Экстракционная установка холодным способом NECTACEL

для растворителядля газовпаровая

Overview
Since its start-up, CELSIUS has built equipment for pharmaceutical industries producing active ingredients by chemical synthesis ways. CELSIUS has also developed the NECTACEL process for the extraction of natural molecules using liquefied gases, for applications beyond pharmacy such as cosmetics, perfumery, flavourings and food supplements.

Green chemistry
Nature contains molecules with interesting properties for health, beauty or nutrition. CELSIUS designs NECTACEL extraction units and equipment for producing extracts, reagents, essential oils, concretes, absolutes or functional ingredients. NECTACEL units are designed with chemical engineering, process engineering and thermodynamics expertise with attention to safety, resource management, energy savings and environmental protection.

Solvents and unit design
Each unit is designed for a specific matrix and extraction solvent. Typical solvent families and modes considered include:

• Steam
• Water
• Alcohol
• Hexane, Toluene, etc.
• Green solvents
• Liquid gases (liquefied gases)

Extraction of natural molecules (definition)
Extraction means transferring molecules from a solid animal or plant substrate to a liquid phase. Terms used vary by trade: matrix, load, bagasse, marc, cake, spent solids, residues, etc. The extraction process commonly involves two successive phases:

• Extraction (solvation, maceration, digestion, decoction, infusion, leaching, percolation, etc.) where the matrix is mixed with a solvent and the molecule of interest dissolves.
• Separation where the solvent is removed (evaporation, desolvation, crystallisation) yielding liquid, solid or suspension extracts; residual solids (spent matrix) are dried.

Solvent selection criteria
Important criteria in choosing a solvent are:

• Solvating power (polarity, ionic character)
• Ability to cross cell membranes (molecular size)
• Thermodynamic properties governing operating conditions and equipment technologies

Secondary and ethical criteria include solvent selectivity, renewability, low energy requirements and operating temperatures that do not degrade the product.

Extraction processes (main types)
Extraction processes differ depending on the solvent state (gaseous, solid, liquid or supercritical):
1. Hydrodistillation
Uses water vapour to entrain molecules by azeotrope formation; used for essential oils; limited to extracts tolerating vapour temperature.
2. Cold enfleurage
Solid solvent process (e.g. grease capturing floral aromas) — difficult to industrialise.
3. Liquid solvent extraction
Common liquid solvents: water, alcohols, hexane, toluene. Solvent/solute separation requires vaporisation (heat, vacuum or both). Considerations: evaporation temperature vs extract stability, harmful residual solvents, need for solvent recycling.
4. Liquefied gases
Liquefied gases are gases at ambient conditions but liquid under moderate pressure/temperature. Advantages compared to steam or conventional solvents: ability to work at ambient temperature, inert/"green" solvents, lower pressure than supercritical CO2, simplified equipment (no mechanical pumping in some CELSIUS designs). The general cycle: liquid solvent extraction → evaporation → condensation → solvent recycling. Key thermodynamic criteria for liquefied gases: liquid in extractor at near-ambient extraction temperature (practical vapor pressure not exceeding ~10 bar at 35°C) and condensation temperature at atmospheric pressure reachable with conventional refrigeration (practical condensation temperature > -30°C at atm). Two inert gas families are considered: alkanes and authorised refrigerant gases (HFCs).

Representative table — Vapour pressures / boiling points (example)
Liquid gas | Butane C4H10 | R134a (1,1,1,2-tetrafluoroethane C2F4H2)
Boiling point at Patm | -0.5°C | -26°C
Vapour pressure at 35°C | 2.3 barg | 7.9 barg

Other extraction variants
5. R134a extraction using a refrigerating unit: refrigerant follows a Carnot-like cycle with a gas compressor (higher complexity and energy consumption).
6. Supercritical CO2 extraction: CO2 inert, inexpensive, good solvent in supercritical state; extraction often at high pressures (>72 bar, typically 300–500 bar for extraction) which increases equipment cost and limits capacity; suitable for pilot units or dedicated large-scale high-value operations (e.g., decaffeination).

NECTACEL pressurised process
NECTACEL is a pressurised liquefied gas extraction process developed to extract polar and non-polar plant or animal molecules. It has a lower investment cost than supercritical CO2 and can be implemented near raw material production sites to avoid transport costs. NECTACEL advantages and design points include:

• Use of liquefied gases chemically inert relative to matrix and extract
• Extraction and separation at ambient temperature beneficial for heat-sensitive molecules
• Small solvent molecules readily penetrate cell membranes
• Possibility to extend solvation with co-solvents
• Extraction and separation at relatively low pressures (< 10 barg) for most solvents
• Extractors built with no mechanical pumping parts (no circulation pump or gas compressor), except a vacuum pump for final drying of residues
• Limited energy needs essentially for solvent evaporation and condensation
• High solvent recycling rate
• Process and system protected by patent

CELSIUS commonly uses butane, HFO1234ze and DME (dimethyl ether) in NECTACEL extractors. NECTACEL facilities are assemblies comprising equipment for extraction, filtration, solvent evaporation, extract concentration, condensation, storage and solvent recycling, designed and assembled turnkey in CELSIUS workshops and compliant with relevant directives and ATEX where applicable.

Fields of application (examples)
Cannabidiol extraction from hemp; Artemisinine extraction from Artemisia annua; oil extraction from oil cakes; pharmaceutical, cosmetic, flavour, scent and nutraceutical molecule extraction.

Testing and pilot units
CELSIUS offers pilot testing: pilot extractors of 1-litre capacity are used for qualitative tests. Industrial units of various capacities (e.g., 200 L) have been implemented for customers and references include academic and industrial pilots.

caractéristiques / spécifications techniques

• Process name / model: NECTACEL
• Manufacturer / brand: CELSIUS (Celsius Process)
• Extraction solvent families: liquefied gases (e.g., n-butane, HFO1234ze, DME), alkanes, authorised refrigerants; also water, alcohols, conventional organic solvents when applicable
• Operating extraction temperature: near-ambient (designed to preserve heat-sensitive molecules)
• Typical maximum vapour pressure in extractor: practical design to keep vapour pressure ≤ ~10 bar at 35°C for liquefied gas solvents
• Condensation requirement: condensation temperature at atmospheric pressure should be > -30°C for practical refrigeration
• Pressure regime: relatively low pressure compared to supercritical CO2 (generally < 10 barg for liquefied gas extraction)
• Mechanical design: no circulation pump or gas compressor for solvent cycle (vacuum pump used only for residue drying)
• Regulatory / compliance: equipment designed to comply with pressure and ATEX regulations (e.g.,/described as DESP 2014/68/EU and ATEX 2014/34/EU where relevant)
• Solvent recycling: virtually all solvent recycled in the process
• Pilot capacities cited: 1 L pilot extractors; industrial references up to at least 200 L capacity in application examples
• Intellectual property: process and system claimed protected by patent