Microwave Vacuum Extraction of Essential Oils Without Solvents
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Solution Overview
Problem
Conventional methods for extracting essential oils from plant matter, such as cannabinoids, require flammable solvents or high-pressure vessels, posing safety concerns and increasing costs, and existing systems are inefficient in separating terpenoids and cannabinoids.
Innovation Solution
A method utilizing microwave energy and high vacuum to vaporize and condense essential oils within a closed loop vessel, eliminating the need for flammable solvents and high-pressure vessels, and incorporating a condenser to collect the liquid phase product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flammable solvents (butane, propane, ethanol) are used for extraction, then extraction efficiency is improved, but safety risks and facility modification costs increase
Solution Approach 1:
The patent replaces the mechanical/chemical solvent-based extraction system with a microwave-based thermal vaporization system. Instead of using flammable solvents to dissolve cannabinoids, the invention uses microwave energy to directly vaporize the essential oils and cannabinoids from the plant material, eliminating the harmful flammable solvent medium entirely while maintaining extraction efficiency
Solution Approach 2:
The invention changes the extraction parameter from solvent concentration to microwave power and vacuum pressure. By controlling microwave power levels (e.g., 100-1000 watts) and vacuum pressure (e.g., 0.001-100 mm Hg), the system achieves efficient vaporization without requiring flammable solvents, thus resolving the safety issue while maintaining productivity
2Productivity
If flammable solvents are used for extraction, then extraction efficiency is improved, but facility modification and equipment costs increase
Solution Approach 1:
The patent replaces the complex solvent handling infrastructure (storage tanks, vaporization chambers, condensation systems for flammable solvents) with a simpler microwave-vacuum system. The equipment requires only a microwave generator, vacuum pump, and basic distillation apparatus, dramatically reducing facility modification costs and equipment complexity while maintaining extraction efficiency
3Object-affected harmful factors
If supercritical CO2 is used for extraction, then safety is improved (non-flammable), but equipment cost and processing size limitations increase
Solution Approach 1:
The patent replaces the high-pressure supercritical fluid system with a low-pressure vacuum-microwave system. Instead of requiring ASME-code compliant pressure vessels to maintain supercritical CO2 conditions, the invention uses vacuum pumps to create low-pressure conditions (0.001-100 mm Hg) combined with microwave heating, eliminating the need for expensive pressure vessel infrastructure while maintaining safety
Solution Approach 2:
The invention changes the pressure parameter from high pressure (supercritical CO2 requires >73 atm) to low pressure (vacuum conditions of 0.001-100 mm Hg). This parameter reversal allows the use of simple, inexpensive vacuum equipment instead of costly pressure-vessel systems, reducing equipment cost while maintaining safety
4Productivity
If conventional extraction methods are used, then processing is achieved, but thermal degradation of essential oils occurs
Solution Approach 1:
The patent changes the temperature parameter by using vacuum conditions to lower the boiling points of essential oil components. Under vacuum (0.001-100 mm Hg), essential oils vaporize at much lower temperatures than at atmospheric pressure, enabling extraction without thermal degradation. The microwave energy is applied selectively to vaporize only the essential oil components, not to heat the entire plant material to high temperatures
5Productivity
If conventional extraction methods are used, then extraction is achieved, but separate decarboxylation steps are required
Solution Approach 1:
The patent merges the extraction and decarboxylation steps into a single simultaneous operation. The microwave energy applied during vacuum vaporization provides the thermal energy necessary for decarboxylation of cannabinoid acids while the vacuum system simultaneously extracts the volatile essential oils and cannabinoids. This integration eliminates the need for separate decarboxylation steps, reducing processing time while maintaining extraction capability
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 effectively separates terpenoids and cannabinoids without thermal degradation, achieves selective extraction, and reduces processing costs by eliminating the need for separate decarboxylation steps, with potential for higher yields and improved molecule selectivity.
Implementation Method 1
using at least one vacuum pump to reduce the pressure within the interior of the extraction vessel with the plant matter therein to an absolute pressure of less than 400 mm Hg absolute pressure
Implementation Method 2
applying microwave energy to the plant matter that is within the extraction vessel while the interior of the extraction vessel is under the reduced pressure
Implementation Method 3
condensing the vapor to a liquid state such that the vapor includes at least a portion of the essential oil, by utilizing the at least one condenser means
Data Source
AI summary
A method of extracting an essential oil from plant matter, starting with providing plant matter to an interior of an extraction vessel, wherein the plant matter includes at least one essential oil. Next, at least one vacuum pump is used to reduce the pressure within the interior of the extraction vessel with the plant matter therein to an absolute pressure of less than 400 mm Hg absolute pressure. Microwave energy is applied to the plant matter while the interior of the extraction vessel is under the reduced pressure, thereby forming a vapor including at least a portion of the essential oil. The vapor is directed from the extraction vessel to at least one condenser vessel. Finally, the vapor is condensed to a liquid state such that the vapor includes at least a portion of the essential oil, by utilizing the at least one condenser vessel.