Three-Phase Extraction Vessel for One-Step Reaction Product Separation
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Solution Overview
Problem
Existing methods for multi-component mixture separation in liquid-liquid extraction are inefficient and require multiple steps, and enzyme reactions in non-aqueous media face challenges with thermodynamic equilibrium and selective product recovery.
Innovation Solution
A three-phase liquid-liquid-liquid extraction system with immiscible fluids and a semi-solid catalyst phase allows for one-step conversion and separation of reactants and products, using differences in fluid affinities to selectively recover reaction products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional liquid-liquid two-phase extraction is used to separate multi-component mixtures, then each extraction step targets only one compound, but multiple extraction steps are required which increases process complexity and time
Solution Approach 1:
The patent combines multiple extraction functions into a single three-phase system. The mixer-settler unit simultaneously performs extraction of multiple compounds (e.g., compound A into organic phase, compound B into aqueous phase) in one operation, eliminating the need for sequential two-phase extraction steps and reducing process complexity while maintaining high separation selectivity
Solution Approach 2:
The three-phase extraction system provides multi-functionality by enabling simultaneous separation of multiple compounds with different affinities. The system can selectively partition different compounds into different phases based on their chemical properties, making a single extraction unit capable of performing multiple separation tasks that would otherwise require multiple dedicated extraction steps
2Quantity of substance
If enzyme reactions are conducted in non-aqueous media to improve substrate solubility and product recovery, then thermodynamic equilibrium becomes unfavorable and selective product recovery is difficult
Solution Approach 1:
The patent segments the reaction system into three distinct phases: aqueous phase for enzyme catalysis, organic phase for hydrophobic substrates/products, and a third phase (e.g., ionic liquid or supercritical fluid) for selective product recovery. This segmentation allows each phase to optimize its function - the enzyme operates in its native aqueous environment while substrates and products are solubilized in appropriate organic phases, and the third phase selectively extracts the product to shift thermodynamic equilibrium
Solution Approach 2:
The third phase acts as an intermediary that selectively interacts with the reaction product. By introducing this intermediate phase with specific solvation properties (e.g., ionic liquids for polar products or supercritical CO2 for non-polar products), the system enables selective product recovery from the organic phase, thereby shifting the thermodynamic equilibrium toward product formation without compromising enzyme activity in the aqueous phase
3Productivity
If traditional mixer-settler extraction apparatus is used, then separation efficiency is limited and additional downstream processing is required
Solution Approach 1:
The patent merges the extraction and separation functions into a single integrated mixer-settler unit operating with three phases. The simultaneous extraction of multiple compounds into different phases within one mixer-settler cycle eliminates the need for multiple sequential extraction units and subsequent complex separation equipment, thereby increasing productivity while reducing overall device complexity
Solution Approach 2:
The three-phase system enables self-service separation where the immiscible phases automatically separate by density gradients in the settler portion of the mixer-settler unit. The organic phase, aqueous phase, and third phase form distinct layers that can be independently withdrawn, providing self-contained separation without requiring additional filtration, centrifugation, or evaporation 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
Enables efficient, selective recovery of reaction products from enzyme reactions, overcoming thermodynamic limitations and reducing the need for additional downstream processing.
Implementation Method 1
the vessel inner volume contains a first fluid with a first density ρ1 and a second fluid with a second density ρ2, with ρ1>ρ2, so that the first fluid forms a lower phase and the second fluid forms an upper phase in the vessel inner volume
Implementation Method 2
the confinement contains a third fluid with a third density ρ3 with ρ3>ρ2 so that the second fluid forms an upper layer and the third fluid forms a lower layer in the confinement inner volume
Implementation Method 3
the at least one reactant and the reaction product have a different affinity for at least two of the first, second and third fluid
Data Source
AI summary
A method and a device are disclosed for converting at least one reactant into a reaction product and separating the at least one reactant. The device includes a vessel with a vessel inner volume and a confinement, submerged in the vessel inner volume, that provides a confinement inner volume in fluid connection with the vessel inner volume. First and seconds fluids, with a respective, higher first density and a lower, second density form respective lower and upper phases in the vessel inner volume. A third fluid with a third density higher than that of the second fluid forms a lower layer in the confinement inner volume, relative to an upper layer formed by the second fluid. The third fluid may be the same as or different from, and is physically separated from, the first fluid. At least one of the first, second, and third fluids is at most partly miscible with the other two, but preferably immiscible. The at least one reactant and the reaction product have different affinities for at least two of the first, second, and third fluids, and at least one of the first and third fluid contains a fourth phase which is a solid or semi solid and is capable of promoting the conversion.