The present invention relates generally to extracting organic compounds from plant material and, more particularly, to extracting organic compounds from plant material using supercritical carbon dioxide or subcritical carbon dioxide liquid generated from dry ice in a sealed container, and separating the dissolved compounds from the carbon dioxide outside the chamber.
Essential oils and other desirable or useful materials found in botanicals including herbs, fruits, flowers, leaves, skins, stems, stalks, roots, seeds, nuts and berries, have historically been extracted using organic solvents, steam distillation, and/or pressing. For example, butane hash oil (BHO) is the essential oil from the cannabis plant extracted using n-Butane as a solvent and a vacuum oven. Each of these extraction methods has undesirable features: for example, incomplete extraction; the necessity of expensive, toxic, caustic, or flammable solvents having significant disposal costs; damage to the extracted constituents from heat; the inability to specifically target desired for constituents for extraction; difficulty in obtaining solvents for home or small business use; and the need for expert personnel and complex apparatus for performing extractions. Additionally use of extraction solvents such as propane, butane, pentane and hexane, or mixtures of alcohols requires processing beyond the extraction process in order to ensure that the extracted materials are safe for use or consumption.
More recently, supercritical liquids have been used for extracting botanicals, largely alleviating problems associated with heating, the need for expensive, toxic, caustic or flammable solvents having significant disposal costs, solvent availability, and the need for expert personnel. Extractions using subcritical/supercritical carbon dioxide have the advantage that CO2 is non-toxic; non-flammable; operates around room temperature; inexpensive; and environmentally friendly. Further, the extraction efficiency of carbon dioxide for certain compounds may be adjusted by increasing or decreasing pressures and/or temperatures of the carbon dioxide, thereby permitting extractions having varying levels of certain compounds. For example, concentrations of less-desirable plant constituents, such as chlorophyll, can be reduced without secondary processing, by choosing conditions which reduce their solubility in subcritical or supercritical carbon dioxide.
Embodiments of the present invention overcome the disadvantages and limitations of the prior art by providing an apparatus and method for selectively extracting organic compounds from plant material.
Another object of embodiments of the invention is to provide an apparatus and method for extracting organic compounds from plant material without the need for caustic and flammable solvents, and complex apparatus.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the apparatus for extracting organic compounds from plant material, hereof includes: a chamber adapted for receiving solid carbon dioxide, and having an opening; a removable cover for providing a gas-tight seal for the opening; a heating element adapted for warming the chamber; a porous container adapted to be placed in the chamber for holding the plant material and permitting the plant material to be contacted by subcritical and supercritical carbon dioxide; a manual vent valve for permitting gases to exit the chamber; a valve for permitting supercritical and subcritical carbon dioxide containing extracted organic compounds to exit the chamber, and a separator for receiving supercritical and subcritical carbon dioxide containing extracted organic compounds from the chamber and for separating the extracted organic compounds from the supercritical and subcritical carbon dioxide.
Benefits and advantages of embodiments of the present invention include, but are not limited to, providing an apparatus for extracting organic compounds from biomaterial without requiring flammable solvents, and wherein the extracted compounds are readily collected from the pressure chamber.
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
Briefly, the present invention includes an apparatus for extracting organic compounds from plant materials using subcritical or supercritical carbon dioxide. The apparatus has a sealable pressure chamber into which carbon dioxide dry ice and the plant materials are inserted, the pressure chamber, once sealed, self-pressurizing as the container and contents are warmed to a chosen temperature, converting the solid CO2 to liquid, or to a super-critical fluid as the temperature and pressure rise above the Critical Point. The chamber can be rotated when subcritical CO2 liquid is employed to improve mixing between the liquid and the plant material. After a suitable extraction time, the carbon dioxide solvent containing the extracted material may be vented leaving extracts behind, or directed into a separator such that the carbon dioxide and extracted material can be effectively separated.
In existing supercritical or subcritical carbon dioxide extractions, a certain quantity of viscous and waxy extracted materials may remain in the chamber and valves after the carbon dioxide solvent is warmed, vaporized, and allowed to exit the chamber. These materials are difficult to remove from the apparatus without the use of solvents or heat. This problem may be in part overcome with recirculating systems. However, in the present apparatus, the separator permits extracted materials to be separated from the carbon dioxide in an efficient manner, with little extracted material remaining in the extraction chamber.
As stated above, subcritical/supercritical carbon dioxide possesses useful properties as an extracting media for botanical and other constituents. In particular, the density of the carbon dioxide solvent may be varied to achieve selective separations by adjusting the temperature and pressure of the carbon dioxide solvent.
Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. In the FIGURES, similar structure will be identified using identical reference characters. It will be understood that the FIGURES are for the purpose of describing particular embodiments of the invention and are not intended to limit the invention thereto. Turning now to
A chosen quantity of dry ice is placed in volume, 34, of chamber 12 for generating liquid carbon dioxide once sealed in the chamber. External heating element, 36, is operated by temperature controller, 38, and temperatures internal to pressure vessel 12 are measured by temperature sensor, 40. Combined pressure relief and vent valve, 42, and pressure sensor, 44, are utilized to control the pressure in chamber 12. As mentioned hereinabove, subcritical carbon dioxide and supercritical carbon dioxide having chosen density can be generated by controlling the temperature and pressure of chamber 12. Safety burst disk, 46, provides system overpressure relief.
Base, 48, supports chamber 12 in an upright position. However, as will be described hereinbelow, rotating or shaking chamber 12 may improve extraction efficiency and time.
Pressure relief valve, 78, provides overpressure venting for chamber 12, and flushing/cleaning port, 78, provides access to fluid line, 82, through which metered fluid passes from chamber 12, passed heater 76, to cyclone separator, 84, which includes: collection vial, 26, having cone-shaped interior, 86, and stand, 88, formed integrally therewith, or attached thereto, exhaust tube, 90, disposed longitudinally along centerline, 92, of vial 26, and in fluid communication with discharge vent tube, 94, cone-shaped separator hat, 96, disposed within vial 26 supported by exhaust tube 90, and spaced-apart from open end, 98, thereof.
In operation, fluid from chamber 12 enters separator 56 through inlet 62, which may be in fluid communication with tube 54 illustrated in
Pressure Vessel assembly jacket, 118, which surrounds pressure vessel assembly, 119, and may be fabricated from metal or other sturdy material, has cylindrical interior surface, 120, onto which is attached cylindrical insulating material, 122, adapted to receive chamber 12, and onto a portion of interior surface, 124, of which, heating element 36 is attached, whereby wall 114 of chamber 12 may be heated to a desired temperature. Cap insulation, 126, surrounds the exterior portion of cap 16, and is adapted to slide into insulated jacket 118. Once assembled, chamber 12 and cap 16 may be slid into assembly jacket 118, which is attached by axle, 128, through rotary bearing, 130, supported by stand 48, to motor, 132, for rotating jacket 118 during the extraction process.
Motor 132 and heating element 36, as well as the elements in separator 56 are activated by controller, 134, through electrical connections, 136, based on programmed input from the user and information gathered by the sensors in separator 56, as will be explained in more detail hereinbelow.
As stated, separator 56 separates the dissolved product from the liquid CO2 solvent, and an integral pressure relief valve is provided with manual vent valve 48 to protect pressure vessel 12 from overpressure, and allows manual depressurization of pressure vessel 12, if necessary. The elements of separator 56 may be integrated into pressure vessel 12 or mounted separately, and accessed using external tubing, as illustrated in
Separator 56 may be operated automatically by process controller 134 with several sequences being anticipated; that is, the order of the various steps may be varied depending on various circumstances.
Cap 16 is removed by pushing down on the cap against tension spring 116, turning the cap counter-clockwise until attachment lugs 106 clear detents 112. The lug and detent combination prevents cap 16 from rotating when pressure vessel 12 is pressurized, and separating the cap from the pressure vessel body. Once the cap is removed, snap-in feed stock chamber porous retaining cover 104 is removed by pulling the cover out over spring detents, not shown in
Turning to
During processing, the pressure vessel assembly 119 may be oscillated one or more times between the charge and processing positions by controller 134 to increase extraction efficiency by mixing any liquid carbon dioxide with the botanical material. Such oscillation may not be required if supercritical CO2 is utilized for the extraction. In general, the solubility of a substance in a dense gas, such as a supercritical fluid, increases as the density increases as a function of temperature and pressure. Therefore, as the temperature/pressure of the supercritical fluid is reduced, a phase separation occurs with dense liquid containing the bulk of the extract and the gas containing very little. Droplets of supersaturated liquid could then be formed as a result of this process. If this such droplets occur within the feed stock material or on the side walls of the chamber, some of the extract may be deposited. Thus, “rinsing” the feedstock material and the chamber walls after a supercritical extraction and prior to separating the product from the liquid CO2 may be beneficial.
After a chosen processing time, the separation cycle begins, wherein controller 134 directs vaporization heater 76 to preheat vaporization chamber, 69, until a specified temperature is reached, then slowly opens liquid flow metering valve 66, to adjust the flow rate, whereby the specified temperature is maintained in the vaporization chamber. To optimize the efficiency of separator 56, controller 134 may also be used to adjust the temperature and flow rate through vaporization chamber 69, such that the velocity and droplet size sensed by aerosol droplet size and velocity sensor 146 most closely matches the design parameters for separator 56 to maximize the separation efficiency and minimize the time for performing the separation process.
A cyclone separator relies on the force from the centripetal acceleration of the entrained particle/aerosol mass to overcome aerodynamic drag and any turbulence present in the gas stream. Therefore, measuring the particle size and velocity provides information to regulate the liquid flow into the vaporizer to prevent turbulence and to optimize the extraction efficiency of the cyclone separator. The volume of liquid being converted into gas will influence the gas stream velocity, the entrained aerosol velocity (typically less than the gas stream velocity), and the resulting aerosol droplet size (probably smaller). In general, the smaller the droplet size the greater the surface area to volume ratio, and the lower the radial terminal velocity induced by centripetal acceleration. Lower radial terminal velocities require longer residence time for the droplets to migrate to the outer walls of the cyclone cone. Increasing gas stream velocity will both increase the aerosol droplet velocity and the associated centripetal acceleration, but will decrease the residence time and may introduce turbulence, which may decrease separation efficiency. Decreasing the liquid flow into the vaporizer will lower the gas stream velocity, increase residence time, and probably increase aerosol size, but will decrease centripetal acceleration. Thus, the optimum liquid flow rate is a complex optimization problem that depends on the properties of the aerosol droplets, the geometry of the cyclone separator, the velocity of the gas stream and particles, and the particle size. Information from the particle size and velocity sensor is necessary, but not sufficient, for making the calculations for an optimization feedback loop.
When the CO2 liquid is exhausted from pressure vessel 12, the temperature of vaporization chamber 69 will begin to rise and liquid flow metering valve 66 is fully opened by controller 134 using motor servo motor 68. Full opening of the liquid flow metering valve and reduction of the pressure in the pressure vessel to atmospheric pressure signals the completion of the separation cycle, and vaporization heater 76 is de-energized, liquid flow metering valve 66 remaining open. If the pressure in pressure vessel 12 does not return to atmospheric pressure between approximately 1 and about 2 min., an error signal is generated. Once an error signal is generated, an operator must reduce the residual pressure in pressure vessel 12 using manual vent valve 48 to at or near atmospheric pressure before the pressure vessel can be opened, because higher residual pressure in pressure vessel 12 will prevent the bayonet attachment lugs 106 on the cap from being rotated past the detents in pressure vessel bayonet slots 112.
After removal of the expended biomaterial, apparatus 10 is ready for another extraction/separation. Cone vial 26 may be detached for accessing the extracted material, and replaced with a new vial, if desired.
Having generally described the apparatus and method, the following EXAMPLE provide additional details.
Chamber 12 may develop significant pressures if the carbon dioxide liquid volume is greater than that of the chamber as carbon dioxide passes through the subcritical liquid state on the way to the supercritical state. Calculations on the sizing and charging of pressure vessels for preventing the vessels from being completely filled with CO2 liquid and becoming over-pressurized, follow, assuming a factor of safety (FOS) of 1.25 (note that 1.15 is the minimum FOS used for most engineering projects), a minimum CO2 liquid density of ρCO2Lmin=0.680 kg/l @ ˜30° C. and 80 bar (1,180 psi); and a solid density of ρCO2Lmin=1.562 kg/l @ ˜78.5° C. and 1 bar. Assuming further a typical Botanical or Plant Material Density for cannabis plants of ρB=0.312 kg/l; a THC solubility, SCO2=0.3%; a THC extraction percentage, ηρ=12%, and a mass ratio of dry ice to botanical material, Rm=40 kg of CO2/kg of Botanical Material (extraction percentage of THC in the botanical material, 12%, (Units of kg[THC]/kg[botanical material]) divided by THC solubility in CO2, 0.03% (Units of kg[THC]/kg[CO2]); leaving units of kg[CO2]/kg[botanical material]), and the pressure vessel charge volumes per kilogram of Botanical material, including the FOS are:
VBM=3.21 l; Volume of botanical material;
VDI=25.62 l; Volume of solid CO2 (dry ice);
VHS=41.52 l; Volume of required head space (with FOS); and
Vtot=70.3 l; Total Volume, from which the Percentage Charge Volumes (Including FOS) are:
V%BM=4.6%; Percentage volume of botanical material;
V%DI=36.4%; Percentage volume solid CO2 (dry ice); and
V%HS=59.0%; Percent volume of required head space (with FOS).
The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
The present application claims the benefit of Provisional Patent Application Ser. No. 62/106,028, filed on Jan. 21, 2015, and entitled “Apparatus and Method for Extracting Organic Compounds from Plant Material Using Carbon Dioxide” by Lisa F. Kinney et al., which application is hereby incorporated by reference herein for all that it discloses and teaches.
Number | Date | Country | |
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62106028 | Jan 2015 | US |