Ethanol Oil Extraction With Phase Separation and Solvent Recycling

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Solution Overview

Problem

Existing solvent extraction processes for oil from oleaginous materials face challenges in efficiency and compatibility with food production standards, particularly due to the use of non-food grade solvents like hexane, which require extensive solvent removal steps and raise consumer concerns.

Innovation Solution

The use of alcohol-based solvents, particularly ethanol, in a countercurrent extraction process with phase separation techniques and solvent recycling, allowing for efficient extraction and separation of oil from solids, reducing residual solvent content and enhancing product quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hexane solvent is used for extraction, then extraction efficiency is improved, but consumer safety concerns increase and extensive solvent removal steps are required

Engineering Contradiction:

Improveextraction efficiencyVSAvoidconsumer safety concerns

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical parameter of the solvent from hexane to ethanol. This parameter change maintains extraction efficiency while eliminating consumer safety concerns, as ethanol is GRAS-approved and can be used in food production without extensive removal steps

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs ethanol as a disposable solvent that can be easily removed through evaporation or distillation without requiring extensive purification steps. The solvent's volatile nature allows for simple removal, reducing both complexity and safety concerns

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Productivity

If hexane solvent is used for extraction, then extraction efficiency is improved, but process complexity increases due to extensive solvent removal steps

Engineering Contradiction:

Improveextraction efficiencyVSAvoidsolvent removal steps

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent changes the physical parameter of the solvent from hexane to ethanol, which has different volatility and safety characteristics. This parameter change simplifies the solvent removal process, requiring fewer and less complex removal steps while maintaining extraction efficiency

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the complex mechanical solvent removal system required for hexane with a simpler system suitable for ethanol. The GRAS-approved ethanol can be removed through simpler evaporation or distillation processes, reducing device complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If alcohol-based solvent is used, then consumer safety is improved, but extraction efficiency may decrease

Engineering Contradiction:

Improveconsumer safetyVSAvoidextraction efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent optimizes the parameters of alcohol-based solvents (such as ethanol concentration, temperature, and pressure) to achieve extraction efficiency comparable to hexane while maintaining the safety benefits of GRAS-approved solvents

Inventive Principle:

Principle #35Parameter changes

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 alcohol-based solvent system enhances extraction efficiency, reduces residual solvent levels, and improves product attributes such as flavor and color, aligning with food safety standards by utilizing GRAS-approved ethanol.

Implementation Method 1

The extractor receives an alcohol-based solvent at a solvent inlet and conveys the solvent through the extractor to a solvent outlet. The alcohol-based solvent may travel in a countercurrent direction through the extractor from a direction of material travel that the feedstock travels through the extractor.

Methodology Applied

Scientific EffectLiquid-liquid extraction: Liquid-Liquid Extraction

Implementation Method 2

To separate the oil from the solvent in the miscella stream, the miscella stream may be cooled to a temperature effective to cause phase separation between the aqueous solvent and the oil in the stream.

Methodology Applied

Scientific EffectPhase separation: Phase Change

Data Source

PatentUS20260092234A1Oleaginous material extraction using alcohol solvent

Publication Date: 2026.04.02 CROWN IRON WORKS COMPANY

AI summary

An oil extraction process may be performed on an oleaginous feedstock using an alcohol-based solvent, such as ethanol. In some examples, an extraction process involves conveying a material in countercurrent direction with an alcohol-based solvent to generate an extracted material and a miscella. The miscella stream is cooled to form a first solvent-rich layer phase separated from a first oil-rich layer, which is then separated to form a first separated oil-rich stream and a first separated solvent-rich stream. In some examples, the first separated solvent-rich stream is recycled back to the extractor and introduced into the extractor at a location different than a location where fresh solvent is introduced into the extractor. Additionally or alternatively, water may be introduced into the separated first oil-rich stream to form a second solvent-rich layer phase separated from a second oil-rich layer, which is then separated to form a second separated oil-rich stream.