Compact Liquid-Liquid Extraction Unit for Rare Earth Elements
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Solution Overview
Problem
Current multistage continuous extraction systems for rare earth elements require a large footprint and significant liquid volume, leading to high costs, despite achieving high separation efficiency.
Innovation Solution
A compact liquid-liquid extraction unit design where the aqueous and organic phases are contacted and separated in a small-volume tank with horizontally opposed sidewalls, allowing for high flow rates and efficient extraction without the need for large settler chambers, and a multistage continuous extraction system comprising multiple such units connected for fluid communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mixer-settler units are used for liquid-liquid extraction, then separation efficiency is maintained, but system footprint and liquid volume become excessively large
Solution Approach 1:
The patent transitions from traditional vertical mixer-settler configuration to a horizontal flow arrangement where aqueous and organic phases move in opposite directions through horizontally opposed sidewalls. This dimensional change enables compact footprint while maintaining extraction efficiency through counter-current contact
2Reliability
If traditional mixer-settler units are used for liquid-liquid extraction, then separation efficiency is maintained, but liquid volume requirement increases significantly
Solution Approach 1:
The horizontal flow configuration through oppositely positioned sidewalls reduces the required liquid volume by eliminating the need for large settler chambers, while maintaining adequate contact time and separation efficiency through the counter-current flow arrangement
3Area of stationary object
If compact extraction units are used, then footprint and liquid volume are reduced, but extraction efficiency may be compromised
Solution Approach 1:
The patent extracts the essential extraction function from the bulky mixer-settler configuration and concentrates it in a compact unit where aqueous and organic phases contact through horizontally opposed sidewalls, removing unnecessary volume while preserving the core separation mechanism
Solution Approach 2:
The design utilizes hydraulic flow patterns where aqueous phase enters through one sidewall and organic phase enters through the opposite sidewall, allowing efficient mass transfer through fluid dynamics without requiring mechanical mixers or large settlement volumes
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 compact design maintains high extraction efficiency while significantly reducing the system's footprint and liquid volume, resulting in substantial cost savings for rare earth element extraction and separation.
Implementation Method 1
an organic phase inlet (30) in a lower portion of one sidewall (11), an organic phase outlet (40) in an upper portion of the other sidewall (12), wherein the organic and aqueous phases are admitted in dispersed particles/subdivided form from one sidewall, move horizontally while exchanging their position upward and downward, and are discharged from the other sidewall
Data Source
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AI summary
A liquid-liquid extraction unit includes an extraction/separation tank (10) into which an aqueous phase in bubble form is admitted from an upper inlet (20) in one sidewall and an organic phase in bubble form is admitted from a lower inlet (30) in the one sidewall. The upward moving organic phase is contacted with the downward moving aqueous phase. After contact, the organic phase is discharged through an upper outlet (40) in an opposite sidewall and the aqueous phase is discharged through a lower outlet (50) in the opposite sidewall.