Solvent extraction unit

Types of Solvent Extraction Unit

Solvent extraction units can be divided into solvent extraction devices and extraction towers.

• Solvent extraction equipment for solid-liquid extraction

  Extraction Equipment for Solid-Liquid: This type of extraction unit is designed to extract valuable components from solid materials using a solvent. It is a combination of extraction and separation. The extraction part takes place in an extractor. The extractor is a cylindrical, vertical vessel with a helical blade along the inner wall that stirs the material. The solvent continuously enters from the upper part of the extractor and is stirred by the helical blade to circulate in a loop. After sufficient extraction, the solvent and material are separated with the help of a filter device. Then, the solvent goes to a separator for distillation or other processes. The separation method varies from filtration, centrifugation, evaporation, and distillation.

• Solvent extraction equipment for liquid-liquid extraction

  The liquid-liquid extraction unit typically comprises an extractor and an equalization extractor. The liquids are mixed in the extractor, where they are stirred to facilitate mass transfer and the formation of emulsion layers. The homogenized mixture is then introduced to the equalization extractor, where the liquid layers settle down. The liquid layers are separated through suitable collection outlets.

• Solvent extraction tower

  These extraction towers are typically tall vertical vessels. A mixture of the solvent and raw material is introduced from the top, and a pure solvent is injected from the bottom. The two liquids are countercurrent, and the solvents will extract the desired material from the raw material.

Specification and maintenance of solvent extraction unit

Specifications

• Capacity: Solvent extraction units typically process 100 kg/h to 2000 kg/h raw material per batch, for example, 300 kg/h in the extraction tower with an annual output of 2400 tons of tea oil.
• Solvent pump flow: The pump flow is 0.437 m3/h, and the speed is 1200 r/min.
• Cyclone: A separation cyclone that separates the solvent from the extracted solid materials. The cyclone is usually made of carbon steel or stainless steel.
• Temperature and pressure control: The solvent extraction unit is controlled and adjusted by intelligent computer programs, such as the electronic control box with PLC that can have Chinese/English display; the pressure and temperature can be real-time monitored.
• Installation: Fixed extraction units of 1200 mm × 700 mm in dimension, 920 kg in weight used for tea extraction on the left side with a small confirming document sheet used for exposing under the direct sunlight that on the right side should apply for another extraction method.
• Condenser: It condenses the vapor of the solvent back into liquid form for reuse in the extraction process.
• Extraction efficiency: The ability of the unit to recover valuable compounds from raw materials.
• Type of solvent used: The extraction efficiency and speed may vary depending on the type of solvent used, such as ethanol, water, methanol, etc.
• Purity of the extract: The level of contaminants or impurities removed from the final extract.
• Dust removal: The efficiency and performance of the extraction unit in removing dust and particulate matter from the extracted air.
• Cooling method: The type and method of cooling used in the extraction unit (e.g., air cooling, water cooling) can affect its performance and energy consumption.
• Power consumption: The power consumption of the extraction unit is expressed in terms of kWh, which is the amount of electricity consumed during the extraction process.
• Noise level: The noise level generated by the extraction unit, usually expressed in decibels (dB).
• Mobility: The extraction unit's ability to be transported or relocated, typically measured in dimensions and weight.
• Safety features: The extraction unit's safety features (e.g., anti-explosion, anti-leak, anti-static) to meet the relevant safety standards.

Maintenance

• Cleaning: Regularly clean the surface and internal parts of the extraction unit to remove residue and contamination. Use the appropriate cleaning agent and equipment to ensure the quality and safety of the extracted products.
• Lubrication: Apply the right lubricant to the moving parts and components to ensure smooth operation and prolong the equipment's life.
• Replacement of wearing parts: Regularly inspect and replace the wearing parts, such as seals, filtering membranes, blades, etc., to ensure the performance and stability of the extraction unit.
• Maintain the extraction solvent: The quality of the extraction solvent will affect the extraction efficiency and product quality. Regularly inspect and replace the extraction solvent to ensure its purity and effectiveness.
• Calibration: Regularly calibrate the parameters of the extraction unit, such as temperature, pressure, time, etc., to ensure that the equipment operates at the optimal extraction conditions.
• Safety inspection: Regularly check the safety devices and systems of the extraction unit, such as leaking protection, grounding, etc., to ensure that they meet the safety standards and requirements.
• In addition, the extraction units may require periodic maintenance and repairs according to the manufacturer's instructions and recommendations. Keeping equipment documentation and records is also important so maintenance and repairs can be tracked and managed effectively.

Scenarios of using solvent extraction units

Using a well-designed solvent extraction unit can provide more than just functional benefits. Ideal models are created mostly for use in large-scale commercial settings like the food processing industry, pharmacy sector, and biofuel facilities.

In the food processing industry, restaurants, bakeries, and poultry, as well as other meat processing facilities, use these units mainly for sourcing cooking oils from various kinds of seeds. Some food manufacturers also use them to extract flavors, fragrances, and food additives from herbs, spices, or plants. Besides oils, breweries and distilleries also use these extraction units to extract ethanol from fermented grains or fruits during the alcohol production process.

Pharmaceutical companies and labs use industrial-grade solvent extraction units to extract active compounds, essential oils, cannabinoids, and natural products from plants. These units also help isolate medicinal compounds and phytochemicals, as well as ensure efficient extraction of valuable bioactive compounds and essential oils from plants, herbs, and fungi. With such efficiency, labs and pharmaceutical companies can perform more studies and tests to develop new drugs and formulations.

Biofuel production facilities rely heavily on large-scale solvent extraction units to extract oil from algae, seed cake, or other organic materials for biodiesel production. The oils extracted are then converted into biodiesel through a transesterification process.

Some chemical manufacturing companies also use separation units to extract specific chemicals or compounds from complex mixtures, as well as to purify chemicals or solvents used in various industrial processes.

How to choose solvent extraction units

Buyers should start with the nature of their raw material when choosing an extractor for solvent extraction. They should select the type of equipment that will efficiently extract the desired solvent. For instance, liquid-solid separators such as percolators are usually suitable for leafy plants.

Buyers should consider the extraction capacity of the unit they want to purchase. They should choose the model whose capacity matches the required production volume. In this case, they might consider the number of extractions per hour and the volume of extraction per cycle.

Buyers should get models that have easy-to-use computerized controls. Such systems will enhance reproducibility and automate the extraction process. They should also get models with user-friendly interfaces for streamlined extraction protocol input.

The safety features of the unit should also influence the buying decision. Go for the extraction apparatus that has the required safety standards and features. This may include proper ventilation to prevent flammable solvent accumulation, pressure relief valves, or explosion-proof electrical components.

Buyers should also get extraction units that are easy to maintain. Such units will come with comprehensive manuals and readily available spare parts. Buyers can also invest in extraction units with maintenance assistance programs or those that come with technical support.

Solvent extraction unit Q & A

Q1: How big is the extraction industry?

A1: The global food and beverage extraction market was valued at $4.66 billion in 2022 and is expected to reach $7.66 billion by 2032, growing at a CAGR of 5.27%.

Q2: Which trends are driving the extraction market growth?

A2: The rise in consumer demand for functional beverages, dietary supplements, and clean-label products is driving the extraction market. The food industry's increasing need for flavor compounds, fragrance, and essential oils extraction is also a significant growth factor. Innovations in extraction technologies are improving efficiency and product quality.

Q3: What are the impacts of extraction industries?

A3: The extraction industries have a huge economic impact. They provide raw materials for several sectors, contributing to industrial growth. Moreover, the extraction sectors create millions of jobs worldwide, both directly and indirectly.

Q4: What are the connection industries to extraction industries?

A4: Solvent extraction connects to various industries. The following are some of the key interconnected industries. The oil refining industry heavily relies on solvent extraction to separate valuable petroleum products from crude oil. The chemical manufacturing industry utilizes solvent extraction for various processes, including the separation of chemicals, purification, and isolating specific compounds.