CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present patent application claims the priority benefit of U.S. provisional patent application 62/749,544 filed October 23, 2019, the disclosure of which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field Of The Disclosure

[0002] The present disclosure is generally related to a biomass extraction process and more particularly related to a method of extracting active compounds from a biomass using pressurized gas.

2. Description Of The Related Art

[0003] The extraction of bioactive or therapeutic compounds from natural biomass sources, including for example plants or microorganisms, has been practiced throughout human history. Plant extracts may contain some or all of the benefits of the plant itself, in a convenient concentrated form. Such extracts are used for a wide variety of purposes, such as fuel, food, personal care, and medicine. Compounds may be extracted from a biomass by using

conventional methods of extraction, such as maceration, decoction, or solvent extraction. Such conventional methods may suffer from various limitations and disadvantages ( e.g ., extraction times may be very high so as to be impractical to scale). For example, subjecting the biomass to a prolonged extraction process may risk modification of the plant profile, negative effects on terpenes, or otherwise cause other undesirable effects that lower the quality or purity of the end product. Traditional methods of extraction may therefore hamper quality and purity of the final product. Further, final concentrated or purified active compounds are often diluted or dispersed into an oil, fat, or other lipid-based excipient or carrier to a desired concentration for certain uses (e.g., in a pharmaceutical, food, or cosmetic formulation).

[0004] Other methods such as supercritical fluid extraction (SFE) make use of supercritical fluids, such as supercritical CO2, to selectively remove compounds from solid, semisolid, and liquid matrices in a batch process. SFE is, however, dangerous and requires very high pressures to be employed (> 70 atm). In addition, SFE is also inefficient and therefore not conducive to high throughputs, as well as environmentally damaging (e.g., producing large amounts of the greenhouse gas carbon dioxide as a by-product).

[0005] Some of the difficulties can be overcome by utilizing solvents that are gaseous at normal atmospheric temperature and pressure but are liquefied at reduced temperatures, increased pressures or by a combination of both. In many cases, the solvent need not be pressurized to the point of being supercritical. The use of liquefied hydrocarbons such as butane and propane are well known for the extraction of cannabinoids from cannabis biomass, such as for the production of "butane hash oil" (BHO).

[0006] However, current pressurized gas extraction techniques and other such current techniques can cause mechanical stresses on components of the equipment. Such stress on mechanical components may potentially cause mechanical failures and extraction problems, such as a leakage. To prevent leakage, monitoring must be included in the process. Mechanical components may not be required because of the use of pressurized gas. Therefore, there is a need for an improved system and a method for extracting the compounds from the biomass during the extraction process.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a block diagram illustrating an exemplary system for extracting active compounds from a biomass.

[0008] FIG. 2 is a flowchart illustrating an exemplary method for extracting active compounds from a biomass.

[0009] FIG. 3 is a block diagram illustrating an exemplary system for extracting active compounds from a prepared biomass using a liquefied gas under pressure.

[0010] FIG.4 is a block diagram illustrating an exemplary system for monitoring a pressure level applied to the slurry.

[0011] FIG. 5 is a block diagram illustrating an exemplary system for depressurizing a chamber holding final formulated extract.

[0012] FIG 6 is a flowchart illustrating an exemplary method for monitoring and maintaining a specified pressure.

DETAILED DESCRIPTION

[0013] Systems and methods of extracting active compounds from a biomass are provided. FIG. 1 is a block diagram illustrating an exemplary system 100 for extracting active compounds from a biomass, and FIG. 2 is a flowchart illustrating an exemplary method 200 for extracting active compounds from a biomass. One skilled in the art will appreciate that, for this and other processes and methods disclosed herein, the functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.

[0014] First, a raw biomass may be provided in a raw biomass chamber 102 at step 202. The raw biomass may contain target compounds for extraction. The raw biomass may be present in a dried, grounded, or non-decarboxylated flower (buds) form of cannabis plants.

[0015] The raw biomass may then be sampled and analyzed at step 204. The raw biomass may be sampled and analyzed in a sampling chamber 104. The raw biomass may be analyzed using a suitable analytical technique, such as an Ultra-High-Performance Liquid

Chromatography (UHPLC). Further, various samples for the gases may be analyzed using a Gas Chromatography-Mass Spectrometry Detection (GC-MS) technique.

[0016] After sampling, the raw biomass may optionally be subjected to decarboxylation via heating to obtain a prepared biomass at step 206. The prepared (e.g., decarboxylated) biomass may be obtained in a biomass preparation chamber 106. In some embodiments, such heating of the raw biomass may involve a heating element similar to a laboratory oven at 125 degrees Celsius for 45 minutes. The prepared biomass may be stored in a biomass storage chamber 108.

[0017] The prepared (e.g., decarboxylated) biomass may then be used to form a slurry by adding a solvent thereto in step 208. In one embodiment, the biomass slurry may be prepared through the combination with a liquefied gas. In another embodiment, the solvent may be selected based on different dielectric and solvent parameter properties. The solvent may be a liquefied gas such as ethane, propane, butane, carbon dioxide or other liquefiable gases and may be stored in a pressurized gas solvent chamber 110. The solvent-to-biomass ratio may be maintained at 10 L/Kg to ease pumping operation of the slurry. A system for extracting active compounds from a prepared biomass using a liquefied gas under pressure is explained with reference to FIG. 3 in conjunction with FIG 1.

[0018] FIG. 3 is a block diagram illustrating an exemplary system 300 for extracting active compounds from a prepared biomass using a liquefied gas under pressure. In one embodiment, the prepared biomass from the biomass storage chamber 108 may be transferred to a biomass hopper 302. After the biomass hopper 302 has been filled with the prepared biomass, the hopper lid 304 may be closed in order to maintain a current level of pressure. The liquefied gas from pressurized gas solvent chamber 110 may be transferred to the biomass hopper 302 in a controlled manner as monitored by gas valve sensor 112. Because the hopper lid 304 is closed and the transfer of the liquefied gas is controlled, the level of pressure within the biomass hopper 302 may be maintained or adjusted in accordance with a desired level of pressure (e.g., based on the selected liquefied gas used).

[0019] The gas valve sensor 112 is a module that may be coupled with a tube 312 that contains a valve 310 that prevents unwanted pressure changes (e.g., to the liquefied gas from the pressurized gas solvent chamber 110) from occurring within the biomass hopper 302. The gas valve sensor 112 may monitor and measure the data related to the liquefied gas stored in the pressurized gas solvent chamber 110, as well as provide digital data 306 to a designated recipient device regarding the same. In one embodiment, the data measured by the gas valve sensor 112 includes the pressure applied to the liquefied gas. Any detected deviations from the desired level of pressure may result in adjustments via the associated valve 310 so as to return the pressure within the pressurized gas solvent chamber 110 or biomass hopper 302 to the desired pressure level.

[0020] The gas valve sensor 112 may then send digital data 306 related to the liquefied gas to a gas controller 114 to be processed. The gas controller 114 may contain at least a gas module 116 and a user interface 118. The gas module 116 may determine whether the digital data is indicative of a pressure level within pre-programmed ranges. In one embodiment, the gas module 116 may determine that the pressure applied to the liquefied gas lies within a specific range. Thereafter, the user interface 118 of the gas controller 114 may display the digital data 306. The gas controller 114 then communicates to the gas valve sensor 112 via a control line 308. The general method of communication between the gas controller 114 and gas valve sensors is illustrated in FIG. 6.

[0021] Based on the received instructions from the gas controller via the control line 308, the valve 310 may be opened to allow the liquefied gas from the pressurized gas solvent chamber 110 to enter tube 312. The tube 312 may be connected to the biomass hopper 302 via a coupler 314 configured to maintain the desired pressure level. Thereafter, the pressurized liquefied gas may enter the biomass hopper 302 via the tube 312 and coupler 314.

[0022] Once the pressurized liquefied gas enters the biomass hopper, the prepared biomass that is already present in the biomass hopper 302 may be combined with the liquefied gas to form a slurry. While pressurization is maintained, the resulting slurry may be transferred to a slurry chamber 120 through an outlet 316 of the biomass hopper 302. The outlet 316 is connected to a tube 318 that contains a valve 320 that likewise maintains the desired pressure level. The tube 318 is connected to the slurry chamber 120. Upon transfer of the slurry to the slurry chamber 120, the outlet 316 of the biomass hopper 302 may be closed to maintain pressure within the slurry chamber 120, which holds the slurry until the slurry can be provided to extraction chamber 122.

[0023] The slurry may be transferred from slurry chamber 120 to an extraction chamber 122 at step 210, where the active compounds from the biomass are extracted into the solvent. Prior to entering the extraction chamber, the slurry may first be monitored by a gas valve sensor 124.

The gas valve sensor 124 may measure certain data related to the slurry. The gas valve sensor 124 is a module that may be coupled with a tube that contains a valve that prevents pressure changes ( e.g ., affecting the slurry contained in the slurry chamber 120) from occurring within the extraction chamber 122. In one embodiment, the data measured by the gas valve sensor 124 includes the pressure level to which the slurry is subjected. The gas valve sensor 124 may communicate digital data to the gas controller 114, which may adjust operations of the gas valve sensor 124 based on the current pressure levels indicated by such digital data. For example, the gas module 116 of the gas controller 114 may determine whether the digital data is indicative of a pressure level within pre-programmed ranges. In one embodiment, the gas module 116 may determine that the pressure within the biomass hopper 302 holding the slurry lies within a specific range. Thereafter, the user interface 118 of the gas controller 114 may display the data. The gas controller 114 then communicates to the gas valve sensor 124 to allow the passage of the slurry into the extraction chamber. A general description of the mechanism between the gas controller 114 and gas valve sensors is further illustrated in FIG. 6.

[0024] Once the slurry is in the extraction chamber 122, the slurry may be subjected to thermal energy by way of microwave heating by a microwave generator 126. In one

embodiment, the slurry may be transported into a reactor portion of the extraction chamber 122. The reactor portion may transport the slurry through the microwave chamber 122 via inter alia a tube). It should be noted that at least one portion of the chamber or the entire chamber may be microwave-transparent. The solvent (e.g., liquefied gas) in the slurry may extract the active compounds from the biomass within the slurry, and such extraction may be facilitated by microwave energy from the microwave generator 126. The resulting slurry may thereafter include a now-spent biomass (from which the active compounds have been extracted) and a solvent-extract mixture.

[0025] The pressure applied to the resulting slurry may then be monitored by the gas valve sensor 130. A system for monitoring the pressure applied to the resulting slurry is explained with reference to FIG. 4 in conjunction with FIG 1. FIG. 4 is a block diagram of an exemplary system 400 for monitoring the pressure applied to the slurry.

[0026] The gas valve sensor 130 is a module that may be coupled with a tube 402 associated with a valve 404 that controls pressure during transport of the post-extraction slurry from the extraction chamber 122 to the filtration and separation chamber 128. The gas valve sensor 130 may measure the data related to the post-extraction slurry in the extraction chamber 122 and provide such data (e.g., digital data 406) to be sent to the gas controller 114. In one embodiment, the data measured by the gas valve sensor 130 includes the pressure applied to the slurry.

[0027] The gas valve sensor 130 may then send digital data 406 to a gas controller 114 to be processed. The gas module 116 may determine whether the digital data is indicative of a pressure level within pre-programmed specific ranges. In one embodiment, the gas module 116 may determine that the pressure applied to the post-extraction slurry lies within a specific range. Thereafter, the user interface 118 of the gas controller 114 may display the digital data 406. The gas controller 114 then communicates to the gas valve sensor 112 via a control line 408. The general method of communication between the gas controller 114 and gas valve sensors is further illustrated in FIG. 6.

[0028] Once the gas controller 114 has determined that the digital data is indicative of a pressure level within pre-programmed specific ranges ( i.e ., adequate pressure), the gas controller may indicate to the gas valve sensor 130 to open the valve 404. Subsequently the post- extraction slurry may then transfer to the filtration and separation chamber 128 via tube 402.

[0029] The post-extraction slurry may now undergo filtration and separation in order to separate the spent biomass from the solvent-extract mixture that contains the extracted active compounds at step 212. Such filtration and separation may be performed by the filtration and separation chamber 128. Thereafter, the spent biomass may be stored in a spent biomass storage chamber 132. It should be noted that the separation may be performed using filtration, centrifugation, and other similar processes. The spent biomass may be incinerated or mixed with a deactivating agent for disposal at step 214. Clay may be used as the deactivating agent.

[0030] The liquid mixture that contains the liquefied gas solvent and the extracted active compounds may be transferred to the solvent recovery chamber 134 to undergo further processing. In the solvent recovery chamber 134, the liquefied gas solvent may be removed from the extract mixture. Upon removal of the solvent, a de-solventized extract may be obtained at step 216 and transferred to a formulation chamber 140. In one embodiment, the solvent may be removed by changes in temperature and/or pressure. For example, the solvent may be removed by reducing the pressure and causing the solvent to evaporate. In another embodiment, the pressure may be maintained, while the temperature is increased, causing the solvent to evaporate. The evaporated solvent may be recovered by increasing the pressure or decreasing the temperature in a solvent recovery chamber 134. The recovered solvent (e.g., the liquefied gas in either liquid or gaseous form) may be stored and used in another extraction process. In one embodiment, the solvent recovered in the solvent recovery chamber 134, may then be pumped using a pump 136 to a storage chamber (e.g., the pressurized gas solvent chamber 110 or associated chamber) for storage for usage in a next extraction cycle.

[0031] In one embodiment, a gas valve sensor 138 may be placed between the separation chamber 128 and the solvent recovery chamber 134. The gas valve sensor 138 may measure data such as the pressure of the liquefied gas separated from the extract. Further, the gas valve sensor 138 may be controlled by the gas controller 114 using the gas module 116. The gas module 116 may ensure that the pressure applied to the liquefied gas lies within a specific range. Further, the pressure applied to the liquefied gas may be displayed by the user interface 118.

[0032] After the solvent (e.g., liquefied gas) has been separated from the extract and transported to the solvent recovery chamber 134, the de-solventized extract may be sent to a formulation chamber 140 at step 218. The final formulation of the extracted active compounds may be made based on pre-programmed parameters (e.g., different concentrations of each active compound, as well as inactive compounds) by the formulation chamber 140. It should be noted that de-solventized extract may be formulated into a final formulated extract using any suitable formulation method.

[0033] Prior to the transfer of the de-solventized extract to the formulation chamber 140, a gas valve sensor 142 may monitor pressure levels in the solvent recovery chamber 134 and the formulation chamber 140. The gas valve sensor 142 may measure certain data including the pressure applied to the extract and/or the liquefied gas. Further, the gas valve sensor 142 may be controlled by the gas controller 114 using the gas module 116. The gas module 116 may ensure that the pressure applied to the liquefied gas falls within a specific range, before allowing the transfer of the de-solventized extract to the formulation chamber 140. Thereafter, the holding chamber of the final formulated extract may be depressurized at step 220.

[0034] An exemplary system for depressurizing the chamber holding the final formulated extract is now explained with reference to FIG. 5 in conjunction with FIG 1. FIG. 5 is a block diagram of an exemplary system 500 for depressurizing the chamber holding a final formulated extract. The final formulated extract may enter a tube 502 having a valve 504. The tube 502 may be coupled to a gas valve sensor 144 for measuring data related to a pressure level applied to the final formulated extract. Successively, the digital data 506 may be sent to the gas controller 114 for processing by the gas module 116. The gas module 116 may determine that the pressure applied to the final formulated extract falls within a specified range. Successively, the digital data 506 may be displayed by the user interface 118. If the pressure is within the specified range, the gas controller may communicate this to the gas valve sensor 144 through a control line 508. If the pressure is within a specified range, the valve 504 may open to allow the final formulated extract to be transferred to an extract hopper 510 through an inlet 512.

[0035] When pressure is applied to the final formulated extract contained in the extract hopper 510, a coupler 514 may be opened to remove the liquefied gas from the final formulated extract via a tube 516 that contains a valve 518. Thereafter, the post-depressurization final formulated extract may be obtained from the extract hopper 510 by opening a lid 520 and stored in the depressurized formulated extract chamber 146.

[0036] The relationship of the gas module 116 and gas valve sensors is now explained with reference to flowchart 600 shown in FIG. 6. FIG 6 is a flowchart illustrating an exemplary method 600 for monitoring and maintaining specific pressure.

[0037] First, the gas module 116 may poll for pressure data from gas valve sensors at step 602. As discussed above, the gas valve sensors may be placed throughout the system as seen in FIG. 1 at 112, 124, 130, 138, 142, and 144. Successively, the gas module 116 may collect the pressure data at step 604. The pressure data may correspond to a pressure applied to the liquefied gas present in the biomass. Successively, the gas module 116 may determine if the pressure lies within a specific range at step 606. In one embodiment, the specific range of the pressure may be 90-110 psig. In another case, a user may program the specified range using the user interface 118.

[0038] The gas module 116 may determine that the pressure falls within a specific range and identify the current process to be normal at step 608. On the other hand, the gas module 116 may determine that the pressure falls outside the specific range, and then the gas module 116 may open a valve via a control line to adjust the pressure so that the pressure falls within the specified range at step 610. Thereafter the gas module 116 may return to step 302 to poll for pressure data again to ensure that the pressure is within the specific range. [0039] It should be noted that each gas valve sensor may have a unique specific range. A decision tree may be used to check the unique range, where each valve may open or close to control the pressure. Furthermore, unique algorithms may be used to delay subsequent changes to specific pressure ranges - for a period of time - after a change was previously made.

[0040] Although the present disclosure and its advantages have been described in detail, various changes, substitutions, and alterations can be made herein without departing from the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the embodiments of the process, machine, manufacture, composition of matter, means, methods, and steps described in the specification. As one will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.