Method for extracting active ingredients from hemp fiber processing byproducts and utilizing waste residues

Abstract

The application provides a hemp fiber processing byproduct active ingredient extraction and waste residue utilization method, comprising the following steps: S1, full-process byproduct fixed-point collection, accurately collecting hemp bone and hemp chip byproducts generated in the hemp fiber field primary processing and factory finishing links; S2, general open biological active ingredient adaptive extraction, taking hemp bone and hemp chip as the exclusive raw material, selecting water extraction, alcohol extraction or auxiliary enhanced extraction process, and directionally extracting active ingredients such as flavonoids, polyphenols and polysaccharides; S3, fine treatment and differential high-value utilization of the extraction liquid, and biological active extract is prepared through concentration, purification and drying; S4, full-amount closed-loop resource utilization of the extraction waste residue, and the solid residue is realized without external discharge through three paths of biomass energy, ecological field improvement and composite filler reuse. The application takes the hemp fiber processing byproduct as the core raw material for the first time, realizes high-value extraction of active ingredients and zero-waste closed-loop utilization of waste residues, and constructs a green circular production system.

Description

Technical Field

[0001] This invention belongs to the technical field of hemp biomass resource utilization, hemp fiber processing and high-value recycling of agricultural and forestry by-products, specifically involving a method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue. Background Technology

[0002] Hemp, flax, ramie, and other bast fibers are high-quality natural green textile raw materials. In the existing industrial processing system for bast fibers, the focus is entirely on the extraction and preparation of finished fibers, with no development or utilization of the vast amounts of byproducts generated throughout the entire processing chain, especially the bioactive components such as flavonoids, polyphenols, and polysaccharides abundant in these byproducts.

[0003] Throughout the initial processing of hemp fiber in the field and the final processing in the factory, processes such as core-sheath separation, opening, impurity removal, and carding generate a large amount of byproducts, including hemp fibers, hemp shavings, and fine fiber residues. In the current hemp fiber processing industry, these byproducts are only treated as low-value fuels, and their rich active ingredients are lost with the smoke. There is a lack of mature and practical recycling technologies and methods, and a closed-loop resource utilization system has not been formed. The large-scale low-value and waste disposal of hemp byproducts rich in valuable bioactive components such as flavonoids, polyphenols, and polysaccharides results in a serious loss of added value in the industrial chain.

[0004] Currently, there is no systematic technical solution in the industry that can be adapted to the extraction of active ingredients from by-products of the entire industrial process of hemp fiber and the closed-loop utilization of waste residue with zero waste. The effective active ingredients in hemp fiber processing by-products have long been in a state of complete waste.

[0005] Meanwhile, the active extracts of hemp disclosed in existing technologies and patent documents all use hemp plant leaves as raw materials, which belongs to the traditional medicinal material extraction approach. This approach is completely disconnected from the industrial processing system of hemp fiber and there is no mature technology for the stepwise extraction of active ingredients using hemp fiber processing by-products (hemp bones, hemp scraps, processing residues).

[0006] Given the current gaps in the industry, developing a technical solution that is compatible with the entire production process of hemp fiber and enables high-value extraction of active ingredients and closed-loop utilization of waste residue has extremely high industrial value and practical significance for filling the technological gaps in the industry, building a green circular system for the hemp industry, and significantly improving the overall economic benefits of the industrial chain. Summary of the Invention

[0007] This invention aims to completely solve the industry pain points in the current hemp fiber industrial processing field, such as the large amount of hemp bone and hemp shavings being discarded or only treated as low-value biomass pellets, and the complete waste of bioactive components. It fills the technological gap in the extraction of active ingredients from hemp fiber by-products and the zero-waste recycling of all materials, and provides a method for the extraction of active ingredients from hemp fiber processing by-products and the utilization of waste residue.

[0008] This invention is the first to use hemp fibers and related byproducts from the entire hemp fiber processing chain as exclusive core raw materials, and establishes an open, multi-process, universal extraction system to selectively extract high-value-added bioactive substances from the byproducts. It also uniquely creates a dual-industry-scale implementation model adapted to the hemp textile industry. 1. Relying on the existing hemp fiber production line and matching extraction equipment, the self-produced hemp shavings, hemp fibers, short hemp fibers and other by-products are centrally extracted and processed. 2. Independently construct a by-product deep processing plant, uniformly purchase waste by-products from various hemp fiber processing plants, and carry out large-scale extraction of active ingredients and resource utilization of waste residue.

[0009] This invention enables differentiated high-value development of active ingredients from waste byproducts and 100% closed-loop resource utilization of extraction waste residue with no external discharge, thus building a green circular production system for the hemp fiber processing industry that is low-energy, zero-waste, and high-value-added from scratch.

[0010] Technical solution To achieve the above-mentioned objectives, this invention provides a method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue, comprising the following steps: S1. Fixed-point collection of by-products throughout the entire process The entire hemp fiber processing process is precisely delineated, focusing on two major byproduct production stages. Hemp fibers and lint byproducts generated throughout the process are collected uniformly, specifically including: 1. Field primary processing stage: After the hemp stalks are harvested, the field process of separating the core and outer skin is completed, and the resulting hard hemp core and fine hemp debris are produced. 2. Factory finishing stage: Fine hemp scraps and fiber residues that fall off during the degumming, loosening, impurity removal and combing process of hemp bark pre-processed in the field.

[0011] This invention is adaptable to two industrialization implementation models and can cover various hemp fiber production scenarios across the entire industry: Mode 1: The hemp fiber production line is equipped with extraction equipment in situ to collect by-products generated during the production process in real time, so as to realize continuous and integrated resource-based treatment; Model 2: Build an independent extraction and processing plant to collect waste by-products from various hemp processing areas across regions, and carry out centralized extraction of bioactive ingredients and resource utilization of waste residue. This model has broad industrial adaptability and flexible operation mode.

[0012] S2, Universal Open-Type Bioactive Ingredient Adaptation Extraction Using collected hemp bones and hemp shavings as raw materials, this invention flexibly selects suitable extraction processes based on the types of target active ingredients, product applications, and production cost requirements to selectively extract bioactive components such as flavonoids, polyphenols, and polysaccharides from the raw materials. This invention establishes a dedicated open extraction system tailored to the low lignin and high-activity component characteristics of hemp by-products, not limited to a single process route, and compatible with various mature industrial extraction methods. Specifically, it includes: 1. Water extraction process: Using purified water as a solvent, high-temperature extraction or room-temperature extraction is used to selectively extract water-soluble polyphenols and polysaccharides from by-products. The process is green and residue-free, and is suitable for large-scale industrial continuous production. 2. Alcohol extraction process: Using aqueous ethanol solution as the extraction solvent, the active components of fat-soluble flavonoids are specifically enriched and extracted, which significantly improves the extraction yield and product purity of high-value flavonoid components; 3. Enhanced extraction process: Depending on equipment conditions and product development needs, conventional industrial extraction methods such as microwave-assisted extraction, ultrasonic extraction, and constant temperature immersion extraction can be used to further improve extraction efficiency and the yield of active ingredients.

[0013] During the extraction process, process parameters such as the feed-liquid ratio, extraction temperature, holding time, and number of extractions can be adjusted independently according to actual production needs. After extraction, solid-liquid separation is achieved through filtration, centrifugation, and other methods to obtain an extract rich in bioactive components and a solid extraction residue.

[0014] S3. Refined processing and differentiated high-value utilization of extract. The obtained extracts are concentrated, purified, and dried according to the extraction system category to obtain bioactive extracts of hemp fiber by-products; the extracts include all product forms such as original extract, concentrated extract, and dried powder, and the protection scope covers all active product forms that can be obtained by this process.

[0015] The preferred core commercial product of this invention is a concentrated extract, which is obtained by concentrating the extract under low temperature and negative pressure. It is a semi-fluid form with high solids, high activity, and can be directly added to daily chemical products. It has the advantages of good solubility, strong compatibility, complete retention of activity, and no need for secondary compounding in industrial applications, making it the optimal product form for the present invention.

[0016] The polyphenol and polysaccharide extracts (including stock solution, extract, and powder) obtained by water extraction system enrichment have excellent antioxidant, antibacterial, and skin-soothing properties, and can be widely used in the fields of daily chemical skin care, food antioxidants, and daily antibacterial products. The high-purity flavonoid extracts (including stock solution, extract, and powder) obtained by the alcohol extraction system have strong antioxidant activity and high added value. They can be applied to functional food raw materials, health care excipients, pharmaceutical intermediates, and biofunctional additives, realizing the gradient development and high-value utilization of the originally waste by-products.

[0017] S4. Complete closed-loop resource utilization of extraction waste residue The extraction residue obtained from solid-liquid separation is subjected to closed-loop resource utilization treatment with zero discharge and zero waste, achieving 100% full utilization of solid residue through multiple pathways: 1. Biomass energy utilization: The dried extraction residue can be used as clean biomass fuel for heating in production workshops, drying materials, and concentrating extracts, replacing traditional fossil fuels and effectively reducing production energy consumption and operating costs. 2. Ecological application and utilization: After decomposition, the extraction residue can be used as organic base fertilizer and soil conditioner in hemp planting bases to effectively improve soil structure and enhance soil fertility, thus creating a green ecological closed loop of "planting-processing-resource return to the field". 3. Resource reuse of composite fillers: The treated extraction residue can be used as a biomass auxiliary filler in the fields of environmental protection boards and biomass composite new materials preparation, realizing the resource recycling of solid waste.

[0018] Preferred Implementation Furthermore, in step S2, the high-temperature water extraction temperature is controlled at 85℃-100℃, a temperature range suitable for industrial continuous and stable production, which can maximize the preservation of the activity of water-soluble active ingredients; the alcohol extraction process uses an ethanol aqueous solution with a volume concentration of 40%-75%, which can be extracted by room temperature immersion or heating reflux extraction, which can maximize the preservation of the molecular structure and biological activity of flavonoid active substances and improve the quality of the extract.

[0019] Furthermore, all waste residues after extraction and utilization according to this invention can be disposed of in a closed loop within the plant area with no solid waste discharge, fully complying with national industrial standards and environmental protection requirements for green, low-carbon, and clean production.

[0020] Beneficial effects Compared with existing traditional hemp fiber processing technologies, this invention provides an industry-first technical solution for waste byproducts of hemp fiber processing, which has disruptive innovative advantages and significant beneficial effects.

[0021] Pioneering a precise resource utilization system for by-products across the entire industry chain This invention is the first to accurately target the two major by-product production scenarios of hemp fiber: field primary processing and factory fine processing. It establishes a dedicated and systematic resource utilization system for hemp bone and hemp scraps, which have been completely discarded by the industry for a long time. It comprehensively covers the entire hemp fiber processing industry chain and precisely fills the gap in the industry for high-value utilization technology without by-products.

[0022] Pioneering open universal extraction process system In response to the current lack of mature byproduct active extraction technology in the industry, this invention establishes a universal open extraction platform compatible with water extraction, alcohol extraction, microwave-assisted extraction, ultrasonic extraction, and constant temperature maceration extraction. The process route can be freely switched according to the development needs of different active products, adapting to different product development directions and factory production conditions. The threshold for industrialization is extremely low, and its industry universality and scalability are extremely strong.

[0023] Unique dual-mode industrialization implementation system This invention breaks through the current gap in the industry's lack of resource-based industrialization solutions, and pioneers two commercialization implementation models: on-site synchronous production in factories and independent centralized processing. It can accommodate the needs of large enterprises for continuous production with large capacity and small and medium-sized enterprises for flexible processing, and is suitable for application by production enterprises of different sizes across the industry, with comprehensive commercialization adaptability.

[0024] Completely overturning the industry's low-value waste status quo, achieving zero-waste, high-value recycling across the entire chain (core innovation) In the traditional hemp fiber processing industry, hemp bones and hemp shavings by-products have 100% no active ingredient extraction process, no high-value utilization pathway, and no closed-loop disposal method. They can only be disposed of through low-end incineration or waste disposal, resulting in a complete waste of precious bioactive resources.

[0025] This invention differs from traditional leaf extraction technology, pioneering the transformation of waste byproducts from the hemp fiber processing industry into high-value-added active extracts for the daily chemical, food, health, and pharmaceutical fields, realizing a value leap from waste to high-end industrial raw materials. Simultaneously, it innovatively achieves a triple closed-loop system of energy, ecological, and material utilization for the extraction waste residue, completely solving the problems of resource waste and environmental disposal of byproducts in the hemp fiber processing industry. It establishes a high-value circular industrial chain for all components of hemp raw materials from scratch, significantly improving the overall economic and ecological benefits and core industrial competitiveness of the hemp industry. Detailed Implementation

[0026] The technical solution of the present invention will be described in detail below with reference to specific embodiments. These embodiments are only for explaining the present invention and are not intended to limit the scope of protection of the present invention. Simple modifications, equivalent substitutions, and optimizations made by those skilled in the art within the core concept and technical framework of the present invention are all within the scope of protection of the present invention.

[0027] Example 1: Preparation of polyphenol and polysaccharide complex active extract by high-temperature water extraction S1. By-product collection: Collect the hemp fibers produced in the separation process of hemp bark and core and the hemp shavings produced in the loosening process. After removing mud and impurities, crush them to 20-40 mesh for later use. S2. Water extraction: Add purified water at a material-to-liquid ratio of 1:12, extract twice at 95℃, and keep at a constant temperature for 90 minutes each time. Combine the two extracts, filter and separate the solid and liquid to obtain water extract and solid extraction residue respectively. S3. Refining process: The obtained extract is concentrated under negative pressure vacuum to obtain an extract paste, or it can be further processed by spray drying to obtain a high-activity polyphenol and polysaccharide complex extract powder. The extract has stable activity and low impurity content, and can be directly used in the daily chemical and food fields. S4. Closed-loop utilization of residue: After drying and dehydration, the extraction residue is used as biomass fuel in the workshop to provide a heat source for the extraction, concentration and drying equipment in this process, realizing closed-loop energy utilization within the plant area with no solid waste discharge.

[0028] The process described in this embodiment is stable, environmentally friendly, and can be produced on a large scale and continuously, effectively realizing the high-value conversion of low-value waste by-products from the processing of Apocynum venetum.

[0029] Example 2: Preparation of high-purity flavonoid active extract using alcohol extraction process S1. By-product collection: Select hemp bones and hemp shavings by-products produced in the entire hemp fiber processing process, remove impurities, dry them at a constant temperature of 45℃, and pulverize them to 40 mesh for later use. S2. Alcohol extraction: 60% ethanol aqueous solution was used as the extraction solvent, the material-liquid ratio was controlled at 1:10, and the extraction was carried out by heating and reflux twice, with each extraction lasting 60 minutes. After solid-liquid separation, the alcohol extract and solid residue were obtained. S3. Refining process: The extract is purified by reducing pressure to recover ethanol and remove impurities. It can be concentrated at low temperature to obtain a high-purity flavonoid extract, or dried to obtain a powder extract. It has a high flavonoid content and excellent antioxidant activity, making it suitable for high-end applications in functional foods and pharmaceutical intermediates. S4. Closed-loop utilization of residue: The solid residue after extraction is decomposed and rendered harmless, and then made into organic fertilizer to be returned to the field for hemp planting bases to improve the planting soil and build an ecological closed loop of "hemp planting - by-product extraction - waste residue return to the field".

[0030] This embodiment specifically improves the extraction purity and yield of high-value-added flavonoid components, resulting in extremely high economic value for industrialization.

[0031] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the technical solution and creative principles of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A method for extracting active ingredients from hemp fiber processing byproducts and utilizing the waste residue, characterized in that, Includes the following steps: S1. Fixed-point collection of by-products throughout the entire process: Precisely delineate the two major by-product output stages of the entire hemp fiber processing process, and collect the hemp fibers and hemp scraps by-products generated throughout the process in a unified manner; S2. Universal open-label bioactive ingredient adaptive extraction: Using collected hemp bone and hemp shavings by-products as exclusive raw materials, the adaptive extraction process is flexibly selected according to the type of target active ingredient, product application direction and production cost requirements to extract bioactive ingredients such as flavonoids, polyphenols and polysaccharides from the raw materials. S3. Refined processing and differentiated high-value utilization of the extract: The obtained extract is concentrated, purified and dried according to the type of extraction system to obtain bioactive extracts of hemp fiber by-products. S4. Full closed-loop resource utilization of extraction waste residue: The extraction residue obtained from solid-liquid separation is treated in a closed-loop resource utilization manner with no external discharge and zero waste, and 100% full utilization of solid residue is achieved through multiple paths.

2. The jute fiber processing byproduct active ingredient extraction and waste residue utilization method according to claim 1, characterized in that, In step S1, the two major by-product production stages specifically include: Primary processing in the field: After the hemp stalks are harvested, the field process of separating the core and outer skin is completed, producing hard hemp core and fine hemp debris; Factory finishing stage: Fine hemp scraps and fiber residues that fall off during the degumming, loosening, impurity removal and combing process of hemp bark pre-processing in the field.

3. The method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue according to claim 1, characterized in that, In step S1, the collection adapts to two industrialization implementation modes: Mode 1: The hemp fiber production line is equipped with extraction equipment in situ to collect by-products generated during the production process in real time; Model 2: Build an independent extraction and processing plant to collect waste by-products from various hemp processing areas across regions.

4. The method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue according to claim 1, characterized in that, In step S2, the adapted extraction process specifically includes: Water extraction process: using purified water as solvent, high-temperature extraction or room-temperature extraction is used to selectively extract water-soluble polyphenols and polysaccharides from by-products. Alcohol extraction process: using aqueous ethanol solution as the extraction solvent to specifically enrich and extract fat-soluble flavonoid active ingredients; Enhanced extraction processes: Microwave-assisted extraction, ultrasonic extraction, and constant-temperature immersion extraction are all available.

5. The method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue according to claim 4, characterized in that, In step S2, the high-temperature water extraction temperature is controlled at 85℃-100℃; the alcohol extraction process uses an aqueous ethanol solution with a volume concentration of 40%-75%, and adopts room temperature immersion or heating reflux extraction methods.

6. The method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue according to claim 1, characterized in that, In step S3, the bioactive extract includes the form of extract solution, concentrated extract, and dried powder product.

7. The method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue according to claim 6, characterized in that, In step S3, the concentrated extract is obtained by concentrating the extract under low temperature and negative pressure, and is a semi-fluid form with high solids, high activity, and can be directly added to daily chemical products.

8. The method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue according to claim 1, characterized in that, In step S4, the multi-path approach to achieve full utilization of solid residue specifically includes: Biomass energy utilization: The dried extraction residue is used as clean biomass fuel for heating in the production workshop, material drying, and energy supply in the extraction liquid concentration process. Ecological application and improvement: After the extraction residue is decomposed, it is applied to the field as organic base fertilizer and soil conditioner in hemp planting bases. Resource reuse of composite fillers: The treated extraction residue is used as a biomass auxiliary filler in the fields of environmental protection boards and biomass composite new material preparation.

9. The method for extracting active ingredients from hemp fiber processing by-products and utilizing waste residue according to claim 1, characterized in that, In step S4, all waste residue after extraction and utilization is disposed of in a closed loop within the plant area with no solid waste discharged externally.