Counter-Current Emulsion Flow Liquid-Liquid Extraction Apparatus
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Solution Overview
Problem
Conventional liquid-liquid extraction methods require mechanical external forces, leading to high energy consumption, maintenance costs, and safety concerns, and struggle with achieving high extraction rates and stable emulsion flow, especially when dealing with particle components that can plug apparatus components.
Innovation Solution
A counter-current type emulsion flow continuous liquid-liquid extraction apparatus that stabilizes emulsion flow and prevents plugging by using a two-head system where the solvent phase is circulated, allowing the particle component to aggregate at the liquid-to-liquid interface without transferring into the solvent phase, enabling efficient extraction of both particulate and dissolved components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical external forces (stirring, vibrating) are applied to mix liquid phases, then extraction efficiency is improved, but energy consumption and maintenance costs increase
Solution Approach 1:
The patent replaces mechanical mixing systems (stirrers, vibrators) with a natural convection-based emulsion flow system. The countercurrent flow of aqueous and organic phases creates automatic emulsification and mixing through their interaction, eliminating the need for external mechanical energy input while maintaining high extraction efficiency.
Solution Approach 2:
The system utilizes the inherent properties of the liquid phases (density differences, interfacial tension) to generate self-sustaining emulsion flow. The continuous countercurrent movement and phase separation occur automatically without external intervention, making the system self-regulating and energy-efficient.
2Productivity
If mechanical mixing is used to achieve stable emulsion flow, then extraction rate is improved, but apparatus complexity and maintenance requirements increase
Solution Approach 1:
The patent eliminates complex mechanical mixing apparatus by using a simple countercurrent flow configuration where phases move in opposite directions through a contactor. The emulsion formation and phase separation occur naturally through fluid dynamics, dramatically simplifying the apparatus structure while maintaining high extraction rates.
3Reliability
If filters or centrifuge separators are used to remove particle components, then solution purification is improved, but device complexity and operating costs increase
Solution Approach 1:
The patent converts the harmful effect of particle components (which would normally require complex separation equipment) into a beneficial feature. Particles aggregate at the liquid-to-liquid interface during the extraction process, and this interfacial aggregation automatically removes particles from the solution without requiring additional filtration or centrifugation equipment.
4Productivity
If particle components are present in the aqueous solution, then extraction process becomes complicated, but plugging of apparatus components occurs
Solution Approach 1:
The patent transforms particles from a problematic contaminant into an integral part of the extraction mechanism. Particles accumulate at the liquid interface where they facilitate phase separation and do not cause plugging because they are naturally positioned at the interface rather than moving through narrow channels or filters.
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 method achieves extraction rates over 90% with stable emulsion flow, facilitates apparatus scale-up, and reduces costs and safety risks, allowing for simultaneous collection of both particle and dissolved components without plugging issues, while being compact and energy-efficient.
Implementation Method 1
Liquid-liquid extraction method (solvent extraction method), by which the target component included in the aqueous solution may be extracted into the solvent (such as organic solvent) that contains extraction agents (extractants) having hydrophobic nature and does not mix with water
Implementation Method 2
the solvent (solvent phase) having hydrophobic nature and not mixing with water
Implementation Method 3
the material transport from one liquid to the other liquid is made reach an equilibrium state by keeping the emulsion state (the state in which the water and the organic solvent are well mixed and formed in emulsion) with continuous stirring and vibration (shaking) operations
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3B
AI summary
The particle components may be collected by using a phenomenon that the particle components in the aqueous phase aggregate at the liquid-to-liquid interface. Both of the particle components and the dissolved components in the aqueous phase may be simultaneously collected if combined with liquid-liquid extraction phenomenon that the dissolved components in the aqueous phase are collected into the solvent phase through the liquid-to-liquid interface. The aggregation phenomenon of the particle components at the liquid-to-liquid interface may be promoted by using an emulsion flow method, a method of applying mechanical external forces (such as stirring and vibrating) or another method combining both the above-mentioned methods.