liquor, often delivering ultra-high purity in a single step. This technology is not only easier to control than traditional piston wash columns, but it also doubles capacity for a given diameter, making it ideal for large-scale operations.
The breadth of GEA’s crystallization applications is truly staggering. In hydrometallurgy, GEA’s systems are instrumental in the production and recycling of battery materials such as lithium, nickel, cobalt, and rare earth metals -critical resources for the global energy transition. Our crystallizers are also used in the manufacture of water-soluble fertilizers, the recovery of phosphates from waste ore, and the treatment of industrial wastewater, including zero liquid discharge (ZLD) applications. In the recycling sector, GEA’s technologies support PET and polycotton recycling, battery material recovery and the reclamation of valuable chemicals from industrial effluents.
The bio-based chemicals and biorefinery sectors also benefit from GEA’s expertise. Here, crystallization is used to purify a range of acids and specialty chemicals derived from renewable resources, supporting the shift toward more sustainable production methods. Meanwhile, in the field of organic chemicals, GEA’s systems purify monomers, acids, alcohols and specialty chemicals that form the backbone of industries from plastics to pharmaceuticals.
What truly sets GEA apart are our testing and validation capabilities. The design of any crystallization plant begins in the laboratory, where GEA’s skilled engineers determine the chemical composition, physical properties and crystallization behavior of any desired product. For sensitive or hazardous materials, GEA can even conduct tests at the customer’s site, ensuring safety and accuracy. Bench-scale laboratory tests and mini-plant trials are used to confirm process concepts and define key parameters, forming the foundation for the design of full-scale industrial plants.
GEA’s Test Centers of Excellence in France and Germany are at the heart of this approach. The French Test Center, with over 1,000 square meters of test area, can validate solutions for industries ranging from food to chemicals. The German Test Center, spanning 1,200 square meters, is equipped for batch, continuous & mini-plant testing and boasts advanced analytical tools such as ICP-OES, AAS and TOC/TIC analysis. These facilities allow GEA to simulate industrial processes with remarkable fidelity, providing customers with reliable data and confidence in the performance of their future plants. When products are too sensitive to transport, GEA’s pilot plants can be deployed at the customer’s site, ensuring that even the most challenging projects are supported by robust testing and validation.
Innovation is at the core of GEA’s work. A new, tested crystallization process for example, represents a leap forward in energy efficiency for the fertilizer industry. By concentrating phosphoric acid while capturing and reusing process vapors, this technology can reduce steam consumption by up to 40%. Rigorous pilot testing, including continuous operation and advanced online monitoring, has demonstrated the feasibility and safety of this approach, paving the way for its adoption on a global scale.
In summary, GEA’s crystallization capabilities are defined not only by technical excellence and a broad portfolio of solutions, but by a deep commitment to testing, validation, and customer partnership. Whether purifying battery metals, recycling valuable resources, or enabling more sustainable chemical production, GEA ensures that every solution is grounded in science, proven in practice and ready to meet the challenges of tomorrow.