Supercritical Fluid Extraction with Integrated Pressure Exchanger
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing supercritical fluid (SCF) extraction processes require full depressurization to remove insoluble compounds, leading to increased cycle time, energy consumption, and mechanical stress, with no commercial method to efficiently separate soluble and insoluble compounds while maintaining high pressure.
Innovation Solution
The use of an integrated pressure exchanger in the SCF extraction process allows for the continuous recycling of SCF by adjusting pressure differentials, enabling the separation of soluble and insoluble compounds without depressurization, thus reducing energy consumption and cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If full depressurization is used to remove insoluble compounds, then separation is achieved, but cycle time increases and energy consumption increases
Solution Approach 1:
The patent segments the separation process into two distinct stages: (1) pressure reduction to separate insoluble compounds while maintaining supercritical conditions for soluble compounds, and (2) subsequent full depressurization only for the soluble compound stream. This segmentation allows insoluble compounds to be removed without complete depressurization, reducing cycle time while maintaining separation efficiency.
Solution Approach 2:
The patent introduces an intermediary separation step using a separator vessel that operates at intermediate pressure conditions. This intermediary device enables partial separation of insoluble compounds before final depressurization, allowing the system to achieve separation goals without subjecting the entire process to repeated full depressurization cycles.
2Manufacturing precision
If full depressurization is used to remove insoluble compounds, then separation is achieved, but energy consumption increases
Solution Approach 1:
The patent segments the energy-intensive depressurization step to apply only to the soluble compound stream after insoluble compounds have been removed. By separating the insoluble compounds at intermediate pressure, the system avoids the energy cost of depressurizing the entire mixture repeatedly, thereby reducing overall energy consumption while maintaining separation efficiency.
Solution Approach 2:
The patent converts the presence of insoluble compounds from a hindrance into a benefit by allowing them to be separated at higher pressures where their physical properties differ significantly from the supercritical fluid. This approach transforms what would normally require energy-intensive filtration after depressurization into a pressure-driven separation that occurs naturally during the pressure reduction phase.
3Productivity
If repeated depressurization and pressurization cycles are used, then SCF is recycled, but mechanical stress on structure increases
Solution Approach 1:
The patent segments the pressure cycling into two distinct phases: (1) a controlled pressure reduction phase that stops before complete depressurization to separate insoluble compounds, and (2) a selective repressurization phase that only repressurizes the soluble compound stream. This segmentation reduces the frequency and magnitude of full pressure cycles, thereby reducing mechanical stress on the extraction vessel while maintaining SCF recycling.
Solution Approach 2:
The patent implements dynamic pressure control where the pressure reduction is adjusted to stop at an intermediate level optimized for insoluble compound separation. This dynamic approach allows the system to adapt pressure levels to specific separation needs rather than undergoing rigid full cycles, reducing unnecessary mechanical stress on the structure while maintaining productivity.
4Manufacturing precision
If additional processing steps are used to remove soluble and insoluble compounds, then separation is achieved, but device complexity increases
Solution Approach 1:
The patent merges the separation of insoluble compounds with the existing pressure reduction step used for soluble compound extraction. By utilizing the pressure reduction phase for dual purposes—both extracting soluble compounds and separating insoluble compounds—the system achieves enhanced separation functionality without adding independent processing equipment or steps, thereby avoiding increased device complexity.
Solution Approach 2:
The patent makes the pressure reduction step multi-functional by designing it to simultaneously achieve soluble compound extraction and insoluble compound separation. This universal approach allows a single process step to perform multiple separation functions, eliminating the need for additional dedicated equipment and maintaining device simplicity while improving overall separation 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 approach enables efficient, cost-effective, and continuous SCF extraction and recycling, minimizing downtime for maintenance and reducing waste streams, while maintaining high pressure and supercritical conditions.
Implementation Method 1
The use of an integrated pressure exchanger in the SCF extraction process allows for the continuous recycling of SCF by adjusting pressure differentials
Implementation Method 2
In typical supercritical fluid extraction processes, the SCF is heated and pressurized above the critical point to transform a sub-critical fluid into its supercritical phase. When the SCF makes contact with a solid or liquid substrate the target molecule and/or compound from within the solid or liquid substrate is extracted
Data Source
AI summary
Processes and apparatuses for compound recovery using supercritical fluid (SCF) are disclosed. An example process involves solvent extraction (including hydrothermal liquefaction and gasification) of a extracted compound using a SCF from a solid or liquid substrate including, but not limited to, microalgae, plant matter, and polymers. The apparatus comprises SCF, an extraction vessel, a pressure exchanger, feedstock, a separate compound, and solid or liquid compound separators.