Continuous Plant Extraction Reactor with Self-Cleaning Annular Filters
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Solution Overview
Problem
Current methods for extracting natural plant-based products, such as terpenes and cannabinoids, are inefficient due to batch processing and high costs, limiting research and development in pharmaceutical and nutraceutical applications.
Innovation Solution
A continuous plant product extraction reactor system using dual reactor assemblies with adjustable filtration elements and self-cleaning capabilities, employing high-pressure extraction fluids and hydrodistillation to separate and collect valuable constituents from plant solids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch extraction processes are used, then extraction of natural products can be performed with simple equipment, but productivity is low and costs are high
Solution Approach 1:
The patent implements continuous extraction by flowing extraction solvent continuously through the plant material bed in a column reactor, eliminating the batch processing steps of loading, extracting, and unloading. The solvent continuously percolates through the material, extracting constituents without interruption, thereby significantly improving productivity while maintaining relatively simple equipment configuration.
Solution Approach 2:
The extraction column is segmented into multiple zones with different particle sizes and flow rates. The plant material is divided into beds of varying coarseness, with coarser material at the bottom and finer material at the top, creating staged extraction zones that improve overall extraction efficiency while enabling continuous operation.
2Productivity
If conventional filtration systems are used, then equipment is simple, but continuous operation is prevented due to clogging
Solution Approach 1:
The filtration system employs dynamically adjustable screen openings that can change aperture size during operation. The screens transition from closed to open positions based on operational needs, allowing continuous operation by preventing clogging while maintaining filtration capability. This dynamic adjustment enables the system to adapt to varying material characteristics without stopping.
Solution Approach 2:
The filtration system incorporates self-cleaning capabilities where the flowing extraction solvent automatically removes accumulated particles from the filter screens. The continuous flow of solvent acts as a self-cleaning mechanism, preventing clogging and maintaining filtration efficiency without requiring external intervention or complex mechanical cleaning devices.
3Productivity
If high-pressure extraction fluids are used, then extraction efficiency improves, but energy consumption increases
Solution Approach 1:
The system optimizes extraction parameters by adjusting particle size distribution, flow rate, and temperature rather than relying solely on high pressure. By changing these parameters, the system achieves efficient extraction at moderate pressures, reducing energy consumption while maintaining high extraction rates. The staged particle size arrangement enhances mass transfer efficiency without requiring excessive pressure.
Solution Approach 2:
The system uses hydraulic principles to optimize solvent flow through the packed column, utilizing pressure gradients created by the column design and material arrangement. The extraction solvent flows under controlled pressure differential, achieving efficient mass transfer without requiring high-energy pumping systems. The hydrodynamic conditions are optimized to maximize extraction while minimizing energy input.
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
Enables efficient, continuous extraction of natural products, reducing costs and enhancing the extraction of valuable compounds like cannabinoids, facilitating research and development in pharmaceutical and nutraceutical fields.
Implementation Method 1
The first annular filter element defines a reaction side being disposed radially inwardly of the outer annular coil and a filtrate chamber 27 being disposed radially outwardly of the outer annular coil. The first constituent is separated from the plant solids through the first annular filter element into the filtrate chamber 27 of the first reactor assembly.
Implementation Method 2
First extracting fluids are disposed at a first temperature and composition and are injected into the reaction side of the first reactor assembly for solubilizing the first constituent of the plant solids.
Implementation Method 3
A screw conveyor is disposed within the reaction side of each filter element with including spiral fins and a central porous shaft
Implementation Method 4
The filtrate chamber 27 of the reactor assembly receives the oil-solvent-stream in which the stream is cooled by way of a cooling element. Thus, the filtrate chamber 27 of the reactor assembly acts as a cooling a collection vessel for the constituent that is extracted from the plant solids.
Data Source
AI summary
A reaction assembly separating plant material from water includes a first annular filter element defining an axis. The first annular filter element is defined by an outer annular coil of flat wire and an optional second filter element is defined by an inner annular coil of flat wire, being generally helical in the axial direction. A cylindrically or frustoconical filter membrane is concentrically disposed between the first and second annular filter element. The filter membrane is porous having aperture size of less than a nano-particulate size of the plant material, but greater than a nano-particulate size of the water molecule. The second annular filter includes adjustable porosity for selectively preventing particles from reaching the filter membrane and selectively cleaning the membrane by reversed flow of water through the membrane. The assembly generates radial and distal flows and differential pressure forces, for use in high throughput industrial, agricultural and municipal facilities.