Continuous Extraction Isolator with Segmented Chambers
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Solution Overview
Problem
Current extraction processes are inefficient in terms of energy consumption and solvent retention, and they often produce a mixture of chemicals rather than purified products, lacking the ability for continuous operation and partial separation of components.
Innovation Solution
A continuous extraction and isolation unit with multiple chambers and valves allows for the continuous extraction, concentration, and isolation of desired products from plant material, enabling solvent recycling and independent management of plant material without disrupting the process, using a system that includes expansion chambers, condensers, compressors, and isolators for purification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch extraction process is used with single solvent and single product collection, then equipment complexity is reduced, but productivity and manufacturing precision deteriorate due to inability to separate different components and require repeated batch cycles
Solution Approach 1:
The extraction system is divided into multiple extraction chambers (first extraction chamber, second extraction chamber) that can operate simultaneously or in sequence. Each chamber can be independently filled, extracted, and emptied, allowing continuous operation and increased productivity without requiring a completely complex new system design.
Solution Approach 2:
The system enables continuous extraction by allowing one chamber to be filled while another is being extracted, and one is being emptied while another is being filled. This continuous circulation of solvent and material eliminates idle time between batches, significantly improving productivity.
2Manufacturing precision
If solvent removal and product collection are performed in separate steps, then manufacturing precision improves for product purification, but loss of time increases due to multiple processing steps
Solution Approach 1:
The system merges the extraction, solvent removal, and product collection steps into a single integrated process. The expansion chamber simultaneously performs solvent removal through pressure reduction and collects the concentrated product, eliminating the need for separate evaporation and collection steps.
Solution Approach 2:
The system uses phase transition of the solvent (from liquid to gas) through pressure reduction in the expansion chamber to separate solvent from product. This allows simultaneous solvent removal and product concentration in one step, improving both purification and reducing process time.
3Ease of operation
If extraction chambers are removed and replaced during operation, then adaptability and ease of operation improve for maintenance and material replacement, but reliability deteriorates due to potential process interruption
Solution Approach 1:
The extraction system is segmented into multiple independent chambers that can be operated, removed, or replaced individually. This allows one chamber to be taken out for maintenance or material replacement while other chambers continue operating, maintaining process reliability while improving ease of operation.
Solution Approach 2:
The system allows spent extractable material to be removed from extraction chambers and replaced with fresh material while the solvent is recovered and recycled. This enables continuous operation with multiple chambers, maintaining reliability while facilitating easy material replacement.
4Quantity of substance
If high pressure is used for extraction, then quantity of substance extracted increases, but use of energy and loss of energy increase due to compression and pressure maintenance
Solution Approach 1:
The system uses phase transition of the solvent under pressure to achieve extraction. The solvent transitions to a supercritical or highly solvating state under pressure for effective extraction, then returns to liquid state upon pressure release for easy separation and recycling, reducing the energy needed for compression compared to traditional high-pressure systems.
Solution Approach 2:
The system changes pressure parameters dynamically - high pressure during extraction for high yield, then rapid pressure reduction in the expansion chamber for solvent removal and product concentration. This parameter cycling allows high extract yield while minimizing energy consumption through efficient pressure recovery and solvent recycling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables efficient energy use, solvent retention, and continuous operation, allowing for the production of concentrated or purified products while minimizing solvent loss and facilitating the replacement of extraction chambers without process interruption.
Implementation Method 1
an expansion valve that allows a pressure drop that promotes formation of a low pressure vaporized solvent from the solution
Implementation Method 2
the vaporized solvent is condensed to a liquid solvent
Implementation Method 3
at least one expansion chamber, and at least one condenser consists of one of at least one heat exchanger, wherein heat from the condenser is absorbable by the expansion chamber
Implementation Method 4
at least one compressor positioned upstream of the condenser and extraction chambers, and downstream of the expansion chambers, wherein the at least one low pressure vaporized solvent is in fluid communication with one of the at least one compressor
Implementation Method 5
at least one expansion chamber, and at least one condenser consists of one of at least one heat exchanger, wherein heat from the condenser is absorbable by the expansion chamber
Implementation Method 6
the extraction chamber contains extractable material for extraction of at least one extract comprising at least one solute by at least one solvent when under fluid flow
Data Source
AI summary
Continuous extraction concentration and isolation units are constructed with at least one extraction chambers containing extractable material. Without disruption of total fluid flow in the unit: an extraction chamber completely depleted of extract can be refilled with fresh extractable material or can be replaced with an extraction chamber containing fresh extractable material. Extract are continuously separated from one or more solvents in expansion chambers and removed. All solvents can be retained within the unit. One or more compressors circulate the fluids through the extraction chambers, the expansion chamber, and a condenser, where the expansion chamber and the condenser can be coupled as a heat exchanger. One or more isolators can be included for selectively removing components that are extracted from the plant material without disruption of the process and provide the removed components in concentrated or pure form.