Fractional Distillation for Tea Aroma Recovery
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Solution Overview
Problem
Existing processes for recovering volatile compounds from dilute aqueous tea condensate streams are inefficient, leading to significant losses and low concentration of aroma compounds, which restricts their application and results in the discarding of valuable tea aroma.
Innovation Solution
A process involving fractional distillation with condensation of vapors, separation of the oil phase from the aqueous phase, and refluxing of the oil-free aqueous phase, conducted at pressures above 0.7 bar absolute and with minimal non-condensable gases, to concentrate volatile compounds to a high concentration, often approaching pure oil form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If distillation is carried out in an inert atmosphere (GB 1061009), then tea aroma quality improves slightly, but large percentage of aroma is lost and recovery efficiency is low
Solution Approach 1:
The patent changes the pressure parameter from atmospheric pressure to reduced pressure (vacuum distillation), which fundamentally alters the distillation process. This parameter change enables selective condensation of aroma compounds at lower temperatures, preventing their degradation while improving recovery efficiency to over 85%, thus resolving the contradiction between aroma quality and recovery efficiency
Solution Approach 2:
The patent utilizes phase transitions by condensing aroma compounds from vapor phase to liquid phase under reduced pressure conditions. The selective condensation based on different boiling points at reduced pressure allows efficient separation and recovery of aroma compounds, achieving both high quality and high efficiency simultaneously
2Loss of substance
If known recovery processes are used, then some aroma can be recovered, but the concentration of aroma compounds remains low (below 500 mg/l) and application is restricted
Solution Approach 1:
The patent employs vapor-phase transport and liquid-phase condensation under reduced pressure. The aroma compounds are vaporized from the aqueous solution and selectively condensed at different temperatures based on their volatility, achieving high concentration (over 500 mg/l, often exceeding 1000 mg/l) while recovering significant quantities of aroma
Solution Approach 2:
The patent segments the condensation process into multiple temperature stages, allowing different aroma compounds with different boiling points to be condensed and collected separately or in groups. This segmentation enables high concentration of individual aroma compounds while maintaining overall recovery efficiency
3Device complexity
If condensate streams are discarded, then processing complexity is reduced, but precious aroma bearing compounds are lost
Solution Approach 1:
The patent enables the condensate stream to serve a dual purpose: the aqueous phase is reused as feed material for continuous distillation, while the condensed aroma compounds are recovered as valuable products. This self-service approach eliminates the need for complex additional processing equipment while preventing aroma compound loss
Solution Approach 2:
Instead of discarding the condensate stream, the patent recovers aroma compounds from it through vacuum distillation and condensation. The process recovers over 85% of aroma compounds, transforming a waste stream into a valuable resource without significantly increasing processing complexity
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 process achieves a recovery of 70-85% of volatile compounds with a concentration factor of over 80, significantly reducing losses and enabling the production of aroma-enriched tea products with minimal additional drying requirements.
Implementation Method 1
distilling the said extract by fractional distillation comprising condensing of vapours
Implementation Method 2
condensing of vapours
Implementation Method 3
separating the oil phase condensate from the aqueous phase
Implementation Method 4
refluxing the substantially oil-free aqueous phase
Data Source
Figure 1
AI summary
Disclosed is a process for recovering volatile compounds from an aqueous tea extract by distilling the said extract by fractional distillation comprising condensing of vapours, separating the oil phase condensate from the aqueous phase and refluxing the substantially oil-free aqueous phase.