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1. Multifunctional integration : integrated extraction, filtration, concentration, solvent recovery and other modules to support continuous or batch production.
2. High efficiency and energy saving : Adopting technologies such as heat reflux and vacuum low-temperature concentration to reduce energy consumption by 30%-50%.
3. Precise control : Automatically adjust parameters such as temperature, pressure, pH value, etc. to ensure process stability.
4. Environmental compliance : Solvent recovery rate ≥ 95%, reducing waste emissions and complying with environmental regulations (such as VOC control).
Description
Introduction
The extraction and concentration system is an integrated equipment designed for the pharmaceutical, food, natural product extraction and chemical industries . It is used to efficiently extract target ingredients (such as active substances, essential oils, pigments, etc.) from natural raw materials (such as plants, Chinese medicinal materials, fermentation broth), and remove solvents or water through the concentration process to finally obtain high-purity concentrates or dry products. The system meets GMP, FDA 21 CFR Part 111 and green production requirements by optimizing extraction efficiency, energy saving and consumption reduction, and intelligent control.
Design Principle
1. Extraction Technology Principle
Hot reflux extraction :
The solvent is heated and evaporated, then condensed and refluxed, forming a dynamic cycle to continuously dissolve the active ingredients.
Closed-loop operation is achieved through jacket heating (steam/thermal oil) and condenser (water cooling/air cooling).
Supercritical CO₂ extraction :
Above the critical point (CO₂: 31.1°C, 7.38 MPa), the fluid has both gas diffusivity and liquid solubility, selectively extracting the target components.
2. Concentration Technology Principle
Vacuum falling film evaporation :
The liquid forms a thin film in a vacuum environment and evaporates quickly (the evaporation temperature is 30°C–50°C lower than that at normal pressure).
Multi-effect series design, repeated use of secondary steam, significant energy saving.
Membrane separation technology :
Reverse osmosis membranes (pore size <1 nm) intercept small molecule solutes and are suitable for desalting or concentrating polysaccharides and polypeptides.
3. System Integration and Optimization
Modular design : Extraction tank, concentrator, and solvent recovery tower are independent modules for easy maintenance and expansion.
Cascade utilization of thermal energy : high-temperature steam is used for extraction first, and waste heat is used for concentration to reduce overall energy consumption.
4. Materials and safety design
Corrosion-resistant material : Parts in contact with solvents are made of 316L stainless steel, titanium alloy, and PTFE to resist acid and alkali corrosion.
Explosion-proof configuration : Suitable for flammable solvents (such as ethanol), in compliance with ATEX/IECEx explosion-proof standards.
Closed operation : Negative pressure environment and sealed flange design prevent solvent volatilization and operator exposure risks.
5. Intelligent control
Adaptive control algorithm : Dynamically adjusts extraction time and solvent ratio based on feedstock characteristics (e.g. moisture content, particle size).
Fault self-diagnosis : Real-time monitoring of abnormal pump pressure and temperature exceeding the limit, triggering shutdown protection and prompting maintenance plans.
Function
1. Extraction process
Dynamic countercurrent extraction : The raw material and solvent flow in the opposite direction, which improves the extraction efficiency (20%-40% higher than the traditional immersion method).
Ultrasonic-assisted extraction : High-frequency vibrations (20–40 kHz) disrupt cell walls and accelerate the release of active ingredients.
Supercritical CO₂ extraction (optional module): suitable for heat-sensitive ingredients (such as essential oils, terpenes), without solvent residue.
2. Separation and filtration
Multi-stage filtration : Plate and frame filtration, centrifugal separation or membrane filtration (microfiltration/ultrafiltration) to remove solid residues and large molecular impurities.
Online detection : Integrate UV-Vis, HPLC or near-infrared (NIR) sensors to monitor the concentration of target components in real time.
3. Concentration and drying
Multi-effect vacuum concentration : low temperature (40°C–60°C) evaporation preserves the activity of heat-sensitive ingredients.
Membrane separation and concentration : Reverse osmosis (RO) or nanofiltration (NF) technology, selectively retaining target molecules.
Spray drying (optional): Converts the concentrate into powder, which has good flowability and is easy to store.
4. Solvent Recovery and Recycling
Distillation recovery : Solvents (such as ethanol, acetone) are separated by distillation towers with a purity of ≥99%.
Condensation energy saving : waste heat recovery system reduces steam consumption.
5. Automated control and traceability
PLC/SCADA system : preset process parameters (extraction time, concentration multiple), support recipe storage and one-click call.
Data integrity : Record temperature, pressure, flow and other data to generate electronic batch records in compliance with ALCOA+ principles.
Application
Pharmaceutical industry : extraction of Chinese medicinal materials (such as astragaloside and artemisinin), concentration of antibiotic fermentation broth.
Food field : plant essential oil (peppermint oil, rose essential oil) extraction, fruit juice concentration, tea polyphenols extraction.
Bioengineering : separation and purification of microbial metabolites (such as enzymes and antibiotics).
Cosmetics : Preparation with natural active ingredients (aloe vera gel, collagen).
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