Modular Solvent Extraction and Distillation for High Throughput
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Solution Overview
Problem
Current botanical extraction technologies are limited in capacity, capability, and consistency, leading to slow processing times, inconsistent output quality and yield, low volume capability, high cost, and logistical inefficiencies, with a need for larger-scale solutions that can handle increased demand while preserving the integrity of valuable compounds.
Innovation Solution
An automated system comprising an extraction reactor, closed-loop distillation unit, and optional second-stage purge chamber, utilizing solvents like ethanol or n-butane, and inert gases like nitrogen, to facilitate continuous extraction and recovery of botanical extracts with high yields and safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual extraction methods are used, then operational simplicity is maintained, but processing capacity and throughput are severely limited
Solution Approach 1:
The extraction system is divided into multiple independent extraction vessels that can operate simultaneously, allowing parallel processing of multiple batches at once. This segmentation enables the system to handle larger volumes of plant material while maintaining manageable individual vessel sizes and operations.
Solution Approach 2:
The system implements continuous operation through multiple extraction vessels operating at different stages simultaneously - while one vessel is extracting, another is being prepared or cleaned. This continuous workflow eliminates idle time between batches and significantly increases overall processing capacity without requiring proportional increases in manual labor.
2Productivity
If single-batch extraction systems are used, then operational simplicity is maintained, but processing time and throughput are reduced
Solution Approach 1:
The system divides the extraction process into multiple parallel batches using separate vessels, allowing simultaneous processing of multiple samples. This segmentation enables overlapping operations where extraction, solvent recovery, and preparation occur concurrently across different vessels, effectively multiplying throughput.
Solution Approach 2:
Multiple extraction vessels operate in continuous sequence with overlapping timeframes - while one vessel completes extraction, another begins, and a third undergoes solvent recovery. This continuous action eliminates sequential bottlenecks and reduces total processing time proportionally to the number of parallel vessels.
3Reliability
If manual solvent removal and handling is performed, then operational simplicity is maintained, but safety risks and solvent loss increase
Solution Approach 1:
The system incorporates automated solvent recovery mechanisms that collectively return solvent vapor to the extraction vessels without manual intervention. The closed-loop design with condensation and recycling systems enables the equipment to manage its own solvent recovery, reducing both safety risks from manual handling and operational complexity through automation.
Solution Approach 2:
A centralized solvent recovery system acts as an intermediary between the extraction vessels and the environment, automatically capturing, condensing, and recycling solvent vapors. This intermediary mechanism eliminates direct human exposure to hazardous solvents while managing the complexity of solvent handling through integrated automation.
4Productivity
If small-scale extraction vessels are used, then operational flexibility is maintained, but volume capability and scalability are limited
Solution Approach 1:
The system uses multiple standardized extraction vessels that can be independently configured and combined. This segmentation allows the system to scale volume capability by adding or removing vessels from the parallel array while maintaining the same operational procedures, thus achieving both high volume processing and operational flexibility.
Solution Approach 2:
The extraction vessels are designed as universal, interchangeable units that can handle various plant materials and extraction parameters. This multi-functionality allows the same vessel design to serve multiple purposes across different applications, enabling volume scaling without sacrificing operational flexibility or requiring specialized equipment for each material type.
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 system enables high-yield, efficient, and safe extraction of botanical compounds at commercial scales, reducing human error and increasing throughput to 10 times the current industry standard, with yields up to 20% and automated safety protocols.
Implementation Method 1
introducing solvent vapor and/or an inert non-condensable gas to the extraction reactor
Implementation Method 2
a closed-loop continuous-flow distillation unit configured to generate purified botanical extract and recovered solvent
Implementation Method 3
a refrigeration cycle with the interior of the extraction vessel acting as an evaporator of the solvent, to sub-cool the substrate feedstock prior to extracting
Implementation Method 4
receive a heated inert non-condensable gas and/or a solvent vapor, wherein the second-stage purge chamber is effective to recover residual solvent contained in the solid material
Data Source
AI summary
Some variations provide an automated system for solvent extraction of a feedstock to produce a botanical extract, fats, oils, or other desirable solute, comprising: an extraction reactor; a distillation unit; and a second-stage purge chamber or a second-stage purge process utilizing the extraction reactor itself. The second-stage purge chamber or process receives or holds the solid material along with a heated inert non-condensable gas and/or solvent vapor, to recover residual solvent contained in the solid material. Other variations provide a process comprising: feeding a raw material and a solvent into an extraction reactor; generating dissolved material in rich solvent and extracted solid material; distilling the rich solvent to generate purified product and recovered solvent; conveying the solid material and a heated inert non-condensable gas and/or solvent vapor into a second-stage purge chamber, or holding the solid material in the same vessel, to recover residual solvent; and recovering the purified product.