Vertical Liquid-Liquid Extraction Unit for Compact Phase Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing liquid-liquid extraction methods for rare-earth elements face challenges in achieving efficient extraction and separation while minimizing equipment size and maintaining control over liquid volumes, particularly when using mixer-settlers and emulsion flow processes.
Innovation Solution
A liquid-liquid extraction unit that uses a single pump to mix and convey an aqueous and organic phase through a feed compartment, reaction compartment, and standing compartment, allowing for efficient extraction and phase separation without the need for agitators, with a spray nozzle or full cone nozzle for fine droplet discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mixer-settlers with agitators are used for liquid-liquid extraction, then extraction efficiency is improved, but equipment size increases and phase separation becomes poor
Solution Approach 1:
The extraction apparatus is divided into multiple stages, with each stage containing a mixer section and a settler section. This segmentation allows for efficient extraction while maintaining compact dimensions, as each stage is optimized for its specific function rather than requiring a single large vessel
Solution Approach 2:
The invention transitions from traditional horizontal mixer-settler configurations to a vertical arrangement where the mixer section is positioned above the settler section. This dimensional change enables better phase separation by utilizing vertical flow patterns and gravity assistance, improving separation efficiency while reducing overall equipment footprint
2Manufacturing precision
If multiple mixer-settler stages are joined together for separating metals with small separation factor, then separation precision is improved, but system size and operational costs increase
Solution Approach 1:
Multiple extraction stages are combined into a single integrated apparatus with vertical stacking of mixer and settler sections. This merging maintains the necessary multiple stages for high separation precision while reducing the overall system footprint and complexity compared to horizontally arranged separate units
Solution Approach 2:
The vertical arrangement of multiple stages allows for compact stacking, enabling high separation precision through multiple contact points while minimizing the horizontal space required and reducing overall system complexity
3Device complexity
If emulsion flow process with pump fluid delivery is used, then equipment construction is simplified, but control of liquid volumes becomes difficult when liquid volumes differ
Solution Approach 1:
The apparatus incorporates level sensors and flow control mechanisms that provide feedback on liquid volumes in both the mixer and settler sections. This allows for automatic adjustment of pump rates to maintain optimal liquid levels, making operation easy even when handling different liquid volumes
Solution Approach 2:
The system includes automatic level control features that self-adjust the fluid delivery rates based on the actual liquid volumes present. When liquid volumes differ between phases, the control system automatically compensates to maintain proper operating conditions without requiring manual intervention
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 unit enables compact equipment design with controlled liquid volumes, maintaining high extraction efficiency and reducing the footprint of multistage systems, while minimizing energy consumption and operational costs.
Implementation Method 1
a mixing feeder for drawing the aqueous phase and the organic phase from the feed compartment, mixing together the phases, and conveying the mixture under pressure to the reaction compartment
Implementation Method 2
a standing compartment in fluid communication with the reaction compartment for separating the mixture that flows in from the reaction compartment into an aqueous phase and an organic phase
Implementation Method 3
with a spray nozzle or full cone nozzle for fine droplet discharge
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A liquid-liquid extraction unit includes a feed compartment for receiving an aqueous phase and an organic phase, mixing feeder such as a pump for mixing the aqueous and organic phases and conveying the mixture under pressure to a reaction compartment where the mixture is subjected to an extractive reaction, and a resting compartment for separating the mixture back into an aqueous phase and an organic phase and from which each phase is recovered.