Continuous Phase Transition Extraction Apparatus
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Solution Overview
Problem
Current extraction methods for natural products, such as solvent leaching, reflux extraction, supercritical CO2 extraction, and subcritical extraction, face limitations including low efficiency, high costs, limited solvent compatibility, and inefficiency in separating both non-polar and polar substances, making them unsuitable for industrial-scale application.
Innovation Solution
A multifunctional continuous phase transition extraction apparatus comprising an extraction system, desorption system, and solvent recovery system, which enables continuous and efficient extraction of natural products using solvents that undergo instant and cyclic phase transition from liquid to gas and back to liquid, allowing for the use of both low and high-polar solvents under low pressure, and includes features like heat exchangers, purification columns, and solvent tanks for efficient solvent recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If supercritical CO2 extraction is used, then extraction efficiency for nonpolar substances is improved, but extraction efficiency for polar substances deteriorates and equipment cost increases
Solution Approach 1:
The patent employs multiple extraction tanks (first extraction tank, second extraction tank) that can operate with different solvents simultaneously. The system is designed to handle both nonpolar substances (using CO2) and polar substances (using alcohols or water) through parallel processing channels, making the extraction system universally applicable to various material types without requiring separate dedicated equipment for each substance category.
Solution Approach 2:
The extraction system is divided into separate functional segments - first extraction tank for nonpolar substance extraction, second extraction tank for polar substance extraction, with independent solvent circulation paths. This segmentation allows each tank to be optimized for specific solvent types while maintaining overall system efficiency and versatility.
2Productivity
If supercritical extraction is used, then extraction performance is improved, but equipment manufacture and maintenance cost increases
Solution Approach 1:
The system operates in subcritical conditions (temperature and pressure below critical points of solvents) rather than requiring full supercritical conditions. This parameter adjustment maintains high extraction performance while significantly reducing equipment requirements, manufacturing costs, and maintenance expenses associated with high-pressure supercritical systems.
Solution Approach 2:
The patent uses readily available, low-cost solvents (CO2, ethanol, water, acetone) that can be easily replaced and replenished, rather than requiring expensive specialized supercritical fluids. The extraction tanks and associated equipment are designed for simple construction with standard materials, reducing capital investment and maintenance costs.
3Adaptability or versatility
If subcritical extraction is used, then solvent flexibility is improved, but extraction time increases and operation becomes intermittent
Solution Approach 1:
The system employs continuous circulation of solvents through heat exchangers and extraction tanks, with solvents being continuously heated, pressurized, and circulated through the extraction medium. Multiple tanks operate in parallel to ensure continuous extraction output, eliminating the intermittent batch operation characteristic of traditional subcritical extraction methods.
Solution Approach 2:
Solvents are pre-heated in heat exchangers before entering extraction tanks, and the system maintains solvents in a pre-conditioned state ready for extraction. This preliminary preparation of solvents ensures immediate effectiveness upon contact with extraction material, reducing overall extraction time while maintaining solvent flexibility.
4Device complexity
If solvent leaching is used, then equipment simplicity is improved, but extraction efficiency deteriorates and solvent recovery becomes inconvenient
Solution Approach 1:
The system uses hydraulic principles to circulate solvents through extraction tanks under controlled pressure and flow rates. Pumps and pressure control systems enable continuous solvent circulation through the extraction medium, significantly enhancing mass transfer and extraction efficiency compared to simple static leaching, while maintaining relatively simple equipment architecture.
Solution Approach 2:
The system utilizes phase transitions of solvents (liquid-gas-liquid cycles) to enhance extraction efficiency. Solvents are heated to increase solubility and circulation rate, then condensed for recovery and reuse. This dynamic phase manipulation improves extraction kinetics and solvent recovery efficiency without requiring complex equipment.
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 apparatus achieves high-efficiency extraction of both non-polar and polar substances with reduced solvent usage and operational costs, enabling industrial-scale application while ensuring safety and reliability through continuous solvent circulation and recovery.
Implementation Method 1
solvents which undergo instant and cyclic phase transition from liquid to gas and back to liquid
Implementation Method 2
phase transition from liquid to gas
Implementation Method 3
phase transition from gas back to liquid
Implementation Method 4
first heat exchanger and an extraction tank
Implementation Method 5
high-pressure pump is disposed on the pipe connecting the first heat exchanger with the first solvent tank and the second solvent tank
Data Source
AI summary
A multifunctional continuous phase transition extraction apparatus comprises an extraction system, a desorption system and a solvent recovery system. The extraction system comprises a first heat exchanger and an extraction tank. The desorption system comprises a second heat exchanger, a first desorption tank, a second desorption tank, a first purification column and a second purification column. The solvent recovery system comprises a first condenser, a second condenser, a first solvent tank and a second solvent tank. Two extraction loops can be formed in the present invention. During the overall extraction process, the phase transition process of the extracting agent is real-time and continuous. The extracting agent goes through continuous phase-transitions and is cyclically re-used. The overall process is operated in an airtight and low-pressure condition, and is multifunctional, safe, reliable, and suitable for the extraction for most natural products.