03 Extractor&Condenser
03 Extractor&Condenser
Essential oils can be extracted using a variety of methods, although some are not
commonly used in the present. The specific extraction method employed is dependent
upon the plant material to be distilled and the desired end-product. The essential oils from
aromatic plants are for the most part volatile and thus, lend themselves to several
extraction, etc.
The vast majority of essential oils are produced by steam distillation. There are,
however, different processes that are used. All of these use water to produce steam, which
is used to extract the most volatile aromatic compounds. The steam is then cooled (in a
condenser) and the resulting distillate is collected. The essential oils will normally float
on top of the hydrosol (the distilled water component) and may be separated off. Steam
distillation is the most commonly used method for extracting essential oils. Many
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traditional distillers favor this method for distilling most oils as they claim that none of
the later methods produce better quality oils (Boucard, et. al, 2005).
which fresh or sometimes dried plant material is placed in a chamber of the still.
Pressurized steam, generated in a separate chamber, is then circulated through the plant
material. The heat of steam forces open the tiny intercellular pockets in which the
essential oils are contained releasing the oils. During steam distillation, the temperature
of the steam must be moderated so that it is high enough to open the oil pockets while
destroying the plants, fracturing or burning the essential oils as has been recommended in
the literature (Sheridan, 2000). Some or most essential oils have been found to be
As the tiny droplets of essential oils are released, they evaporate and mingle with
the steam, travelling through a pipe into a condenser. The steam and oil vapor are then
lower than about 65C in previous work done by Sheridan et. al (2000), and the mixture
can be separated using various gravity related techniques. Due to immiscibility of the oil
and water at low temperature, the essential oil can be separated from the water by either
decanting off the water or skimming of the oil from the top as the oil is less dense than
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water at these conditions. The density of some essential oil such as lavender oil has been
known to average 0.89 g/L, as opposed to 1g/L (Ndou, 1986) for water at room
distillation is referred to as floral water or distillate and retains many of the therapeutic
properties of the plant. Thus, floral waters are valuable in skin care for making facial
mists and toners and are also preferred to essential oils when treating a sensitive
material from its non-volatile parts. If the final product is too sensitive to heat or
flowers (Rose, Violetta, and Geranium), gums and resins. The raw material is placed in a
glass, vessel and soaked with a suitable solvent (petroleum, ether or benzene). After the
extraction, the solids are separated from the liquid mixture. The latter is heated so that the
Alternatively if the solvent is more volatile, such as ethanol, it could be vaporized leaving
advantageous in producing essential oils with whole fragrances that would otherwise be
destroyed or altered during steam distillation. Therefore this extraction technique can be
used to extract essential oils from very fragile plants to produce higher amounts of
essential oils at lower costs (Ndou, 1986). There are, however, some disadvantages
associated with the solvent extraction technique. Solvent residues often contaminate the
product causing side effects which make the use of essential oil undesirable for skin
applications but could still be fine fragrances or perfumes (Ndou, 1986). Therefore with
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solvent extraction effective separation of the extracted oil from the solvent is necessary to
oleoresin which is more concentrated than essential oils with an even wider application in
currently being applied in the process industry, which competes with conventional
processes such as steam distillation and organic liquid (solvent) extraction. It has been
widely accepted by many investigators that SFE provides a rapid and quantitative method
for extracting essential oils from aromatic plants that compares favorably with steam
temperature and pressure both exceed their critical values, without being far from the
critical state (Gaspar et. al, 2002). At these elevated conditions, the properties of the fluid
All materials have a critical point, but for some materials, however, this state is
more easily reached than others. Carbon dioxide s the most frequently used fluid in
extracting essential oils and its application and technique have been extensively
taking advantage of the fact that above critical conditions of 31.1C and 78.8 bar, carbon
dioxide cannot be liquefied by any further increase in pressure. Whilst the carbon dioxide
is in this supercritical state, the dense gas gains a considerable solvent power, dissolving
the primary target such as the essential oil in the plant material. The pressure is the
dropped in the separator, causing the carbon dioxide to lose its solvating power and hence
releasing the extracted oil drops, leaving behind a high purity essential oil extract. This
are of research is currently being pursued and analyzed by various researchers such as
(Gasper et al., 2002), in their work for various pharmaceutical companies worldwide, in
safe with no harmful residues like solvents in the extracts that would be found for solvent
extraction as discussed before. The operating temperatures are relatively low, which
enables thermally labile compounds to be extracted. This method of extraction has also
(Simon, 1990) as a new method; potentially commercially viable but is less common and
1988) is cold pressed expression, or scarification. It has been used mainly to obtain citrus
fruit oils such as bergamot-, grapefruit-, lemon-, lime-, mandarin-, orange-, and tangerine
In this process, the fruit is rolled over a through with sharp projections that
penetrate their peels thereby piercing the tiny pouches containing the essential oil. The
fruit is then pressed to squeeze out the juice from the pulp thus releasing essential oils
from the pouches. The essential oils rise to the surface of the juice and are separated by
centrifugation.
competitive for specific raw material than methods such as supercritical fluid extraction
as it is extremely fast, cheap and does not pollute the extracts, although it does not
Some flowers, such as jasmine or tuberose, have such low contents of essential
oils and so delicate that heating would destroy their blossoms before releasing the
essential oils. In such cases, an expensive and lengthy process called effleurage is
sometimes used to extract the essential oils. As described in the literature (Stahl et al.,
1988), flower petals are placed on trays of odourless vegetable or animal fat, which
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absorb the essential oils from them. At the end of every day or even after a few hours,
when the vegetable or fat has removed as much of the essential oil as possible, the
depleted petals are removed and replaced with fresh ones. This procedure is repeated
until the fat or oil becomes saturated with the essential oil. Adding alcohol to this
effleurage mixture separates the essential oils. This method employs a similar operating
to its efficient volumetric heat production. The volumetric heating of the bulk as opposed
to transferring heat from the surface, inwards, is more efficient, uniform and less prone to
instantaneously shut the heat source makes enormous difference to the product quality
and hence the production economics. The raw material is heated directly by microwaves
and this brings about quality consistency and minimizes the impact on the environment as
opposed to using fossil fuels or less efficient, indirect electrical heating systems.
Specifically in the essential oil extraction, microwave mediated processes are highly
desirable due to their small equipment size (portability) and controllability through mild
increments of heating. However, so far the microwave technology has found application
in very few industrial bio-processing installations due to the lack of available data on
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Meireles, 2013).
The sensing and close control of microwave process is a challenging science and
3.1.2 Factors Affecting the Yield and Quality of the Essential Oils
The yield and quality of essential oils have been known to vary due to a number
The technique for the distillation method should be chosen on the basis of oil
boiling point and nature of herb because heat and temperature may alter the distillation
characteristics.
Condition of raw material is significant because other material like roots and seed
will not yield essential oil easily if distilled in their natural state. Such materials have to
Improper loading of the herb may result in steam channelling causing incomplete
distillation.
Proper control injection rates and pressure in boiler operated units is essential in
should not be too high because this can result in oil loss due to evaporation.
Different constituents of the essential oil get distilled in the order of their boiling
points. Thus the highest boiling fractions will be last to come over when, generally, very
little oil is distilling. If the distillation is terminated too soon, the high boiling constituents
will be lost.
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Tanks should be well steamed for multiple crop distillation. Tank / equipment
Most essential oils are obtained from plant material by a process known as steam
distillation. Steam distillation is based on the principle that essential oils are volatile in
steam and generally insoluble in water. The fundamental nature of steam distillation is
close to 100C at atmospheric pressure. The mixture of hot vapours will, if allowed to
pass through a cooling system, condense to form a liquid in which the oil and water
comprise two distinct layers. Most essential oils are lighter than water and form the top
layer. The steam that is used for the distillation is generated either within the vessel that
contains the plant material or by an external boiler. The use of steam generated within
the vessel requires that the plant material be supported above the boiling water by a grid.
The water is heated directly using a burning fuel or by heat exchanger coils. The
simplicity of the method makes it suitable for small scale industrial production. If steam
is generated by an external boiler, it is introduced into the base of the vessel via an open
coil, jets or similar device(s). The advantages of this type of generation are that it is
relatively rapid and allows greater control by the operator. The vessel can be emptied and
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recharged quickly. With the instant reintroduction of steam, there is no unnecessary delay
Steam distillation process for the extraction of essential oils from plant materials
The dictionary defines steam as "the gas or vapour into which liquid water is
changed by boiling, especially when used under pressure as a source of energy". The
whatever pressure and temperature are suitable for the end use. The secondary objective
is to provide such steam at the lowest possible cost. These objectives translate into
"operational efficiency". There are many boilers available for steam generation. Some are
high pressure boilers and other medium to low pressure boilers. Most process steam in
industries falls under medium / low pressure. For the purpose of essential oil production,
low pressure steam is generally used. The capacity of the boiler will depend on the size of
The extraction chamber is simply a fixed bed where the hot steam helps to release
the aromatic molecules from the plant material since the steam forces open the pockets in
which the oils are kept in the plant material. The molecules of these volatile oils then
escape from the plant material and evaporate into the steam. The temperature of the steam
needs to be carefully controlled at a temperature just high enough to force the plant
material to let go of the essential oil, yet not too high as to burn the plant material or
decompose the essential oil. The steam, which then contains the essential oil, is passed
through a cooling system to condense the steam, which forms a liquid from which the
essential oil and water are then separated. The steam is produced at slightly greater
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pressure than the atmosphere and therefore boils at above 100 C, which facilitates the
removal of the essential oil from the plant material at a faster rate and in so doing
Heat exchanger is a device that provides the flow of thermal energy between two
or more fluids at different temperatures. The vapours from extraction chamber are cooled
by passing them down a tube that is immersed in a flow of water. The condensate runs by
gravity into a container in which the oil and water separate due to their differing specific
gravities: the "Separator". Heat exchangers are used in a wide variety of applications.
These include power production; process, chemical and food industries; electronics;
1. Recuperators / regenerators
The major construction types are tubular, plate and extended surface heat
exchangers. Tubular heat exchangers are built of cylindrical tubes. One fluid flows inside
the tubes and the other flows on the outside of the tubes. Tube diameter, the number of
tube length, the pitch of the tubes, and the tube arrangement can be changed. Therefore,
there is considerable flexibility in their design. Tubular heat exchangers can be further
classified as follows:
Shell- and tube heat exchangers are built of tubes mounted in large cylindrical
shells with the tube axis parallel to that of the shell. They are widely used as oil coolers,
power plant, steam generators in nuclear power plants, in process applications, and in
chemical industry. One fluid stream flows through the tubes while the other flows on the
shell side, across or along the tubes. In a baffled shell-and-tube heat exchanger, the shell-
side stream flows across between pairs of baffles and then flows parallel to the tubes as it
flows from one baffle compartment to the next. There are wide differences between shell-
and-tube heat exchangers depending on the application. The main design objective here is
exchanger with fixed tube sheets, the shell is welded to the tube sheets and there is no
access to the outside of the tube bundle for cleaning. This low-cost option has only
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Cleaning of the tube is easy. A number of shell-side and tube-side flow arrangements are
used in shell-and-tube heat exchangers depending on heat duty, pressure drop, pressure
level, fouling, manufacturing techniques, cost, corrosion control, and cleaning problems.
The baffles are used in shell-and-tube heat exchangers to promote a better heat transfer
coefficient on the shell-side and to support the tubes (Charles & Simon et al., 1990).
3.1.4.4 Separator
The mixture of condenser oil and water runs into the separator where the lighter
insoluble oil floats on the surface and accumulates slowly and from where it is drawn off
The water, or rather water containing the more water soluble constituents
extracted by the steam, known as the hydrolat or "floral water" is drawn off continuously
from the bottom of the separator. Or, in separating the water from the oil, the water layer
was carefully run out from the bottom of the decanter by opening the tap until its
meniscus is just at the calibration mark. The contents that remained inside the decanter
which were now the oil layer and the water between the tap bridge and the bottom of the
calibration mark were weighed on the electronic analytical balance. The isolation of the
water from the essential oil has to be done as carefully and accurately as possible in order
to minimize the effect of human error due to any inaccuracies in leveling the water and
oil layer to coincide with the level calibration mark (Charles & Simon et al., 1990).
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In steam extraction to convert any liquid into a vapour we have to apply energy in
form of heat called the latent heat of vaporization. A liquid always boils at the
temperature at which its vapour pressure equals the atmospheric / surrounding pressure.
For two immiscible liquids the total vapour pressure of the mixture is always equal to the
sum of their partial pressures. The composition of the gas mixture will be determined by
the concentration of the individual liquid components and their respective partial
pressures. As known, the boiling point of most essential oil components exceeds that of
Consider a sample of an essential oil having a component 'A' with a boiling point
of 1900 C and water having a boiling point of 100 C; when these two immiscible
liquids are brought together, and once their vapours have reached saturation, the
temperature will immediately drop to 99.5 C, which is the temperature at which the sum
Therefore in a mixture of water and essential oil the saturated vapour above the mixture
is:
(3.2)
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Thus any essential oil having high boiling point range can be evaporated with
steam in a ratio such that their combined vapour pressures will be equal to the
atmospheric pressure and can be isolated from the plants by the wet distillation process
(Guenther, 1960).
The procedure for extraction of essential oil is outlined below from a study
conducted by Junare et al. (2015) in which a design of pilot plant for extraction of
with an outlet and steam flow control valve, is used to transfer steam to the base of a
stainless steel extraction chamber. The extraction chamber is a large pot of stainless steel
elevated position in the extraction chamber. After passing through the plant material,
steam is released through the top of the jacket into a condenser coil, constructed from
stainless steel tubing. The extraction chamber is connected to the cooling vessel via a
metal pipe. The condenser coil is immersed in a stainless steel drum, which is cooled by
passing water, with a hose, through the drum. An outlet, at the top of the drum, allows the
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hottest water to run out to be replaced by cooler water. A second outlet, at the base of the
Steam is used as the stripping medium for the extraction from plant material using
the experimental equipment. Each of the samples prepared are processed individually as
described below in three separate batch samples. Firstly, the extraction chamber is
checked to make sure that no other substance is present which could contaminate the
extracted oil.
Secondly, during the processing of each batch, the material is placed into the
Steam distillation is commenced certain time after harvest; by which the sample
of plant material is placed in the sample holder (extraction chamber). The distillate is
collected using separating funnels at a water flow. For the first sample, the known
working pressure is operated and after some time, the first drop of mixture is collected
(water and oil). The batch is discontinued once the flow of steam from the boiler ceased.
It is necessary to note that when the pressure reached the respective desired operating
condition, stripping is started by opening the steam flow valve which releases the steam
to flow into the steam line and eventually to the extraction chamber. The exit line of the
condenser is observed for the first condensate is taken to be the initial extraction time of
Empty decanters are set in position to collect the condensate at intervals once the
recorded at the different time intervals while the work progressed. At the end of each
experiment extraction run, all the decanters were capped and set to stand on a decanter
rack ready for their contents to be analysed both qualitatively and quantitatively.
The system is switched off and the contents (leached plant material) of the
extraction chamber are emptied. The equipment has to be cleaned each time before the
next run, by running steam through it to ensure that all the extracts which could have
condensed on the equipment are removed to avoid cross contamination with the extracts
The steam distillation unit consists of the extractor chamber and condenser unit.
The unit and its frame are observed to be rusty, dysfunctional and dirty. This is shown in
Figure 3.3 below. Also, the interior chamber parts are not seen as the chamber is bolted
tightly. Some of the bolts are missing while others are rusty and torn. Thus, it is clearly
very difficult to determine the exact mechanism of the equipment. The mechanical and
thermal systems of the process are damaged and some parts are either missing or broken.
The two motors used to operate the system are rusty and damaged. The absence of the
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steam generator as the source of steam for the process is noted. Some piping systems are
not present such as those of the condenser. The pressure gauge placed at the top of
condenser is impaired. The unit is also not covered with proper thermal insulation system.
At the bottom portion of the chamber is sharp edged metal that may harm the students if
disassembled. Disassembling is difficult since some of the bolts and nuts are too rusty to
twist. Moreover, the dismantling of the trays is harder because their attachments to the
rotating shafts are very strong. The disassembling process, however, is carried out. The
inside of the chamber is inspected and it is found out that there are lots of dried leaves
which are probably raw materials used in the experiment and the bottom is rusty. The
interior is cleaned with leaves taken out. Further, the whole unit is cleaned thoroughly
with water and detergent and dried. Afterwards, the exterior surface of the equipment, as
well as its frame, is sprayed with metallic paint. The resulting cleaning and painting
improves greatly the general appearance of the equipment. The sharp edged metal at the
bottom portion is covered with cartoon so as to prevent any harmful accident. The
determined number of bolts needed to enclose the chamber is 64 but it is known that only
10 are in the acceptable condition. The necessary dimensions for profiling the equipment
3.3.4 Problems
2. Dirty and rusty interior chamber Clean thoroughly the interior with water
possible.
3. Missing and rusted bolts Replace these with new ones with same
4. Rusted and Damaged motors Replace with new ones as repairing the
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performance.
5. Hardened shafts, trays and joints Run certain amounts of lubricating oil to
regions.
one.
8. Dysfunctional condenser The condenser should be disassembled
9. Sharp-edged metal at the bottom Obtain a new fitting steel plate and attach
10. Unnecessary frame space The portion of the frame besides that of
11. Missing and broken parts of the Determine the exact mechanism or
extraction process.
13. Absence of piping systems Piping systems for the condenser outlet
fluid.
15. Absence of steam flow control valve A valve should be installed along the