A continuous mixed-suspension, mixed-product removal (CMSMPR) crystallizer with automatic computer control and data acquisition was constructed. Operating this CMSMPR at rpm's greater than 100 rpm assures well-mixed conditions. The crystallization of NaCl, an impurity in a concentrated CaCl2 solution, was performed by cooling under well-mixed conditions. Atomic absorption spectrometry (AAS) and inductively coupled plasma-atomic emission spectrometry (ICP-AES) have been used to measure solution concentrations. Scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), light microscopy and particle size analyzer with advanced laser light scattering have been used to characterize the crystals produced by the CMSMPR crystallizer. Octahedral NaCl crystals are observed. Steady state crystal size distribution (CSD) is observed at nine to ten times the mean residence time for the crystallizer. The CSD has been analyzed to look at the details of nucleation, growth, and aggregation rate as a function of crystallization temperature, rpm, and feed flow rate with the application of a Hounslow's constant aggregation rate equation. (c) 2004 Elsevier B.V. All rights reserved.