Solvent Extraction Venting System for Toxic Vapor Control Below LEL
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Solution Overview
Problem
Solvent-based extraction systems for plant oils often fail to achieve 100% solvent recovery, leading to the release of flammable or toxic vapors during routine operations, posing hazards to operators and requiring stringent safety measures, including costly explosion-proof electrical components.
Innovation Solution
A safety system that integrates a computer-programmed control system with a closed loop solvent extraction system and a ventilation system, automatically venting toxic gases and vapors when they reach a selected air level below the Lower Explosive Limit (25% LEL), preventing vessels from being opened until a predetermined solvent level is reached, and activating ventilation and alarms to ensure operator safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solvent-based extraction systems are used for efficient plant oil extraction, then extraction efficiency is improved, but solvent recovery cannot achieve 100% leading to vapor release hazards
Solution Approach 1:
The system performs preliminary solvent recovery operations before vessel opening by automatically monitoring solvent levels and initiating venting sequences. The control system calculates remaining solvent quantities and prevents vessel opening until predetermined solvent levels are achieved, proactively eliminating the hazard before it can manifest.
Solution Approach 2:
The system continuously monitors solvent levels, vapor concentrations, and system pressure through sensors and provides real-time feedback to the control system. This feedback loop enables dynamic adjustment of venting operations and provides automated warnings to operators, ensuring solvent recovery reaches safe levels before any vessel is opened.
2Ease of operation
If manual operation procedures are used for extraction systems, then operational flexibility is maintained, but operator variability and human error increase safety risks
Solution Approach 1:
The control system performs self-monitoring of solvent levels, automatic calculation of remaining solvent quantities, and self-regulation of venting operations. The system serves itself by automatically preventing vessel opening until safety criteria are met, eliminating reliance on operator judgment and ensuring consistent safety execution.
Solution Approach 2:
The system replaces manual operator decisions with automated electronic control systems that monitor solvent levels, calculate recovery percentages, and control venting sequences. This substitution of mechanical/manual operations with automated electronic control eliminates human variability while maintaining operational flexibility through programmable parameters.
3Object-affected harmful factors
If stringent explosion-proof electrical standards are implemented, then operator safety is protected, but equipment costs increase significantly
Solution Approach 1:
The system converts the potentially harmful solvent vapors into a controllable parameter by implementing automated monitoring and controlled venting. By actively managing vapor release through programmed sequences and real-time monitoring, the system eliminates the need for expensive explosion-proof electrical components while maintaining enhanced safety through intelligent control.
Solution Approach 2:
The system changes the operational parameters by implementing automated solvent level monitoring and controlled venting sequences that maintain vapor concentrations below hazardous levels. By dynamically adjusting venting rates and timing based on real-time solvent recovery data, the system creates a inherently safer operating environment that reduces electrical safety requirements.
4Object-affected harmful factors
If continuous mechanical ventilation is used to handle vapor release, then vapor concentration is controlled, but energy consumption and utility costs increase
Solution Approach 1:
The system implements periodic or on-demand ventilation activated only during specific operational phases when solvent release is anticipated. The control system triggers ventilation sequences based on real-time monitoring of solvent levels and recovery progress, rather than maintaining continuous operation, thereby reducing energy consumption while maintaining vapor concentration control.
Solution Approach 2:
The system activates ventilation in advance of anticipated solvent release events, such as before vessel opening or during transfer operations. By pre-positioning the ventilation system to operate only when needed based on process stage and solvent recovery status, energy is consumed only during critical periods rather than continuously.
Data Source
AI summary
A safety system, under the control of an operator, used for venting toxic or hazardous gas and vapors from a work space. The safety system includes a control system, programmed by a computer, a control panel, a human machine interface (HMI), a gas detector, and an alarm. The HMI is adapted for use by the operator and for operating the safety system. The safety system includes a mechanical solvent, or gas (CO2) based, chemical extraction system, used for extracting oils from oil-bearing plants. The extraction system, comprising a solvent recovery system, is attached to and under the control of the control system. The safety system includes a ventilation system attached to, and under the control of, the control system. The ventilation system is used for venting the gas and vapors from the work space.