Continuous Extraction Unit with Quick-Disconnect Valves
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Solution Overview
Problem
Existing continuous extraction processes face challenges in efficiently transferring and replacing extraction chambers without disrupting fluid flow, achieving rapid equilibrium partitioning of extracts, and minimizing solvent loss and energy consumption.
Innovation Solution
A continuous extraction unit (CEU) with multiple extraction chambers and a double phase change heat exchanger, utilizing quick-disconnect valves and a compressor for fluid flow, allows for the rapid replacement and recharging of extraction chambers while maintaining continuous operation and minimizing solvent loss, using a double phase change heat exchanger for efficient solvent separation and energy management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If extraction chambers are replaced in a continuous extraction unit, then extract removal rate is improved, but solvent loss and disruption of fluid flow occur
Solution Approach 1:
The continuous extraction unit is divided into multiple extraction chambers (first EC, second EC, third EC) that can be independently replaced. Each chamber has quick-disconnect valves that allow individual chamber replacement without stopping the entire system, enabling continuous operation while maintaining extract removal rate and preventing solvent loss.
2Productivity
If extraction chambers are replaced frequently, then extract removal efficiency is improved, but energy consumption increases
Solution Approach 1:
The system maintains continuous fluid flow through the extraction unit by using multiple chambers in sequence. While one chamber is being replaced, others continue extraction, eliminating downtime and maintaining constant productivity without additional energy consumption for system shutdowns and restarts.
3Productivity
If rapid chamber replacement is implemented, then throughput is improved, but complexity of operation increases
Solution Approach 1:
The third extraction chamber is pre-filled with fresh extractable material and placed under vacuum before replacement is needed. This preliminary preparation allows for rapid chamber exchange without time-consuming filling and evacuation steps during the replacement process, simplifying operation while maintaining high throughput.
4Speed
If equilibrium partitioning is achieved rapidly, then extraction speed is improved, but time for chamber residence is reduced
Solution Approach 1:
Multiple extraction chambers are arranged in sequence, allowing the system to maintain continuous operation. While one chamber achieves equilibrium partitioning, another is being replaced, and a third is being prepared. This segmentation enables rapid extraction speed without requiring extended residence time in a single chamber, as the system throughput is maintained by the series arrangement.
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
The CEU enables continuous, efficient extraction with constant extract removal rates, minimizing energy consumption and solvent loss, while allowing for rapid chamber replacement and equilibrium partitioning, enhancing throughput and waste management.
Implementation Method 1
at least one compressor, wherein at least one first compressor situated to provide fluid flow in a fluid flow portion of the CEU
Implementation Method 2
condensation of a gas to liquid occurs in one portion of the heat exchanger
Implementation Method 3
evaporation of a liquid to gas with a liquid-gas separation of extract from a solvent occurs rapidly
Implementation Method 4
an expansion valve promotes vaporization and separation of a liquid solute extract and gaseous solvent in a single unit
Implementation Method 5
an expansion chamber (EXC) with a heat transfer tube that is proximal to or shared with the SC
Data Source
AI summary
Continuous extraction units (CEUs) are constructed that allow switching of extraction chambers (ECs) that contain extractable material (EM) and extract solution. Extraction chambers can be removable and replaceable, where the CEU has a fluid flow portion and a liquid transfer portion. Quick-connect valves allow exchange of ECs in the CEU while under flow without solvent loss. Alternatively, the CEU employs pairs of ECs where a first EC at equilibrium partitioning of an extract solution drains to an expansion chamber (EXC) with an expansion valve (EV) and a heat transfer tube situated proximal to or shared with a solvent condenser (SC) to form of a double phase change heat exchanger (HE). Solvent from the SC fills a paired EC containing EM. A second pair of ECs has a first EC with EM and solvent establishing equilibrium and a second EC that is emptied of spent EM, filled with fresh EM, and readied to receive solvent.