A Thermodynamic Approach for the Prediction of Oiling Out Boundaries from Solubility Data

Many pharmaceutical molecules, fine chemicals, and proteins exhibit liquid-liquid phase separation (LLPS, also known as oiling out) during solution crystallization. LLPS is of significant concern in crystallization process development, as oiling out can compromise the effectiveness of a crystallization and can lead to operational problems. A comprehensive methodology that allows a process scientist/engineer to characterize the various phase boundaries relevant to oiling out is currently lacking. In this work, we present a modeling framework useful in predicting the binodal, spinodal, and gelation boundaries starting from the solubility data of a solute that is prone to oiling out. We collate the necessary theoretical concepts from the literature and describe a unified approach to model the phase equilibria of solute-solvent systems from first principles. The modeling effort is validated using experimental data reported in the literature for various solute-solvent systems. The predictive methods presented in this work can be easily implemented and help a process engineer establish the design space for a crystallization process that is affected by liquid-liquid phase separation.