Patent Application
20200392059
The present invention relates to a novel and useful mobile crop processing system for removing moisture and extracting oils from plant materials such as hemp. The present invention also relates to a method of using the system and a method of farming plant materials such as industrial hemp using the system.
Cannabidiol including terpenes (CBD), one of many compounds found in the Cannabis sativa plant, is generally recognized for its health benefits. Typically, CBD is concentrated in CBD oil and does not give the psychotropic feeling generally associated with tetrahydrocannabinol (THC), the most active ingredient in the Cannabis sativa plan. CBD has been found to reduce chronic pain and inflammation and to reduce or prevent withdrawal symptoms when quitting smoking or other substances. It has also been shown effective for treating epilepsy, neurodegeneration, neuronal injury, and psychiatric diseases. Some researchers have further found that CBD suppresses the growth of some cancerous cells and promotes their destruction. Additionally, CBD may reduce anxiety-related behaviors in people with post-traumatic stress, general anxiety, panic, social anxiety, and obsessive-compulsive disorders. Other promising research suggests that CBD may be useful for treating Type 1 diabetes, acne, and Alzheimer's disease.
The CBD most commonly used for its health benefits is extracted from industrial hemp plants. In order to satisfy legal requirements, industrial hemp contains only a trace amount of THC (less than 0.3% THC) in addition to CBD. There are many varietals of industrial hemp including some specifically bred to be high-resin cannabis and therefore CBD-rich while maintaining only trace amounts of THC. CBD-rich hemp differs from hemp grown for seed or fiber by being bred for larger flower size and quantity of flowers, making its shape closer to a Christmas tree. There is no established method of harvesting CBD-rich hemp on a large scale, but common methods include being sickled at the base by hand or tractor and left to dry in the field or removed from the ground and brought to an extraction facility, dry the whole plant or strip flowers and dry the flowers only, then chopping it or milling it to a powder. At the facility, solvents such as ethanol or CO2 extraction is often used, which is among the cleanest ways to extract CBD oil from the hemp plant. CO2 extraction involves filtering plants through a series of chambers that control temperature and pressure to isolate CBD at a 90% efficiency. Alternatively, ethanol extraction involves introducing the solvent ethanol to the hemp to extract CBD, which produces a very high volume of full spectrum hemp extract without unwanted components. After extraction with ethanol or CO2, the oil undergoes chromatography to remove unwanted phytochemicals. Some CBD oils also undergo decarboxylation to increase bioavailability and winterization to remove fats. CBD oil can be consumed directly or it can be mixed with carrying oils such as hemp seed oil or coconut oil, turned into capsules, or processed into a powder or slab isolate form.
As the popularity of CBD products continues to rise, farmers are facing challenges in the field. The plants are commonly seeded or transplanted as seedlings at 5 foot intervals and then grown to 5′-6′ tall plants before harvesting. The plants also may be topped to increase leaf production, which causes them to be bushy and top-heavy. Additionally, some plants are dried in the field before harvesting. Unfortunately, as a result, the plants are particularly susceptible to wind, hail, and bird damage or rotting if excess precipitation occurs. One method to combat such damage is to swath the plants, but swathing introduces other hazards such as considerable risk of seed quality loss and increased levels of microbial contamination if hail or rain flattens the swath onto the ground. Alternatively, the plants can be harvested before drying to minimize environmental damage, but then they require additional aeration and drying before the leaves can be stored or stripped for processing. Most large scale farmers will use natural gas or propane dryers. Accordingly, space is needed to accommodate timely aeration and drying. Drying, for example, may require sufficient space where the stalks can be hung upside down, preferably in a cool and dark location with sufficient air movement. Accordingly, it would be desirable to minimize damage to hemp crops due to prolonged exposure to environmental hazards by providing a system and method allowing for earlier harvesting. It would also be desirable to minimize the need for additional space and time for drying hemp that was harvested with higher moisture content.
In accordance with the present invention a novel and useful mobile crop processing system and method of farming plant materials such as industrial hemp using the system is provided. The mobile crop processing system includes a self-propelled forage harvester with a chopper head or a modified picker, depending on the crop, that shears and chops plant material such as hemp in the field and a mobile and field-based extraction system having a mobile extraction assembly that preferably includes a pre-treatment assembly, a field-based extraction assembly, and a transporter that moves products and materials between the mobile extraction assembly and field-based extraction assembly. The forage harvester preferably pulls one or more trailers, on which sits the mobile extraction assembly of components. Preferably the forage harvester pulls two trailers, one on which sits the pre-treatment assembly components of the mobile extraction assembly and another on which sits the additional mobile extraction components including an inlet hopper or an optional feed hopper, a dewatering and maceration assembly, and a first separation assembly. The plant material is delivered to the pre-treatment assembly in the field as it is being cut via a chute on the forage harvester. The output of the pre-treatment assembly is then delivered directly and preferably with a screw auger to the inlet or feed hopper, which holds the pre-treated plant material or slurry and delivers it to the mobile extraction assembly for immediate processing in the field. Optionally, the plant material can be delivered directly to the dewatering and maceration assembly where pre-treatment is not wanted. Also optionally, where field conditions might prevent excessive movement of the mobile extraction assembly components, they can be positioned stationary near or on the field and the forest harvester may pull a third trailer for collecting and moving crops. The third trailer can receive the plant material and then deliver it to the mobile extraction assembly for processing.
In addition to the pre-treatment assembly, the mobile extraction assembly includes a dewatering and maceration assembly, a mobile or first separation assembly, and a transport container. With the dewatering and maceration assembly, the mobile extraction assembly dewaters the pre-treated plant material (or untreated plant material where no pre-treatment assembly is present) through a series of screw presses. Approximately 4,000-8,000 lbs. of plant material can be dewatered per hour through the series of screw press operations, and if needed for better recoveries, it can be followed by additional maceration with a solvent. Next, with the first separation assembly, a first crude oil consisting of oil, fats, waxes, terpenes, solvent, and additional water is then separated from the resulting biomass with a separator such as a decanter centrifuge or ambient filtration skid after which a refined crude oil consisting of oil and solvent is separated from the first crude oil with an oil water separator and collected in a collection tank. The refined crude oil is transferred from the collection tank to the transport container for transport with a transport vehicle to the field-based extraction assembly.
The field-based extraction assembly includes an additional separator, a container for collecting essential oil, and a container for collecting reclaimed solvent. After the refined crude oil is delivered to the field-based extraction assembly, the cannabinoid/terpene-rich oil or essential oil is separated from the solvent using a wiped film evaporator. The essential oil is collected in the essential oil container for further processing and reclaimed solvent is collected in the reclaimed solvent container for reuse by the mobile extraction assembly in the solvent extraction process.
With both the mobile and field-based extraction assemblies, any unwanted moisture and biomass encountered during processing is discarded in the field or collected in a container or other receptacle for other purposes if desired. The process from chopper or modified picker to output of refined crude oil takes approximately 30-60 minutes. The process from refined crude oil to essential oil takes approximately 15-30 minutes.
A method of farming plant material such as industrial hemp using the mobile crop processing system of the present invention involves first planting and growing suitable hemp for harvesting. Once the hemp is ready to be cut, the mobile crop processing system is brought to the field. The hemp flower is harvested and then may be additionally cut into pieces or plant material using the chopper/modified picker and forage harvester of the mobile crop processing system and preferably delivered via the forage harvester's chute to the pre-treatment assembly of the mobile extraction assembly. After pre-treating the hemp, it is conveyed to the inlet or feed hopper of the mobile extraction assembly. The additional components of the mobile extraction assembly process the plant material and produce refined crude oil that is then transferred with the transporter to the field-based extraction assembly. The field-based extraction assembly processes the crude oil and produces essential oil and reclaimed solvent. With both the mobile and field-based extraction assemblies, any unwanted moisture and biomass is preferably discarded into the field. The mobile crop processing system operates as needed until the entire field of hemp, or until a desired portion of the field, has been cut and processed. After the field has been cleared, additional hemp can be planted and the cycle can be repeated. For a field of about 120 acres, the mobile crop processing system can process 4,000-8,000 lbs. of plant mass per hour for a total processing time of about 60-120 hours. Over one year of continuous farming, it is anticipated that over 20,000 lbs. of essential oil can be recovered at a yield rate of about 76%. While the method is described with respect to farming hemp, other plant materials can be farmed according to the same method.
For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments of the invention which should be taken in conjunction with the above described drawings.
Various aspects of the present invention will evolve from the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings.
The mobile crop processing system 10 of the present invention is illustrated in
The trailer 30 of the present invention preferably cooperates with or is coupled to the forage harvester 20 such that it can be towed behind the forage harvester 20 and can operate in a field. Optionally, as long as it is capable of remaining in close proximity to forage harvester 20, the trailer 30 can be pulled by another vehicle, or it can be an independently self-propelled vehicle capable of transporting equipment. Trailer 30 can be a single trailer or it can be a series of trailers such as trailer 30a and trailer 30b as shown in
Positioned on trailer 30 are several components and subassemblies of mobile extraction assembly 40a. Optionally, a feed hopper 32 is positioned on trailer 30 as part of or in addition to mobile extraction assembly 40a to cooperate with and receive plant material from the chute 24 of the forest harvester 20 or from a pre-treatment assembly 480 of the mobile extraction assembly 40a. Alternatively and preferably, mobile components 40a are positioned on first and second trailers 30a and 30b such that the pre-treatment assembly 480 cooperates with and receives plant material from the chute 24 of the forest harvester 20 and an inlet hopper 400 cooperates with and receives pre-treated plant material from pre-treatment assembly 480, as shown in
The additional field-based extraction assembly 40b of the mobile and field-based extraction system 40 are removably or permanently located in the field 12 being harvested. Preferably the field-based extraction assembly is positioned near a power source (not shown). Optionally, the field-based extraction assembly 40b can be also carried by trailer 30 or another vehicle so that they can also be relocated, or the field-based extraction assembly 40b can be mobile components that operate alongside the mobile extraction assembly 40a when using a mobile power source (not shown). The field-based extraction assembly 40b includes a second extraction assembly that receives the crude oil output from the mobile extraction assembly 40a and removes and separates solvent and essential oil from the crude oil.
Transporter 35 can be any structure, which includes slides, conveyers, carts, and vehicles, that is capable of moving large objects and materials such as containers of crude oil, solvent, and essential oil between the mobile extraction assembly 40a and the field-based extraction assembly 40b. Preferably, transporter 35 is a self-propelled transport vehicle such as a forklift, as illustrated in
Additional aspects of the mobile and field-based extraction system 40 are illustrated in
As shown and described in
Pre-treatment assembly 480 includes a mixing vessel 418 for receiving plant material 500 from forage harvester 20 via its chute 24, a solvent tank 422 that supplies mixing vessel 418 with solvent 522, and a screw auger conveyer 482 that delivers a slurry 518 output from mixing vessel 418 to an inlet hopper 400 (with or without optional spray bars 400a) positioned among the remaining mobile extraction components such that it cooperates with dewatering and maceration assembly 484, which is shown in
Pre-treatment assembly 480 of mobile extraction assembly 40a also includes solvent tank 422 positioned on trailer 30 or first trailer 30a, optionally in or on a mobile extraction assembly housing. As shown in
Preferably, screw presses 410, 414 are horizontal cone type auger presses or any type of dewatering screw press that optimally use 210,000 to 250,000 lbs.-inch of torque. In the preferred embodiment of mobile extraction assembly 40a and dewatering and maceration assembly 484, the series of screw presses are stacked with additional hoppers 405 (with or without optional spray bars 405a) so that the screw presses are in communication with each other as shown in
For the second embodiment of mobile extraction assembly 40a and dewatering and maceration assembly 484 and as shown in
Next, for both the first and second embodiments of mobile extraction assembly 40a and dewatering and maceration assembly 484, through either direct communication with a second screw press 414 via a second inlet hopper 405 (optionally equipped with second spray bars 405a) or indirect communication with the second screw press 414 via a screw conveyer 412, the first biomass 510 output of the first screw press 410 is delivered to screw conveyer 412 for further processing. The second screw press 414 further presses the first biomass 510 to produce a second biomass 514. The second biomass 514 is a press cake with a reduced moisture content compared to the moisture content of the beginning plant material. While the series of screw presses described herein includes only first and second screw presses 410 and 414, it is anticipated that additional screw presses, screw conveyers, and inlet hoppers can be included in the series to produce a press cake with greater moisture reduction. Preferably, the series of screw presses is capable of turning 85% moisture content plant material into 50% moisture content biomass. The moisture 560 removed from the plant material 500 from the series of screw presses will be discarded into the field 12. The extracted moisture 560 preferably is discarded to the field 12 immediately, or it may be collected in a container or other receptacle for further use.
Each of the hoppers 32, 400, and 405 optionally include spray bars 32a, 400a, and 405a, which can be mounted thereon as shown in the Figures. Spray bars hold solvent or any treatment solution that might aid in processing of plant material 500. Preferably, where spray bars are used, the spray bars are configured to deliver solvent or a treatment solution to the contents of the hopper on which or near which the spray bars are positioned. For example, spray bars 32a are preferably positioned along upper edges of feed hopper 32 and are configured to deliver solvent or treatment solution to plant material 500 when it is present in hopper 32. Also preferably, the spray bars are in communication with a source of solvent or pretreatment solution. For example, spray bars 400a could be in communication with a solvent tank 422 that also supplies a solvent 522 to components of mobile processing assembly 40a.
The second embodiment of dewatering and maceration assembly 484 further includes mixing vessel 418, as shown in
Solvent 522 is preferably is an organic or a non-polar solvent. For example, solvent 522 may be n-butanol. Alternatively, solvent 522 may be a hydrogen-infused aqueous solution and optionally one with a pH of 12. Solvent 522 also can be derived from common food products that mimic the properties of non-polar solvent, which preferably can be reused several times. Preferably, solvent 522 is mixed at an approximate 1:1 ratio by total mass to second biomass output 514. Solvent 522 can be mixed with second biomass 514 at additional ratios, however, including at ratios of 1:5 by total mass. Biomass 514 macerates in solvent 522 in mixing vessel 418 for 10 to 20 minutes and becomes a slurry 518.
For the second embodiment of mobile extraction assembly 40a and dewatering and maceration assembly 484, slurry 518 can be directly transferred or optionally pumped from mixing vessel 418 to first separation assembly 486 with a third pump 424, which are all connected and in fluid communication, or it can be subjected to sonication extraction (not shown) or ultrasound assisted extraction (not shown) to reduce use of solvent 522. Additionally and as shown, however, mixing vessel 418 can be in communication with a hydrodynamic cavitation reactor 429 so that slurry 518 can undergo further treatment before being pumped as reactor output 460 to first separation assembly 486. Third pump 424 is preferably a progressive cavity pump.
For the first and preferred embodiment of mobile extraction assembly 40a, which is shown and described in
For the first embodiment of mobile extraction assembly 40a and as with the second embodiment of mobile extraction assembly 40a, the series of screw presses are optionally in communication with first pump 416. For the second embodiment, however, the output 514 of second screw press 414 is transferred next to first separation assembly 486 directly or optionally via a third pump 424, which are all connected and in fluid communication. Alternatively, it can be subjected to sonication extraction (not shown) or ultrasound assisted extraction (not shown) to reduce use of solvent 522. Additionally and as shown, however, second screw press 414 can be in communication a hydrodynamic cavitation reactor 429 directly or via an optional first pump 416 so that second biomass 514 can undergo further treatment before being pumped as reactor output 460 to first separation assembly 486 with third pump 424.
First separation assembly 486 is in communication with dewatering and maceration assembly 484 directly or via and optional third pump 424 to receive slurry 518, biomass output 514, or reactor output 460 and separate out a first crude oil 526. First separation assembly 486 includes a first separator 426 that is in communication with third pump 424 or dewatering and maceration assembly 484. First separator 426 is preferably a decanter centrifuge that is optionally modified with a floater scalping disk for enhanced performance. Alternatively, it can be an ambient filtration skid. First separator 426 separates a first crude oil (water, crude oil, fat, waxes, terpenes, and solvent) 526 from the biomass in slurry 518. The first crude oil 526 communicates directly with or is optionally pumped from first separator 426 with an optional fourth pump 428 to a separation tank 434, and the remaining 45 microns +/− biomass 562 is discarded in the field 12. First separator 426, optional fourth pump 428, and separation tank 434 are all in communication to facilitate the transfer or movement of first crude oil 526. Fourth pump 428 preferably is a transfer or centrifugal pump. Crude oil may be extracted about 25-35 minutes after the plant material was initially chopped, and optimally, the crude oil is extracted only 25 minutes after the plant material 500 was initially chopped.
The solvent/water separation tank 434 of the first separation assembly 486 removes the remaining water or moisture 560 from the first crude oil 526, leaving only a combination of substantially oil and solvent referred to herein as second or refined crude oil 534. The water or moisture 560 is collected in a container (not shown) in communication with tank 434, or it can be immediately discarded in field 12. The refined crude oil 534 is preferably collected in a fixedly or removably attached collection tank 436. Separation tank 434 and tank 436 can be in immediate or direct communication with each other, or they can be indirectly connected through an additional pump (not labeled), as shown in the Figures. Tank 436 preferably holds the refined crude oil 534 until it is ready for further processing, at which time it can be transferred to a movable intermediate bulk container 430 or introduced to the field-based extraction assembly 40b through direct or indirect connection or communication. Alternatively, refined crude oil 534 can be divided such that a first part 534a of refined crude oil 534 will be transferred to removable bulk container 430 or field-based extraction assembly 40b and a second part 534b of refined crude oil 534 will recirculate back to mix tank 418 to increase the saturation of the oil in the solvent and depending on whether there was full saturation on the first pass.
Field-based extraction assembly 40b includes a second separator 440, which receives the refined crude oil 534 or the first portion of refined crude oil 534a. Refined crude oil 534 or first portion of refined crude oil 534a can either be pumped to second separator 440 with a sixth pump (not shown) where all components of the extraction system are mobile or, more preferably, transported in movable container 430 to the second separator 440 and field-based components 40b with transporter 35. Preferably, second separator 440 is an oil and solvent separator 440 and more preferably is a wiped film evaporator. Second separator 440 separates essential oil 540 from solvent 522 and is in communication with an essential oil container 450 for receiving and collecting essential oil 540 for further processing. Second separator 440 also is in communication with solvent feed tank 422, optionally through an intermediary pump, or with a reclaimed solvent container or tote 431, also optionally through an intermediary pump. Where second separator 440 is in communication with solvent feed tank 422 such as when field-based extraction assembly 40b is also mobile, the reclaimed solvent 522 can be immediately reused by the mobile extraction assembly 40a. Alternatively and as shown in the Figures, movable container 431 is configured such that it can receive and collect reclaimed solvent 522 and be transported back to solvent feed tank 422 with transporter 35 or another transporter. The time it takes to remove the essential oil 540 from the crude oil is about 15 to 25 minutes. Optimally, it takes only 15 minutes to separate the essential oil 540. The total time to process the cut plant material and recover essential oil 540 is therefore about 40 to 60 minutes.
The system described herein can be used in the field to expedite the moisture removal from plant material such as industrial hemp and then to extract the essential oils, as illustrated in
There are several possible advantages to using the farming method and mobile crop processing system of the present invention. For example, farmers may find processing is safer as solvent extraction methods with a lower flammability class can be used in an outside environment thereby limiting hazards to workers. Additionally, the smaller footprint of the mobile crop processing system allows for processing about 1 acre of industrial hemp per hour, which reduces harvest and processing costs compared to traditional drying and processing systems. Processing in the field also may facilitate quick capture of the natural profiles of the hemp plant (tricomes, terpenes, CBDA). Finally, the ability to move the mobile crop processing system between fields allows for multiple operations to be harvested in a single season.
While in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention.
This application claims the benefit of co-pending provisional U.S. Application No. 62/984,044 filed Mar. 2, 2020 and co-pending provisional U.S. Application No. 62/860,429 filed Jun. 12, 2019.
| Number | Date | Country | |
|---|---|---|---|
| 62984044 | Mar 2020 | US | |
| 62860429 | Jun 2019 | US |
