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Volume 115
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Ultrasound-assisted negative pressure crystallization of ammonium sulfate: Synergistic effects and intensification mechanisms
Qian Zhang a b, Guang Fu c, Shuo Xu b, Dongbin Wang a b, Thiquynhxuan Le a b *, Libo Zhang a b *
a State Key Laboratory of Complex Non-ferrous Metal Resources Clean Utilization, Kunming University of Science and Technology, Kunming, 650093, China
b Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming, 650093, China
c Yunnan Chihong Zinc and Germanium Co., Ltd., Qujing, 655011, China
10.1016/j.partic.2026.06.003
Volume 115, August 2026, Pages 401-414
Received 7 April 2026, Revised 6 May 2026, Accepted 6 June 2026, Available online 9 June 2026, Version of Record 20 June 2026.
E-mail: quynhxuanlt@kust.edu.cn; zhanglibopaper@126.com
Highlights

• Ultrasound-assisted negative pressure crystallization of ammonium sulfate solution.

• Yield increased by 27.64 g and direct yield improved by 36.80% compared to negative pressure crystallization.

• MSZW narrowed by 33%, solid-liquid transition time shortened by 35.7%, and solution viscosity reduced by 5.7%.

• Crystals with more uniform size, regular morphology, and enhanced crystallinity are obtained.


Abstract

Although negative pressure crystallization of ammonium sulfate can mitigate low yield and long processing time in atmospheric pressure crystallization, it still faces challenges in enhancing crystallization efficiency and achieving a uniform crystal size distribution. To address these issues, this study proposed an ultrasound-assisted negative pressure crystallization technique. Under optimized conditions (pH = 7, 300 rpm, 80 °C, 45 min, 180 W, 0.03 MPa), the yield increased by 27.64 g and the direct yield improved by 36.80% compared with negative pressure crystallization. XRD and FTIR confirmed that this process maintained the crystal structure of ammonium sulfate while enhancing crystallinity. Mechanistic studies revealed that, compared with negative pressure crystallization, the synergistic effect of ultrasound narrowed the metastable zone width (MSZW) by approximately 33%, lowering the nucleation energy barrier. Ultrasound cavitation generated numerous bubbles, providing heterogeneous nucleation sites and localized supersaturation driving forces, which jointly accelerated nucleation and reduced the solid-liquid transition time by 35.7%. Furthermore, compared with the negative pressure crystallization system, the ultrasonic negative pressure crystallization reduced the solution viscosity by 5.7%, enhancing mass transfer and crystal growth. Ultimately, ultrasound-assisted negative pressure crystallization produced crystals with more uniform size and more regular morphology, offering important theoretical insights for improving ammonium sulfate crystallization processes.

Graphical abstract
Keywords
Ultrasound; Negative pressure crystallization; Synergistic intensification; Ammonium sulfate
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